PLANT April 2012

$12.00

Volume 71, No. 03 April 2012

www.plant.ca

GREEN ADVANTAGE A competitive strategy

Roxul makes sustainability its business

HIGHLIGHTS Metal alert for laundered shop towels WSIB’s unfunded liability is huge!

How to build a lean work cell Plan to profit when you exit your business Revolutionary eVox: An easy rider

PM 40069240

NEW EXPANDED TECHNOLOGY SECTION

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Editorial

Innovation: It’s up to SMEs

T

he Harper government has decided to get more bang for taxpayers’ innovation buck, revamping how the $12 billion in funding is distributed. Of particular note is the $3.6 billion SR&ED tax credit program that will be streamlined and made more efficient. However, there are some in manufacturing who question how effective some of the budget measures will be.

We have one of the most generous tax credit programs in the world aimed at encouraging innovation, yet Canada has one of the poorest levels of achievement among the 34 Organisation for Economic Co-operation and Development (OECD) nations.

We currently occupy 20th place, which represents a slide from 15th in 2008. As a share of GDP, our investment in R&D has declined since 2005. By 2008, it had fallen to 1%, compared to an OECD average of 1.6%. Financing by business fell from 50% in 2006 to 48%, while government financing increased from 31% to 32%.

Since innovation is key to productivity growth, it’s not surprising Canada lags in that measure too – holding at about 72% of the US level.

The Conference Board of Canada gives Canada a D for innovation, ranking us 14th out of 17 developed countries. We’re doing better with aerospace exports and writing more scientific papers, but in the remedial class for all other pertinent measures, particularly commercialization 101.

The budget is addressing this failure by cutting the tax credit for large firms from 20% to 15%, while channelling more resources to small firms that will continue to get 35%; however no one gets to deduct capital expenses and facilities.

While Finance Minister Jim Flaherty wants to shake up the innovation file, he has taken a contrary position to some of the recommendations made by a governmentappointed panel examining the effectiveness of R&D programs. It recommended large firms be excluded from the capital expenditures measure and the value of the tax credit be increased from 20%.

The changes will cost larger companies $1.4 billion over three years, notes Jayson Myers, president and CEO of Canadian Manufacturers & Exporters (CME), who questions the wisdom of eroding investment spending by the larger firms.

He told Canadian Press most of the R&D in Canada comes from bigger and mid-sized companies. Although they will likely continue to spend on R&D, he wonders whether they’ll make those investments in Canada.

Jack Mintz, chair of public policy at the University of Calgary – also pondering the government’s focus on SMEs who are not the greatest source of innovative capacity – reminds us that since large companies are responsible for much of Canada’s innovation, such changes to the tax credit regime will likely have a negative impact on R&D. The Canadian Council of Chief Executives, a group representing Canada’s biggest firms, is generally supportive of the budget, but it also cautioned that some of the changes may reduce Canada’s attractiveness as a location for research and development.

“In particular, the proposal to eliminate the tax credit for research-related capital expenditures could hurt capital-intensive companies that conduct R&D in Canada,” it said in a statement.

Despite these concerns from business, the Harper government is betting on smaller enterprises to crank up Canada’s dismal innovation performance.

SMEs have been notoriously tight with investments in R&D, as well as machinery, equipment and technology – even in good times. Their reluctance to spend can be blamed, in part, on difficulties securing venture capital. The budget attempts to mitigate this obstacle by expanding the amount of available funding.

It’s time for SMEs to step up and prove the government’s faith in their innovative spirit is well placed.

Joe Terrett, Editor Comments? E-mail jterrett@plant.ca.

Publisher: Michael King 416-510-5107 mking@plant.ca, mking@cienmagazine.com

District Sales Managers: Amanda Bottomley 416-859-4527 abottomley@canadianmanufacturing.com Catherine Martineau (Quebec) 647-988-5559 cmartineau@bizinfogroup.ca Deborah St. Lawrence 416-510-6844 dstLawrence@canadianmanufacturing.com Derek Morrison 416-510-5224 dmorrison@canadianmanufacturing.com Ilana Fawcett 416-510-5202 ifawcett@canadianmanufacturing.com

Group Editorial Director: Lisa Wichmann 416-510-5101 lwichmann@canadianmanufacturing.com

Market Production: Barb Vowles 416-510-5103 vowlesb@bizinfogroup.ca

Editor: Joe Terrett 416-442-5600 ext. 3219 jterrett@plant.ca

Circulation Manager: Diane Rakoff 416-510-5216 drakoff@bizinfogroup.ca

Assistant Editor: Matt Powell 416-510-5145 mpowell@plant.ca

Editorial Advisory Board: Robert Hattin, Hattin Holdings • Ron Harper, Cogent Power • Greg MacDonald, Wentworth International Services • Roy Verstraete, Anchor Danly

Vol. 71, No. 03, April, 2012 Executive Publisher: Tim Dimopoulos 416-510-5100 tdimopoulos@bizinfogroup.ca

Contributing Editors: Ron Richardson, Steve Gahbauer Art Director: Kathy Smith 416-442-5600 ext. 3215 ksmith@plant.ca

www.plant.ca

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BIG MAGAZINES LP Vice-President of Canadian Publishing: Alex Papanou President of Business Information Group: Bruce Creighton

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COVER IMAGE: STEPHEN UHRANEY

Features

>> SUSTAINABILITY

10 PRODUCTION Roxul covers the green bases with its product line and how it runs plant operations.

12 GREEN MANUFACTURING How to set up an energy management system.

>> INNOVATION

12 INJURY PREVENTION Technologies in development rapidly adjust vehicle-seating performance.

13 PRODUCT LAUNCH Procycle is shaking up the North American e-bike market.

PROJECTS Six university projects receive $34 million in automotive R&D funding.

>> MANAGEMENT

14 EXPORTING Investing in China offers great opportunity, but with many challenges.

15 EXIT STRATEGY Plan ahead and develop a business strategy that maximizes value and your return.

ADDING VALUE Fatten your bottom line by adding services to your product offerings.

>> OPERATIONS

16 INSURANCE Ontario’s unfunded WSIB liability could mean much higher rates.

MAINTENANCE How Stora Enso uses operator-driven reliability to reduce maintenance costs; Why motors fail.

17 THINK LEAN How to set up work cells that drive lean manufacturing.

>> TRENDS

18 CAREER BUILDING iCME portal brings together qualified job seekers and manufacturers.

EMPLOYMENT Manpower forecasts a respectable employment environment in the second quarter

>> TECHNOLOGY

19 SAFETY Laundered shop towels present a metals risk.

21 PRODUCT FOCUS A showcase featuring workplace safety products.

22 PRODUCTS AND EQUIPMENT What’s new in industrial products, machinery and equipment.

27 PLANTWARE Hardware and software for managing plant operations.

Departments

4 Industry View 8 Labour Relations 9 PLANT Pulse

29 Events 30 Postscript

PLANT—established 1941, is published by BIG Magazines LP, a division of Glacier BIG Holdings Company Ltd. Tel: 416-442-5600, Fax: 416-510-5140 80 Valleybrook Dr., Toronto, ON M3B 2S9 PRIVACY NOTICE: From time to time we make our subscription list available to select companies and organizations whose product or service may interest you. If you do not wish your contact information to be made available, please contact us via one of the following methods: Phone: 1-800-668-2374 Fax: 416-442-2191 E-mail: privacyofficer@businessinformationgroup.ca. Mail to: Privacy Officer, 80 Valleybrook Drive, North York, ON M3B 2S9 SUBSCRIBER SERVICES: To subscribe, renew your subscription or to change your address or information contact us at 1-800-387-0273.

SUBSCRIPTION PRICE: Canada $69.95 per year, Outside Canada $143.95 per year, Single Copy Canada $12.00. Plant is published 6 times per year except for occasional combined, expanded or premium issues, which count as two subscription issues. Contents of this publication are

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protected by copyright and must not be reprinted in whole or in part without permission of the publisher. Publications Mail Agreement #40069240. Performance claims for products listed in this issue are made by contributing manufacturers and agencies. No responsibility for the accuracy of these performance claims can be assumed on the part of PLANT or BIG Magazines LP. Contents copyright© 2012 BIG Magazines LP, may not be reprinted without permission.

PLANT receives unsolicited materials including letters to the editor, press releases, promotional items and images from time to time. PLANT, its affiliates and assignees may use, reproduce, publish, re-publish, distribute, store and archive such unsolicited submissions in whole or in part in any form or medium whatsoever, without compensation of any sort. This statement does not apply to materials/pitches submitted by freelance writers, photographers or illustrators in accordance with known industry practices.

We acknowledge the financial support of the Government of Canada through the Canada Periodical Fund CPF for our publishing activities.

ISSN 1922-5261

PLANT 3

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Departments

>> Industry View

>> Bulletins Metal processor Samuel, Son & Co. Ltd. has acquired Gary, Ind.based Stanrail Corp., a manufacturer and distributor of railcar components for an undisclosed price. Stanrail employs 122 workers and operates from a 155,000 square-foot facility where it makes uncoupling levers, boxcar floors, roofs and doors.

H2O Innovation Inc. has won $2.8 million in new contracts for custom-built water treatment systems in the US and Canada.

One of the projects involves a wastewater treatment and water reuse system for an unnamed oil and gas company in northern Alberta that will treat sanitary wastewater from a work camp.

Another project involves building and delivering a nanofiltration, reverse osmosis system for drinking water going to Hillsboro, ND. Sofame Technologies Inc. will custom manufacture “environmentally efficient” water heating and recovery equipment for a new 192-bed hospital construction project in Augusta, Me. No financial details were provided but the Montreal manufacturer said the hospital's green design will save 12 million gallons of water and $900,000 a year in operating costs.

Azure Dynamics Corp. is abandoning a planned financing and seeking court protection from its creditors. The maker of hybrid and electric components and powertrain systems for commercial vehicles said the decision came after the Ontario Securities Commission said it wouldn’t sign off on a prospectus for an offering of units.

UK-based industrial group Tomkins Plc, jointly owned

by Toronto-based Onex Corp. and the Canada Pension Plan Investment Board, is selling its Schrader tire pressure monitoring division to Madison Dearborn Partners LLC for cash and a small minority equity interest in Madison’s parent company.

Proceeds of the $505 million sale are expected to be used primarily to pay down debt.

Xstrata Coal British Columbia, a subsidiary of Swiss global mining giant Xstrata PLC operating in BC’s coal industry, reports JX Nippon Oil & Energy Corp. will pay US$435 million for a 25% stake in the coking coal operation in BC’s Peace River Coalfields. Metallurgical coal is used to make steel.

4 PLANT

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Bombardier collaborating with China’s COMAC Looking for synergy between CSeries and C919 passenger aircraft

MONTREAL: Bombardier Aerospace has signed a definitive agreement with China’s state-owned Commercial Aircraft Corporation of China Ltd. (COMAC) to develop program commonalities between the company’s CSeries and COMAC’s C919 aircrafts.

The manufacturers have agreed to cooperate on four distinctive projects to be executed as part of the first phase of COMAC and Bombardier’s long-term collaboration.

Signature ceremony with (front) Pierre Beaudoin, president and CEO of Bombardier Inc. The four initiatives will focus and Jin Zhuanglong, chairman of COMAC. PHOTO: BOMBARDIER on the cockpit human-machine both planes. (crew) interfaces, electrical sysThe deal won’t involve any ownership transfer tems, the development of aluminum-lithium stanor job changes. dards and specifications, and customer services.

Bombardier already has about 100 employees All four projects are to be completed over the working in China. next 12 months and in conjunction with the C919 COMAC, founded in May 2008, is a civil aircraft development schedule.

OEM involved in aircraft integration and is mainly Both planes are very similar, able to carry engaged in the research, manufacturing, testbetween 110 and 190 passengers each. COMAC ing, and flight testing of civil aircraft and related says it will develop the C919’s cockpit after the products.

CSeries to harmonize training so pilots can fly

CelluForce opens NCC demonstration plant in Quebec Nanomaterial to be used by collaborators in a variety of products MONTREAL: The world’s first NanoCrystalline Cellulose (NCC) demonstration plant has been opened at the Domtar pulp and paper mill in Windsor, Que. CelluForce, a joint-venture of pulp and paper producer Domtar and forestry research firm FPInnovations, hopes to reach a production target of 1,000 kilograms a day this year.

Trials integrating the material into the manufacture of different products are taking place through technical collaboration agreements between CelluForce and 15 companies based in Canada, the US, Europe and Asia. Products include paints and coatings, films and barriers, textiles and composites.

The plant was built in 14-months thanks to funding of $36 million from Natural Resources Canada (Pulp and Paper Green Transformation Program and Transformative Technologies Program) and Quebec’s Natural Resources and Wildlife Department.

The 33,000 square-foot facility will employ 30 people once production is at full capacity.

NCC is a nanomaterial derived from wood fibre that improves the strength (up to three times, while using half the amount of material), durability and toughness of manufactured products. It reduces damage caused by wear, abrasion and light. The nanomaterial also

incorporates into systems to make light reflective structures (tunable from ultraviolet to infrared), impermeable to gas and stable over time.

The bio-product is also completely natural, renewable, recyclable, compostable and biodegradable.

For instance, optical films enhanced with NCC can be used in specialty packaging, biosensors and security devices. The bio-product can also be used as a filler in magnetic paper, and electronic memory cards and readers.

A report last year by the Forestry Products Association of Canada (FPAC), The New Face of the Canadian Forest Industry: the emerging bio-revolution, suggests the burgeoning NCC extraction industry is worth a potential $200 billion globally.

