Demm Engineering & Manufacturing March 2013

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Safety first

Everyone has to be involved

Product watch

We profile the latest technology

Food processing How to improve sustainability

Heat exchangers

Reduce cost and improve efficiency

Automation and control Machines replace nimble fingers

Maintenance matters When downtime costs money

Now including

THINKING THINK Pump and Valve Specialties are delighted to announce they have been appointed sole New Zealand distributor for Wilden air-operated, double diaphram pumps.

Our dedicated staff are highly skilled in all pumping applications and we offer full service and back-up for every pump we sell.

Pump & Valve Specialties have conveniently located branches throughout the country. We can provide expert advice and a targeted solution to your pumping needs.

Call our specialist Wilden line today on 0800 WILDEN.

EL NOT PARALL !

IMPORTED

nly We are the o en official Wild Z! supplier in N ducts All Wilden pro “genuine” include their nty! factory warra

0800 WILDEN • AUCKLAND • WANGANUI • WELLINGTON • CHRISTCHURCH

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Ed Says Pressures to deliver the goods on time, within budget, and to an acceptable standard are with us all the time.

Cutting a corner here or there when manufacturing goods may be an option now and again, but there’s one place cuts shouldn’t be made – workplace safety.

At the end of each working day, everyone should be able to go home without so much as a scratch as a result of doing their job.

Plenty of firms talk about their ‘safety culture’. But as safety expert Simon Lawrence writes in this edition, safety is much more than a culture. It has to come from the top down and be embraced by every single member of staff – all the time.

Lawrence says safety at work should be a collective environment in which people have the knowledge, time, space, support, processes, tools and equipment to get every job done safely.

He cites the UK’s Health and Safety Executive, which says: “Organisations with a positive safety culture are characterised by communications founded on mutual trust, shared perceptions of the importance of safety and confidence in the efficacy of the preventative measures.”

Most weeks the Department of Labour updates its website detailing an accident that left a worker seriously injured, sometimes unable to work again.

For example, a man’s 5.5 metre fall at work left him with a broken pelvis and injuries to his face. As a result, Wellington’s Ebert Construction was fined $33,750 and ordered to pay $29,000 in reparations to the worker for not providing a safe workplace.

In more serious accidents, the cost to an injured worker in both quality of life and loss of future earnings can be stark.

The cost to the country in ACC assistance is something we all have to pay for.

As Lawrence says in his commentary: “If you want a strong culture, whether it is safety or quality or innovation, you have to make no compromises, take no prisoners, insist on the best, enable your people, remove barriers to creativity and celebrate your successes.”

Work safe.

Steve Hart Editor

DEMM Engineering & Manufacturing Magazine has a copyright and may not be reproduced in whole or in part without the written permission of the publisher. Neither editorial opinions expressed nor facts stated in advertisements are necessarily agreed to by the editor or publisher. Whilst all efforts are made to ensure accuracy, no responsibility will be taken by the publishers for inaccurate information, or for any consequences of reliance on this information.

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Contents 2 News 6 Product watch 14 Food processing 22 Safety 28 Heat exchangers 30 Automation & control 34 Maintenance matters 35 Craig Carlyle, MESNZ 38 Electrical 43 Allan Hill, NZEI

NEXT TIME Features coming up in the next edition include; oil & gas, compressors, robots, dust control & filtration, test & measurement.

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Editor: Steve Hart, Email: editor@demm.co.nz Advertising Frank Atkinson, Email: frank@adrenalin.co.nz Publisher: Cathy Parker, Email: cathy@adrenalin.co.nz Designer: Email: Rob@adrenalin.co.nz Subscriptions: subs@adrenalin.co.nz Proof reading: George Ward

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NEWS

Coming events

Engineers to converge on Christchurch SouthMACH will bring together more than 100 machinery, engineering and manufacturing technology suppliers from across New Zealand and Australia on the 29 and 30 May at CBS Canterbury Arena in Christchurch.

Among them is Motion Solutions NZ, distributors of EPSON Robots and a leader in advanced robotic technology.

Leading the industry with best in class cycle time, precision and motion range, the new EPSON C3 Compact six axis robots provide superior performance for even the most demanding and complex applications.

The Advantage NZ Petroleum Conference

Alfra magnetic base drills and bevellers will be available on the PowerPac stand and because of the huge amount of potential steel work in Christchurch it will be a good time to upgrade to current models that are more compact and user-friendly.

PowerPac will have stock available during the show so visitors can take delivery on the spot.

Visitors will find the latest equipment and technology on show and free entry includes two days of constructive seminars and workshops.

Visitors can save time by pre-registering to visit online free at www.southmach.co.nz

28 April – 1 May, Sky City Auckland Convention Centre. www.nzpam.govt.nz

National Manufacturing Week 2013 7 -10 May, Melbourne Convention & Exhibition Centre. www.nationalmanufacturingweek.com.au

Vanz Conference 2013 14, 15 & 16 May at Sky City Function Centre, Hamilton. www.vanz.org.nz

SouthMACH 2013 29 & 30 May at the CBS Arena in Christchurch. www.southmach.co.nz

MHL 2013 Materials Handling & Logistics 3 & 4 July, ASB Showgrounds, Auckland. www.mhlshow.co.nz

Digital clamp meters recalled

New Zealand Oil & Gas Expo 2013

Fluke Corporation is recalling Digital Clamp Meters that were manufactured between 1 September 2010 and 1 October 2012. The products are the Fluke 373, 374, 375, and 376 Digital Clamp Meters.

Fluke reports that issues with this products relate to the printed circuit assembly that may not be properly fastened to the test lead input jack.

This may result in inaccurate voltage readings, including a low or no voltage reading on a circuit energised with a hazardous voltage, presenting a shock, electrocution, or thermal burn hazard.

The recall involves meters with the model and serial numbers listed below. Any serial number preceded or followed by the letter “R” is not affected by this recall notice.

www.nzoilandgasexpo.co.nz

Model Manufacture Dates Starting Serial No

Ending Serial No

Fluke 376 Sept 2010 – Feb 2011 14270001

15909999

Fluke 375 Sept 2010 – March 2011 14270001

16079999

Fluke 374 Oct 2010 – Feb 2011 14270001

16379999

Fluke 373 Sept 2010 – Oct 2012 14270001

21950000

Fluke says that owners of these clamp meters should stop using them and send them back for repair.

See http://goo.gl/zvGWP to check if your unit is affected by the recall.

NHP gets an App The NHP eCatalogues App offers a quick way to access NHP literature in one location.

The App sends automatic updates to the App, with notifications provided to keep users up to date. Download it from the iTunes store.

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March 2013

11 & 12 September, TSB Stadium New Plymouth.

SKF National Maintenance Engineering Conference 2013 12 & 13 November, Novatel Rotorua Lakeside. www.mesnz.org.nz/nmec/ Send details of your industry event to Editor@DEMM.co.nz

Jenkins returns to Steelfort Steelfort Engineering has appointed John Jenkins as manager–commercial products, to handle business development for the firm.

Jenkins was manager of the firm’s HEVAC & R division until 1999.

His career started as an engineering draughtsman, he moved into production planning and operated as Protech Engineering in the 1980s. Steelfort purchased that firm in 1986 when he was the Palmerston North site manager.

NEWS

Airforce composite dust extraction Egmont Air has installed a sophisticated ATEX rated reverse-pulse dust collection system in a Whenuapai Air force workshop.

The air-force workshop facility required a dust extraction system to capture dangerous and harmful composite dust particles generated from grinding, sanding, and polishing precision military composite aircraft parts.

The state-of-the-art dust extraction system features high-efficiency cartridge technology, automatic reversepulse cleaning, rotary–valve discharge, safety back-pressure non-return valve, all items being ATEX certified to minimise explosion risk.

Dust collection is a necessary requirement in many industries including composites. Airborne dust including nuisance dust is not only a house-keeping expense but also reduces worker productivity and product quality.

Ten years ago effective dust control in manufacturing facilities was uncommon. Today governments dictate particulate emission control, breathable dust, which is typically less than or equal to five micron is small enough to penetrate deep into the lungs, with serious health consequences.

The cost of uncontrolled dust goes beyond worker health, Inhalable dust, which averages 10 micron, not only gets trapped in the nose, throat, upper respiratory tract and irritates eyes and skin, but it can also build up on machinery and components, causing premature wear and maintenance.

Dust can also affect product quality. The composites industry is complex in terms of materials and methods and with that is an increased sensitivity to contamination. Composites, whether it is raw material manufacture or final assembly,

are sensitive to both air borne and surface contamination.

While dust extraction has long been viewed as simply a cost of doing business, a well-designed system can have a positive effect on the bottom line. Companies are now realising that dust extraction when done correctly is an investment and results

in less waste and re-work, lower housekeeping costs, less equipment maintenance, better product quality and greater worker productivity.

System design involves consideration of factors that impact the effectiveness of dust containment technology, including the dust collection

method, fan size, motor power rating and filter media.

The selection of which depends on careful evaluation of the application and calculations of air volume, capture hood design, duct layout design and waste capture method.

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NEWS

Service sector starts 2013 on a positive note The service sector showed a pick-up in expansion for the start of 2013, according to the BNZ - BusinessNZ Performance of Services Index (PSI).

The PSI for January was 52.6. This was up 1.1 points from December, following a 3.6 and 2.7 point fall in the two previous months (A PSI reading above 50.0 indicates that the service sector is generally expanding; below 50.0 that it is declining).

Compared to previous January results, the 2013 value was lower than 2012, but higher than 2011.

BusinessNZ chief executive Phil O’Reilly says the stop in slipping expansion levels, along with activity/sales and new orders/sales in positive territory, at least starts the year off on a positive note.

“Activity is certainly patchy,

with differences evident across regions, industries and size of business,” he says.

“However, on a wider scale, New Zealand’s result for January sits only marginally below the JPMorgan Global PSI value of 53.6, which shows solid if unspectacular level of expansion.

“Despite the pick-up in expansion, the proportion of negative comments from respondents (52.7 percent) remains higher than those with positive comments (47.3percent), with the comments themselves having a strong seasonal influence due to the Christmas/holiday season.”

BNZ head of research Stephen Toplis says that while the global environment has improved in recent months, there still remain significant threats.

“From New Zealand’s point

Visit New Zealand’s Largest Machine Technology Trade Show for 2013

of view, the strength of its nearest neighbours, rather than the US and Europe, are of greatest interest. While the consensus view about the Australian economy is that it will remain one of the fastest growth areas in the developed world, there are increasing risks to this view,” says Toplis.

“Our exporters are exposed to the Australian economy, and this is facing some significant obstacles to its export sector, including cost structure increases, a high Australian dollar and a lower-cost-supply response elsewhere in the world.

“However, how China performs will also affect Australia’s strength, and at present there is good reason to be optimistic.”

The seasonally adjusted BNZ - BusinessNZ Performance of Composite Index or PCI (which combines the PMI and PSI) for January saw both options for measuring the PCI in expansion after a continued slip at the end of 2012.

The GDP-Weighted Index (53.1) increased 1.9 points from December, while the FreeWeighted Index (53.9) rose 3.1 points over the same period.

This was the highest result for both measures since October

2012, and the second highest since the middle of 2012.

Only two of the five main sub-indices were in expansion during January. However, these involved the lead sub-indices of new orders/ business (57.6) and activity/ sales (53.5), which were both up from December.

In contrast, employment (49.9) slipped back after a slight pick-up in December, while stocks/inventories (49.9) produced an identical result following last months’ decline in activity. Supplier deliveries (48.1) recovered somewhat from December, although still in contraction.

It was the tale of two Islands when examining activity by region. In the North Island, the Northern region (50.9) continued to slip from the previous month, but remained in positive territory.

The Central region (54.4) led the way for January 2013, recovering from a decline in activity during the previous month. In the South Island, the Canterbury/Westland region (49.8) continued to show increased momentum (although still in technical contraction), while the Otago/Southland region (42.0) fell back sharply after three consecutive months in expansion.

AB Equipment becomes Bobcat and Portable Power dealer See JETBLACK prototype on stand 55.

29th – 30th May 2013

CBS Canterbury Arena Addington, Christchurch

www.southmach.co.nz 4

March 2013

AB Equipment will distribute the full line of Doosan heavy products. These include mini excavators, heavy excavators, wheel loaders, wheel excavators, log loaders and articulated dump trucks.

In addition it will handle the Bobcat range including mini excavators, skid steer loaders, compact track loaders, telehandlers, utility vehicles, Toolcat machines and Bobcat attachments, and the Portable Power range including compressors, generators and lighting towers.

AB Equipment has 18 branches throughout New Zealand and 310 staff servicing the New Zealand construction equipment market.

NEWS

Manufacturing decline not just a dollar story The decline in the manufacturing sector is much more than a simple exchange rate story, the Governor of the Reserve Bank has said.

In a speech to the New Zealand Manufacturers and Exporters Association in Auckland on 20 February, Graeme Wheeler said factors such as globalisation, outsourcing and international supply chains, along with competition of low-cost producers and rising global demand for services meant that the relative importance of manufacturing had been declining in all but the poorest countries for the past 40 years. New Zealand was no exception.

Wheeler acknowledged the New Zealand dollar was significantly overvalued in terms of economic fundamentals, and this was a headwind for some in the manufacturing sector. But he said there are no simple solutions available to the Reserve Bank.

“Some of the strength in our real exchange rate is due to global financial imbalances and the weakness of the US dollar in particular.”

Near-zero interest rates and quantitative easing by other central banks have pushed up

currencies such as the New Zealand dollar, and domestically, New Zealand’s poor savings record is also to blame.

Wheeler says the Bank stands ready to intervene in the currency when circumstances are right and to use the Official Cash Rate as required. It is also investigating the use of macroprudential tools that will help to support monetary policy.

While commentators have suggested a wide range of alternative policy responses to lower the New Zealand dollar, there are no quick fixes available to the Reserve Bank.

“Our economic challenges are different from the US, Euro area, and Japan, and quantitative easing would increase inflation, raise inflation expectations, stimulate asset prices, and lead eventually to higher interest rates.

“Efforts to improve the level and productivity of capital that labour works with, to reinforce ongoing fiscal adjustment, to re-examine the factors that diminish and distort the incentives to save and invest, and to reduce dependence on the savings of others, have to be a major part of the solution.”

Read the full speech at: http://goo.gl/fHMye

Picture-perfect idea for smartphones Riding the wave of the growth in smartphone use is Tuatara Covers in Auckland.

Run by Anna Wilson, the firm can print almost anything on its range of smart phone covers – from photos to company logos.

Director Steve Wilson says images are embedded into the fabric of its covers so they can’t be scratched off. The firm, which manufactures its smartphone cases, uses gas sublimation printing and says the printed images will last the life of the phone.

“We infuse the image into the fabric of the cover,” says Wilson.

The firm’s product and printing service was launched in December 2012.

Wilson says his firm’s customers so far have included the All Blacks, the Super 15 and it is talking with a New Zealand bank who wants

covers printed for its staff’s smartphones.

Steve Wilson is the director of Talbot Technologies in Christchurch, which has a history of labelling medical products and printing gaming machine fascias.

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PRODUCT WATCH

Mono Pumps distributes Sulzer Pumps Mono Pumps (NZ) has been appointed as the major distributor for Sulzer Pumps throughout New Zealand and the Pacific Islands.

Mono Pumps has been providing high pressure pumping solutions to the agricultural, industrial, food and beverage, and wastewater sectors in New Zealand for more than 30 years, with pumps, solid waste grinders and screening systems designed and manufactured by Mono at its manufacturing and research facilities in Manchester and in Melbourne.

Mono Pumps (NZ) is part of the worldwide NOV Mono Group, one of the world’s leading providers of specialised water and wastewater solutions and products with facilities in Australia, Britain, The US, France, Argentina and China.

Sulzer Pumps is one of the world’s leading pump manufacturers, recognised for state-of-the-art, energy efficient and high performance pumping solutions. The company provides a wide range of pumping products, services and related equipment for the oil & gas, hydrocarbon processing, power generation, pulp & paper, water and waste water, and general industries.

General manager of Mono Pumps (NZ), Shazad Ibnul, says the arrangement with Sulzer Pumps brings an exciting and additional capacity to the New Zealand organisation.

“Together, we now have the ability

Engineers at Sulzer Pumps assemble a multistage pump.

to provide high volume pumping applications for farming, irrigation, mining, general industry, large scale water supply and power generation,” he says.

Mono Pumps has been providing pumping, aeration, grinding and screening products to the wastewater sector in New Zealand for more than three decades.

This includes the Seaview wastewater treatment plant upgrade in Wellington; the upgraded Army Bay wastewater treatment plant which is responsible for treating wastewater of the rapidly growing area north of Auckland, and the Thames Coromandel District Council’s Eastern Seaboard waste water treatment plant upgrades.

Ibnul says that Mono Pumps also

Official distributor named for Wilden pumps Pump & Valve Specialties has been appointed sole authorised distributor for Wilden pumps in New Zealand.

Wilden developed the air-operated diaphragm pump in 1955 and has been a market leader ever since. Pump & Valve Specialties has four offices across the country.

Industrial sales manager Matthew Scarlett says: “Wilden’s large installer base combined with Pump & Valve’s vast product range and geographical coverage make for a winning partnership well received in the marketplace.

“With 17 years experience in the airoperated diaphragm pump business there is a wealth of knowledge and experience across all applications.

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March 2013

“As well as the longstanding Prof lo, Pro-f lo X and Accu-f lo air valve systems, the ever extending range of specialty pumps such as HS and Sanif lo sanitary hygienic pumps mean that the advantages of the AOD pump can now be experienced across a wider range of applications.

“The expanding and evolving product line combined with the dependability and support required from our customers makes our offering second to none. With a dedicated service and test facility and guaranteed turn around times reliability and performance can be assured.”

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Go to www.demm.co.nz/enquiry quote: D130306a

leads agricultural pumping solutions with its range of high-performance dairy eff luent pumps that are revolutionising dairy farming methods throughout the country.

“New Zealand dairy farmers in particular, recognise that Mono’s progressing cavity (PC) pump systems are more powerful and cost effective than centrifugal pump systems. Mono’s PC pumps are enabling farmers to beat rising energy and maintenance costs while also providing a far superior method of managing effluent irrigation management,” he says.

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Go to www.demm.co.nz/enquiry quote: D130306

0927

PRODUCT WATCH

Go anywhere pumps Enerpac’s XC Series cordless pumps offer the performance capabilities of an electric or pneumatic powered pump with the convenient portability of a hand pump.

The cordless powered pumps provides a portable, cost-effective solution for remote locations that delivers the speed, power and longevity of a corded pump, says Enerpac Australia and New Zealand regional manager Tony Brooks.

Designed to satisfy the need for a long-lasting pump that can be used in hard-to-access areas, XC-Series cordless pumps are constructed of lightweight materials, equipped with a powerful, onehalf horsepower motor and feature 28-volt, Lithium-Ion battery technology.

With its bladder reservoir, Enerpac’s cordless pumps eliminate venting and offer leak-free operation in any orientation.

Plus, the overall body, handle and trigger have been ergonomically engineered to maximize ease-of-use and portability.

XC-Series cordless pumps deliver oil flow of 2.05 litres (125 cubic inches) a minute at its low-pressure setting and .25 litres (15

MOVIMOT

®

For standard Variable Speed drive solutions, SEW-Eurodrive offers Movimot®, the ingeniously simple idea of combining a Geared Motor with an integrated frequency inverter.

Despite the integrated frequency inverter, the unit needs only a minimum of additional space compared to the standard gearmotors and can be supplied in all standard versions and mounting positions with and without brake for supply voltages of 380 to 500V AC. Power range 0.37 to 4.0kW Low cost installation Vector oriented motor-control and four-quadrant operation with or without mechanical brake Simple operation via incorporated fixed or remote wired keypad Alternative control function via PLC or optional fieldbus modules The plug-in type inverter makes for quick installation

can be combined with all SEW motors & Gearmotors operates from any standard 3 phase power supply integrated motor control, protection and monitoring functions including motor brake if fitted

pump and the operator from excessive amp draw or temperatures, and a trigger lock-off mechanism that protects against unintended operation during transport.

Ideal for a wide range of industries, such as mining, construction, industrial, power generation and more, the XC-Series solves diverse and demanding applications requirements, including: lifting, pushing, pulling and cutting.

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Quality European Manufacturing • Motors • Gear Components • Control Technology

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digital readout of speed percentage adaptable to most industry requirements easily replaced in case of service call

Motors • Brake motors • Servo motors • Geared motors • Gear units • Control Technology AUCKLAND 82 Greenmount Drive, East Tamaki. Ph: (09) 274 5627. Fax: (09) 274 0165 PALMERSTON NORTH Ph: (06) 355 2165 CHRISTCHURCH 10 Settlers Crescent, Ferrymead. Ph: (03) 384 6251. Fax: (03) 384 6455 Email: sales@sew-eurodrive.co.nz • Web: www.sew-eurodrive.co.nz

On board or Remote Speed Selector

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cubic inches) a minute when operating at full pressure, up to 700bar (10,000 psi).

Additionally, the lithium-ion technology ensures XC-Series pumps provide end users with the battery runtime necessary to accommodate demanding application requirements.

Enerpac’s XC-Series promotes operator safety by removing trip hazards associated with traditional powered pumps. Safety features include overload protection circuitry, which safeguards both the

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PRODUCT WATCH

Ultra cool calibration Fluke Calibration, a leader in precision calibration instrumentation and software, introduces the 9190A Ultra-Cool Field Metrology Well, a small, lightweight, and accurate dry-block calibrator with best-in-class stability.

The 9190A is ideal for pharmaceutical, biomedical and food processing applications that demand strict quality control and regulatory process compliance. This includes on-location validation and calibration of RTDs, thermocouples, thermometers and other temperature sensors.

The 9190A conforms to EURAMET cg-13 guidelines for best measurement practices for temperature dry-block calibrators. This means its specifications for accuracy, stability, axial (vertical) uniformity, radial (well-to-well) uniformity,

loading and hysteresis have been thoroughly and carefully defined and tested.

The 9190A has a wide temperature range (-95 to 140 degrees Celsius) to cover the coldest and warmest temperatures required in pharmaceutical, biomedical and food processing applications. Operating at ultra-cold temperatures is not typically available with a calibration bath.

The 9190A uses no bath fluids, which keeps clean rooms clean, makes it easier to transport and delivers faster heating/cooling rates. It offers best-in-class temperature stability (plus-or-minus 0.015 degrees Celsius) for consistent and accurate results.

The 9190A with “process” option features 4-20 mA connectors, a reference

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March 2013

thermometer input and a 4-wire PRT/RTD input with an accuracy of plus-orminus 0.02 degrees Celsius.

It also has a reference sensor control to minimise the effects of the axial gradient when a reference PRT is aligned with short sensors.

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Print on anything Case coding just got easier than ever thanks to Linx Printing Technologies, and the launch of a new thermal inkjet (TIJ) printer.

The Linx TJ725 offers a high resolution, digital solution for coding onto outer cases, boxes, shelf ready trays and packaging.

Supplied in just a few pieces out of the box, it is simple to fit without needing a service engineer or specialist installation tools. No training is needed and you can be up and running within minutes.

Linx’s Active Cartridge Care System saves money and cuts waste by slowing the nozzle drying process, making first prints more reliable every time.

The nozzles are covered and protected when not in use and uncovered automatically when the first product is sensed, so the TJ725 is ready to produce high quality prints as soon as they’re needed.

The replaceable ink cartridge with integral printhead is key to the coder’s efficiency, as there is no risk of expensive printhead repairs or replacement.

The TJ725 also allows easy, tool-free, repositioning of the printhead. So the printer can

be set up quickly and easily in the correct printing position during product changeovers, or when moving the printer between lines – saving production time.

The built-in speed sensor automatically detects both the line speed and direction, which means no separate encoder is needed.

For operators, the colour screen clearly shows the message selected as it will be printed, reducing the risk of coding errors.

The TJ725 can print messages up to a height of 12.5mm, with a range of fonts and resolutions up to 300dpi, on line speeds of up to one metre/sec.

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Go to www.demm.co.nz/ enquiry quote: D130310a

PRODUCT WATCH

Servo technology for everyone The high costs and complexity of servo drive technology are now a thing of the past thanks to the electric cylinder EPCO from Festo.

At the heart of its positioning system is the Optimised Motion Series. The electric cylinder is a prime example of the easy and low-cost use of electric cylinders in factory automation. With the two software tools WebConfig and WebDiag, web

configuration and web diagnostics are incredibly simple in conjunction with the motor controller CMMO. As a result, the electric drive is just as easy to handle as a pneumatic cylinder. The motor integrated into the actuator is also partly to thank for this – as are the preassembled cables, suitable for use with energy chains and available in three sizes.

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quote:

With its various mounting accessories, it fits into any installation.

Go to www.demm.co.nz/enquiry D130311

Compress your costs Industrial Air Systems has brought to market a cost-effective compressed solution designed to match today’s tight operational cost demands.

The firm claims that its recent appointment of their rotary screw compressor brand – Pneutech, combines high performance, high quality and reliability together with low operating costs, delivering $1,000s of annual production savings back to your bottom line.

Based in the USA, Pneutech Group is actively involved in supplying compressed air solutions from small to very large

industries across the world, including USA, Europe and Australasia.

It offers you global experience, unique products, superior pricing and flexible service packages.

Having strong synergies with worldleading manufacturers, Pneutech screw compressors also bring to the market the most competitive, direct-from-factory pricing in the industry, which is backed by unparalleled service support available 24 hours a day, 365 days a year.

The vast Pneutech line-up includes its renowned direct driven ‘RSCR’ stationary

electric models available in 7.5Kw to 280Kw, as conventional lubricated or oil-free type for the food industry.

• Go to www.demm.co.nz/enquiry quote: D130311a

We’ll keep you moving in 2013 EQM has sourced the world’s best transmission products directly for you

Contact us now 0800 147 847 or visit www.eqm.co.nz

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PRODUCT WATCH

3D printing saves time and money Leptron is a leader in remotely piloted helicopters focusing on law enforcement, military and civilian uses.

The firm’s RDASS 4 is an unmanned aerial vehicle (UAV) that weighs only two kilos and can be in the air at five minutes notice.

Its four battery-powered electric motors enable it to hover at a height of 30 metres with an 800-metre line of sight. The device carries a wide range of cameras and other electronic equipment.

A typical military application for the RDASS 4 is to provide an armoured vehicle with the ability to see over the horizon and inspect terrain or structures that might present a danger. Computer simulation has shown that the device can increase survivability of an armoured vehicle by 50 per cent. The RDASS 4 also has many other applications including police work.

The fuselage of the RDASS 4 is constructed in a series of nested sections called layers that fit together similar to Russian dolls. The company has developed multiple designs for each layer for specific civilian and military applications.

Each layer can be easily interchanged with the others to be tailored specifically to the needs of a particular application without substantial additional cost or delivery time.

When designing the RDASS 4, Leptron engineers faced the challenge of developing eight variations of complex fuselage components in a short period of time to beat potential competitors to market.

The plastic components that form the shell for the layers must withstand functional and crash tests where the

The RDASS4, five minutes away from being launched, and partly made using a 3D printing machine.

food processing sector because they can withstand high water pressure (1400PSI) and incredibly hot water (maximum 80°C).

“This is important when it comes to food hygiene and the sterilisation of equipment as they can tolerate extreme changes in humidity and temperature”.

EQM also stocks a full range of STM gearboxes that are interchangeable with other brands and features an input coupling system that eliminates fretting in the keyway, as well as allowing it to be easily assembled or disassembled.

fuselage components,” said John Oakley, CEO of Leptron.

Fused Deposition Modelling (FDM) technology is an additive manufacturing process that builds plastic parts layer by layer, using data from CAD files.

Leptron now uses the Dimension 3D Printer to quickly build end-use parts for the RDASS 4. The core components take 48 hours while smaller components average six hours to print. The printed parts are suitable for form and fit evaluation, functional testing and end use parts.

Using the same Dimension machine for making prototype parts reduces up-front investment and enables Leptron to build UAVs without a machine shop. The plastic parts needed for prototypes and eight production craft were built for only $100,000 in eight months.

“We made approximately 200 design changes during the course of the project,” says Oakley. “They included everything from reinforcing the structure to shoring up weak areas to making aerodynamic improvements.

“Every single part has changed a minimum of four times. FDM gave us the flexibility to make these changes without incurring a significant time or cost penalty. It would not have been possible for a company of our size to design and build this product using conventional manufacturing methods.”

Tasman Machinery is one of the founding machinery suppliers to the plastics manufacturing industry in Australia and New Zealand, having been founded in 1972.

D130312a

D130312

RDASS 4 is flown into the ground. The craft must demonstrate the ability to be easily repaired and flown again after the crash. A minority of parts have mechanical requirements that cannot be met by plastic so they are made of metal.

Using the traditional approach, injection moulding, it would have cost US$250,000 and taken six months to build tooling for these fuselage components. Another problem is that any design changes after the tooling was built would have required expensive and time-consuming modifications to the tooling. Major changes would have involved even greater costs and delays to build new tooling.

“We investigated various rapid prototyping technologies and discovered that the FDM process could provide components that met the mechanical requirements for all of our plastic

Online information to keep you moving Food processing & packing companies can easily access detailed information about a full range of equipment that will keep them moving in 2013.

EQM Industrial’s website www.eqm. co.nz has a selection of the world’s best transmission products imported from companies such as ABI, DAGU, Challenge and STM. To make it easier for engineers, the website lists products within each brand and also vital information such as ratios and sizes.

The ABI stainless steel gear motors, manufactured in the Netherlands, are top of the line and well suited for the

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March 2013

• Go to www.demm.co.nz/enquiry quote: • Go to www.demm.co.nz/enquiry quote:

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FOOD

Air knife cuts costs After washing and filling, bottles on a production line can be too wet to label satisfactorily. Surface moisture ruins the appearance of the label and affects its adhesion to the bottle.

It also affects the cardboard crates into which the bottles are packed and can encourage the growth of fungal spores.

This means slow line speeds to allow some natural drying, poor product appearance and cases rejected by customers.

The Secomak air knife can be the best solution here, being the most efficient method of removing or controlling unwanted moisture on any surface.

Secomak air knives are versatile in applications and are broadly used in bottling, canning and packaging industries for food and beverage production.

Cleaning and drying fruit and vegetable is also done with air knives.

Nu-Way says the system is more cost effective than compressed air nozzles, saving up to 85 percent in running costs.