That same report suggests there is massive export potential for the wood chips that will provide the NCC. Increased production of pulp and paper products worldwide pushed global trade of wood chips up by 25% in 2010.

China led that growth, increasing wood chip imports by 400% since 2009, according to Wood Resource Quarterly, a global sawlog and pulpwood price data and market information report.

Regulatory process begins for Surmont Multi-stage oil sands project to produce 120,000 bpd

CALGARY: MEG Energy Corp. is gearing up the regulatory process to build and operate a 120,000 barrel-per-day operation in Alberta’s Athabasca oil sands region.

The Calgary-based energy company with an in-situ development at Christina Lake is looking to expand its production capability at its nearby Surmont property in the Southern Athabasca region.

“We know the area geology, we have established strong relationships with regional stakeholders, and it’s relatively straightforward to link the project into existing pipeline and transportation infrastructure,” said MEG president and CEO Bill McCaffrey.

The company expects to submit a regulatory application by the middle of the year.

The project will use steam-assisted gravity drainage (SAGD) technology and include multiwell production pads, electricity and steam cogeneration, water and bitumen treatment, similar to MEG’s Christina Lake operation.

MEG currently produces about 30,000 barrels per day, and aims to grow that to 300,000 over the next decade through expansions at Christina Lake and Surmont.

Teva sells Mirabel plant to Halo TORONTO: Generic drug maker Teva Canada is selling its Mirabel, Que. manufacturing plant to Halo Pharmaceutical, a contract manufacturer.

Financial terms were not available, but 150 employees

Empire scores $30M media attraction WINNIPEG: Empire Industries Ltd.’s Dynamic Structures business has been awarded a $30-million contract to design, engineer and manufacture the mechanical and structural systems of a media attraction.

The Winnipeg manufacturer of specialized engineering projects said the contract, for an unidentified global customer, will take about two years to complete.

Empire has also sold its KWH Constructors and Somerset Engineering business units for $1.4 million to an unidentified buyer.

The sale is part of the company’s plan to reduce its investment in domestic steel fabrication and erection outside of Alberta and to deploy more of its resources towards expanding its engineered products businesses.

Empire owns 49% of ACE Industrial Services, which operates in the oil sands industrial maintenance services market, and a 45% share of a Chinese joint venture company in the steel fabrication market in Asia.

will continue to work at the plant where Halo plans to grow its commercial contract manufacturing business and product development activities.

“With the acquisition of this state-of-the art facility, Halo’s market reach will expand to Europe in addition to the US and Canadian markets,” said Mohd Asif, CFO of Halo Pharmaceutical, based in Whippany, NJ. Teva said the sale, to close on June 30, is subject to Competition Bureau approval, the conclusion of manufacturing agreements between Teva Canada and Halo, and receipt of manufacturing permits.

Teva Canada, the Torontobased division of generic drug maker Teva Pharmaceutical Industries Ltd., has more than 1,700 employees.

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Industry View << Departments

CAT invests $20M in SC plant

>> Careers

Sumter to be chief source for hydraulic cylinders PEORIA, Ill.: Caterpillar Inc. is investing $20 million in the expansion of its manufacturing facility in Sumter, SC, a move that will create more than 80 jobs over the next two years.

The facility currently produces small hydraulic cylinders used in a variety of CAT products. The additional capacity will bring the production of large hydraulic cylinders from the company’s Joliet, Ill. facility to Sumter.

Once the expansion is complete, the Sumter facility will be the primary source for small

and large hydraulic cylinders for North and South America. The expansion will allow the Joliet facility to focus on increasing production for other components currently produced there.

The expansion includes an additional 170,000 square feet, wghich will bring the plant’s total footprint to approximately 275,000 square feet.

This is Caterpillar’s second big investment since closing its Electro-Motive locomotive plant in London, Ont., putting 450 unionized and additional salaried staff out of work.

Claude Samson, citing personal reasons, has resigned as CFO and corporate secretary of ProSep Inc., a Montreal manufacturer of separation technologies for the energy sector. The company is now looking for his replacement.

A CAT heavy hauler used by Suncor Energy at its oil sands operation in Fort McMurray, Alta.

PHOTO: SUNCOR ENERGY

We need to join Trans-Pacifi c Partnership to access Asia

C.D. Howe says the pact could account for 40% of trade and 50% of GDP globally TORONTO: Canada needs a seat at the Trans-Pacific Partnership (TPP) talks because a pact could account for nearly 40% of the world’s trade, says a C.D. Howe Institute report.

Trade expert Laura Dawson notes the new trade pact could eventually account for half of global output and 40% of trade.

“Membership would position Canada to build trade ties with Asia’s rising economic powers, whose double-digit growth rates far outshine those in the West,” notes Dawson, president of Dawson Strategic and a member C.D. Howe’s international economic advisory council. “Canada is coming late to the talks. The question now is whether Canada can join the action.”

She says the TPP could expand

to include all of APEC, even China; a grouping representing 54% of global GDP. Joining the negotiations now rather than when it’s a done deal will allow Canada to take advantage of the early business expansion that comes with new trade pacts.

But she cautions Canada will encounter some obstacles. It had a chance in 2005 to join the group, but chose not to.

Prospective partners will now judge Canada’s suitability to join negotiations already in progress and among those is New Zealand, which opposes Canada’s dairy supply management regime. In a 2010 review, US officials declined to support Canada’s case for entry.

The report argues positive support from the US could override

objections by others.

She recommends reminding Congressional leaders of Canada-US alignment on key issues such as standards, investment and labour, and emphasizing continued progress on Canada-

Orbite to convert pilot plant to HPA

MONTREAL: Orbite Aluminae Inc. is converting its Cap-Chat, Que. pilot plant to commercial-scale production of high-purity alumina.

The Montreal-area developer of alumina extraction technologies intends to produce one tonne of high-purity alumina (HPA) per day when production begins, increasing to up to five tonnes per day in 2013.

The company said the pilot plant produced alumina and other oxides on time and on budget applying its proprietary extraction process to aluminous clays.

High-purity alumina (99.99%+) is widely used in several high-tech and industrial applications such as fibre optics and LED lighting for home and automotive applications. It’s also used in the production of high-pressure sodium vapour lamp tubes, the manufacture of video and computer equipment, metallographic polishing and the polishing of optic and electronic materials.

Ottawa invests in Saskatchewan CCS REGINA: The federal government is investing $14 million in Aquistore, a carbon capture and storage demonstration project near Estevan, Sask., creating 50 jobs.

CO2 will be stored deep underground in the Williston Basin that spans southeastern Saskatchewan, southwestern Manitoba, North and South Dakota and Montana.

The sedimentary basin is made up of alternating porous rocks, such as limestone, sandstone and non-porous rocks, such as shales, anhydrite and salt.

The first phase of the Aquistore project running to the end of 2013 will involve research, evaluation and the drilling of a test well for the injection of water and a small amount of CO2.

In the second phase, Aquistore will integrate with a commercial-scale CO2 capture, transport and storage operation. The source of the captured CO2 will be SaskPower’s Boundary Dam, with delivery set for in 2014.

The Petroleum Technology Research Centre (PTRC) will manage the project in collaboration with partners in the private sector and academia.

The Saskatchewan Ministry of Environment is also investing $5 million through its Go Green Fund.

www.plant.ca

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US economic cooperation.

The C.D. Howe Institute is a Toronto-based think tank.

Download Can Canada Join the Trans-Pacific Partnership at www.cdhowe.org/pdf/Commentary_340.pdf.

Bombardier Business Aircraft has expanded its global sales force. The Montreal-based aeropace division of Bombardier Inc. has appointed Tim White as regional vice-president of sales for Western US. The licensed pilot was previously senior vicepresident, sales, Americas, for Cessna Aircraft Co. He replaces Scott Westfall who is now sales director for the Rocky Mountains territory. Denis Jubinville is now sales director, US, Pacific Southwest. Antony Regillo has been promoted to sales director, Canada. Denise Bell has been promoted to sales director, Southeast US. Jan Dressel has resigned as president and CEO of Torontobased solar module manufacturer Soventix Canada Inc. Philipp Neff, managing director of Soventix GmbH and member of the Soventix Canada board replaces Dressel as CEO. Connacher Oil and Gas Ltd. has appointed Peter Sametz, former president and COO, interim CEO. Gregory Boland has joined the Calgary energy company’s board. He’s the president, CEO and co-chief investment officer of West Face Capital Inc., an 11.7% Connacher shareholder.

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PLANT 5

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Departments

>> Industry View

CVTech sets up subsidiary

FedDev funds Ivaco mill expansion

Will service the Ontario energy industry DRUMMONDVILLE, Que.: CVTech Group Inc. is setting up a subsidiary in Stouffville, Ont. that will service the province’s energy sector.

The company said it’s setting up Riggs Distler Inc. to deliver maintenance and construction services to the utility and heavy industrial markets.

CVTech said it would operate in a 8,000 square-foot facility on a three-acre site that will employ 10 administrative and technical staff, and potentially 70 field workers.

“The Ontario market offers interesting business opportunities for the energy sector following the adoption by the province of a long-term energy plan calling for investments of $87 billion over a 20-year period,” said president and CEO Andre Laramee.

CVTech is a management company. Its Thirau Ltée subsidiary provides maintenance of transmission and distribution lines in Quebec and the eastern US.

Ontario's long-term energy plan attracts CVTech’s Thirau Ltée maintenance subsidiary.

PHOTO: THINKSTOCK

Its other subsidiary, J.J.L. Déboisement Inc., specializes in controlling vegetation around power lines and in clearing rights of way.

L’ORIGNAL, Ont.: Ivaco Rolling Mills, one of North America’s largest producers of steel wire rod, has received $10 million in funding through FedDev Ontario’s Prosperity Inititiative to support an $80 million plant expansion and upgrade.

The expansion will increase the annual volume and variety of steel billets Ivaco produces by 225,000 tons. It will also introduce cost-saving technology to improve profitability and reduce the environmental impact of its operations.

The project must complete an environmental assessment.

Ivaco Rolling Mills produces one of largest variety of wire rod sizes of any North American rolling mill for the automotive, oil and gas, mining and construction industries in Canada and around the world.

Ivaco’s mill was originally constructed in 1971. The plant that supplies the steel billets was built in 1975.

The company anticipates the expansion will create 50 new permanent jobs and 200 short-term construction jobs.

FedDev Ontario funds opportunities for jobs and economic growth in Ontario.

>> Feedback

I was kind of surprised when I read the Think Lean article, “Sustainable change” in the March 2012 issue of PLANT. For years, we in the veneer business have made great effort (with success), to convince people that wood veneer is a wonderful, green alternative to solid wood cabinets, doors, wall panelling, etc.

Comparing an organization’s lack of lean depth to the durability of veneer (the article, and the cover line: Veneer lean: looks good, lacks depth...) is damaging for our industry.

I don’t have to tell you that the veneer industry provides jobs to a lot of people in Canada. Just in our small town of StRaymond in Quebec (8,000 people), about 75 to 100 people work with dedication to produce the best product, and they have been doing so for about 25 years!

And we are one of the biggest employers in town following the closure of all those sawmills and paper mills over the years.

I wish the expression “veneer lean” would disappear forever!

I really appreciate your publication but I’m sure you can understand our feelings about that article.

We are proud of our product and our industry.

INCENT

T FI

BI G

GE

S IVE

NEW

Expression “veneer lean” unfair to the industry

R PRO

Mario Déry Plant manager St-Raymond Veneers, St-Raymond, Que. We’d like to hear from you. Send letters to j.terrett@plant.ca with your name, address and phone number. Letters will be edited.

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6 PLANT

April 2012

12-04-18 1:28 PM

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Departments

>> Labour Relations

Free trade won’t boost manufacturing

BY KEN LEWENZA

T

he Harper government seems hellbent on signing as many free trade pacts as possible, covering a broad swath of trading partners including small players (such as Honduras and the Dominican Republic), politically charged ones (Colombia in 2011) and countries that could significantly alter our industrial make-up (Korea, India, Japan and the European Union). Yet Canada’s direct experience with “free trade” deals in recent decades suggests workers haven’t

The NAFTA deal of 1994 helped lower the competitive bar on “wages, benefits and working conditions… ” been served well, particularly those in the manufacturing sector.

The NAFTA deal of 1994 helped lower the competitive bar on wages, benefits and working conditions, enabling corporations to relocate capital investments across the continent, often to undercut collective agreements. It also awarded private investors new rights and privileges (including a legal mechanism to challenge government decisions).

Only a few years later, the World Trade Organization (WTO) undertook a review of the Canada-US Auto Pact and in 2001 ordered that it be dismantled, a move that’s helped kill thousands of Canadian auto assembly and parts jobs.

In the past decade, more than half a million manufacturing workers have lost jobs. And the losses are not just coming off the assembly line. Workers in the trades, product design engineers,

researchers, computer technicians and in-plant management have been affected.

Today, manufacturing employs just one in 10 Canadians, a far cry from the 1970s when the rate was nearly double.

And there’s no evidence free trade benefits Canada’s trade performance. In fact, the trade balance has suffered.

In 1996, Canada enjoyed a $12 billion trade surplus in manufactured goods with the rest of the world. Today, that surplus has turned into a deficit of $90 billion.

Across the five free trade agreements Canada has signed and implemented (US, Mexico, Israel, Chile and Costa Rica), we’ve seen imports increase 8.67% annually while exports have increased just 4.77%.