“They are easy to install and require minimum maintenance. Using high velocity centrifugal blowers (HV fans), that require no inline filters or pressure relieve valves, further contributes to the reducing maintenance costs,” says the firm.

The air knife is available in two cross sectional sizes, 75mm and 25mm. This is the diameter of the air entry spigot.

The maximum length of the 25mm air knife is 500mm.

Units over 1000mm length have air entry at both ends.

We’ve been supplying Secomak air knifes for

Australian and New Zealand industry for almost 20 years and can guarantee great quality of this product and

provide best customised solution to your need.

•

Go to www.demm.co.nz/ enquiry quote: D130314

The Hygienic Belt Drive for Food Conveyors Fisher Food Grade Motorised Drums are the hygienic alternative to gear motor drives for the food industry • IP66 PROTECTION • ALL DRIVE COMPONENTS ENCLOSED • IDEAL FOR FOOD GRADE INSTALLATIONS

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March 2013

Packaging show unwrapped Auspack Plus 2013 is a ‘must-attend’ exhibition on the packaging and processing calendar and will be held at the Sydney Showgrounds, Sydney Olympic Park, from Tuesday 7 to Friday 10 of May. The event is run by the Australian Packaging and Processing Machinery Association.

Visitors can expect to see more than 240 exhibitors, from 13 countries, including 58 international exhibitors, and taking up more than 7,000 square metres of floor space.

See: www.auspackplus.com.au

FOOD

Reotham’s polymer range perfect for increased food safety Designers and operators of food production lines must adhere to strict legislation to ensure consumers can buy food that’s safe to eat.

This includes avoiding any kind of contamination such as from foreign particles or lubricants during production or transport. The use of special materials can significantly reduce this risk.

Detectable polymers, which can be picked up by metal detectors, are suitable for such applications. Lubricantfree polymer plain bearings and rolling bearings avoid contamination through oils and greases.

If they are also made of FDAconforming materials which are “suitable for use with foods”, their direct contact with food is

safe. One particularly important area for perfectly hygienic food production is materials that effectively prevent the growth of bacteria, viruses and mould.

In order to guarantee that foreign particles can be picked up quickly and reliably in food, the detectability of materials is vital. For this reason, Igus has developed a polymer energy chain made of a detectable polymer.

Even tiniest fragments of the blue material can be detected by all standard metal detection systems, and can be removed automatically. Customers from the food and pharmaceuticals industries can use the durable, corrosion-free and versatile polymer energy chains in their machines and lines without concern.

Another new product for the food sector is from the Iglidur PRT family of lubricant-free polymer rotary table bearings.

The bearing of the PRT 01 design is made of corrosion-free stainless steel. The sliding elements between inner and outer ring are made of the Iglidur material A180.

As an FDA-conforming special polymer, A180 is suitable for contact with food and humidity. With their low profile and rigid design, lubricant and maintenancefree polymer rotary table bearings can replace lubricated ball bearing rotary tables or

rotary connections.

The food-conforming polymer rotary table bearings are available ready to fit – initially in size 200 (inner diameter 200mm) and in all other sizes in the future.

The Igus Chainflex range of cables designed for use in moving applications, are being extended by a special antimicrobial series (CFSpecial) for food-related applications. The only visible difference between the highly bending-resistant jacket material and other cables is its blue colour.

•

Go to www.demm.co.nz/ enquiry quote: D130315

NEW ZEALAND’S ONE STOP

HOSE REEL SHOP Flexible packaging grippers One gripper system can now be adapted to virtually any packaging and palletising process to provide flexibility and performance in the food and beverage industry.

UniGripper, from Tepro of Sweden, is an intelligent vacuum gripper system that automatically senses the presence of products and creates the necessary lifting force where it is needed, providing a flexible, effective and economical material handling solution that is capable of handling a wide variety of food products.

The patented UniGripper can handle pallets, boxes, bottles,

cans and glasses and other products in singles, trays or full layers with, or without shrink wrapping.

Contact rubbers are fixed to a screw-on plate that is quickly and easily removed for cleaning or replacement in the event of damage – reducing line downtime.

Unigripper is available in a standard module system or can be custom-built and delivered complete in any size required to suit the specific application.

It can be divided into several chambers making it possible to control each chamber.

• Go to www.demm.co.nz/ enquiry quote: D130315a

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FOOD

Innovating to improve sustainability in the NZ dairy industry By Sian Stimson.

To compete in today’s world market, New Zealand has had to innovate to differentiate itself from global competition, many of which are located closer to the primary customer base.

One company that has embraced this challenge is Waikato Milking Systems.

Founded in 1978, when it was a part of the plastics division of Alex Harvey Industries, the company has been through many changes, including being owned by US company DEC Corporation before undergoing a management buyout in 2001.

Although Waikato Milking Systems has a 62 percent share of a burgeoning domestic market, with New Zealand the world’s biggest exporter of cow’s milk, it has recognised that its future growth will come from exporting its technology and equipment.

The company has four

The Centrus rotary platforms in action.

divisions, one of which is Rotary Platforms NZ. Their focus is on the design, development and manufacture of rotary platforms, which are an efficient method of milking large-scale herds, by creating a steady flow of cow traffic to cups-on.

They were looking for a new

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March 2013

approach to their products, something that would take advantage of advanced technologies and materials, and would appeal to the progressive farmers both at home and overseas.

As a result, the Centrus platform was launched, which, the company claims, is the world’s first composite rotary platform for the dairy industry.

The first Centrus platform was manufactured in 2009 and since then 24 composite platforms have been installed at customer sites, accounting for eight percent of the firm’s total installations.

Customers to date have been New Zealand based, and tend to be younger farmers embracing new technology and looking for the most environmentally-friendly product that promises a good lifespan. The composites solution supplied by Gurit addresses these issues.

Composite materials provide a solution for the deck sections that is lighter, and indeed stronger, than the alternative concrete platforms.

By replacing the concrete elements of the platforms with composites, the weight of a 54-bail platform is reduced by 80 percent.

However, the new design will still sustain rigorous use by 54 cows when fully loaded,

at an average of 600kg each – a total of 32.4 tonnes. The lighter weight platform also means there is less friction on the drives and running gear, resulting in reduced wear and tear. And the composite materials offer reduced ongoing maintenance, as the deck is not corroded by the cleaning chemicals or the cows’ urine.

The deck sections are constructed of a sandwich laminate, comprising a foam core, double bias and quadriaxial E-glass fabrics, reinforced with a high strength hybrid aramid/glass woven cloth, and laminated using a resin infusion process.

Recyclability of infrastructure is likely to become a major driver in the dairy sector, and Rotary Platforms wants to stay ahead of the game, so they were pleased to adopt G-PET. G-PET, a recyclable structural foam core has excellent mechanical properties and is compatible with all types of composite processing.

This new foam, recently launched onto the New Zealand market by Gurit, offers extremely high compressive properties, critical when you have over 400 tonnes of cattle traversing the platform daily.

Rotary Platforms expects this new composite solution to have

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FOOD

The finished milking system.

a lifespan 25 percent longer than its concrete platforms.

To aid Rotary Platforms in its quest for innovation, production efficiency and product quality, Gurit supplies its composite materials in kitted format. Each of the nine layers of material is CNCmachine cut to the exact shape and size required for the build, clearly labelled and packed in the order to be used.

“We decided to use Gurit kit as it eliminated the need for time consuming hand cutting at our own manufacturing facility,” says Josh Janmaat, composite division manager at Rotary Platforms.

“The kit design and cutting process is very accurate compared with hand cutting, which allows us to apply more stringent quality controls to the finished product. A huge benefit to our customers.”

The kits are provided with step-by-step construction guides to save time in the manufacturing process, ensure repeatability and allow

efficient training of new staff.

Rotary Platforms and Gurit have worked closely to refine kit design, materials choices and construction process.

“We enjoy working with the Gurit team,” says Josh. “They are able to respond to our material supply requirements quickly as they are based locally here in New Zealand, with the kits manufactured at their Auckland facility. And their flexible design team are always on hand to deal with any questions or new requests.”

As demand for environmentally-friendly, advanced technology solutions increases within the global dairy industry, and as the composite platform continues to prove a success, Waikato Milking Systems plans to export its innovation, with Australia and the UK firmly in its sights.

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The finished composite part – one of nine sections that make up a rotary platform.

17

FOOD

Low output PET bottle blowing machines Sipa, a maker of stretch blow moulding machines for the production of PET bottles, has released a new line of machines called ‘Start Blow’ that are specifically designed for emerging markets entering the PET bottle market.

Available in two versions, with two or four cavities, the machines from the Italian firm are capable of producing bottles at output speeds from 2,000 to 6,000 bottles an hour.

Both models are fully electric, with servo drives governing principal movements, including stretch rods. Every machine axis movement is under closed loop control.

“The market for bottled water continues to grow at around eight per cent every year,” says Enrico Gribaudo, general manager of Sipa.

“But the growth is shifting to emerging markets. With

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March 2013

Start Blow, we are meeting the needs of new entrants into the market, and we are offering a solution that fits with local requirements. When companies start up, they need to learn to walk before they run, and learning with Start Blow is very easy.”

The compact machine incorporates a number of technologies such as lowenergy infrared heating, a high efficiency neck aircooling system and quick and precise stretch and blow functions.

The ‘Start Blow’ range has been designed with a user-friendly interface and a simple and reliable preform loading system. They will be manufactured in Sipa’s facility in China and will have an ex works delivery time of approximately 45 days.

The firm has also updated its Robby Rack robot that

has been designed to handle large returnable bottles into racks for washing, refilling and storage.

This modular robot can carry out palletising and de-palletising cycles, and is currently operational in a number of packaging plants around the world, running at 500 cycles an hour at a maximum speed of 2,600 bottles an hour.

The Robby Rack has a small footprint and can be adapted to each bottle size and shape. The six axis robot is equipped with the latest generation control system and incorporates various ‘smart’ functions such as torque control and identification of the load wrist necessary for the large payloads of 120kg plus.

It has a compact modular head with several gripping points and there are a number of heads available including

heads with up to 10 grippers for racking round bottles, combination gripping heads for triangular bottles and heads specially designed for the de-racking cycles. The gripping heads have been designed for a quick change which takes no more than two minutes.

•

Go to www.demm.co.nz/ enquiry quote: D130318

FOOD

How to accurately measure containers Accurate measurement of the thickness of thin-walled items such as blowmoulded plastic bottles is now easier following the release of the Magna-Mike 8600 Hall Effect Thickness Gauge from Olympus NDT. The instrument is a portable thickness gauge that uses a magnetic method to make reliable thickness measurements on non-ferrous materials. It is a versatile tool, which can be used in a wide range of applications including measurements of thermo-formed plastic trays, extruded tubing, and automotive tear seams.

The Magna-Mike 8600 can also be used on glass and composites, as well as aluminium, brass, copper and titanium, with a thickness range from 0.001 mm to 25.4mm.

Taking a measurement is a simple procedure. The magnetic probe is held or scanned on one side of the test material while a small target ball is placed on the opposite side or dropped inside a container.

The probe’s Hall Effect sensor measures the distance between the probe

tip and the target ball, which is instantly displayed as an easy-to-read digital thickness reading. Material properties do not affect the instrument’s accuracy.

The Magna-Mike features both straight and angled magnetic probes with replaceable wear caps to increase durability and reduce replacement costs.

An expanded assortment of magnetic and non-magnetic steel target balls, discs and wire targets makes the Magna-Mike the ideal instrument for applications with complex geometry where ultrasonic thickness measurements are difficult or impossible. Non-destructive measurement capabilities allow for pinpoint thickness readings in tight corners and grooves.

The instrument also boasts powerful standard thickness measurement features such as minimum and maximum scan and a strip chart view feature. The colour LCD display with full VGA resolution provides superior readability and a simple keypad makes it easy to access important functions. USB, RS-232, and VGA outputs are provided for

connection to external displays.

The Magna-Mike’s internal data-logger provides onboard storage of thickness data of more than 475,000 thickness readings in various file formats. The unit also features a MicroSD card slot for additional storage and data transfer.

The 8600 can export data to the MicroSD card in CSV or text formats that can be copied or pasted into almost any Windows program.

The included WinXL interface program allows users to send thickness readings directly to an Excel spreadsheet.

• Go to www.demm.co.nz/enquiry quote: D130319

19

THE UPSIDE OF MAINTENANCE: $500,000 SAVED

USE PLANNED MAINTENANCE TO REDUCE ENERGY COSTS Some production processes are tricky. With finely balanced systems, it’s pretty obvious that any changes need to be high value, and not jeopardise day-to-day operations.

annually with payback in one and a half years. It also helped Nelson Pine reinforce its brand reputation for sustainably produced wood products.

Specialised energy systems auditors can identify efficiency opportunities, and offer solutions that will reduce energy costs for your business. They also give you the confidence that efficiency improvements can be put in place without affecting production.

Process Engineer James Cameron at Nelson Pine

Take Nelson Pine, for example. After a fan systems audit, the company upgraded its fan motor controls fitting in with planned maintenance schedules.

This resulted in a 33% reduction in energy use, which equates to a cost saving of around $500,000

www.eecabusiness.govt.nz

EEC2718A/DEMM

says, “The expert help we received gave us the confidence that we could deliver savings, without disrupting production”.

For pumping and fan systems efficiency, talk to an EECA BUSINESSTM programme partner – they can help you with expert advice and unlock any funding that may be available to you.

FOOD

TO SEE HOW MUCH YOUR BUSINESS CAN SAVE, CONTACT ONE OF OUR PROGRAMME PARTNERS Programme partners providing pumping and/or fan systems efficiency: Demand Response Ltd (pumping & fans) Location: Auckland, Hastings, Wellington Contact: Mark Davis (Auckland), 027 632 6956 Rowan Hains (Hastings), 06 878 1090 Stephen Gillespie (Wellington), 04 472 6060 DETA Consulting Ltd (pumping & fans) Location: Christchurch Contact: Jonathan Pooch, 03 377 6510 Enercon Ltd (pumping & fans) Location: Christchurch Contact: Kees Brinkman, 03 384 7905 Energy Management Solutions Ltd (pumping & fans) Location: Nelson Contact: Erin Roughton, 03 5380 686 Energy NZ Ltd (pumping & fans) Location: Auckland Contact: Andy Logue, 09 488 0942 Energy Veritas Ltd (pumping & fans) Location: Auckland Contact: Graeme Burke, 09 476 7677 ITES Ltd (pumping & fans) Location: Auckland Contact: Edgar Ludwig, 09 524 4754 Ivan A Fraser (pumping & fans) Location: Auckland Contact: Ivan Fraser, 09 410 5008 MAS Engineering (pumping & fans) Location: Tauranga Contact: Kit Wilson, 07 577 6228 Norman Disney & Young Ltd (pumping & fans) Location: Christchurch, Auckland Contact: Peter McBride (Christchurch), 03 365 0104 Contact: Stephen Hogg (Auckland), 09 374 1468 Ahika Consulting (pumping) Location: Dunedin Contact: Lloyd McGinty, 03 742 1093 Fanzone Air Systems (fans) Location: Auckland Contact: Ian McKernan, 09 444 7323 Windsor Engineering Group (fans) Location: Wellington Contact: Michael Hampton, 04 232 8080

Industrial Air Systems saves Industrial Air Systems says its Pneutech Aluminium compressed air pipe system saves both installation and operational costs and is ideally suited to reticulating air in the food industry.