Indeed, Canada trades more favourably with nations with no deals in place, yet the Harper government has made free trade a cornerstone of its economic plan.

In the coming year trade talks for a new Comprehensive Economic and Trade Agreement (CETA) with Europe will wrap up, and if signed, could establish a beachhead for similar deals.

What about the trade deficit?

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What’s alarming about the dialogue surrounding CETA is that officials in the Department of Foreign Affairs and International Trade as well as representatives of the Canadian Manufacturers & Exporters suggest it could be a boon to our manufacturing base.

How can this be, when Canada currently faces a manufacturing trade deficit with the EU of $27 billion? How can it be that goods we export to Europe consist mainly of raw, unprocessed materials while what comes back are mainly finished manufactured goods?

A 2010 study conducted by Canadian Auto Workers economist Jim Stanford shows the Canada-EU CETA could cost us up to 150,000 manufacturing jobs. And losses will grow exponentially if similar trade deals are struck with other nations, such as India and Japan. Each of them has a planned program of industrial development and they’re actively building and reinforcing the foundations of their competitive manufacturing sectors.

We must commit to fostering a healthy, vibrant manufacturing sector in Canada – one that arrests the downward spiral of jobs and investment. Getting there will require active industrial policies (such as Canadian-content regulations) for strategic government investments, better management of our overheated dollar, improved rules for foreign investment and a long-overdue industrial jobs strategy.

More unbalanced free trade will keep us moving farther along the wrong path.

Ken Lewenza is the president of the Canadian Auto Workers Union, which represents 225,000 workers across the country in 17 different sectors of the economy. E-mail cawcomm@caw.ca.

Comments? E-mail jterrett@plant.ca.

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8 PLANT

April 2012

12-04-05 2:41 PM

Economy << Departments LABOUR PRODUCTIVITY 1997-2010 Canada

1.3

NL

3.9

PEI

1.6

NS

1.6 2.0 1.2

Ont.

1.2

Man.

SOURCE: STATISTICS CANADA

NB Que.

1.9

Sask.

1.8

Alta.

0.6

BC

1.2 0.0

0.5

1.0

1.5 2.0 2.5 3.0 average per cent change

3.5

4.0

4.5

Economic growth is picking up the pace

Investment in plants, machinery and equipment was more important to labour productivity growth from 1997 to 2010 than human capital or technological innovation. Gains were highest in Alberta and Saskatchewan from investments in resource-related activities.

RBC says exports to US will help boost GDP to 2.6%

B

CAPACITY UTILIZATION TRENDING UP

per cent 84

80.5

82 80

83.4 SOURCE: STATISTICS CANADA

78 80.0

76 74 72 70 68

70.7 I 2007

III

I 2008

III

I 2009

III

I 2010

III

I 2011

ECONOMIC DE VELOPMENTS AND TRENDS

III

Manufacturing operated at 80.4% of its capacity in Q4, up 1.4% with increases in 12 of the 21 industries. Transportation equipment, machinery, chemical products, plastic products and metal products industries contributed the most to this growth.

SOURCE: STATISTICS CANADA

MANUFACTURING SALES ADVANCE $ billions seasonally adjusted 56 54 Current dollars 52 2002 constant dollars 50 48 46 44 42 40 38 36 34 32 30 J J J J 2009 2010 2011 2012

usiness is looking better for manufacturers, particularly those in Ontario. Canada’s economy is expected to pick up the pace this year with stronger growth in the US, according to a report from RBC Economics Research.

Growth in 2011 was a moderate 1.8%, but the RBC Economic Outlook says signs of strength in the US economy, low interest rates, solid balance sheets across corporate Canada and elevated commodity prices are setting the stage for continued expansion with real GDP of 2.6% in both 2012 and 2013.

“The country’s main engines of economic activity from the early days of the recovery – consumer spending and residential investment – are likely to play supplementary roles as the economy shifts into slightly higher gear on the road ahead,” said Craig Wright, RBC’s senior vice-president and chief economist.

The report says high commodity prices and strong corporate balance sheets will boost business investment’s overall contribution to economic growth by 0.8% and 0.9% this year and next. As the US economy improves, Canada will benefit from demand for exports such as autos, machinery and lumber.

“We expect the strengthening US labour market will continue to spur auto sales south of the border, boosting demand for Ontario-made motor vehicles and parts,” said Wright. “Ontario’s economy relies disproportionately on the US market and this turnaround in the automotive sector will play an important role in boosting provincial exports.”

Exports account for 30% of GDP, and approximately three-quarters of them go to the US. RBC forecasts ex-

ports will return to the pre-recession peak level in 2013, with net exports boosting growth 1% in 2012 and 0.3% in 2013. However, it says the tightening of fiscal policy will likely have a restraining effect on economic growth.

Sluggish job growth of 2,000 per month will give way to stronger hiring going forward, says the report. RBC predicts the unemployment rate will fall to 6.9% by the end of 2013.

Regionally, Western Canada will top growth rankings this year, led by Saskatchewan and Alberta with Manitoba following closely. Newfoundland and Labrador, BC and Ontario are expected to grow at rates close to the national average. Growth in Quebec and the remaining Atlantic provinces will be below the national average.

Productivity growth is steady Statistics Canada reports labour productivity increased 0.7% in Q4 after a 0.6% increase in Q3, but the growth was driven by a 0.2% decrease in hours worked and a 0.5% increase in output. Year-over-year growth was up 1.1%, putting Canada ahead of the US for the first time since 2006.

TD Economics expects productivity will be better this year, but economist Leslie Preston said an increase in unit labour costs is a concern. Since the recession, unit labour costs have been growing faster than in the US, and with a higher value loonie, the picture is worse.

On the plus side, Preston said investment in machinery and equipment has been strong over the past two years, suggesting Canadian businesses are working to become more globally competitive.

A drop in aerospace production was reflected in the 0.9% decline of manufacturing sales from December to January to $49.6 billion. Lower sales in primary metals, machinery and other transportation equipment also contributed to the decrease.

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EI CLAIMS INCREASE IN JANUARY

numbers 350,000

300,000 SOURCE: STATISTICS CANADA

• Product Quality • Environmental Impact

250,000

200,000

150,000

J

J 2009

J 2010

2011

J 2012

There were 12,400 more people receiving regular employment insurance benefits in January, an increase of 2.3% to 561,100. Nationally, claims and renewals rose by 1.6% to 3,700 for a total of 242,300. There were increases in eight provinces, the largest in Quebec.

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• Warranty

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www.plantmagazine.ca/rsc/ 106

PLANT 9

12-04-11 9:18 AM

Sustainability

>> Production

INSULATING its competitive edge Roxul’S SUSTAINABILITY drive PAYs OFF Milton manufacturer says greener plant upgrades give it a competitive advantage.

By Matt Powell, Assistant Editor

W

ith increasing focus on the environment and concern about climate change, running a greener operation is not only good for the environment, it could make a company more competitive.

In fact, a Canadian manufacturer in Milton, Ont. is running a sustainable operation while making insulation that prevents the warm and cool energy produced by wind turbines, solar panels and other power generators from escap-

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ing your home.

Roxul Inc., a subsidiary of Denmark’s Rockwool Insulation A/S, produces fire-proof, water resistant and energy efficient stone wool insulation made from at least 75% recycled material at its facilities in Milton and Grand Forks, BC. Product with 93% recycled material is also produced on a per project basis at an extra cost.

The company’s efforts have earned it the distinction of being the first stone wool insulation producer in the world to get certification from the US-based International Code Council Evaluation Services (ICC-ES) for innovative building materials, components and systems.

Stone wool is derived from a volcanic by-product called basalt rock. Roxul says the stone wool saves 12 times as much

energy per pound in its first year as the energy used to produce it.

But the company’s sustainability credibility isn’t confined to its product. During production, it recycles waste materials, heat and water, which Roxul claims is giving it a competitive advantage.

“It’s not only about being a corporate citizen, it’s also a strategic goal,” says Ion Leoveanu, the Milton facility’s factory manager. “We like to talk the talk and walk the walk. It’s difficult to claim you’re making a product that saves energy and reduces your carbon footprint if

1. A blast furnace liquefies rock, basalt and slag.

April 2012

12-04-11 12:55 PM

Factory manager Ion Leoveanu looks down the conveyor line as product comes from the stacking area on its way to packaging.

PHOTOS: STEPHEN UHRANEY

water use by 50% with a waste and rain water recycling system, an energy recycling system was installed to re-use heat needed for the manufacturing process, and a company wide, zero waste-to-landfill protocol was implemented.

“In Canada we’re very close to that,” says Leoveanu.

Even the production process is one with the environment. Not only are the furnaces powered by recycled energy, the rocks are sourced from Drain Bros., a local supplier in Havelock, Ont., a sleepy blue-collar town of 4,500 about three hours north-east of Milton.

Automation upgrades

you don’t follow those same principles in your own plant.”

Rockwool has more than 25 operations worldwide and employs more than 8,800 people in 30 countries. The company’s Canadian operations started in Milton in 1988. It acquired a second manufacturing facility in Grand Forks in 1995. By 2005, both operations were at full capacity, so it was time for some improvements.

By 2009, they were upgraded at a cost of more than $160 million, a project that involved reducing their environmental impact. The company cut municipal

The group produces most of its own machining and equipment through Rockwool’s engineering group in Denmark, which provides more control over the impact the machines have on the environment.

“We also have a number of proprietary technologies such as spinning, wool processing and cutting machines,” he adds.

When it comes to automating those machines, the company relies on Siemens products, which include integrated control, monitoring and communication devices.

“There are no longer any manual operations within our manufacturing process; it’s completely automated,” says Leoveanu. “We had one manual packaging operation left, but when the plant was upgraded in 2009, we automated that process as well.”

To make the stone wool, Roxul combines volcanic basalt rock, waste and coke briquettes with steel slag. The combination is melted down in a cupola furnace ­– the same kind used in foundries to melt cast-iron and bronze ­– at 1,500 degrees C. The melt runs out of the furnace onto a machine that spins it into fibres.

Small amounts of binder and oil are added, then the wool is collected on a

2. Freshly spun wool travelling quickly along the conveyor.

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10-11-PLNT.indd 11

belt conveyor in the spinning chamber.

The structure and density of the wool is adjusted before it enters a curing oven, then it’s led into cutting machines and moves on to the packaging equipment, where it’s finally ready to ship.

Off-gases collected from the cupola furnace, spinning chamber and the curing oven are cleaned in filters and after burners before they enter the chimney.

Any waste materials collected during production are re-used as feedstock in future manufacturing.

Roxul says the recycled stone wool is also used as a raw material in bricks.

Since 2001, the company has reduced landfill waste by 13% across the entire Rockwool Group.

“The process is truly built around the cupola furnace,” says Leoveanu. “It’s basically a blast furnace that efficiently melts down the stones and other raw materials.”

The heat makes it ideal for substituting virgin raw materials, such as rock and steel slag, with waste materials of similar chemical composition, so the same material is used multiple times.

Throughout the entire Rockwool Group more than 300,000 tonnes of waste materials have been recycled and re-used.

Although Leoveanu wouldn’t provide specifics about its facilities, the approximately 650,000 square-foot plant operates four shifts 24/7. The company wouldn’t provide financial information either, but according to Industry Canada, Roxul has domestic sales of at least $5 million and has sales in the US of more than $10 million.

Roxul’s insulation was tax-credit redeemable under Natural Resources Canada’s ecoEnergy Retrofit program, which provided grants of up to $5,000 for homeowners to offset renovations that lower energy costs and reduce environmental impact.

As the economy continues its recovery, Roxul is maintaining a green focus by ensuring good intentions meet reality and operations comply with final product aspirations. “We’re a corporation with manufacturing facilities around the world, but at the Canadian operations, we have our own parameters to follow and goals to achieve,” says Leoveanu.

“They centre around waste elimination and reducing our carbon footprint.”

Green is on in Canada, and Roxul is right in the thick of it.

Comments? E-mail mpowell@plant.ca.

3. A roller softens cured wool prior to preparation for cutting.

4. A robotic arm stacks packaged insulation onto pallets.

PLANT 11

12-04-05 2:42 PM

Innovations

>> Injury Prevention

>> Green Manufacturing

9 steps to EnMS Continuously improve with ISO 50001

BY BRETT WILLS

W

ith rising costs, heightened concerns about the environment and rising pressures from external stakeholders, manufacturers are paying a lot more attention to managing their energy consumption.

An energy management system (EnMS) addresses these issues while maximizing energy performance. It applies international best practices, measurement and reporting disciplines, drives continuous improvement and promotes energy efficiency throughout the supply chain.

ISO 50001 provides a structured and disciplined approach to continuous improvement of energy performance that can be implemented alone or integrated with other standards such as ISO 14001 or 9001. Follow these simple steps to develop an effective EnMS based on the ISO 50001 framework.

1. Communicate economic and other benefits of a structured energy management approach versus a non-structured approach to management, then organize a balanced EnMS committee with reps from operations, facilities and finance.

2. Create an energy policy that communicates the organization’s commitment to continually improving energy performance over time.

3. Your EnMS should include the following: • Sources of energy use such as electricity, natural gas and steam. Document a minimum of three years use by month for each one in a spreadsheet or use other software to create a baseline.

• A metric for each source of energy. These indicators become a normalized baseline of use that future performance will be measured against.

• Realistic but challenging reduction targets relative to performance indicators. Include specific reduction numbers and an associated timeline. Targets may also include phasing in the use of renewable energy.

• Specific action items for achieving reduction targets. For each action item, assign a champion and due date.