This is because it combines the hugely beneficial properties of polished aluminium conduit with simple-to-use and inexpensive nylon push-in fittings, giving the best of both worldsefficiency and economy.

In fact, in most instances the new IAS piping can be easily and rapidly installed without the need of professional labour, and as the piping is extremely lightweight can be easily hung by one installer.

Industrial Air Systems’ aluminium pipe system is also very rigid, requiring less than half the supports as needed by most alloy or galvanised pipe installation. There is no risk of sagging (and resulting water accumulation)as in poly piping and no rusting as in galvanised piping, and the set-up continues to look professional in years to come.

This reduces the risk of potential plant damage and costly production downtime caused by harmful water and rust contamination.

The thin-walled aluminium piping makes for very high airflow rates when compared to other piping and will transfer up to twice the airflow for the same outside wall diameter.

This higher air transfer means lower air compressor operating pressures significant power savings while reducing the workload and wear on the compressor and plant operated.

The Industrial Air aluminium air piping utilises lightweight and strong nylon push-lock style fittings, which can be disassembled and reused at any point down the track. This means the system can be very simply extended added to, or altered as is so often the need with growing compressed air requirements.

Industrial Air NZ’s director says the new Aluminium air piping is ideal for use in the food industry due to its corrosionfree characteristics, while the very smooth exterior finish can be easily washed down to prevent aid a germ-free environment.

IAS NZ’s aluminium air piping is available in 20mm up to 63mm sizes and is suited to reticulate air volumes from 20 to 1000cfm.

• Go to www.demm.co.nz/enquiry quote:

D130321

EEC2718B/DEMM

21

SAFETY

Make it safety first and the culture will follow

By Simon Lawrence

When managers talk about their ‘safety culture’ they could just as well be talking about how happy or excited they are. Talking about a culture, having a programme for it, even measuring it, is like trying to quantify an intangible.

I have always believed that a safety culture is a product of doing things well, just as happiness is a product of a combination of things feeling right in your day. I said ‘day’ deliberately, because these sorts of things are fragile and transient, unless the conditions continue to support them.

So when anyone says they have a great safety culture, I feel like saying: “Do you mean today or yesterday?” I could ask, rather unkindly, whether the employees know about it. But I don’t.

Even in safety-critical organisations, such as aviation or mining, where deliberate and systematic safety routines must exist, I don’t believe safety is a result of safety routines. It is a product of a wide set of organisational characteristics, but there’s a load of human behavioural factors that have to work right, or all the paperwork in the world is futile.

You can make the hardware as safe as houses, but errors are largely human.

That’s because we do the complex and variable stuff. The hardware just has to perform the same function day in, day out.

Safety in all occupations is largely a function of individual behaviours and decisions, (given that first the environment has to be made safe within the meaning of what is practicable and reasonable). Even when equipment fails, that’s often a failure in design, maintenance or use/abuse. But we can’t blame people.

Generally speaking, people don’t tend to take risks. Either they don’t understand the risk, or, for some reason, they don’t have the means to do it safely or they are under some other pressure to get something done.

Environment To my way of thinking, safety is primarily a collective environment in which humans have the knowledge, time, space, support, processes, tools and equipment to get a job

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March 2013

Protecting your health and safety at works means more than just wearing a pair of ear defenders.

done safely. We can’t manufacture safety culture. It is something I believe arises as a result of doing a lot of things right.

The general concept appears to be that ‘culture’ is glue that holds organisations together – the shared beliefs, behaviours, attitudes and values. Others argue that not all members of the group would respond in the same way in any given situation, so a culture is not a uniform set of behaviours. It will depend on function and purpose of groups and individuals.

In any case, would we want everyone behaving much the same?

However, there appears to be a general consensus that ‘culture’ includes intangible things such as beliefs, ideas, norms, attitudes, roles, practices, characteristics, priorities, shared beliefs, commitment, styles, proficiencies, trust and perceptions etc.

Take a look at those words. Now ask yourself what ‘programme’ can change things such as those.

I would suggest that most organisations introducing a safety culture programme: ● Don’t have a clue what they are talking about. ● Will not achieve it. ● If they get near it, will probably kill it off by strangling it at birth with more programmes, more paper and more corporate twaddle.

The UK Health and Safety Executive appear to have understood the concept better than most. Its definition of safety culture is: “The product of values, attitudes, competencies and patterns of behaviour that determine the commitment to, and the style and proficiency of, an organisation’s safety and health programmes.

“Organisations with a positive safety culture are characterised by communications founded on mutual trust, shared perceptions of the importance of safety and confidence in the efficacy of the preventative measures.”

That word ‘product’ is a key concept in

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SAFETY



my view. A product in that context means several factors have combined together to get a result that is bigger than the sum of all its parts.

If this concept is correct (and it feels right to me), then it is plainly ridiculous to aim for the product. That’s like trying to stack four blocks and three blocks to make 12.

That adds up to seven.

But if you are good at doing each part, they start to multiply exponentially. Then you get a product that you could never have created using building blocks.

How do you get there?

‘Experts’ have come to the conclusion that getting a safety culture is the result of dividing the task into a series of sub goals, such as risk assessments, audits, systems, training, then measuring each of those to find weaknesses and strengthening by process, measurement, process, measurement, process.

Of more use is the model of a dynamic reciprocal relationship between

psychological, behavioural and situational factors. So instead of being solely concerned with shared perceptions and beliefs, it can be argued that safety culture is the product of many interactions between people (psychological), jobs (behavioural) and the organisation (situational).

I have long advocated that there are only two key organisational attributes that really work in health and safety – these are leadership and employee participation. We have to have systems and safe workplaces, but the behaviours of people when they are at work cannot be influenced solely by process and procedure.

All the ‘good stuff’ that has to happen for health and safety at work will always be ‘good stuff’. But where human behaviour is concerned, where is the X factor?

Excellence Here’s my theory: To use a sporting analogy, when a great sports team is on the way up, what did it take to turn that greatness on in the first place? And what does it take to turn

the success into a dynasty? What changes a team from good to great?

It’s not enough to put in place process and procedure. Something else has to happen and it’s not something anyone can create. It’s something that happens when skilled, trained people combine with strong, unequivocal leadership and collaborate to achieve a common goal.

The real rocket fuel happens when the team starts winning and all the players and staff focus confidently on the next success.

Confidence, cooperation, peer support and freedom to act within the agreed aims of the organisation all become aligned.

Without the leadership, without the open and positive lines of communication, without the players supporting and working together, the team would be an also-ran.

This does not necessarily mean the players have to be the best in the world. But they have to have the environment to excel in.

In a nutshell, if you want a strong culture, whether it is safety or quality or innovation, you have to make no compromises, take no prisoners, insist on the best, enable your people, remove barriers to creativity and celebrate your successes.

Participating with employees doesn’t mean you have to be Mr Nice Guy. In fact, you may not gain respect if you are. But it does mean every voice is heard, every person feels they can make a difference, everyone knows they have a role to play and everyone is valued and encouraged to be their best.

Simon Lawrence, director of SafetyPro.

Simon Lawrence is the director of Safety Pro, a provider of health and safety training programmes for all industries.

His tertiary qualifications include BSc (Hons) Environmental Science (University of Plymouth, UK). He worked as the health and safety coordinator for Alcan New Zealand before joining Melbourne based Richard Oliver, a risk management consultancy, in 1991. He launched SafetyPro in 1999.

On the web www.safetypro.co.nz

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SAFETY

Explosion-proof products

Imported Containers For many manufacturers and distribution organisations, unloading imported containers is an everyday occurrence, not attracting any extra special safety concerns.

Increasingly, this is being challenged, as more evidence is accumulating that there are serious safety risks, associated with toxic gases found inside some containers.

Studies in New Zealand, Australia and many other countries, consistently show that around 20 percent of containers have unsafe, sometimes life-threateningly high levels, of a range of toxic gases. These include gases such as fumigants (methyl bromide and phosphine are common) but also gases desorbed from the cargoes (formaldehyde from furniture and other elements, toluene for shoes, Benzene from machinery, etc).

These gases have been classified into a number of health-related categories – none of them what you would want to be breathing in: fumigants are neurotoxins (Canterbury University is investigating the linkage with motor neurone disease), formaldehyde and benzene are carcinogens, and the list goes on.

Customs authorities in a large number of countries have been aware of the presence of toxic gases, and have strict procedures in place, to make sure their staff are not exposed. These procedures include using a gas monitor to check for gas before opening, and then force ventilating the container, if unsafe gases are found. Large multinational companies are also adopting similar procedures.

There are solutions available, and government authorities such as the DOL and EPA are working on ways to keep the business community better informed about the risks, and alternative ways to protect unloading staff.

This risk area, is likely to get a lot more attention in future – forward thinking businesses may want to move ahead of the pack and start considering this sooner rather than later.

• Go to www.demm.co.nz/enquiry quote: D130324b

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March 2013

Since 1968, the Cortem Group has been designing and manufacturing explosionproof electrical equipment for use in hazardous areas.

Thanks to a continuous effort in technical innovation and improvement, the firm is able to provide a range of products and solutions for onshore and offshore applications.

As part of the NHPEx solutions offering, products from Cortem include terminal and control enclosures, custom assemblies, lighting fixtures and plugs and sockets.

With the addition of the Cortem Group’s range of hazardous area components to these already established suppliers and products, NHPEx can deliver one of the most comprehensive ranges of hazardous area solutions.

Combined with Rockwell Automation and NHP’s other supply partners, NHPEx offer a total solution that includes control devices, terminals, distributed I/O, tripwire switches, barriers and sight and sounds products.

“At NHP we can design and build customised assemblies in our Melbourne based IECEx certified workshop which provides shorter lead times and delivers on value to both our New Zealand and Australian customers,” says the firm.

• Go to www.demm.co.nz/enquiry quote: D130324

Personal noise monitor The 3M Noise Indicator alerts users to potentially dangerous noise levels, helping identify areas where hearing protection may need to be worn.

Users simply clip the Noise Indicator to a shirt or jacket; its LED delivers a clear indication when noise levels exceed a potentially hazardous threshold.

Red flashing LED indicates noise levels are equal to or above 85 dBA – hearing protection may be required. Green flashing LED indicates noise levels are below 85dBA – hearing protection may not be necessary.

The 3M Noise Indicator’s small size and lightweight design make it ideal for workers in a variety of industries. With a rechargeable battery that operates for up to 200 hours between charges, it’s an economical investment for use in an employee hearing awareness programme.

The NI-100 can be used as an effective training tool within a noise management programme and to help

ensure workers know when and where to wear hearing protection.

Occupational hygienists and/or safety officers can also use it as a mapping tool to determine where noise studies are necessary.

• Go to www.demm.co.nz/enquiry quote: D130324a

You call us for help

COLENSO0003

Call us for training too

Becoming a competent first aider is more than just getting a certificate. St John First Aid Training has the widest range of courses from First Aid Level 1, to Advanced Resuscitation. We provide Refresher courses, and comply with NZQA requirements. More importantly though, our convenient classes are held by experts with real field experience. Paramedics and event volunteers are our teachers because we know that first aid is more than an academic exercise, it can make the difference between life and death.

stjohn.org.nz/First-Aid

0800 FIRST AID 25

SAFETY

Take machine safety seriously Process automation firm Festo’s safety concept covers not only motors and controllers but axis mechanics.

“While the subject of machine safety is not new, it will continue to play a key role in machine and plant construction,” says Fredrik Stal, the firm’s head of product management electric drives.

“In applications that are not protected by safety guards, but where people can come into direct contact with plant components, all electromechanical systems must have integrated safety functions to guarantee adequate risk reduction.

“Users must be offered an overall safety concept, which supports monitoring of the axis mechanics as well as safety-related clamping or braking.”

Stal says that in the past, operators sometimes had to make do with a retrofitted safety concept. Many would take any safety switching device and wire the STO function. They also replaced the servo motor with a motor with a brake.

“Many machine manufacturers think that this is enough,” he says. “However, this does not take all possible errors into account, as a coupling assembly error or a cracked toothed belt in the reversing unit could render the brake useless.

“These errors would cause the slide unit and the load to fall, causing serious injury.

Furthermore, undetected bearing damage could stretch the toothed belt or damage to the recirculating ball bearing guide could cause the axis to drop by several millimetres after a crash. The slide could

therefore cause crushing.”

Stal believes a fully integrated solution monitors the axis mechanics and allows safety-related clamping or braking.

“This is exactly what the safety-related electric axis EGC with dual-channel displacement encoder and clamping unit from Festo does,” he says.

“The mechanical system can be monitored by a motor encoder (first channel) and a linear displacement encoder (second channel).”

Stal says these drive-related safety functions can be monitored by the certified safety system CMGA for motor controllers.

Conventional safety command devices such as emergency stop switches, protective door switches, light curtains and laser scanners can be connected to the system.

As soon as these trigger a safety requirement, a safety-related stop such as an SS1 or SS2 is triggered via the safety system CMGA or safely limited speed is monitored in set-up mode. For ease of use, there are prevalidated application programs for many machines. These reduce the complexity of a programmable safety system to the simplicity of a safety relay.

The Drager X-am 2000 has been specially designed for personal monitoring. The one to four gas detector reliably measures combustible gases and vapours as well as O2, CO and H2S. In combination with an external pump, the X-am 2000 can be easily adapted to measure confined spaces before entry. Reliable measurement technology, long sensor life and easy operation combine high safety with a low cost of ownership.

For improved safety when facing unknown and potentially explosive hazards – the sensor provides dependable warnings in the event of explosive atmospheres thanks to the high level of sensitivity of the catalytic Ex sensor.

It not only responds quickly to explosive gases and combustible organic vapours, but is also highly resistant against sensor poisons such as silicone and hydrogen sulfide.

The sensor’s resistance, in combination with its long-term stability, provides it with a lifetime in excess of four years, which can help reduce your operational costs.

D130326

D130326a

The safety axis EGC is a fully integrated solution that monitors the axis mechanics and allows safetyrelated clamping or braking.

• Go to www.demm.co.nz/enquiry quote: • Go to www.demm.co.nz/enquiry quote:

Banded earplugs Traditional banded hearing protectors have several major shortcomings relative to other hearing protectors – constant rubbing of the band against equipment and clothing, low attenuation and poor fit.

The E-A-R Swerve from 3M addresses these issues and more.

They feature a contoured design that floats around the neck, limiting contact with collars and helmets/hats.

The contemporary behind-the-head design to encourage compliance among younger workers. Its durable lightweight

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Stay safe with a Drager monitor

band rebounds well for frequent on and off wearing.

Swerve is ideal for workers in dirty environments as there is no need to roll the plugs. The quick insertion and removal also makes it great for managers or supervisors who need to enter and exit noisy environments often.

• Go to www.demm.co.nz/enquiry quote: D130326b

SAFETY

Fall protection

How to accurately assess fire protection needs

DBI-Sala’s FlexiGuard fall protection access systems provide the user with a mobile overhead anchorage point that can be moved around from application to application, ideal for situations where an overhead structure is unreachable or does not exist.

“FlexiGuard has been developed to keep workers as safe as possible when working on heavy duty transportation equipment, loaders, trucks, aircraft, oversized equipment and much more,” says Zoran Nikolić, engineered systems manager for Capital Safety Australia & New Zealand.

“Our team of engineers, operations staff and safety experts are able to ensure you receive the right access solutions for your application.”