• A plan to increase employee awareness around energy consumption. Create a separate plan for training those directly responsible for driving energy performance and have a plan for communicating ongoing energy performance.

4. Implement action items along with awareness, training and communication.

5. Document energy use monthly. Control documents by assigning responsibility for data input, and password protect the documents.

6. Regularly monitor, measure and analyze energy performance with an eye on spikes and anomalies. Adjust plans and procedures as required.

7. Conduct regular audits of the system to ensure continued adherence to the plan and targets. Document any nonconformances and determine root causes. Apply solutions that address the root cause of non-conformance.

8. Have senior management conduct regular reviews of the overall system. Request ideas for improvement and adjust plans, actions and procedures as required.

9. Continually improve energy performance by improving awareness, training and communication plans. Increase energy reduction targets and leverage best practices to sustain identification of energy reduction opportunities.

Implementing an EnMS is a simple way to maximize energy performance to realize enhanced cost savings while also accelerating the journey towards sustainability.

Brett Wills is the director of the Green Enterprise Movement and a senior consultant with High Performance Solutions in Cambridge, Ont. E-mail bwills@hpsinc.ca.

Comments? E-mail jterrett@plant.ca.

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WHIPLASH protection Across Canada, costs of whiplash claims exceed $2 billion.

PHOTO: THINKSTOCK

R&D LOOKS AT AUTO DESIGN THAT LOWERS RISK Technology in development rapidly adjusts seating performance.

BY DOUGLAS ROMILLY

M

ost consumers and fleet buyers don’t realize how important seats and head restraints are in a rear-end crash. Properly designed and adjusted, they lower the risk of whiplash.

In 2005, the Insurance Corp. of BC estimated up to 20% of the average insurance liability went directly to covering the costs of whiplash claims. Extrapolated across Canada, these costs exceed $2 billion per year, excluding an additional social burden resulting from pain and suffering, lost productivity and absenteeism.

Yet existing minimum compliance regulations do not provide an adequate level of safety for a broad range of vehicle occupants. Few carmakers exceed minimum compliance levels, incorporate automatic head restraint moves with seat adjustments, or provide active/dynamic head restraints.

Dynamic systems are typically activated by the occupant hitting the seatback during a rear impact by triggering a mechanism that moves the head restraint to reduce the gap between it and the occupant’s head.

Many of these systems are designed assuming a “typical” occupant or rely on that occupant to initially adjust the system while seated.

With support from several industry partners and the

AUTO21 Network of Centres of Excellence, researchers at the University of British Columbia (UBC) are working on a project that focuses on enhancing whiplash safety by raising awareness and making seating systems safer.

A 2008 study presented at the World Congress on Neck Pain concluded that 35% of serious neck injuries would be prevented if people purchased vehicles with good head restraints and adjusted them appropriately.

UBC researchers are developing technologies that use both critical occupant and collision information gathered through sensors to rapidly adjust the safety performance of the seat. These new systems include adaptive positioning that does not rely on the occupant to position the head restraint. An energy absorbing seat reduces transmitted energy to the occupant during a rear-end crash, significantly lowering neck and head accelerations. Adaptive structures optimize crashworthiness based on the severity of the collision and specific characteristics of the occupant.

Combining these systems with resources to support and educate Canadians on best whiplash protection practices will reduce both the social and economic costs of these injuries.

Douglas Romilly is a professor at the University of British Columbia and leads the AUTO21 Project “Prevention: Reducing Occupant Injury in Rear End Collisions.” Visit www.auto21.ca.

Comments? E-mail jterrett@plant.ca.

April 2012

12-04-11 11:24 AM

Product Launch << Innovations

Easy e-rider

Hot new wheels for urban cyclists

Procycle intends to shake up North American cycling with the innovative eVox, an e-bike that travels up to 150 kilometres on a one-hour charge.

By Matt Powell, Assistant Editor

N

othing focuses people on green energy alternatives like skyrocketing gasoline prices. At $1.33 per litre and climbing, alternatives to fossil fuels are looking pretty good, especially in cities.

Sure, there’s always public transit, scooters or even bicycles, but now you can add the growing popularity of electric bikes (e-bikes) in European and Asian countries to the list. They’re affordable, require no gas and they’re easy to maintain.

One issue, though, is batteries. They’re generally very heavy, lack range and require a lot of time to charge.

A Quebec bicycle manufacturer intends to change that and as a result, how Canadian city dwellers get around.

Its new e-bike has a range of up to 150 kilometres and requires only one hour to re-charge the lithium-ion battery.

Procycle, a bicycle manufacturer in Saint-Georges, Que. that owns the Rocky Mountain and Miele bike brands, will introduce its first e-bike – the eVox – this spring to the Canadian market.

Although a relatively small city, Saint-Georges is often considered the Metropolis of Beauce Region because it’s the largest city, but it’s also an important manufacturing centre for textiles, steel forgings, garage doors, truck trailers and – of course – bicycles. In fact, SaintGeorges has a special relationship with the world of cycling. It hosts (for almost 25 years) one of the more important cycling events in North America. The Tour de Beauce attracts as many as 150 professional cyclists from around the world who race up, down and around the region’s hills and streets.

However, Procycle is aiming for more conventional enthusiasts with the eVox. “The market is pretty new for electric bikes in North America,” says marketing manager Jacques Dutil.

But the company could be onto something big. A report by clean-tech market firm Pike Research suggests worldwide sales of e-bikes could top more than 460 million units by 2016.

The company hopes the eVox will revolutionize the North American market for e-bikes. Procycle managed to shrink the size of the battery and motor with its DynaMe propulsion system, which supplements pedalpower through five levels programmed into an on-board computer system.

What sets the eVox apart is the one-hour recharge time.

“Since the charger is included in the rear-rack, riders

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13-PLNT.indd 13

charge on the go instead of having to buy a second battery, something the competition is pretty insistent on at point-ofpurchase,” says Dutil.

“Riding around with that second battery makes the bike superheavy and reduces range capabilities.”

The eVox’s 120/240volt removable charger weighs only two pounds.

The Canadian-made eVox is sized to meet the needs of 95% of the population and weighs in at a manageable 60 pounds with the motor and charger attached (48 pounds without). DynaMe provides three propulsion modes: pedal assist, which supplements pedalling efforts based on five computerized options and has a range of up to 150 kilometres; freedom mode, a pedalfree option with an operating range of 40 kilometres; and bike mode, which allows riders to use the eVox as a traditional bicycle without the assistance of the electric motor. In freedom mode, riders have the option of

removing the lithium-ion battery and charger to reduce the bike’s weight.

The company spent three years and “millions of dollars” developing the concept, and conducted rigorous market testing to make sure the idea was road-worthy in the Canadian market. Potential users insisted the eVox had to look and feel like a traditional bike, avoiding the typical bulkiness and complications of older e-models.

The DynaMe system provides three propulsion modes.

Comments? E-mail mpowell@plant.ca.

PHOTOS: PROCYCLE

Making it simple “The electric part of the bike is there to help out, but it had to be simple,” says Dutil. “It’s really useful when going up a hill or into the wind, but can’t be the bike’s sole power. It’s really designed for people who still want to be active and ride something that truly resembles a bike.”

To do that, the company hid all the electrical wiring within the frame – something other e-bike manufacturers have been unable to do, says Dutil.

The eVox will be the first Canadian-made e-bike on the market. Although parts are sourced from China, all assembly will take place at Procycle’s 205,000 squarefoot facilities in Saint-Georges where 70 employees build each unit along an assembly line. Dutil says Procycle has opted to stick to the Canadian market once the eVox hits stores this spring. Market expansion will depend on how well the e-bike does at home.

The Canadian market represents virtually untouched territory.

“There are e-bikes out there, but they’re all made in China, based on one design, but sold under different brand names – none of it is Canadian made. We wanted to change that,” says Dutil.

Procycle is aiming for sales of more than 1,000 units at a price of about $2,795 for each of two models. All going well, the US market will be next, followed by other global markets over the next two years.

If sales take off, Procycle should consider adding to the city’s rich cycling tradition with a race of its own: the eVox Tour de Beauce.

>> Projects

Automotive R&D gets a $34M injection

Six university projects receive federal and industry funding

A

utomotive R&D is getting a boost with a $34 million grant for six projects. The funding includes almost $19 million from the fiveyear Automotive Partnership Canada initiative and nearly $15 million from industry and other partners. The following projects will receive money: • McMaster University in Hamilton is getting $2.3 million to collaborate with Bruker Ltd., General Motors of Canada Ltd. and HEKA Electronics Inc. to improve the performance of lithium batteries.

• Simon Fraser University in Burnaby, BC is getting $5.5 million to work with a team of scientists representing nine universities to reduce the cost of PEM fuel cells. They’ll be checking out alternative non-platinum metals and fabricating advanced layer structures. Industry partners include Automotive Fuel Cell Corp., Ballard Power Systems, BIC Inc., GM Canada and Hydrogenics.

• The University of Waterloo has been awarded $3.7 million to examine the fabrication and performance feasibility of magnesium-intensive multi-material automotive structures. Industry partners include Cosma International, 3M Canada, Huys Industries, Meridian Lightweight Technologies, CANMET Materials Technology and Laboratory (Natural Resources Canada).

• Dalhousie University in Halifax is getting close to $4.2 million to rapidly identify cell chemistries and operating ranges that deliver the best performance and calendar life from lithium batteries. Industry partners include 3M Canada, GM Canada, Magna E-Car Systems, Medtronic Energy and Component Center and Nova Scotia Power.

• Dalhousie University is also getting $2.2 million to look at low-cost ways to use titanium as a lightweighting material. It will be working with Kingston Process Metallurgy and Wescast Industries.

• The University of Windsor in Windsor, Ont. will use $1 million to achieve tech-scale production of electrohydraulic forming (EHF). This process involves the discharging of a high-voltage current between two electrodes submerged in a fluid and using the pressure wave to form a sheet metal blank against a die at very high strain rates. Ford Research and Advanced Engineering, Amino North America Corp., Novelis Global Technology Centre, ArcelorMittal Dofasco and CANMET Materials Technology Laboratory will be involved in the project.

PLANT 13

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Management

>> Exporting

China: Opportunity or overwhelming challenge?

By Mark Drake

P

You can put a price on workplace safety and efficiency.

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You demand a productive workplace.

One that’s as compliant with safety regulations as it is efficient.

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Made in U.S.A.

orcupines, the old joke goes, make love carefully.

That also goes for international traders thinking about tackling the Chinese market.

As usual Foreign Affairs and International Trade Canada (DFAIT) sums it up well: “China is a country of phenomenal potential with its 1.3 billion population, rising middle class, exceptionally positive growth rates and relatively low inflation. At the same time it’s also a vast and complex country where conducting business can be difficult. Obtaining reliable information is a challenge, as is forging the right connections. The financial and taxation aspects of doing business there are intricate [and] key challenges include import barriers, inadequate intellectual property rights enforcement, subsidy practices and low transparency in contracting processes.”

One might add that there is generally an inconsistent application of regulations, a mind-boggling bureaucracy and corruption at most levels of government. Western leaders also fear (per The Economist) increased nationalism, rapidly growing military capability and sense of victim hood – not perhaps the ideal background for Canadians to pursue trade and investment.

Yet China is already the second largest economy and the IMF thinks it will be the largest – on a purchasing power parity basis – by 2016, thus extremely important for Canada. China is our biggest export destination in Asia, and now second overall, nudging out the UK and Japan, with merchandise exports of $13 billion.

Priority trade Export Development Canada’s web site (www.edc.ca) has a good up-to-date overview of the Chinese economy and some excellent links to related sites. DFAIT has an embassy in Beijing, and nine trade supporting offices throughout the country.

Although Canadian exports are primarily resourcebased (wood pulp, canola seed, coal and nickel), the department has identified seven priority areas of significant potential: aerospace, agriculture, automotive, electric power generation, ICT, metals and minerals (including oil and gas) and rail urban transit.

The local Trade Commissioner Service offers help in assessing market potential, finding qualified contacts and resolving business problems. The Chinese value personal relationships. They take time to develop, but are vital.

A change of leadership is scheduled to take place at the 18th Chinese Communist Party Congress later this year, when the 12th five-year plan will be introduced stressing socially and environmentally sustainable

growth – around 9% to 10% in the past few years, but is likely to fall slightly.

Although the state-owned enterprises were scaled back some years ago, those that remain have increased in size and dominate the oil, power generation, automobile, railway, aviation and financial sectors. They’re potential customers but often harder to deal with than firms in the private sector. The World Bank rates China #79 out of 183 in terms of ease of doing business, #151 for starting a business and #179 for obtaining construction permits.

Transparency International’s Corruption Perception Index places China at 3.6 (where 10 is least corrupt). That’s better than Russia at 2.4 but way behind Taiwan at 6.1 and Singapore at 9.2. By comparison Canada is 8.7.

Recommendations for export success include having a niche or specialized product or service, and finding a reliable and trustworthy local partner. Douglas Woollings, CEO of Interfast, recently offered some good advice about dealing in China during a chat with the National Post. He stressed the importance of speaking with other companies who already work in China, making sure the product or service is “best in class” or at least second, learning the culture of the country, being a good listener and not too aggressive, and above all not trying to do it everything overnight.

I would add that having a good policy in place to protect intellectual property is essential to prevent (or at least limit) patent or trademark infringement and the manufacture of imitation products (knock-offs). It’s also smart to have good local legal counsel.