With seven access systems in the range, each FlexiGuard solution is dependent on the industry, environment and specific design constraints, including government standards.

“These access systems are robustly built and are typically rated for up to at least two users. Fixed or adjustable in height, they provide an active fall protection solution for a wide range of applications,” says Nikolić.

Each system is delivered with detailed operation manuals and instructions for use tailored specifically to each piece of equipment, site and use.

Although preventing fire is not always possible, being adequately prepared can help to minimise fire damage to people and property.

However, according to fire protection specialist Wormald, many companies continue to make simple mistakes that can affect their level of protection.

“Having basic fire protection equipment is essential for a business or facility of any size but it is important that the correct fire protection equipment is in place”, says Dave Hipkins, technical manager with Wormald.

“For example, a water fire extinguisher should never be used on an electrical switchboard; electrical fires are best treated with powder or carbon dioxide extinguishers.

“Carrying out a comprehensive assessment of the premises will help identify potential fire hazards and help determine the different types of fire protection required – whether it is a basic fire extinguisher or fire hose reel, a sprinkler system, a passive fire solution or a more advanced fire suppression system.”

Wormald’s range of fire suppression systems includes the VanQuish system, a ‘dry’ system specifically designed for cold storage facilities, and the environmentally-friendly Inergen gaseous fire suppression system which is suitable for data centres and facilities housing mission critical equipment.

• Go to www.demm.co.nz/enquiry quote: D130327

Store owner fined after forklift collision A company that previously operated a Taupo supermarket has been fined $22,750 with $15,000 reparation ordered following an accident where a store merchandiser was hit by a forklift – crushing his left foot and severing two of his toes.

The Taupo District Court heard that on 20 February 2012 a visiting merchandiser was restocking shelves at the Pak ’n Save on Ruapehu Street prior to the store opening when a forklift struck him from behind. His left foot was trapped under the wheel causing crush injuries and fractures to his foot and resulting in the amputation of two toes.

The general manager Health and Safety for the Ministry’s Central region, Murray Thompson says: “Although

the defendant had a clear policy on not operating forklifts in store during opening hours and forklifts were identified on the hazard register, these steps did not adequately manage the hazard outside of normal business hours when staff, visitors and forklifts were all working in the same space.

“Prior to the store opening when the shelves are being restocked is a very busy time. The defendant should have identified this and taken steps to segregate people and forklifts with clear instructions to staff and other workers.

“Many businesses work in a high pressure environment. This should not compromise the safety of employees or visitors as was the case here leaving a man seriously injured.”

In addition to having the correct fire protection equipment in place, staff members, particularly those assigned to a company’s fire safety team, should be fully briefed and trained on what to do in the event of a fire.

According to Hipkins, fire wardens have a considerable amount of responsibility for the wellbeing of a building’s occupants but they are often unaware of the full extent of their duties.

“Basic fire safety training should be provided to all staff and it is important that each staff member is aware of the various classes of fire and the appropriate fire equipment to be used for each. Fire wardens should be fully trained on their responsibilities and operation of fire equipment and emergency warning and communication systems in their premises.”

Providing appropriate signage for fire safety equipment is also essential to denote its proper use. Hipkins says: “It is very important that wherever a fire extinguisher or any fire safety equipment is located, the correct signage is next to it so a user knows exactly what it should be used for. It is equally important that fire exit signs are in place so that, in the event of an evacuation, people can be directed to escape potential danger quickly.”

Hipkins also advises that regular servicing and maintenance of fire equipment and fire protection systems helps ensure that they will work appropriately if and when required.

• Go to www.demm.co.nz/enquiry quote: D130327a

27

heat EXCHANGERS

R&D lead to cost savings for all Advance Boiler Services has been working to develop innovative ways to reduce fuel costs and improve the overall operational efficiency of boiler systems. Feed water economisers, for heat recovery, is a proven technology for reducing boiler fuel consumption.

With grants available from EECA this has allowed small to medium-sized boiler owners the opportunity to reduce their plants carbon footprint as well as enabling the waste heat to produce a profitable energy source.

A heat recovery unit has been proposed to one of its clients, a food processing company, to extract the heat energy out of the flue gasses emitted by the boilers.

Advance Boiler Services has worked on a project to design small fin tube heat exchangers for extracting heat energy from flue gases of 2 X 0.9 MW boilers. Theoretical heat and mass transfer calculations were done for predicting rates of heat transfer between water and the flue gasses.

The heat exchangers of 53kWs were

designed to heat the water in a 60,000L tank by circulating it through heat exchangers and saving the need for direct steam input for steam injection, reducing fuel consumption to produce the extra heat load.

It has been working to standardise the heat exchanger size to minimise the capital cost and payback time for other clients.

Some actions offer immediate savings and other associated benefits while others involve an upfront cost that can be recovered within a few months or years. The main aim of their research was to: ● Reduce the amount of energy required to produce hourly steam usage. ● Reduce the amount of pure steam being lost in production. ● Reduce the make-up water requirements. ● Reduce the amount of chemicals required.

Reduce the overall CO and CO2 emissions from the boilers.

Advance Boiler Services (NZ) diversified from servicing boilers to also include the manufacture of heat exchangers in 2003 as a continuation to improving the efficiency

of their clients’ plants.

To date it has supplied heat exchangers to the timber, oil and gas industries, various heat exchangers including for milk powder processing for the dairy industry and air heaters for the food industry in both NZ and Australia.

• Go to www.demm.co.nz/enquiry quote: D130328

Heat is on to deliver cool and fresh The country’s heavy reliance on New Zealand’s food processing industries requires an exceptionally good temperature verses time gradient to ensure products reach both local and overseas markets in premium condition. This is just one industry sector that Steelfort’s Heat Exchange Division produces products for.

The division manufactures Castle, a range of standard unit coolers and a wide variety of finned tube items to meet the specific and technical demands of this market.

In conjunction with the country’s experienced refrigeration engineers, the Steelfort in-house team use a mix of heating and cooling design programs. These programs are interpreted to predict the thermal primary and secondary surface area requirements that are the key parameters for the finned tube radiator block.

The Autodesk Inventor CAD package optimises the sheet metal fabrication portion, to provide complete and professional design packages.

A wealth of knowledge, depth skill and industry experience gained over more than 60 years from direct involvement, has positioned the company to operate equally well in local and export markets.

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March 2013

One product in particular, Air Handler Units (AHUs), combines CAD and Computer Numeric Controlled machinery to produce profiled and contoured panel.

Staff mould these around the stainless steel plate fins on expanded stainless steel tubes and mount the coil block with its stainless steel circuited bends and headers, into stainless steel tube sheets.

The results are a robust and totally

A Castle condenser by Steelfort.

hygienic, easily sanitised product that form a key element with the overall process.

The firm design and manufacture solutions to solve client’s problems. This often required the use of a variety of international safety & design codes. The welders are regularly being tested by third party organisations to ensure they have current welding certification.

• Go to www.demm.co.nz/enquiry quote: D130328a

Air-Handling Units

Produced complete with stainless steel housing and transitions fabricated to meet industry standards Designed to achieve a specified duty and to condition the air to meet individual specifications Can incorporate filters, heaters, chillers and demisters Can be supplied with fan and stand Suitable for corrosive atmosphere Designed to suit site limitations Enquiries to Craig Beissel - Sales Engineer 06 350 1350 027 505 0731 c.beissel@steelfort.co.nz

500 Rangitikei Street Palmerston North • P 06 350 1350 enquiry@steelfort.co.nz • www.steelfort.co.nz Established 1946

29

AUTOMATION

Boxing clever with plastic clips The distinctive clips on Sistema’s plastic containers are well-known in households in New Zealand, and around the world.

They had traditionally been attached on the base of the firm’s plastic boxes, but when it introduced a new range that featured smaller clips attached to the lid, issues in the manual production process led to the search for an automated solution – to lower costs and increase efficiency.

Sistema’s engineering manager Oliver Jensen says that while the company is always looking for ways to keep costs down through automation, there were a few other reasons for prioritising the automation of the lid clipping process.

“It was actually quite difficult for workers to physically apply the clips to the lids,” he says. “The clipping process is also run offline, which means the lids are moulded and sealed first. They are then collected and clipped separately, meaning one automation solution would work for multiple products, as opposed to being restricted to one line.”

Having already worked with Sistema to install a camera-guided robotic labelling system, ControlVision was tasked with integrating the hardware and software to enable the automation of the clipping process.

A major challenge of the project was ensuring precise accuracy for the clip placement while maintaining a high speed on a moving conveyor, as there was a tolerance of less than 0.5mm for the clip to be successfully applied. It was also vital that the system could handle a wide range of lid sizes and shapes, as well as different clip colours.

In the system, two conveyor belts carry the lids and clips separately in parallel.

Encoder feedback is employed to enable the accurate tracking of the clips and lids on the moving conveyors.

Upstream of the robots, a Basler Scout scA640-74gm camera captures an image of the clip, which is sent to the VisionServer software to determine its position. Once the position is determined, VisionServer guides one of the Dual Adept Cobra s600 robots into picking up the clip.

A separate, higher resolution camera then captures an image of a corresponding lid, which is also processed by the VisionServer software to locate its position. This guides the robot into applying the clip, and the process is

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repeated for the second clip. As all lids have either three or four clips, the second robot applies the third and/or fourth clip downstream.

As well as managing the robot cell, ControlVision’s VisionServer framework also acts as the human-machine interface (HMI) for the system, enabling easy configuration of parameters and monitoring of the whole operation.

Since the clipper has been installed, clips are now applied to lids at a rate of one every two seconds. This equates to double the output of the previous process, with operators now able to run twice the volume of product.

“There’s no product changeover procedure, any lid on the conveyor can be clipped since the system looks for any clip position on a lid, regardless of the shape

or size. For example, even if we were doing a run of round lids, if there was a square lid placed in between them, the clips would still be applied,” says Jensen.

Thanks to the success of this technically challenging project, Jensen says Sistema is now considering the installation of additional camera-guided robot clippers to further production lines.

• Go to www.demm.co.nz/enquiry quote: D130330

Extreme cables from Treotham Automation H07RN-F cables from Treotham Automation are reticulated elastomer insulated and sheathed, flexible Class 5 cables that are designed to supply power to electric motors and many other types of electrical equipment.

Due to their extreme flexibility and high mechanical strength, H07RN-F cables are ideal for power transmission in both fixed and mobile installations and have the capacity to withstand weathering, oils, greases, mechanical and also thermal stresses.

Other applications include materials handling equipment, mobile power supplies, drainage, water treatment and extreme industrial environments.

H07RN-F cables are manufactured using compounds with higher service temperature and voltage resistance than those indicated in international standards, with nominal voltages of up to 1000 V being possible due to the high dielectric properties of the cable insulation material.

These cables feature Class 5 flexible plain copper to BS EN 60228:2005 (previously BS6360), insulated with EPR (Ethylene Propylene Rubber) Type EI4 to BS7655, a PCP (Polychloroprene) Type EM2 to BS7655 sheath and have a conductor operating temperature -30°C to +60°C (85°C max).

•

Go to www.demm.co.nz/ enquiry quote: D130330a

AUTOMATION

Aussie dairy firm gets a lift Machines and software that help companies automate their production lines are getting faster, smarter and cheaper.

That’s the view of Alex Van Dijk, sales and marketing, at RML Engineering in Hamilton. He says automation technology is changing rapidly as robots are becoming more nimble and cameras are used more often as the ‘eyes’ of the machine.

“Machines such as case packers are getting a lot more intuitive,” he says.

“There are a lot more cameras being used, and the sensors are becoming more perceptive.”

One machine the firm recently designed and built for Fletchers was to help the firm stack roof tiles more quickly.

“The tiles, as they are presented to the machine, can appear before it at any angle and at different heights… the machine literally has to find the tiles, pick them up and stack them correctly. Packing machines use a range of lasers and sensors to determine how to complete the task.”

Among the firm’s clients is drinks firm Lion Dairy in Sydney, which bought two of its p255 top load carton packers. These machines were based on a modified design that handle a range of different bag and box sizes.

Both machines are set up to handle the customer’s initial 10-litre bladder format of dairy product into a freshly plucked and erected box. These are glue closed and elevated to the outfeed.

Van Dijk says by integrating the elevators into the case packer frame, his firm was able to provide Lion Dairy with a more compact and cost effective solution to replace an older machine that had been supplied by another firm.

“Our machines are capable of running at up to 18 boxes a minute, but these were de-rated to 15 a minute to meet project requirements,” he says. “The Lion Dairy case packers are reasonably simple, but we were able to design the machine to meet a specific requirement.

“In this case, the client needed the cases exited at a high level – so our machine has a built in elevator. This meant it had a small footprint, saving the client space on the floor, it also gave it a price advantage over having two separate machines – you only need to guard one section of it instead of two.

“Because we have been in business for over 30 years, and have so much

experience in automating production lines, when any company comes to us – be they food or pharmaceutical, etc – we can help. We have a portfolio of standard machines that can be tailored to almost any purpose.

“Our machines have to be flexible because they are frequently used for more than one purpose by our clients. In Europe, companies may have a machine dedicated to doing one thing, they have the volume to do that. But here, and in Australia, volumes are smaller, so more is needed from machines that do automated processes.

“In Europe, companies may have a machine dedicated to doing one thing, they have the volume to do that. But here, and in Australia, volumes are smaller, so more is needed from machines that do automated processes.”

– Alex Van Dijk, sales and marketing, RML Engineering.

“With Lion Dairy, we started off with a standard machine, but there was quite a lot of modifications done, to reconfigure them, so they did the job required. This saves money and means we can get machines delivered more quickly than starting with a blank sheet of paper.”

Elsewhere the firm has supplied machines to Nestlé’s Cambria Park factory in Auckland.

Its automated production line includes a number of specially made machines from RML that include tub conveying, tub inverting and blowing, barcode checking, police stop gating, settling vibration equipment, check weigh reject, and lidding equipment.

RML not only designs and builds its machines, it writes its own software to run them too.

“If we have software that has run a similar machine in the past we will grab it and modify it,” says Van Dijk.

“Everything is done in-house, except painting and laser cutting.”

Before delivery, the firm’s machines are fully tested using dummy stock

By Steve Hart

RML’s automation manager Daryl Joyce checks over case packer wiring installation.

from clients.

“The Lion Dairy job meant we completed a factory acceptance trial, with the client present,” says Van Dijk.

“What we want to avoid doing is installing a machine, particularly in another country, and then having to work on it on-site, in a live factory. We ask the client visit our factory, see it in operation and sign it off as acceptable.

That means that when a machine leaves New Zealand we know for a fact that it is a proven machine.”

Van Dijk says while the future is exciting for the automation industry, finding the staff to design, build and code the software needed has been challenging.

“If we put an advert out there we get lots of responses, but it is key to our business to have really high calibre people,” he says.

“Nowadays we partner with universities such as Waikato, and offer placements to students during summer. We get smart people, and start them off with our ideas.

Some of our best people have started here as graduates, we have a graduate programme and are always investing in the future.”

• Go to www.demm.co.nz/enquiry quote: D130331

Two RML robotic packing machines undergo factory acceptance testing (FAT) in Hamilton workshop prior to delivery.

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AUTOMATION

TechnoWrapp hits the big 50 TechnoWrapp has celebrated the installation of its stretch wrapping machines across every continent of the world – reaching 50 different countries.

The firm manufactures a range of wrapping machinery for palletised loads including turntable, rotating arm and rotating ring machines with and without top sheets for covering the load.

The B300 machine is the latest edition to its product range and is claimed by the firm to be the fastest rotary arm wrapping machine currently available, and has an arm with a patented ring guide that rotates around the load at 45rpm, wrapping 130 pallets an hour with 10 wraps for each pallet. The ring

is floor mounted to assist the rotary arm during rotation.

The machine contains an EP-V1 electronic pre-stretch system with a tacho generator adjustable from the HMI touchscreen that enables smooth dispensing of the film and a high degree of pre-stretch.

Technowrapp stretch wrapping machines are designed to keep film usage to a minimum, which is achieved by pre-stretching the film by more than 400 per cent. On a pallet measuring 800mm x 1200mm x 1500mm high, using nine layers of film and a standard film reel of 500mm wide x 23µm: only 96 grams of film is used.

Its patented Syncro device enables the clamping, cutting and welding of the film

while in motion, which saves considerable time as the film is cut and sealed while it is being removed from the wrapping area.

As the pallet / load is static, the stability and integrity of the stack is maintained during the high speed wrapping process.

• Go to www.demm.co.nz/enquiry quote: D130332

Embedded PC for motion control The new CX9020 Embedded PC represents remarkably compact, state-of-the-art PC Control. The fanless unit is equipped with a powerful 1GHz ARM Cortex A8 processor, 1GB RAM and is suitable for a wide range of PLC and motion control applications in small and medium-sized machines, systems or buildings.

The Embedded PC integrates a CPU, numerous IT connectivity solutions and optional interfaces, a power supply and a direct I/O interface for Beckhoff I/O systems, all in a compact housing.

In combination with the TwinCAT automation software platform from Beckhoff, the CX9020 system becomes

a high-performance PLC and motion controller that can be used with or without visualisation.

It uses the Microsoft Windows Embedded Compact 7 operating system. The extended operating temperature range between -25 +60°C enables application in demanding environments covering a wide range of manufacturing facility types and outdoor applications, including wind turbines and solar power plants.

• Go to www.demm.co.nz/enquiry quote:

D130332a

High-speed wide mouth jar cutting Maer of Girona Spain, specialists in the design and manufacturer of high-speed rotary trimmers for neck cutting of plastic bottles and containers, has released the WM500 TC 10 rotary cutting machine for the high-speed, low-cost production of PET large mouth containers for products such as mayonnaise and sauces.

The WM500 TC is designed to cut off the dome of a PET container that was produced for Blow-trim technology.

This technology allows for the efficient and low-cost production of wide mouth containers by using standard narrowneck pre-forms, eliminating expensive injection mould tooling and saving energy, resins and cycle times.

The wide mouth finish is built into the

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same bottle mould rather than into the pre-form. The blow moulded jar has two portions: the threaded neck finish and an upper dome that is removed in an online process. This provides processors with a lightweight, unbreakable jar alternative to those made of glass.

The new machine has outstanding

versatility, as it enables the handling of containers that do not require cutting to pass through the online machine, saving a bypass of the cutting machine. It can process necks with diameters ranging from 45mm up to 110mm.

• Go to www.demm.co.nz/enquiry quote: D130332b

There is nothing more enduring than stainless steel AT THOMPSON HUTTON ELECTRICAL WE SPECIALISE IN STAINLESS STEEL CABINETS, CONTROL ENCLOSURES AND PUSH-BUTTON BOXES. WE SUPPLY NATIONWIDE. NEW ZEALAND’S LEADING MANUFACTURER AND STOCKIST OF STAINLESS STEEL ENCLOSURES Thompson Hutton Electrical have been in the Stainless Steel enclosure business for 28 years.

Our products and designs have been time tested in the harsh New Zealand environment.

Through continuous improvement we continue to bring new and better products to the New Zealand market.

● Custom cabinets and enclosures ● Switch Panels ● Control Enclosures ● Push-button Boxes

FOR USE IN THESE AND OTHER INDUSTRIES: ● Dairy ● Beverages ● Food processing ● Meat ● Wine ● Brewing ● Pulp & paper ● Electrical ● Automation ● Electronic ● Water treatment ● Sewerage ● Chemical ● Pharmaceutical

THOMPSON HUTTON ELECTRICAL 2007 LTD PHONE: 09 276 7511 Email: info@thompsonstainless.co.nz

Web:www.thompsonstainless.co.nz

33

MAINTENANCE MATTERS

Reduced wind turbine maintenance with carbon brush holder A carbon brush holder, set to reduce maintenance costs for doubly fed generators in wind turbines, is being introduced by Carbex.

The Carbex V-type brush holder ensures that all the carbon brushes push against the slip ring with equal force, preventing uneven wear and premature brush replacement. This also reduces electrical and mechanical losses, lowering the temperature of the carbon brushes and improving their lubricating properties. In addition, remote monitoring is simplified, as only one switch per phase is required.

A traditional brush holder set-up includes

a number of brushes that are fitted around the slip ring and adjusted individually.

Brushes typically wear unevenly as each has different pressure against the slip ring. The V-type holder eliminates these variations.

The brushes are fitted and locked into position in single brush pockets. Through equal load on all carbon brushes, and lower temperature, the V-type holder gives longer life to the brushes, resulting in longer service intervals.

The design of the V-type holder simplifies fitting and facilitates service, saving time while on site. The compact holder is located

just inside the inspection hatch of the slip ring compartment for easy access. Only one adjustment is required for the holder. There is no need to adjust the angle and contact surface of the individual brushes.

The design is modified for the requirements of each OEM to fit the existing bolt holes in the shield.

The metal parts are machined, which means tooling costs are eliminated for the OEM. The V-type holder is designed to offer the lowest life cycle cost possible, from the factory to service on site.

•

Go to www.demm.co.nz/enquiry quote: D130334

Productivity potential revealed at process heat workshop Business commentator Rod Oram explained how energy efficiency can fuel business innovation and growth at an EECA Business process heat workshop, on 12 February in Auckland.

Using energy worth more than $2 billion dollars every year, process heat systems (furnaces, boilers and ovens) are used in most industries – from bread making to milk powder production, and timber processing.

EECA business project manager Pramesh Maharaj says improved process heat systems efficiency is one of the biggest opportunities for New Zealand manufacturers to make cost savings, increase productivity and enhance green credentials.

“The workshop was a great success,” he says. “Having more than 50 process heat users and energy efficiency experts sharing their experiences and knowledge really helped raise awareness of the opportunities in process heat.

“Participants particularly enjoyed hearing Rod Oram explain how process heat energy efficiency connects to the big picture for the national economy.”

Oram also spoke about the critical need for senior level executives, particularly CEOs and CFOs, to make energy efficiency a business priority.

The workshop included case study presentations from companies that have benefited from improved process heat efficiency.

Highlights included wood

ARE YOUR STAFF NOT ‘GETTING’ IT? IS MAINTENANCE MANAGEMENT OR HEALTH AND SAFETY GIVING YOU A HEADACHE? Unlock your staff’s potential with either of our inspiring and informative short course training sessions: •Maintenance Management Basic Training or •Health and Safety Made Simple From only $220 + GST per person check our website for details and session dates

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March 2013

processor Nelson Pine, that saved more than $2.5 million in two years through improved process efficiency and reduced heat wastage; and Energy Plant Solutions, Business commentator Rod Oram speaking which recently at the EECA Business installed a 95 process heat workshop in February. percent efficient boiler and heat recovery system for a new milk powder near Balclutha.

Pramesh Maharaj says EECA Business expects to hold similar workshops over the coming months.

•

Go to www.demm.co.nz/enquiry quote: D130334b

Identifying potential fuel problems Fuel is often overlooked as a key component of equipment, but as fuel costs increase and the challenges that widely varying climate in our country produces, keeping fuel in your storage tanks and dispensing systems free of contamination and in excellent condition is becoming even more important.

Modern engines are highly sensitive to the fuel quality and machine efficiency rapidly declines if poor or contaminated fuel is used.

The Gough Analytical fuel analysis programme provides an expert review of fuel condition, identifying any impurities and biological, fungal or bacterial growth

that could lead blockages or component damage, resulting in poor operational performance and reliability issues.

In addition to the firm’s standard tests, it offers a more detailed rapid analysis on diesel fuel oils. Diesel is an organic fuel, providing an ideal environment for microscopic fungi, yeast and bacteria to feed and grow. With specialised testing developed in the aviation industry now available for other applications we are able to rapidly pinpoint poor fuel condition and its causes, help you go get keep your assets working hard.

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MAINTENANCE MATTERS

National Conference issues call for papers

By Craig Carlyle, secretary MESNZ. The Maintenance Engineering Society (MESNZ) is a non-profit society run entirely by volunteers who squeeze their society time between the pressures and responsibilities of the real world.

You would think that the Christmas/ New Year period would mean that not much would be achieved by these fine gentlemen (and ladies).

Well, you would be wrong.

While the rest of the world was focused on the endless summer, the team at MESNZ has been busy working on its services and resources.

Incoming committee chairman Karl Hayward is juggling his new responsibilities along with his newsletter responsibilities. Glen Pepper and Larry Wiechern are laying out the Network Evening schedule, while Dr James Neale is doing the same for the Webinar Series.

Enquiries are already rolling in for the MESNZ Engineering Scholarship and edu-guru Bill Sole is preparing the 2014 programme in readiness for prospective participants.

The showstopper of course is the 2013 SKF National Maintenance Engineering Conference. Planning for this (and the 2014 event) started as patrons were leaving the 2012 event and has continued in earnest since then.

Exhibition demand is unprecedented for 2013 with a dozen exhibitors

signed up already and even though the organisers have rehashed the layout to allow more exhibitors, you can bet your grandmother’s bingo money that the “House Full” signs will be hoisted again this year.

Sponsorship spots are in hot demand too, with SKF again grabbing the coveted premium spot of event sponsor.

With a long and respected history of participation and support for engineers and our national conference, SKF stepped up to the plate to ensure the society keeps delivering. If you see someone on a bus with a SKF shirt on, give up your seat for them; they are heroes.

The speaking schedule has been laid out, Barry Robinson and Larry Wiechern head up the team seeking presenters and papers. Approximately 13 papers will be presented, all with an holistic relationship to maintenance and line management.

The topics are drawn from a mix of subjects representing the technical, line management, operations and business responsibilities facing engineers in modern industry: Preventative Maintenance, Maintenance Management, Technical Generic/ Case Study, Training, Business Case Management, HR/Team/Employee Management, Employment Law, and Health and Safety/Compliance.

The emphasis is on brevity and enlightenment, with a focus on case studies and peer experiences.

While the framework for the 2013 event is already well underway, opportunities exist for your suggestions.

If you would like to nominate a speaker or topic, we are always keen to listen, or if you think you have would like to contribute with a case study based paper, you can download our Speaker Pack on the conference “call for papers” webpage: www.mesnz.org.nz/nmec/ call-for-papers.asp. Contact details for Barry Robinson and Larry Wiechern can also be found on the same page.

The society has made a conscious decision to retain the conference in Rotorua, retaining the newly renovated Novotel Lakeside venue for the November 12 and 13 conference.

Registrations are open for exhibitors and attendees and can be found on the website (www.mesnz.org.nz\nmec\) or by contacting event manager Leanne Powley on (09) 296 1333, info@adminoncall.co.nz So, you can’t say you haven’t been warned. Check out the new look conference web pages, put a circle around 12 - 13 November, get your registration under the nose of your boss now before his holiday bliss evaporates, and look out for the newsletter and scholarship.

SKF Reliability Systems Excellence in Reliability Solutions

Engineering Solutions With over 100 years of global expertise, SKF Engineers can tap into a wealth of knowledge across all industrial segments and applications. Our qualified engineers can assist in redesigning assets through • bearings - modelling applications using new and approved SKF solutions seals - designing and manufacturing to suit your application • lubrication - running calculations to ensure the right grease is being used at the right quantities at the right intervals • power transmission - running calculations to ensure your drives are energy efficient,

SKF’s Engineering team understand maintenance, which works well with Proactive and Predictive Maintenance. It is one thing to know when bearings are going to fail but for SKF it’s important to understand why they failed and establish the root cause, because only then can the problem be eliminated or prevented from happening again. After which SKF can redesign these assets, if necessary, to ensure longer life and better reliability.

Other Services available: • Reliability Training Solutions • Maintenance Strategy Design • Asset Management Services

• Proactive Reliability Maintenance • Integrated Condition Monitoring • Remote Diagnostic Centre

For further information contact your local SKF Authorised Distributor or email marketing.skfnz@skf.com

www.skf.co.nz 35

MAINTENANCE MATTERS

Get out of a tight spot One of the time-consuming tasks facing energy and engineering contractors during maintenance shutdowns is how to quickly, safely and cost-efficiently break open the multitude of hydraulic cylinders found on excavators, dump trucks and mobile and static plant.

While it is important to regularly inspect such cylinders to avoid breakdowns and production hold-ups, it is often difficult to break them open with standard wrenches that cannot generate enough torque.

Hydratight, which employs light (21.25kg) but powerful torque multipliers of a proven design originally developed to turn the heavy turbines of aircraft engines in one solution.

The Hydratight Model 8200 torque multiplier provides 16262 Nm ((12000 ft lbs) rated output capacity – in a compact tool only 432mm long, 318mm wide and 178mm high, which can fit readily into most maintenance spaces and is easy to handle without operator stress.

When downtime can cost millions By Tobias Wolf.

“These tools have terrific and precise power and precision, coming from a range of products used to service military and civil aircraft ranging from the joint strike fighter and C130 Hercules, to Boeing airlines up to the 787,” says Hydratight business development manager – mining, Mark Leggott.

“The tool’s unique design enables more torque to be transferred with less weight, enhancing safety and ease of use. The unique design also extends the life of the tool, enhancing reliability where it is applied in the workshop or on-site.”

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Go to www.demm.co.nz/enquiry quote: D130336

Modern steel plants around the world are producing myriad steel variations and alloys to keep pace with the enormous global demand for this metal.

Generally these large systems comprised of heavy machinery are, or must be, operated around the clock in three shifts seven days a week. Shutting off or shutting down the system for scheduled maintenance of individual components, e.g. motors, gearboxes or couplings, is generally avoided because a so-called ‘freeze-up’ condition of the system (e.g. slag bath) must be prevented. Therefore, maintenance free components are used to the extent that it is possible.

For the most part, the system is safe in normal operation. But what happens beyond the scope of normal operation?

In these cases it is the profitability of the entire system that is at stake.

Such large systems made up of heavy



Leaders in Strategic Asset Management Is the management and maintenance of your assets critical to your business objectives?

Do you need to drive down asset related costs and improve performance?

Do you need to control safety and operational risk?

Your Partners in Excellence The Asset Partnership NZ is amongst New Zealand’s leading Maintenance and Operations Management consulting organisations. We specialise in helping our clients make efficient and effective use of their investments in physical assets.

What We Do We work with our clients to improve Asset Management, Maintenance, Production, Engineering and Supply Chain processes. We achieve rapid results by working with people in positions of influence within such processes and instil skills and transform organisational culture to create ongoing value.

So, whether you require up-skilling through one of our world class training courses, or your organisation is embarking on a significant process improvement programme, The Asset Partnership NZ can help you leverage best practice using our vast experience.

guy.brandon@assetpartnership.com

36

March 2013

M: 021-543605

www.assetpartnership.com

MAINTENANCE MATTERS



machines must be put back into operation as quickly as possible. This is where a mechanical safety coupling from R+W Couplings offers maximum protection against destruction of components in the drive train.