There is no shortage of information around. The Canada-China Business Council (www.ccbc.ca ) has more than 200 members who either do business in China or have an active interest in the country. The Asia Pacific Foundation based in Vancouver (www.asiapacific.ca) has a colourful and interesting 19-page report on its site based on a 2010 survey of 95 companies active in China.

In summary one respondent says of doing business there: “Nothing is easy, anything is possible.” HSBC has published a 50-page report on “Doing Business in China” (2010) dealing mostly with actually setting up a business, taxation, employment law and conditions of trade (www.hsbc.com).

No doubt China offers magnificent opportunities, but as with the porcupine, getting close requires patience and care.

Mark Drake is former president of Electrovert Ltd. and the Canadian Exporters’ Association. E-mail corsley@ videotron.ca.

Comments? E-mail jterrett@plant.ca.

>> Global Data World in Figures: Stats a-plenty

Grant Thornton and The Economist provide the app

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Find the reel you need at

hannay.com

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ant to know where Canada ranks in the global economic league? Or who is the most generous aid donor? How about which country has the lowest divorce rate?

The World in Figures contains a wealth of economic, socio-demographic, cultural and environmental statistics from The Economist and is now available as a free iPad app, thanks to a partnership between advisory firm Grant Thornton International Ltd. and the global business magazine.

It includes country scores and rankings on more than 200 topics from foreign debt, life expectancy and natural resources, to business competitiveness, innovation and Facebook use. Detailed statistical profiles cover the world’s major economies’s lots of international trivia. Here are some interesting Canada facts you’ll find: • Canada ranks third in the number of publicly listed companies (behind India and the US).

• Canada is third in aluminium production, fourth in zinc and fifth in nickel production. We’re third in the Top 10 producers of oil and natural gas.

• Canada placed seventh in global competitiveness. Hong Kong was first, followed by the US and Singapore.

The free World in Figures app is available from the iTunes App Store.

14 PLANT

April 2012

12-04-05 2:46 PM

Exit Strategy << Management

>> Adding Value

Plan ahead with a solid exit strategy that maximizes value and your return.

Services offer revenue stream

By Stephen Shaw and Glenn Fraser

Report notes higher profit margins

T

hinking of selling your company?

It’s a buyer’s market out there so have a solid exit plan. And don’t assume many successful years in business will be enough to net the best results.

That was the case when a new entrepreneur who, when the time came to sell, did much better than the owner of a long-established business.

Taylor had only been operating her beverage processing business for four years while Rae, the owner of a similar but larger enterprise, had been running the company successfully for more than 20 years. Both owners wanted to sell their operations – Taylor to free up capital to launch another enterprise and Rae to retire.

When a purchaser expressed interest in buying a beverage processing operation, Rae was still in the “thinking through it” stage while Taylor had a detailed plan regarding what she wanted, what she could offer a purchaser and how a transition would unfold. In fact, Taylor was so well prepared that the sale of her business was completed within just a few months and, having received her asking price, was on the way to launching her next enterprise.

Business owners who have focused for many years on maintaining a competitive edge often ignore their most important advantage – optimizing returns from exiting the business. Bear in mind the buyer’s market will likely continue for decades as a stream of baby boomers sell their companies and retire.

Getting the best terms Even if you don’t intend to leave your business for several years, creating a plan now gives you more options. You have time to properly structure your operation as an investment, groom a successor, build value and capitalize on tax opportunities.

Here’s what’s involved in developing an exit plan: 1. Clarify needs and objectives.

Align personal and business objectives, establish an appropriate time frame and ensure expectations are achievable and objectively assessed against market realities. Clear goals are the foundation of an effective plan. Do you want to pass the company along to family members or key employees, or sell it to the buyer who offers the best price? Do you want your loyal workforce to be retained?

What financial returns do you expect?

Do you want to be involved in the business following a sale? What do you need to enjoy the retirement you visualize?

What are your wishes for your estate?

What is your preferred time frame for a transition?

2. Integrate relevant personal and business strategies. Determine what needs to happen to achieve your goals.

Review personal and family needs, retirement, succession, estate, contingen-

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S

With baby boomers getting set to retire, it’s a buyer’s market for manufacturing companies.

PHOTO: THINKSTOCK

Selling your company

?

Make it your business to have a sharp competitive edge cies, taxes, insurance, legal, risks, business structuring and business value. Exit planning also helps to attune the advice of advisors, ensuring their recommendations are consistent with goals.

3. Address business value. Enhancing the value of the owner’s business is key to the success of an exit plan. Potential purchasers typically expect to see healthy cash flow and earnings, but they often have other expectations, which the planning process will identify. These may include: • A strong management team • An effective employee retention program • Accurate, accessible actionable, and timely financial records • Documented processes and systems • Up-to-date articles of incorporation and tax filings • Cost controls • Manageable debt • A solid customer base • Strong inventory turnover • Facilities in good repair • Equipment in good working order • Up-to-date and relevant marketing and sales strategy • Well established and respected brand within the specific market An exit plan also details what needs to be done, when and by whom. Every dollar of profit yields up to three dollars of proceeds in a sale. Taking more time to build value strengthens the performance of the

operation. Knowing what will drive value maximizes it. Exit planning involves estimating a value range for the business and identifying the elements – such as financial management, benchmarking, and human capital.

4. Document an action plan. It details steps, timing and responsibilities.

This provides an opportunity for a business owner to share the plan with all of the stakeholders. The plan also serves as a tool for communicating expectations and measuring progress.

Taylor’s exit plan proved to be a significant advantage in attracting the right purchaser. The buyer was particularly impressed by strategies outlined in the plan that addressed how the business model could continue expanding post transition.

A well-defined exit plan provides benefits that extend well beyond the financial rewards of selling the company. It will simplify your affairs, provide clarity to everyone involved, reduce stress – and help you realize your dreams.

Stephen Shaw (stephen.shaw@mnp. ca) is the national and regional leader of MNP Corporate Finance Inc. (www. mnpcororatefinance.ca). Glenn Fraser (glenn.fraser@mnp.ca) is the leader of the GTA region Food & Ag Processing practice of MNP (www.mnp.ca). Call (416) 596-1711.

mall and medium-sized manufacturing firms that add services to their product offerings can enjoy higher profit margins, more stable revenues and greater competitive advantage, says a Conference Board of Canada and McGill University report.

The Quebec-based report offers the following reasons why product manufacturers should integrate services into their core offerings: • Profit margins are higher than products.

• Revenue is more stable because services are more resistant to economic cycles that affect investment and equipment purchases.

• Substantial revenue generated from an installed base of products with a long life cycle.

• They add value and strengthen the supplier-customer relationship.

SME Manufacturers in Quebec: Adding Services to Boost Competitiveness and the Bottom Line, is based on case studies, literature reviews and an online survey of 113 Quebec manufacturers. It shows 95% of SMEs who offer services gain revenue.

Of these, about one-quarter obtain between 21% and 60% of their revenue from service offerings. A further 67% get between 1% and 20% of their revenue from selling services.

There are challenges, though. The chief one identified by 45% of respondents is the need to employ highly skilled personnel. Other challenges were accessing client needs and identifying what specific services to provide. In-house expertise and knowledge of their products, knowledge of foreign languages and regulations, knowledge of clients’ needs and providing timely solutions were key to successfully delivering services.

Another approach that Quebec SMEs can adopt to compete globally is to integrate with the production networks of multinational corporations (MNCs). The Integrating Quebec SMEs Into Production Networks: A Spur to Competitiveness, report identifies several factors behind successful networks: • The presence of world-class MNCs to provide access to large markets and knowledge.

• Close lateral relations among SMEs to share information about markets and technology.

• Forums for communication between and among MNCs and SMEs. • Forums for collaboration between and among industry and academic institutions.

• SMEs willing to foster innovation by hiring highly trained people.

• Government cooperation to ensure, for example, appropriate transportation, communications and financial infrastructure.

Access both reports at www.e-library.ca.

Comments? E-mail jterrett@plant.ca.

Comments? E-mail jterrett@plant.ca.

PLANT 15

12-04-10 11:05 AM

Operations

>> Insurance

WSIB: Ontario’s $19.7B liability

>> Maintenance

Making ODR work

Revenues and assets aren’t keeping up The liability could be even higher. CD Howe calls for “urgent corrective action.”

By Mike Ouellette

O

ntario faces a $19.7-billion unfunded liability at its Workplace Safety Insurance Board (WSIB), according to the C.D. Howe Institute, a Toronto-based think-tank.

In a report titled: The Hole in Ontario’s Budget: WSIB’s Unfunded Liability, authors Colin Busby and Finn Poschmann say the pace of revenue collection and asset accumulation at WSIB has not matched growth in current and expected benefits.

The study says a fair-value accounting method would result in an unfunded shortfall of about $4,100 per insured worker in Ontario or $2,900 per taxpayer.

The WSIB reports an unfunded liability of $12.3 billion. It arrived at this figure by discounting future benefits by 7%, reasoning that its investments have averaged returns of 7% over the last 15 years.

But this formula does not take into account the thrashing investments took over the past several years nor does it account for the guaranteed nature of its future payouts.

The study’s authors say if a more realistic 3% rate is applied, the WSIB would post total liabilities of $31.3 billion.

WSIB defends its accounting, with a spokesperson responding via email saying: “We are confident that our estimates of the size of the [unfunded liability] are based on sound actuarial and generally accepted accounting principles. This has

>> Tech Tips Why motors fail

The WSIB liability could take up to 25 years to pay off.

been confirmed by an independent audit of the WSIB’s consolidated financial statements.”

The spokesperson also said the CD Howe report is “generally supportive of the current direction we’re taking to reduce system costs while improving the services we deliver to the workers and employers of Ontario.”

Trouble for business

Industrial motors use more than 90% of all the energy in a process plant. When they fail, it’s usually because of external causes.

Failure studies show: • 41% are related to bearings.

• 37% are due to windings.

• 30% are caused by misapplication and/or incorrect operation.

• 12% are related to various accessories and/or the system.

• 10% can be blamed on the rotors.

That may be the case, but uncertainty surrounding WSIB payments, rates and structure represent trouble not only to taxpayers and businesses already operating in the province, but on businesses considering locating or investing in Ontario.

“The WSIB is an elephant-sized problem for employers, employees and potentially taxpayers that will not be reported in the Ontario budget,” says Colin Busby, senior policy analyst. “It urgently needs corrective action.”

Indeed, someone is going to have to pay for these liabilities at some point.

WSIB is raising its rate by 2% in 2012 to

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perator-driven reliability (ODR) has reduced sudden failures and unplanned shutdowns in Stora Enso’s pulp and paper mill in Varkaus, Finland by a significant margin.

Timo Jurvanen, production superintendent at paper machine Nr. 3, said the pressure was on the mill to increase its performance and quick results were important, so the company chose to go for ODR because it was easy to implement.

ODR is an approach to maintenance and reliability that is comparable to TPM but much simpler. As in TPM, the idea is to assign some maintenance-related tasks to the machine operators, such as spending more time on analysis and maintenance planning, while doing some of the routine inspections and work themselves.

As they work with the machine, they monitor trends and report potential problems to the maintenance planner who prioritizes and plans for required actions.

This allows the actual reliability specialists to focus on root cause analysis and efficient planning.

No overtime required

Most causes are external

From a Motor Diagnostics and Motor Health Newsletter by SUCCESS by DESIGN, with permission.

Stora Enso avoids 20 critical failures

PHOTO: THINKSTOCK

an average of $2.40 per $100 of payroll.

Busby estimates that paying theestimated $12.3 billion liability would take a rate of $2.80 over about 15 years.

To pay off the liability estimated by C.D. Howe, rates would have to jump to $3.10 per $100 of payroll and they would have to stay that high for up to 25 years.

“The prospects of rising premiums could change the province’s attractiveness to businesses or change a company’s preference of investing in capital equipment versus hiring workers,” says Busby. “This has lots of impacts on business decisions.”

The WSIB is an independent trust agency that administers compensation and no-fault insurance for Ontario workplaces. It’s funded entirely by employers.

About 1,100 claims are registered every working day.

Mike Ouellette is the editor of CanadianManufacturing.com. E-mail MOuellette@ canadianmanufacturing.com.

A steering group laid the groundwork for ODR at the Varkaus mill, and all five shifts received a two-hour theoretical introduction plus a two-hour walk-through on site.

Then it was just a matter of getting started and fine-tuning the process along the way.

Each of the ODR inspection routes takes about 15 minutes. This enables the operators to fit them into their schedules without the need for overtime.

“We spend less time on the inspections now and can focus on the most critical assets,” says Vesa Nyyssönen, the company’s vibration analyst. “This means we can make better analyses to find the root cause of problems.”

ODR fits very well into Stora Enso’s operator maintenance strategy, says development manager Mikko Nieminen, who coordinates operator maintenance within the company’s Finnish mills. He notes it also provides an easy-to-use but advanced tool for data collection and storage that can be introduced to the operators.

This system identified about 20 possible critical failures in six months, contributing to a reduction of unplanned machine stops by half a per cent during the first year. Stora Enso is now implementing ODR in the remaining Varkaus units and in the company’s other Finnish production sites.

The initial investment to get ODR up and running paid for itself in the first month.

Says Jurvanen: “The cost is minimal compared to the benefits. It’s not an issue.” ­– Steve Gahbauer, Contributing Editor Information sourced from SKF Canada Ltd.­

Comments? E-mail jterrett@plant.ca.

April 2012

12-04-11 11:26 AM

Think Lean << Operations There’s nothing simple about a workcell. They’re set up to make production more efficient, ensure the best quality and simplify plant processes on the shop floor.