The specification for such a safety coupling is sized for a factor of 1.3 – 2.0, for example, over the motor’s pull-out torque or pull-up torque. Should a crash occur during normal operation, the instantaneous torque in the drive train increases over-proportionately.

The coupling is able to disengage the crash side from the side still intact within a matter of milliseconds, preventing a complete outage of all components.

Because of the safety coupling’s rapid separation, the maintenance crew will most likely only have to make a single replacement or, better yet, simply clear the jam. The coupling’s maintenance free design, above all in combination with its re-engaging function, makes the system’s return to normal operation possible in a remarkably small amount of time.

For such crash situations, the engineer has a choice between shear pin couplings or hydraulic couplings.

Their disadvantages in comparison to mechanical safety couplings from R+W are distinct. A shear pin coupling is less expensive to buy but it also requires a great deal more time to put back into operation. The pins (and usually their bushings too) must be completely removed.

Afterwards the coupling must be adjusted again before new pins and bushings can be inserted, all at the expense of enormous maintenance overhead. This type of coupling also requires very experienced maintenance personnel because an incorrectly performed repair will cause the coupling to disengage at incorrect torque levels in the future.

These difficulties add up to extreme costs in the event of a stoppage. An overload coupling operating on a hydraulic principle has the advantage of an extremely compact design.

If the coupling disengages due to an overload, multiple safety valves will be blown out of the coupling by oil under pressures of up to 1,000 bar. The contamination of machine components in the vicinity of the coupling is considerable.

After the system is at a standstill, these individual valves must be replaced and then the coupling must be refilled with oil injected by a special pump, precisely controlling oil pressure to determine the proper disengagement torque. Such hydraulic safety couplings do indeed separate the drive and driven components at the rated torque in the event of an overload, but attached components are able to free-wheel only after a certain delay, occasionally leading to additional component damage.

Under some circumstances this delay can lead to additional component damage. In the design of the R+W mechanical safety coupling, all of these disadvantages were examined and addressed. The R+W functional principle, using disc springs, puts the torque limiter back into operation immediately.

There is no need to replace any expendable parts like pins or valves. Furthermore a disengagement event does not spray hydraulic oil onto adjacent components. But the most important factor is, maintenance personnel and the system’s operating authority have 100 percent assurance the coupling will again disengage the next time a problem arises, and at exactly the same torque, and without the possibility of putting the coupling back into service incorrectly.

ISN S

PHERICAL ROLLER BEARINGS with patented DODGE IMPERIAL™ adaptor mount system for damage free shafting and easy 15 minute mounting.

30 to 140mm

Premium sealing and 100% contact up to ±1 degree of misalignment.

E-Z KLEEN™

BALL BEARINGS FOR FOOD/BEVERAGE

Polymer or Stainless Steel FDA/ USDA Approved Bearings ¾" to 2" and 20 to 50mm.

PARA-FLEX™ SHAFT COUPLINGS

Fast and easy installation with patented GRIP-TIGHT™ shaft mounting, high misalignment and vibration tolerance plus a 5 year element warranty

★ Assembled to Order – Many Options ★ Input – Motorised • C-face for NEMA/IEC motor • Solid Shaft ★ Output – Solid Shaft and B5/B14 Flange • Hollow (straight or tapered) • Single/Double Shaft • Shrink Disc ★ 0.18 to 55kW

Distributed throughout New Zealand by

www.johnbrooks.co.nz

Christchurch 0800 37 38 39

Auckland 0800 48 49 50

Wellington 0800 24 34 44

Tobias Wolf is a product manager at R+W Couplings.

37

Reliable power supplies and commercially viable circuit design Faults in production are difficult to eliminate in their entirety – for example, short circuits may appear in the wiring, or consumers may experience malfunctions. Ideally, the machine or plant should be able to continue operation without interruption.

The fuse protection on the secondary side of the 24V power supply plays an important role in this. Thanks to the SFB technology provided by Phoenix Contact’s Quint Power power supplies and matching circuit breakers, production can continue unabated.

Parallel to the control system, a number of other consumers, such as sensors and actuators, may be connected to the power supply. In order to minimise downtimes, each circuit should be protected individually. When a short circuit occurs, only the faulty circuit is disconnected from the power supply and the control system continues to operate without interruption.

Commercially-available circuit breakers are the most economical solution for this.

These can trip electromagnetically or thermally via a bimetallic strip. If it is to trip within just a few milliseconds, the integrated solenoid requires a significantly higher current than the rated current of the circuit breaker.

Manufacturers usually specify AC currents for the short-circuit currents required for electromagnetic tripping.

Users must take into account that when compared to AC applications, the DC values are higher by a factor of 1.2.

Circuit breakers are available with different trip characteristics, whereby in the industrial environment, circuit breakers with either a B or C characteristic are used the most. Characteristic B requires three to five times the rated current of the circuit breaker for AC, and three to six times the current for DC applications. Therefore, 150A is required for a 25A circuit breaker with a B characteristic in order to trip under unfavourable conditions within just a few milliseconds. The C characteristic requires five to 10 times the rated current for AC, and five to 12 times the current for DC applications.

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March 2013

Reliably tripped When power supplies only provide a low power reserve, this causes thermal tripping, which can last several seconds or even minutes. A tripped circuit breaker makes fault finding easy. However, within this time, the 24V DC voltage of the power supply has already dipped and the control system failed.

In the worst case, the power supply supplies a current that is too low or only provides a brief current reserve of just a few seconds. In this case, the circuit breaker does not trip and fault finding turns out to be time-consuming and costly.

Phoenix Contact’s Quint Power power supplies feature SFB (selective fuse breaking) technology, which means they trip magnetically. A module with rated values of 24V and 20A, for instance, supplies one control system and three additional loads.

Each circuit is protected using a 6A circuit breaker with a B characteristic.

The 25m copper cables have a diameter of 2.5mm².

If, in this example, a short circuit occurs at the display because of a damaged cable, using its SFB technology, the 20A power supply briefly supplies six times the rated current, i.e., a maximum of 120A. The circuit breaker reliably trips at 10 times the rated current in the magnetic

range of its characteristic. The circuit breaker involved trips within 3 to 5ms, while the other loads continue to operate uninterrupted.

In spite of the short circuit that has occurred, the control system is continuously supplied with 24V DC and continues to operate without any interruption.

Tripping time Whether a circuit breaker trips fast enough depends, among other things, on the length and diameter of the cable that is used to connect the load. In this case, it is not just the high current that the power supplies can provide which is decisive.

The high current can only flow during the short circuit and magnetically trip the circuit breaker if the impedance of the faulty circuit is low enough. Which power supply with which cable diameter and which cable length immediately trips the circuit breaker is shown in a table.

This simplifies the design of the machine or plant.

As a wide range of different consumers are available on the market, it can be a challenging task to find the right type of circuit breaker protection. In practice, circuit breakers are often oversized, as the matching current rating is not offered with the B characteristic. Circuit breakers with a C characteristic are used instead.

ups

However, these are significantly slower to respond, and the cable lengths need to be minimized accordingly.

Phoenix Contact’s new CB type circuit breakers are based on the SFB characteristic curve. This characteristic was developed specifically for Quint Power SFB type power supplies in order to trip even more quickly and reliably.

The characteristic curve is based on the C characteristic but has a much lower tolerance so that there is less short-circuit current. This lessens the load on the cables and on the connected consumers.

Cable distances can also be longer, as the decreased tripping current is not limited by the cable resistance so soon.

The SFB-matched circuit breakers trip reliably even when the cable distances are very large or the cable diameters very low. Compared to conventional circuit

a component width of just 12.3mm, feature an integrated signalling contact to report the current machine or plant status. The new system is complemented by the bridging concept of the Clipline Complete range of terminal blocks. Fast and easy connection is ensured through push-in technology.

breakers with a C characteristic, the cable distances can be up to 30 percent longer.

If, for example, a 2A circuit breaker with a C characteristic is required, the current caused by a short circuit will be no more than 24A. To ensure reliable tripping, the distance between the power supply and the consumers should be no more than 14m with a 1mm² copper cable. If a 2A circuit breaker with the new SFB characteristic is used, on the other hand, it takes only 20A to trip in time.

The cable distance can therefore be extended to 18m. Sensors and actuators are frequently preassembled, with cable diameters as low as 0.22mm² or 0.34mm².

This greatly limits the available distances, and the necessary protection is usually not given anymore.

The new circuit breakers, which have

Conclusion In order to trigger circuit breakers magnetically, and thus quickly, SFB technology delivers a current that is six times higher than the rated current for 12ms. Faulty current paths are selectively turned off, the fault is localised, and important system components remain operational. Especially when extremely long cables are being used.

•

Go to www.demm.co.nz/enquiry quote: D130338

Riello UPS expands its master HP series Riello UPS now includes a higher input 600kVA model in its popular range of Master HP series UPS. Already chosen by hundreds of companies and organisations to power the world’s data centres and installations, this range is ideal for power protection of corporate wide, large network and industrial applications.

Thanks to the double conversion on-line technology achieved with IGBT and DSP control, and with particular attention given to energy efficiency, reliability and compactness, the Master HP 600 model is one of the most compact UPS available today.

The ‘Smart Active’ function allows the unit to monitor the condition of the mains power, and then selects the best operating mode to maintain resilience whilst increasing operational efficiency to 99 percent.

When in a parallel redundant configuration, the energy-saving function allows the intelligent management of energy consumption with a gradual activation of the UPS modules, depending on the actual needs of the load.

• Go to www.demm.co.nz/enquiry quote:

D130339

Mission critical users demand high reliability The Ablerex UPS range is a highquality cost-effective solution from Electrotest Ltd for mission critical users who demand high reliability, availability, and performance for critical electronic equipment and computer loads.

These UPS’s feature double conversion True Online Technology, field-proven full Digital Signal Processor (DSP), and utilise uniquely patented inverter control technology.

With a pure sine wave output for compatibility with all kinds of loads, this range also feature unity input power factor to meet today’s standard for energy saving and ref lected harmonic pollution, ECO mode for

high efficiency to save power, zero or near-zero transfer times to prevent load interruption, and the i-batt feature to prevent deep discharge of batteries.

The UPS’s can be either tower or rack mount configuration and come standard with monitoring and shutdown software. Network monitoring is available thru the optional SNMP cards and the user can be alerted via SMS & E-mail to issues on their network.

Extended runtimes are no problem with the addition of matching battery cabinets and maintenance is a breeze with a modular system design and hot swappable batteries.

•

Go to www.demm.co.nz/enquiry quote: D130339a

39

Singer ready to celebrate its Diamond Jubilee

World’s first USB 3.0 oscilloscopes launched The first PC oscilloscopes with a USB 3 interface have been released by Pico Technology.

“USB three ports are appearing on most new computers and laptops,” says the firm’s managing director, Alan Tong.

“Buyers of USB oscilloscopes will expect to benefit from the higher data transfer rate. With the new PicoScopes, large data captures and streaming of large data sets are now much faster.”

The PicoScope 3207A is a two channel USB oscilloscope with 250 MHz bandwidth, 1 GS/s sampling rate, 256 MS buffer memory and a built-in function generator.

Basic timebase accuracy is ±2 ppm.

Other features include digital triggering for accurate, stable waveform display, and equivalent-time sampling, which boosts the effective sampling rate to 10 GS/s for repetitive signals.

The PicoScope 3207B has 512 MS buffer memory and an additional 32k-sample arbitrary waveform generator with 100 MS/s update rate. As the scope obtains its power from the USB port, there is no need for an external power adaptor.

The oscilloscopes are supplied with the PicoScope software for Windows, which turns your computer into a powerful oscilloscope and spectrum analyser. The software includes many advanced features such as automatic measurements, serial decoding of RS232/UART, SPI, I2C, CAN, LIN and FlexRay data, and mask limit testing, that are only available as expensive add-ons for most competing scopes.

Software updates are free of charge.

A free software development kit (SDK) is also available for those who wish to write their own data-acquisition programs.

Example code in a number of languages is included.

The PicoScope 3207A and 3207B USB 3.0 oscilloscopes, available from Metermaster, are priced at only $2,360.00 and $2,564.00 (+GST) including a set of two probes.

•

Go to www.demm.co.nz/enquiry quote: D130340

40

March 2013

North Island’s leading, locally-owned electrical contractor, the Singer Group, will celebrate its diamond jubilee in November.

CEO Jeff Mclaren joined the company some 13 years ago and for the last seven years has been in control of the company’s direction.

A ‘maintenance man’ through-andthrough, Waikato-educated and trained Mclaren has considerable experience in all sectors of the North Island electrical industry from power generation, through industrial and large-scale projects to retail and commercial. He has pioneered projects to train apprentices in partnership with large industrial employers, and recently launched a programme to upskill those part-time workers, available for shutdown’ work at large facilities; to increase their marketability and mobility – to lead to more regular employment.

In the Waikato, a Singer specialist electrical and mechanical mobile workforce ‘takes its workshop with it’ to effect faster repairs and cut downtime.

In recent years, Mclaren has developed a reputation as the ‘go-to’ man for wining major contracts like the University of Auckland’s Business School, the Eden Park upgrade, massive data centres, hospitals, educational and government facilities, and many major commercial buildings in the Auckland and Hamilton CBD. The company has long-standing relationships with a wide range of organisations including Genesis Energy, Contact Energy, the Universities of Auckland and Waikato, Progressive Food Enterprises, Air New Zealand and many other household names, as well as specialist appointments with two of the world’s three leading electrical companies, Schneider Electrical and Siemens.

A successful enterprise in anyone’s eyes. But Mclaren is a restless achiever, ready to test new ideas and implement the best of those – to keep pushing the envelope.

So, how will Singer celebrate the milestone – a rarity in the industry?

“I thought long and hard on that one and wanted whatever we came up with to be part of what will take this company to the next stage of its development.

And it needed to signal to our people, customers and the industry that we plan to be innovative and competitive – not just going forward with the same-old, same-old until we fall over, like Mainzeal construction company.

“Over the years, Singer has gone from a maintenance company, with some successes in new construction projects; to a capital projects and maintenance company; before splitting into three, by adding automation. When I took the reins I felt we needed to collapse those ‘silos’ and integrate into a solutions-based operation, increasingly using the best technology to deliver services, including solving problems which customers didn’t realise they had.

“How would we achieve that? By hiring the best people in the industry, providing them with the environment to achieve, giving them the tools to perform at the highest level and supporting them with a growing cadre of engineers and trades-people who will fill the gaps left by a generation reaching retirement. These youngsters, who have grown up in the technological age, intuitively understand what technology can do in the hands of competent people and will help take Singer to the next level of excellence.

“So, you asked me what we will do – we are committing to training 60 top-level apprentices over the next 10 years, to ensure that our now well-accepted ‘Powerful Solutions’ will be delivered not only by our top-end experts, but the quality and qualifications of our people – across the board – will be such that every member of our field force will be a ‘practical consultant’, capable of seeing both the big-picture and also delivering the appropriate ‘Powerful Solution’.

“No, we won’t be moving to a bigger and smarter head office. As well as that investment in the 60 trainees, our funds will go into more high-tech equipment and field vehicles. You can imagine the database we have developed over the last six decades. The best aspects of that will be available to support staff anywhere in the field.