It’s all in the

tion must be completed in less than the total takt time so additional time is allowed for loading and unloading or positioning. A quicker measurement or test step places less constraint on product motion between steps. For example, a measurement process that captures all the information about a part in one go will permit shorter total takt time and a higher pace of production flow.

Using takt time reorganizes work packages. If

By Richard Kunst worker one performs actions A1 through A5 and worker two performs actions A6 through A8 then a orkcells are at the heart of lean. They reduction in takt time would mean three work packincrease productivity and quality, while ages to fit the new shorter/faster pace. They might simplifying material flow, management be package 1 (A1 to A4), package 2 (A5 to A6) and and accounting systems. How well they work package 3 (A7 to A8). Now three people are doing depends on subtle interactions of people and the work that was achieved by two. equipment. Each element must fit with the others Subdividing work-packages rather than working in a smoothly functioning, self-regulating and selfin parallel on unchanged packages of actions is improving operation. new to many people. This way of working requires: A cell’s design is an engineering concern that • a flexible workforce willing to accept changes proceeds through a logical sequence of steps in routines; where compromises between conflicting require• a multi-skilled workforce, since people may be ments or technical limitations are made. Doing it asked to pick up actions performed by others; well requires a comprehensive knowledge of the • flexible work cells – what two people do today elements of a workcell, their functions and interacmay need three people tomorrow; tions. The following elements are key to success• more hand-offs, so no significant overhead; ful workcell design: • simple workflow, so what the process delivers 1. Select the products. Find compatible is clear to all; families of products that a group of machines • speeding up production steps because the new can process without creating other difficulties. context of each action encourages innovation.

Many problems arise from attempting to combine How do you get lean buy-in from cell team too much variety. Important tools are enterprise members? Follow these steps: value stream mapping and group technology.

1. Treat each of them like a customer.

Which products belong together in a workcell?

2. Create a set of experiences that walks them What is the design production rate for the cell? Is from current to desired belief. reserve capacity needed?

3. Overcome the valid “no.” Most people don’t 2. Engineer the process. Understand every say “no” to be difficult. Maybe it’s risk; so mitigate process event and the times required for setup, it. If it’s time; find the time. personnel activities and machine cycles. Calcu4. Call in reinforcements. Would someone else late the number of people, machines or workstaWork cells run on sophisticated socio-technical systems.

PHOTO: THINKSTOCK influence team members more? Engage that tions needed and in what sequence? What equipRealistically, people never maintain 100% efficiency person’s help. ment should be employed and how much of it? How and there may also be stoppages for other reasons, so Don’t rely on hope. Own it. And do the hard work. many people are needed? What lot size is appropriate? allowances are needed to set up your line and run at a After all, an idea unrealized is worth very little at all.

3. Define the infrastructure. Its elements support proportionally faster rate. the process but do not touch the product. They include Takt time has direct implications concerning the Richard Kunst is president and CEO of Kunst Solucontainers, scheduling, balance methods and motivaallowable time for completing individual steps in a protions Corp., which publishes the “Lean Thoughts” tion. Consider the following: duction process, especially those that modify the prode-newsletter. E-mail rkunst@kunstartofsolutions.com.

• Methods for material handling. uct and observe/control the process. Similarly steps that • How the workload will be balanced. require a part be placed in an accurately fixtured posiComments? E-mail jterrett@plant.ca.

• Production scheduling.

CIEN Island6_Layout 1 12-04-05 2:49 PM Page 1 • How much work in process is necessary.

• How to motivate people.

• How to assure quality.

4. Laying out the cell. Task procedure diagrams can be simplified. Start with the process chart and move directly to a layout.

• What is the best physical arrangement?

• How do we handle external constraints?

• How do we integrate with the overall layout?

Design flow and work breakdown structure by calculating takt time, the maximum time allowed to produce a product to meet demand. In a lean manufacturing environment, the pace time is set equal to the takt time.

Takt time is defined as T= Ta/Td, where: Ta = Net available time to work [minutes of work/day] Td = Total demand [units produced/day] T = Takt time [minutes of work/unit produced] The net available time for work to be done excludes break times and any expected stoppage time, such as scheduled maintenance or team briefings.

If you have a total of eight hours in a shift less 30 minutes lunch, 30 minutes for breaks, 10 minutes for YEARS LIMITED a team briefing and 10 minutes for basic operator maintenance checks, then net available time is 400 minutes.

If customer demand is 400 units a day and you run one shift, your line would be required to spend a www.dvsystems.ca sales@dvsystems.ca 1-800-668-8558 maximum of one minute to make a part to keep up.

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design

How to engineer a workcell and get buy-in from the team

5

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built better

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PLANT 17

12-04-10 11:53 AM

Trends

>> Career Building

iCME: A virtual matchmaker Portal brings together employers, job seekers

H

aving trouble filling key positions that require specific industrial skills and experience? Maybe you’re looking for a job that could use your skill set but focusing the search is proving to be a challenge.

Canadian Manufacturers & Exporters (CME) aims to narrow the gap between job vacancy and successful candidate with a simple-to-navigate national web portal that acts as a virtual match-making service. But iCME (Innovative Careers in Manufacturing and Exporting) also provides tools for all the stakeholders involved to help fill job needs and interest next-generation workers in manufacturing careers. It’s now operational at www.icme.ca and there are more than 200 jobs already posted.

“The shortage of skilled employees in the manufacturing 09 FLIR Complete Solutions e60 CIEN Feb12:8.125x10.875

sector is not looming, it’s upon us,” says Jeff Brownlee, CME’s vice-president of public affairs and partnerships.

“We were getting calls on a daily basis from CME members, employers, manufacturers, colleges and universities asking us if we had a tool that would help them connect.”

Indeed, the Conference Board of Canada projects the country will be short 1 million workers by 2020, while CME anticipates a deficit of 500,000 over the next decade, and a shortage of 800,000 in the oil sands by 2030.

“If you’re a manufacturer in Fort McMurray, Alta., posting a job through traditional channels might yield a response, but chances are it won’t,” says Derek Lothian, national communications manager, who developed the project. “iCME is set up as a one-stop shop that 1/31/12

11:50 AM

Page 1

Get the

Running short of workers for industry.

connects people with the resources that will fill their employment needs.”

Job postings are tagged with iCME essentials such as experience, education and skills, which quickly narrows the search for qualified candidates without having to compile and sift through a lot of resumes.

The site offers resources for employers needing help with job-related issues such as apprenticeship information, or what to consider when hiring internationally trained staff, and there’s help for job seekers who, for example, are looking for a career in international business. “[Manufacturing] is not all welding and metal stamping. There are some really cool jobs in manufacturing and we wanted to bring them to the forefront,” says Lothian.

The project is backed by stakeholders from government, industry and academia, which Lothian says will also help to push the message to their constituents.

Postings will cost $299 but job seekers and employers can create profiles for free. CME members and PLANT readers (user code: PLANT) can post jobs free until May 1.

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PHOTO: THINKSTOCK

>> Employment

Upbeat hiring climate forecast for Q2

Manufacturing: respectable

C

anadian manufacturers are reporting a slightly diminished, yet respectable hiring climate during the second quarter of the year, according to the latest results of the Manpower Employment Outlook Survey.

The Manpower Group, a global human resources company with offices in Toronto, polled 1,900 employers to determine whether they plan to add personnel or decrease employment levels, with a positive balance indicating the level of enthusiasm for hiring.

The Q2 reading is 13%, down slightly from the previous quarter’s 15%.

Manufacturers of durable goods are anticipating a “hopeful” hiring climate with a 13% net outlook, down from Q1’s 18%, but an improvement over the 12% recorded for the same period last year.

Non-durables employers report an outlook of 10% indicating a “respectable hiring climate” for the second quarter, 13% in Q2.

The survey also reveals 21% of employers plan to increase their payrolls in the next quarter, while 5% anticipate cutbacks.

Seventy-two per cent expect to maintain their current staffing levels while 2% are unsure of their hiring intentions.

Manpower says this quarter’s outlook has been strengthened by oil sands mining in Alberta. Overall, the sector is showing a 21% net outlook, 5% more than the previous quarter but down 4% from the same period last year.

Comments? E-mail jterrett@plant.ca.

18 PLANT

April 2012

12-04-10 8:07 AM

Safety << Technology

Be aware of metal residue on fresh shop towels.

PHOTO: KIMBERLEY-CLARK

>> Productivity

SIRIUS ABOUT CONTROL

Laundered SHOP towels METAL

RESIDUES POSE A POTENTIAL HEALTH RISK A study shows workers could ingest unsafe levels during regular use.

W

orkers handling laundered shop towels may be exposing themselves to metal levels that exceed allowable limits.

Gradient, an environmental and science risk consulting firm in Seattle, Wash., conducted a study on behalf of Kimberly-Clark Professional, a global supplier of paper products and cleaners for industry and consumer markets.

The company makes WYPALL Wipers, a disposable shop towel.

An analysis of towels provided by 26 North American manufacturers, 15 of them Canadian, shows plant workers using a typical number of shop towels (12 daily) may be exposed to metals such as lead, chromium, cadmium and antimony

at concentrations many times above those allowed by maximum contaminant or action levels.

“Our analysis indicates that shop towel users may unknowingly ingest higher amounts of metals than what is allowed in drinking water,” said Barbara Beck, principal at Gradient. “It’s important for safety managers and plant workers to understand metal contamination levels in laundered shop towels so they can make informed decisions about their use.”

Freshly laundered shop towels were shown to carry metal residues that may transfer to the hand, migrate to the mouth and be ingested at too high a level.

In Canada, exposure to lead in drinking water is limited to 10 parts per billion. In the US, it’s 15 parts per billion. The study shows daily intake from shop towels may be up to 21 times higher than the intake that would be associated with the US lead action level.

Seven metals were found in all the tested towels – antimony, beryllium, cadmium, cobalt, copper, lead and molybdenum.

Here are some of the health effects associated with heavy metals that exceeded toxicity: • Beryllium can cause sensitization, lung and skin disease.

• Cadmium and cadmium compounds are known to cause cancer as well as kidney, bone and lung cancer.

• Cobalt exposure at high levels can result in lung and heart effects, dermatitis and liver and kidney effects.

• Copper when orally ingested may cause nausea, vomiting/diarrhea, liver damage, kidney damage or death.

• Long term exposure may lead to result in severe damage to the bloodforming, nervous, urinary, and reproductive systems.

For study analysis results, visit www. thedirtonshoptowels.com.

MODULAR BUILDINGS BUILDINGS ON THE GO A shipping container is so much more than a “container.” Provincial Partitions is turning them into field offices, storage buildings, hazardous materials storage, barracks and housing.

Indeed, the Mississauga, Ont. manufacturer of modular buildings and partitions recently supplied four of its ready-to-ship Proflex containers to an engineering/manufacturing firm that’s sending them to Africa for use in a wastewater treatment application.

Each container had checker-plate steel flooring and metal interior walls and was modified to include standard and roll-up doors for easy access, HVAC, windows and mechanical tie-ins for all utilities. There’s one other major plus: these buildings are easy to ship because...they’re containers! www.pro-part.com www.plantmagazine.ca/rsc/ 1

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Building Proflex containers.

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he economists, the analysts and consultants have all made the point: Canadian manufacturers need to improve their productivity to become more globally competitive. Siemens Canada Ltd.’s Industry Automation division in Burlington, Ont. has launched three new product lines to help them do so.

Sirius Innovations, the next generation of the Sirius Modular System of power control products, comes in two frame sizes up to 25 hp with increased power performance to 42 A, and a 45-mm footprint that makes more efficient use of space.

Sirius modular control.

IO-Link communication modules reduce control wiring and the units quickly snap onto the contactors of direct, reversing and wye-delta motor starters up to 30 hp. The modules also allow status and diagnostic data communication to the Totally Integrated Automation platform. AS-Interface communication modules for motor starters have also been added to the product line.

The second launch product is the new arc-resistant tiastar motor control centres (MCC) aimed at general construction, water and wastewater, oil and gas and general process industries that comply to ANSI/ IEEE C37.20.7. There are three of them: • H2O is designed specifically for the water and wastewater industries. It has integrated drives and protects assets by tracking pump and motor deterioration.

• Smart, for process industries, delivers increased operational transparency, advanced diagnostics, plus easier troubleshooting and start up. An autonomous back-up function ensures continued operation.

• Base is designed for use in general construction, healthcare and hospitals.

Siemens has also added new solar inverters for the rooftop market to its product line. The SINVERT PVMs range from 12 kW to 24 kW and they’re capable of more than 98% peak efficiency.

Capable of megawatt-range output, the line includes PVM12, PVM16, PVM20 and PVM24 models for roofs of industrial buildings or ground-mounted plants, commercial office buildings, public spaces and municipal buildings. www.siemens.ca/siriusinnovations www.plantmagazine.ca/rsc/ 2

PLANT 19

12-04-05 2:48 PM

CIEN

Health & safety AIr SAMPLEr hANDLES ruGGED CONDITIONS

GLOvES fOr ELECTrICAL PrOTECTION

Sample pumps must be accurate and rugged to survive different work environments while collecting physical samples for further analysis. TUFF air sampling pumps from Casella CEL work in numerous environments thanks to a sealed case with over-moulding, protecting it from moisture, extreme temperatures, solvents and impact.

With a flow range from 5 ml/min. to 4.5 l/min., the pumps handle a wide range of applications, such as industrial hygiene monitoring of dusts, fumes and gases.

All pumps have a double-acting diaphragm mechanism with precise digital control for real-time flow control and stability across a range of sampling media. Casella CEL is an instrument manufacturer based in Amherst, NH. www.casellausa.com

Strong and flexible ARC rubber insulating gloves from Magid Glove & Safety have advanced dielectric properties for electrical applications.

Made with natural rubber latex, the gloves come in a variety of configurations, including Class 00, Class 0, Class 1 and Class 2; 11-, 14- and 16-in. lengths; and multiple colour options. The contours reduce hand fatigue, minimize chaffing and ’re flexible to simplify working with small parts.

Magid Glove & Safety Mfg. Co. LLC, based in Chicago, makes hand protection products. www.magidglove.com

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Collects air samples.

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MONITOr GASES rEMOTELy The Ventis LS multi-gas detector looks for gases that could creep into workplaces across oil and gas, chemicals, petrochemicals, metals, mining, forest products and utilities industries.

It’s part of Industrial Scientific’s Accenture Life Safety Solution, which uses Wi-Fi and location-based technologies to remotely monitor hazardous environments.

The company, a Pittsburg, Pa. provider of gas detection services, says Ventis LS detects H2S, O2, LEL, CO, SO2 and NO2 and alerts users through audible, visual and vibrating alarms. The instrument’s Checks for six gases.

gas level information is transmitted over Cisco’s Unified Wireless Network using the gas detector’s integrated Wi-Fi Tag from AeroScout, then to a control room, where an operator quickly locates the employee in danger and organizes rescue operations.

A separate alert is sent to the control room if a lack of motion is detected or a worker activates the detector’s panic button.

Operators can also venture outside the plant with the same functionality using a combination of Wi-Fi and cellular communications. www.indsci.com/accenture-life-safety-solution

Insulated gloves.

>> Handling Application

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MAkE fOrkLIfTS COLLISION-AWArE

Kirk Key Interlock Co. and Utility Relay Co. (URC) have teamed up to minimize arc flash risk. A power panel switch with door interlocks from Kirk are combined with URC’s Quick-Trip system to reduce arc flash hazards when feeder breakers are racked in or out for maintenance.

The PPS switch and door interlocks come in standard, medium and heavy duty configurations to replace a standard padlock, which does not provide isolation or ensure proper activation.

The system prevents access unless the Quick-Trips system is engaged.

Turning the Kirk PPS key activates the arc hazard system and releases the key. The released key is then used in the next sequence, releasing the keys needed to unlock the feeder compartment doors fitted with interlocks. The feeder compartments must be locked and the keys returned before the first key needed to turn off the Quick-Trip system, will be released.

URC is a manufacturer of microcontrollers based in Chagrin Falls, Ohio. Kirk Key, based in Massillon, Ohio, produces mechanical interlocks, electro-mechanical interlocks, solenoid key release units, time delay key release units, and transfer panels. www.utilityrelay.com

The Crossing Guard forklift collision awareness system from Flow-Rite Safety Solutions Inc. requires the detection of two separate motions to trigger an alert, reducing the number of nuisance alarms.

It also detects the presence of motionless individuals, which directly addresses a common cause of forklift accidents and fatalities.

The system monitors a definable detection area with four adjustable sensors that completely cover the risk area. Depending on the location, sensors can be infrared and/or ultrasonic. In production pick up areas and other locations where infrared may be impractical, an optional weight-sensitive sensor model is available.

All models sound an audible alarm coupled with a high-intensity LED alarms light.

Crossing Guard uses a microprocessor that collects and saves sensor activities, aiding the investigation of an occurrence. This may result in additional training, changes in procedure and possibly a rearrangement of stored product to reduce collision potential.

The standard system is powered by a low-cost, eco-friendly solar panel that trickle charges a rechargeable DC battery using energy from ambient warehouse light.

A second battery triggers a low battery alert, warning that the primary battery needs recharge, repair or replacement.

As an option, Crossing Guard plugs into an existing low voltage power source.

Flow-Rite Safety Solutions Inc. is a Burlington, Ont.-based developer and provider of safety products. http://crossingguardsafety.com Detects motionless

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Power panel lock out.

rEDuCE ArC fLAShES

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Counterbalances heavy loads.

frIENDLy ErGONOMIC MANIPuLATOrS SIGCO Inc., a glass and architectural metal fabricator/ distributor, needed an ergonomic manipulator for its manufacturing facility in Westbrook, Ma. Jason Tardiff, SIGCO’s operations manager, wanted something that would address safety concerns but also enhance productivity.

HAECO, a Loveland, Ohio-based manufacturer of Famatec Handling Solutions equipment and other industrial products, had the answer: pneumatically powered Famatec Friendly ergonomic manipulators.

“The Famatec Friendly precisely counterbalances heavy loads allowing a single operator to suspend, rotate, tilt and transfer product – eliminating worker fatigue and injury as a result of manual lifting,” says Tardiff.

In SIGCO’s case, a 500-lb. product that used to be handled by as many as five employees is now manipulated by just one.

HAECO notes using a standard jib crane and hoist result in awkward movements and swinging of the product. The Famatec manipulator uses a single, intuitive control. A special safety device that supports it until reaching its destination protects the release of the product.

SIGCO has five Famatec manipulators installed at its Maine plant, each rated to handle load capacities up to 550 lb., and there’s also a 1,100-lb. model with a working radius of up to 20 ft.

End-of-arm tooling options include suction cups, magnets and specialized grippers for custom industrial applications. www.ergonomicmanipulators.com www.plantmagazine.ca/rsc/ 8

workers.

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12-04-10 11:46 AM

Product Focus << Technology Check liquid levels

Bridge the relay gap

Emerson Process Management’s Mobrey horizontal magnetic float level switches have been certified IEC61508 by Exida to attain safety integrity level (SIL) 1 for a single device and SIL 2 for a pair of devices. The switches are now covered by the required failure modes, effects and diagnostic analysis (FMEDA) report by the international standard for electrical, electronic and related technologies.

They’re typically used in the oil and gas, power, refining and chemical industries for high and low liquid level alarm, overfill alarm and pump control duties.

Certified switches make it easier to design and implement a safety system for process applications that comply with the functional safety standard.

Emerson says magnetic coupling delivers reliable operation even in extreme pressure and temperature environments.

Measurements are unaffected by changes in process temperature, dielectric or the presence of vapours. There are a range

of flanges, floats and switching outputs for all types of liquid level applications, but no glands or linkages that could cause leaks, or springs that require maintenance.

The snap action mechanism ensures a clean make or break of the switch contacts and a hermetically sealed switch mechanism to eliminates freezing and corrosion of contacts and moving parts.

Emerson is a manufacturer of automation products based in Austin, Tex. www.mobrey.com

The compact VAS-2A8L-KE4-8SE safety module from Pepperl+Fuchs bridges the gap between low-end relays that can’t adapt to evolving needs and high-end options too costly for smaller applications.

The safety controller has four redundant safe inputs, two independent safe electronic outputs and runs on standard 24 VDC, allowing the use of any safety device with dry contacts or electronic safe outputs.

Removable terminals simplify installation and field service. An intuitive dragand-drop application interface simplifies the configuration of even complex safety operations in just minutes. When the configuration is downloaded into the safety controller, documentation is automatically created and all necessary data is backed up on a memory card.

Pepperl+Fuchs, based in Twinsburg, Ohio, is a manufacturer of factory and process automation products. www.sensing.net/safety

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IEC61508-certified.

Lock ensures safe pigging system operation Closure locks from Netherlocks Safety Systems eliminate the danger of improper operation of pigging system valves by ensuring correct operational procedures are followed.

Pigging systems are used to insert a pipeline inspection gauge into a live system transporting gas or liquid media to perform various maintenance operations. Dealing with such high-pressure levels, pigging operations require a precise sequence of valve operations. The lock protects against improper operation of the closure door, where common accidents include: opening the closure door while pressure still remains inside the vessel; opening the main process valve while the closure door is not fully closed; and opening the closure door while a high concentration level of toxins still remains inside the vessel.

A series of keys lock into place and can’t be removed out of sequence. This guarantees workers always follow the correct valve operation procedure.

Netherlocks is a Houston-based supplier of safety and valve control systems for major industrial operations. www.netherlocks.com Closure door protection.

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Comfort and protection.

Protect eyes from impacts Conqueror safety eyewear from Gateway Safety provides comfort as well as protection.

The glasses are certified by Underwriters Laboratories to meet the ANSI Z87.1+ high impact standard and now come with blue lenses and a black frame.

They’re lightweight, have a soft rubber nosepiece and ergonomic, contoured temple tips that prevent pinching.

Gateway Safety is a manufacturer of safety products in Cleveland, Ohio. www.gatewaysafety.com

Industrial Training International is opening a subsidiary in Edmonton. ITI Canada will include local management, trainers, and support administration. The Woodland, Wash.-based company provides training for cranes, heavy equipment and rigging.

Following a run-up of more than 20 points in January and February to its highest level in more than six years, NEMA’s Electro industry Business Confidence Index (EBCI) for North America retreated 0.5 points to 72 in March. NEMA, an association representing electrical equipment and medical imaging manufacturers, reports future North American conditions remain “strongly positive,” jumping 11 points to 86 in March, its highest reading in more than a year.

Tim Colpitts, a second-year student in the Welding Engineering Technology Program at Northern College in Kirkland Lake, Ont., is the 2012 ESAB Canada Post-Secondary Scholarship winner. His interests are in ultrasonic, radiographic, and liquid dye penetrant testing methods. Welding and cutting products manufacturer ESAB Group Canada established the scholarship to further support post-secondary education students who choose a career in welding and welding technology.

The Bearing Specialists Association (BSA) has an Industry Brief on Wind Power that details the use of bearings in wind turbines components. Download it at www. bsahome.org, under Tools You Can Use.

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The Prairies office of WESCO Distribution Canada LP, a Markham, Ont.-based distributor of industrial automation controls, has won a “Distributor of the Year” award from Omron Industrial Automation for its “outstanding sales performance.” Omron, a manufacturer of industrial products, cited WESCO’s excellent sales growth, particularly in the oil and gas sector based in Edmonton.

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>> Supply Line

9/9/11 2:35 PM

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CIEN CONNECTORS

Controllers Pressure regulation accuracy

12-10 AWG wire range.

Solar connectors inter-mate Automation Systems Interconnect Inc.’s ASIPV solar connectors are compatible and mate with industry standard 4-mm connectors.

They come with a 1,000 VDC (IEC), 600 VDCV (UL) and 25 A rating. Both male and female contacts have a wire range of 12-10 AWG. Snap lock mating ensures secure connections and metal crimp pins made of a tin-plated copper provide low contact resistance and protect against corrosion.

Automation Systems Interconnect is a Mechanicsburg, Pa.- based supplier of electrical components for the solar industry. www.asisolarproducts.com www.plantmagazine.ca/rsc/ 13

ControlAir Inc.’s Type 330/340 air filter regulator withstands harsh environments while providing accurate pressure regulation and filtration.

It’s available in 1/4 in.

NPT porting for normal operation and 1/2 in. NPT porting for high flow requirements.

ControlAir, a manufacturer of preci- Withstands sion, pneumatic and harsh environments electro-pneumatic control products, says the automatic drain option prevents moisture from being retained in the unit and carried downstream.

The Type-330/340 provides instrument quality air to valves, pneumatic controllers, transmitters, transducers, valve positioners, air cylinders and a wide range of pneumatic control systems for applications such oil and gas processing, food processing, pulp and paper and wastewater treatment.

ControlAir manufactures precision pneumatic and electro-pneumatic controls in Amherst, NH. www.controlair.com www.plantmagazine.ca/rsc/ 15

winding, laminating, cross-cutting, calendaring, perforating, embossing, coating, flying saw, die cutting and traversing.

Components of the box are preprogrammed functions. Sample applications demonstrate how each function is implemented into a machine design.

Some of the applications are ready-touse after only minor modifications and even include basic HMI functionality. www.usa.siemens.com/converting www.plantmagazine.ca/rsc/ 16

MATERIAL HANDLING

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Low profile belt conveyors

SCREEN PRINTING

Dorner’s Precision Move technology for its 2200 low-profile belt conveyors provides a gang drive option to power and move multiple conveyors from one common motor.

The gearmotor drives multiple conveyors at the same speed with positive-drive belting, a feature the Hartland, Wis.based manufacturer of conveyor systems says is useful in automation, sortation, vision inspection, part positioning and indexing applications.

The gang drive is typically located in the middle of the conveyors, freeing up the ends to interface with other equipment.

The 2200 mid-drive can be located anywhere along the frame between the two ends for maximum flexibility. www.dornerconveyors.com www.plantmagazine.ca/rsc/ 17

Fast strap smaller packages

The HARTING Technology Group has launched an angled version of its RJ Industrial 10 G Ethernet connector. Rated IP 20 for the office IT environment, this ultra-flexible, lockable, eight-wire RJ45 requires no tools or expertise to assemble.

The manufacturer of connectors with a Canadian office in Saint-Laurent, Que., says the 45 degree cable outlet can be mounted in four different directions to ensure correct cable outlet direction with the same item number every time.

This safe, robust and industry-compliant connector is also multi-port capable. The RJ45 features an industrial strength actuator with locking lever protection and optional colour coding tabs for saving patch cable-ID and parameters.

The insulation displacement terminations are fitted for flexible and rigid wires with profiles ranging from AWG 27/7 to AWG 22/1. Cables with a diameter of between 4.5 and 8 mm connect.