“Being independent of product manufacturers and suppliers, means our guys on the job can use our significant buying power to access the most appropriate product at the best price, cutting out the ‘ticket-clickers’ who often

lineup in this game,” says Mclaren.

Singer will be launching a new serviceoffering in this area as part of its 60th celebrations, later in the year.

What innovation and developments does he see for the industry and how will these impact on electricity users and Singer?

“I’d like to think we have grown into a trusted, practical, local company which does what it says it will do. Our ethos is artisan. We diagnose your problem, tell you what needs to be done and then we do it. It’s all in-house, not a different subbie, in a different van, every couple of days.

“Our high-tech analysis tools will hunt down the source of your poor power quality, harmonics and cutting your consumption, improving your level of energy-efficiency, thereby saving you money and often eliminating the need to buy the new equipment some ‘besuited expert’ had told you that you needed.

“Often, these days we are switching off equipment, because it provides no real benefit to the customer.

“Personally, I’m revelling in the way maintenance, often the least regarded aspect of electricity management by boom-bust companies, is moving back into the centre of everything we do now – only this time the new technology, being used by more highly-trained, practical electricians and engineers, is delivering a ‘total cut-through visual + data’, eliminating guesswork and ‘let’s take a chance and try something’.

“We are pioneering, in the NZ industry, the use of thermographers, trained to the highest international standards (not just some casual wondering around a site with a cheap device which he pretends to understand) to provide customers with a ‘100 percent Pure condition baseline’ at the outset and similar readings at the conclusion of energy-efficiency improvements we have implemented; thereby ‘taking the guesswork out of what our Powerful Solutions have delivered’.”

According to Mclaren, only once a customer has a profile of the functioning of a system and the quantum and condition of the load it is carrying can the whole panoply of ‘reliability- centred maintenance’, the more traditional planned maintenance, root-cause analysis, 24/7 support etc be brought to bear in optimising a customer’s complete

Singer’s CEO Jeff Mclaren.

electrical system.

“Too many companies take over premises, new or 10th-hand, without establishing, upfront, the baseline condition of the incorporated electrical system. Nor do they when equipment is added or new devices are linked to it, especially the growing numbers non-linear devices, switch mode power supplies, electronic ballast, etc.

“That’s a recipe for disaster, so I’m surprised the insurance industry hasn’t been more interested in these measures until now. Call it a WOF, if you like – an independent, expert review of what exists, rather than hiding behind the brand of equipment or assuming the company that’s been ‘looking after’ you is up to scratch in the modern electrical industry,” Mclaren says.

That’s the now and the immediate future. What does he see in 2020, which would be double the seven years since he took over Singer?

“Energy efficiency won’t just be a goal, or a few LED lights, but an established basic requirement, across the board. Gas, thermal and hydro-powered generation will evolve to squeeze every last watt out of the process. We’ll see alternate powergeneration devices attached, to say, a sluice-gate run-off, to add an incremental wattage to the local grid. Growing energyindependence, with increasing volumes of locally and on-site generation will be the order of the day.

“And look to photovoltaic technology to come of age,” Mclaren says.

0800 474 643 www.singergroup.co.nz

41

Measure the power PowerLogic PM700 series power and energy meters offer outstanding quality, versatility and functionality in a costeffective, ultra-compact unit.

OEMs, panel builders and customers in industrial, buildings or infrastructure environments will find the meters ideal for replacing analogue meters or for adding metering to custom panels, switchboards, switchgear, gensets, motor control centres and UPS systems.

The meters are simple to use and offer large, bright LCD displays. They can be used for stand-alone metering or seamlessly integrated with PowerLogic power and energy management systems.

The meters are available in four models with incremental features. All models offer power, demand, energy, signed power factor, frequency and THD measurements, with higher models offering a choice of digital inputs, outputs, RS-485 communications and alarm functions.

Perfect for monitoring right down to the tool level, the meters’ IEC Class 1 or Class 0.5 certified accuracy make them suited for many applications.

The meters come with an integrated display and can be quickly panel mounted through a square cutout using two clips with no tools required. A small panel footprint and shallow 50mm (1.97 inch) depth behind the mounting surface maximises free space for other electrical devices inside a switchgear cabinet when mounted on the door.

This makes the meters suitable for low voltage switchboards, shallow

cable compartments or on stand-alone machines. In addition, the PM700 can be mounted on DIN-Rail by ordering a new kit.

All models are compatible with low and high voltage four-wire wye and three-wire delta systems and are suitable for three-phase (3P, 3P + N), two-phase and single-phase systems.

Direct connect inputs up to 480 V AC line-to-line or use voltage (potential) transformers for higher voltage systems.

All models offer a universal AC or DC power supply.

Model PM750 and PM710 meters are compatible with PowerLogic facilitylevel or enterprise-wide power and energy management systems. Real-time and min/max data can be automatically retrieved for analysis at the system level.

Compatible with PowerLogic ION Enterprise, PowerLogic System Manager, PowerLogic PowerView and PowerLogic Tenant Metering software. Modbus compatibility supports integration with building automation, SCADA and other third-party systems.

•

Go to www.demm.co.nz/enquiry quote: D130342

T-ILE4x current transducer

A new twist on energy-efficiency lighting Ecopoint has added the LEDisong to its range of environmentally-friendly LED lighting solutions.

The LEDisong is the first energy efficient light bulb to look and feel like a traditional light bulb.

Paul Wilton, Ecopoint’s founder and director, says: “The bulb is brighter than the average energy efficient light bulb, uses less power, fits into any light fitting and turn on instantly.

“It is truly a game changer in the sense that no changes need to be made to a light fitting, the bulb fits straight in.”

The LEDisong bulb is available in four different bulbs. They save up to 95 percent energy, and like all Ecopoint products, they come with a five-year warranty; other bulbs, including curly CFL bulbs and traditional bulbs, carry no warranty.

According to Ecopoint, to run a 100W bulb for 12 months for 5.5 hrs/day at 22c/kw it costs $44 a year, while the cost of running an LEDisong bulb in the same typical domestic setting is $2.86.

Like Ecopoint’s other LED lighting solutions, the LEDisong boasts an ultra long life: when used for 5.5 hours per day, the LEDisong bulb will last for 25 years.

The T-ILE4x current transducer converts a sinusoidal AC current into a 4-20mA output signal. The transducer has a built-in ring type current transformer, with the input achieved by passing the current carrying conductor through the central hole in the housing.

An external 24Vdc power supply in series with the output provides the current to drive the device; i.e. loop powered.

The input current range is selectable using a jumper that is accessible from the bottom of the transducer.

Two models are available. The T-ILE4L ranges Go to www.demm.co.nz/enquiry Go to www.demm.co.nz/enquiry 5A, 10A, 15A, 20A and T-ILE4H ranges 25A, 50A, quote: D130342a quote: D130342b 75A, 100A. The units conform to IEC 60688.

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42

March 2013

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Allan Hill, national secretary/manager NZEI.

Cut price deal for Standard AS/NZS 3000 The New Zealand Electrical Institute has negotiated a deal with Standards NZ, for members with the purchase of AS/NZS 3000 amendment No 2 at significant discount on the normal retail price, and much better than the normal 20 per cent discount offered to similar organizations.

This is just another reason to belong to a leading organization that provides more benefits to its members than other, similar organizations.

A new hardcopy version of AS/NZS 3000 with Amendment 2 incorporated is available in a robust A5 ring binder, instead of a spiral bound standard. This will make it easier to include future amendments and provides a more robust standard for on-site use by electricians.

AS/NZS 3000 sets out requirements to select and install electrical equipment, and design and test electrical installations, especially for the essential requirements for safety of persons and livestock from physical injury, fire, or electric shock.

Standards New Zealand published Amendment 2 to AS/NZS 3000:2007 Electrical installations (known as the Australian/New Zealand Wiring Rules) in December 2012. Amendment 2 incorporates the requirements of the New Zealand-only Amendment A, which was published in September 2011. Amendment 2 also includes new requirements for: • Inverter energy systems.

• Warning signs in roof spaces where the installation of thermal insulation could interfere with recessed downlights.

The new requirements will reduce the possibility of thermal insulation being installed incorrectly and will reduce fire risk from recessed downlights.

• Electrical equipment associated with gas appliances and no-go zones around gas cylinders. The new clause for gas appliances includes requirements for isolation of electrically powered appliances and specifies the hazardous areas around gas bottles, gas meters, and regulators, within which electrical equipment is prohibited • Air conditioners and heat pumps.

Isolating switching requirements

for air conditioners and heat pumps incorporating compressors are specified.

In addition, Amendment 2 includes several changes to clarify the technical requirements of the Standard and make it easier to understand.

Standards New Zealand Representation

By Alan Cuthbert.

Due to a number of factors, the meeting of EL-001 scheduled for February 2013 did not take place and has been rescheduled for early April.

The main matters set down for attention is the content of amendment No. 3 of AS/NZS 3000 Wiring Rules, and the future format of AS/NZS 3000 in the short and long term.

EL-001-24 (AS/NZS 3010) A meeting of EL-001-24 for the revision of AS/NZS 3010 Generator sets, has also been scheduled to occur following the EL-001 meeting. It is also proposed to update the present content of AS/NZS 3010 and to extend the coverage of the generator set connection arrangements required for 1 + 1 and N + 1 generator set configurations.

These arrangements are in common use in electrical installations for which a very high availability of AC mains power supply is required, such as large data centres.

The internal supply configuration of small portable generating sets used as an alternative AC mains power supply to an electrical installation is also to be reviewed and corrected as necessary.

EL-042 (AS/NZS 5033, AS/NZS 4777 and AS/NZS 62109) AS/NZS 5033 The committee drafting of a corrective and updating amendment of AS/NZS 5033 has been completed and has been submitted to the secretariat for final editing and styling for release for public comment.

The corrective and updating amendment has been due new developments in the international installation practices and also to clarify the application date for the use of IEC 62109 inverters in both Australia and New Zealand when using AS/

NZS 5033:2012. Publication will occur following consideration of public comments received and the associated standard publishing approvals.

AS/NZS 4777 The committee drafting of the new AS/NZS 4777 parts 1 and 2 has been completed and has been submitted to the secretariat for final editing and styling for release for public comment. This has been completely revised and from a date to be fixed prior to publishing the completely revised standard will require the use of inverters complying with IEC 62109. Publication will occur following consideration of public comments received and the associated standard publishing approvals.

AS/NZS 62109 Invertors An approved Standards Australia project is held for the production of AS/ NZS 62109 standard cloned from IEC 62109, and committee work is scheduled to commence shortly.

Currently this work has been held up due to a pending international standard amendment to fully complete IEC 62109, and the AS/NZS committee work for the drafting of AS/NZS 5033 and AS/NZS 4777.

For AS/NZS 62109 use, the IEC 62109 will be cloned with little or no additional requirements or changes being required, for use in Australia and New Zealand.

A draft will be released for public comment later this year. Publication will occur following consideration of public comments received and the associated standard publishing approvals.

Adoption of some standards by Electricity (Safety) Regulations 2010, as part of formal recognition arrangements of Standards by the Electricity (Safety) Regulations 2010, a large number of standards are formally recognized in schedules 2 and 4 of the Electricity (Safety) Regulations 2010.

A number of standards have revised since the current Schedules 2 (approximately 50 standards) and 4 was updated in November 2010.

It is proposed to update schedules two and four in an amendment No. 3 of Electricity (Safety) Regulations 2010, which is currently expected to be approved and issued and to come into effect on 1 July 2013.

Contact New Zealand Electrical Institute Email: nzei@xtra.co.nz Ph: 0800 693446 Web: nzei.co.nz

New Zealand Electrical Institute Inc.PO Box 64-258, Botany, Manukau 2163 Phone: 09 271 1901, Mobile: 021 613 448.Email: nzei@xtra.co.nz

43

New-format Fluke VT02 visual infrared thermometer Fluke Corporation has introduced its VT02 Visual IR Thermometer, a troubleshooting camera with an infrared heat map.

Until now, electricians and industrial, HVAC and automotive technicians have had to choose between single-point infrared thermometers and highresolution thermal imagers (infrared cameras).

The VT02 fills the gap for when a single-spot temperature reading isn’t enough and a high-resolution thermal image is more than users need. One tool combines the visual insight of a thermal imager, the visual images of a digital camera, and the point-and-shoot convenience of an infrared thermometer.

Conducting inspections for

electrical, industrial, HVAC/R and automotive applications is faster with the VT02 than an infrared thermometer, which requires multiple readings and manually recorded results.

The VT02 instantly detects problems using blended thermal and digital imagery. It will display and save images as full visual, full infrared, or in three blended modes (25, 50, and 75 percent).

Markers pinpoint hot and cold spots indicating the hottest temperature with a red box and the coldest with a blue box. A temperature reading is provided at the centre point. Images are saved to the micro-SD card, eliminating the need to write down single or multiple measurements.

Coming up in the April 2013 issue SOil and Gas Industry SCompressors SRobots SDust Control and Filtration STest and Measurement For informatiom email: frank@adrenalin.co.nz

Read an article in this magazine and want to know more?

It's simple, fill out the form and fax it in to 09 478 4779 or mail it to: DEMM Engineering & Manufacturing reader enquiry, Freepost 4359, PO Box 65 092 Mairangi Bay, Auckland 0754, or for quicker results go to

www.demm.co.nz/enquiry or email frank@adrenalin.co.nz Reader reply form Reader enquiry number:________________________________________________________ Name:_____________________________________________________________________ Your business name:__________________________________________________________ Position:___________________________________________________________________ Phone numbers:______________________________________________________________ Email:_____________________________________________________________________ Postal __________________________________________________________________________ ___________________________________________________________________

Affordable, compact, and intuitive, the VT02 operates with focus-free simplicity, expanding the user base from senior to junior technicians and broadening the applications for in-house staff as well as creating new business opportunities for service contractors.

Images from the VT02 can be imported into SmartView analysis and reporting software, included with the VT02, to produce professional reports that document problems detected or repairs made for management and customer review.

•

Go to www.demm.co.nz/ enquiry quote: D130344

PC for industrial use Phoenix Contact has launched an industrial PC to meet demands in the areas of process visualisation, robotics, and industrial automation.

The Valueline P7000 industrial PC is a powerful, configurable solution and is maintenance-friendly.

This IPC can be configured as a box PC with various mounting options or as a classic panel PC – and can be used in ambient temperatures up to 45°C. The TFT touchscreen monitors, available in sizes between 12-inch and 24-inch, allow complex processes to be visualized.

Equipped with Intel Core-i7 processors, the PCs offer exceptional processor and graphic performance. With the integrated turbo boost technology, more performance is there when needed.

The hyper-threading technology increases processor performance to allow threads (tasks) to be more efficiently processed. This is complemented by fast DDR3 memory with ECC support and solid state drive (SSD) storage with fast single-level cell (SLC) memory technology.

The hardware is supported by Microsoft Windows XP Professional or Windows 7 Ultimate operating system in the various embedded versions.

The IPCs set themselves apart as a result of an intelligent fan concept based on an external convection blower.

Contrary to integrated fans, this concept prevents dust from being whirled up on the mainboard. Further, the integrated power management of the processor reduces energy consumption.

Important components such as the replaceable hard disk or the CMOS battery can be easily and quickly accessed thanks to the maintenance-friendly design.

• Go to www.demm.co.nz/enquiry quote:

44

March 2013

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