With data transfer rates up to 1/10 Gbit Ethernet, the 10 G series is twice as fast as previous versions. www.harting.com www.plantmagazine.ca/rsc/ 14

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Integrates fall converting lines and machines.

Toolbox provides PLC control The Simatic converting toolbox module from Siemens Industry Inc. provides PLC-based process control, completing the application set that includes Simotion, a group of high-performance motion control converting solutions, and the Sinamics DCC (drive control chart) module.

The toolbox integrates full converting lines and machines centralized on the Simatic S7 PLC platform. Functions include centre winder, sectional drive control and a host of converting process and large functions. Systems are implemented in Ladder, structured text or in a graphical functional block language.

Siemens, the German industrial products company with US operations in Elk Grove Village, Ill., says machine builders will reduce the time required for engineering, programming, commissioning and documentation by as much as 80%.

Modular open functions are included for

It handles packages of up to 600 mm high and 800 mm wide. Its strap feed system makes coil changes easy.

EAM-Mosca, based in Hazle Township, Pa., is a supplier of semi-automatic, automatic and operator-less strapping systems for industry. The company has a sales office in Whitby, Ont. www.eammosca.com

Drives multiply conveyor systems.

Ultra flexible, lockable.

Angled connectors

Simultaneous feeding.

The ROM-Fusion from EAM-Mosca Corp. quickly straps smaller packages and bundles.

It handles up to 55 straps (up to 5 mm) per minute, which works well with two operators feeding from the front and back of the machine.

Mammogram paddle image.

Deep-screen printing Systematic Automation Inc.’s Model HLT screen-printing machine prints up to 76-mm deep into a plastic tray with an image as close as 3 mm to the inside wall of the tray.

Screens are pre-registered to the master screen chase. Change over from one size plastic part to the next is done while maintaining registration. Images are preregistered on the screens according to the stops for the variously sized plastic parts.

Systematic Automation is a Farmington, Conn.-based manufacturer of screen-printing machines. www.systauto.com www.plantmagazine.ca/rsc/ 19

MILLING ADAPTABLE Ultra fine milling USES LESS energy The Raymond Ultra Fine Mill outputs materials five times finer and consumes up to 50% less energy than other mill technologies.

Alstom Power Inc.’s Raymond operation, a Warrenville, Ill.-based manufacturer of industrial milling equipment, says the system delivers material as fine as 50% passing 2 microns, or as coarse as 50% passing 10 microns.

A shaft rotates convex rolls inside the concave grinding rings of the air-swept Vertical ring mill. vertical ring mill to reduce materials to high degrees of fineness in a multi-stage process. Air flow carries ground material through the classification process to achieve the desired grade.

The compact mill features a low classifier speed, highly accurate fineness separation and versatile grinding elements that adapt to meet product size specifications. www.alstom.com/power www.plantmagazine.ca/rsc/ 20

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Products and Equipment << Technology LIGHTING Light up with super halogens The L61 dock light from Lind Equipment Ltd. uses LED technology that’s bright enough to light up an entire 53-ft. trailer.

Lind says the L61 uses only 16 W of power, compared to 500 W for a traditional quartz halogen dock light.

The LEDs are rated for over 50,000 hours. Rated for over 50,000.

The housing is made from a tough polycarbonate polymer that stays strong and impact resistant even in cold temperatures.

Lind is a Markham, Ont.-based manufacturer of portable electric products. www.lindequipment.net

output power from six models ranging from 1.75 to 4.2 A with self-adjusting output voltage from 15 VDC to 54 VDC. All models are enclosed to the IP67 standard in an extruded aluminum metal case.

The GLC-100 has efficiencies in the 90% range with active power factor correction greater than 0.90 on every model.

All units have over voltage, over current and over temperature protection, and they’re RoHS compliant.

Green Watt Power is a division of Calex Mfg., a manufacturer of power products based in Concord, Calif. www.greenwattpower.com www.plantmagazine.ca/rsc/ 23

MACHINING

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Explosion proof LED Larson’s Magnalight EPL-BS-70LED100X12 explosion proof light uses advanced LED technology to deliver low voltage bright light in hazardous locations and environments It produces 6,020 lumens and is equipped with an inline transformer that steps down standard 120 V-277 VAC current to 12 VDC for applications requiring low voltage operation.

Illuminate hazardous locations.

Larson, a Kemp, Tex.-based manufacturer of industrial LED lighting, says the light uses seven 10-W Cree LEDs and advanced PWM LED driver technology.

The housing is made of copper-free aluminum with a ¾-in. thermal shock- and impact-resistant tempered glass lens.

A thermoset powder-coated finish and threaded joints using non-drying lubricant provide added durability and reliable explosion proof protection. www.magnalight.com www.plantmagazine.ca/rsc/ 22

Rugged casing.

Power supply for all lighting The GLC-100 constant current AC/DC LED power supplies from Green Watt Power handles virtually any lighting application.

Universal-full range AC input voltage of 100 to 277 VAC offers reliable 100 W

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Corrosion controlled.

Cutting fluid for hard metals CIMTECH 610 metalworking fluid from CIMCOOL Fluid Technology delivers synergistic performance on difficult-tomachine ferrous and non-ferrous alloys without corrosion or staining.

The product is formulated for hard, brittle metals such as inconel, titanium, stainless steel, aerospace alloys and hardened steel. Chlorine, sulphur or phosphorus EP lubricants are not needed. The fluid has a near neutral pH, providing good corrosion control on ferrous metals and doesn’t stain aluminum or other exotic alloys.

CIMCOOL, a Cincinnati manufacturer of metalworking fluids, recommends it for tough operations, noting it’s low foaming, and provides good part visibility for operators. www.CIMCOOL.com

HMC 1250/1600 for extreme application flexibility, providing a maximum 3,000 mm work-zone swing and 15,000 kg pallet load capacity.

With its 360,000-position contouring table, the 5-axis HMC delivers 56 to 100 kW spindle power, 35 kN Z-axis thrust, and super-rigid, full-contouring hydrostatic rotary table. www.mag-ias.com Eight spindle options.

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SURFACE TREATMENT Surface grippers with grit Abrasive Diamond Surface Grippers from Fixtureworks feature surfaces comparable to 100-grit sandpaper bonded permanently to a stainless steel pad that won’t slip on smooth or slippery surfaces.

The urethane-covered bearings have a smooth surface for smooth, quiet and non-marring operation. A urethane outer surface that’s permanently bonded to a steel insert press-fits onto standard cam followers to prevent metal-to-metal contact and damage to finished or delicate Prevents metal-to-metal contact. surfaces.

Fixtureworks is a Fraser, Mich.-based manufacturer of workholding technologies, material handling and machine tool components and fixturing accessories. www.fixtureworks.net www.plantmagazine.ca/rsc/ 26

Canada’s Largest

HEALTH & SAFETY EVENT

Celebrated Keynote Speakers JOHN FURLONG Chief Executive Officer Vancouver 2010 Olympics Organizing Committee

Living Leadership

www.plantmagazine.ca/rsc/ 24

MICHAEL KERR Motivational Speaker, Business Trainer and Humour in the Workplace Expert

Cut hard metals MAG’s modular HMC 1250/1600 horizontal machining centres, engineered for high-precision, high-productivity machining of large aerospace, power generation, pump, valve and off-road equipment parts, now include eight spindle options to suit special-purpose or general machining requirements.

The 6000 and 8000 rpm/46-kW (61.6hp) tilt-spindles – with +90/-120 degree A-axis travel – join an all-around 10,000 rpm/46-kW (62-hp) spindle, high-speed 24,000 rpm spindle, high-torque 2600 Nm/80-kW (1,918 ft.- lb.) spindle and two live spindles (110- or 130-mm diameter).

A high-torque spindle cuts hard metal while the live spindles extend W-axis reach by up to 800 mm for deep cavity milling.

MAG, a German machine tool and systems manufacturer with Canadian offices in Mississauga, Ont., has built the

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CIEN TEST & MEASUREMENT

2-in-1 digital storage

Measures liquids and solids Use the OPTIFLEX 1100C level meter from Krohne Inc. for liquids and solids in non-explosive environments.

The company, a manufacturer of measuring instruments based in Duisburg, Germany, says the 2-wire, loop-powered OPTIFLEX 1100 C is available with a standard 20-m cable or segmental coaxial probe for liquids and a 10-m cable for solids.

It’s also available with an integrated display and keypad, eliminating the need to open the housing cover for configuration. A blind version is also available. Multiple blind versions can be configured on site using a single HMI service tool.

The OPTIFLEX 1100 C uses TDR (time domain reflectometry) technology that measures levels independent from physical property variations such as dielectric constants, pressure or density. The meter doesn’t require wet calibration. It’s immune to linearity problems in irregular tank shapes and has no fragile or moving parts. www.krohne.com www.plantmagazine.ca/rsc/ 27

Position and speed feedback.

Feedback from rotary encoders Heidenhain’s EBI 1135 small rotary encoders and revolvers act as feedback systems for position and speed control of highly dynamic servo motors used on automation technology and industrial robots.

The EnDat 2.2 pure serial interface transmits high-resolution absolute position value to improve transmission reliability, in particular in environments with high electromagnetic noise potential (such as on welding robots).

Heidenhain is a Schaumburg, Ill. manufacturer of measurement and control equipment. www.heidenhain.us

Engineers get space-saving 2-in-1 test instruments for signal analysis and stimulus response testing with the 2540B-GEN and 2542B-GEN digital storage oscilloscopes from B&K Precision.

Both are fitted with waveform generation at 60 MHz and 100 MHz, 1 GSa/s DSOs. The 2540B-GEN with 20 MHz AWG and the 2542B-GEN with 40 MHz AWG generate sine, square, and arbitrary waveforms from the generator output terminal.

Combining DSO and AWG signals are captured and stored directly from the oscilloscope’s channels to the generator’s internal memory. User-defined arbitrary waveforms can also be edited using Comsoft PC software and uploaded to the instrument.

B&K Precision is a manufacturer of test and measurement instruments in Yorba Linda, Calif. www.bkprecision.com

up to 250 psi when the system is activated.

The P-1590 is used on the water supply side of a wet system where water is available to the sprinkler head at up to 300 psi.

AMETEK, a manufacturer of electronic instruments and electromechanical devices in Horsham, Pa., says both models feature a polycarbonate one-piece ring and crystal window, plus an impact- and chemical-resistant moulded case. www.ametekusg.com www.plantmagazine.ca/rsc/ 31

WATER JET

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Sensor keeps flares smokeless

Eight operating pressures.

High pressure water jet NLB has expanded the operating range of its 125 Series convertible water jet pump units to include ultra-high pressures. All models can be converted in about 20 minutes to any of eight operating pressures, from 6,000 to 40,000 psi (414 bar to 2,800 bar), using NLB’s conversion kit.

Fast conversion to 35,000 or 40,000 psi offers more flexibility to do jobs with a single water jet pump unit.

NLB, a Wixom, Mich.-based manufacturer of high-pressed water jet systems, says this flexibility is enhanced by the range of flows (4.4 to 32.5 gpm, or 16.5 to 123 lpm) and a choice of engines, 125 hp or 145 hp (93 kW or 108 kW).

NLB has 22 convertible water jet pump units capable of operating at 40,000 psi. www.nlbcorp.com Ver FNL Date Apr 8, 2012

technology covers a large The Model FM flare monitor for smoketarget area and comes less petrochemical flares with a standard or rugprevents smoke before it is For wet or dry systems. ged housing. It mounts produced, rather than at ground level, typically reacting to it.

Gauges monitor within 1,500 ft. (457 m) Williamson Corp., a sprinkler pressure from the base of the stack. The Concord, Ma. manu P-1590 and R-1590 sprinkler system strength of the measured signal facturer of temperature gauges from AMETEK US Gauge are decreases with the square of measurement instruments, designed for use on wet or dry sprinkler the distance. says it’s also the only optical product systems.

Optical resolution is D/17 (60 of its type that’s unaffected by the The R-1590 retarded air gauge is used ft. at 1,000 ft.). introduction of steam. on the sprinkler-head side of the control www.williamsonir.com The Model FM senses conditions in a dry system to monitor line air Docket MA038-479 Clientvalve IMAGEWEAR that precede the formation of pressure. It also accepts water pressures Unaffected by steam. www.plantmagazine.ca/rsc/ 29 Ad: Clothes Spread www.plantmagazine.ca/rsc/ 32 Job Magazine Specs Double-Truck: 14" x 4.875" soot, not soot particulates. It Pub/Printer Canadian Plant Magazine Material Deadline April 9, 2012 monitors the ratio of carbon to oxygen within the flame, and its continuous output signal is proportional to that ratio and therefore proportional to the tendency of the flame to smoke.

When the signal indicates that oxygen is becoming relatively scarce, a successful control scheme adds oxygen to the flame before the signal reaches the critical setpoint at which soot would form.

Thanks to its special narrow-band infrared filters, the Model FM’s output is reliable even through dirty optics, fog, rain, and snow (within limits). The output signal typically goes to a proportional-integral-derivative (PID) system that activates a control valve to modulate the amount of added air or steam as needed, ensuring there’s always ample oxygen for the combustion to be complete, all without the need for operator intervention.

In facilities that use steam, no steam is wasted.

It comes standard with through-thelens sighting and an adjustable swivel bracket for simple installation and alignment. The sensor’s dual-wavelength

Whatever your people do, wherever they need

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Products and Equipment << Technology SENSORS Accurate industrial scanning The DXH15-10-000A outer member rotating BLDC motor from BEI Kimco Magnetics meets high accuracy requirements for a variety of industrial scanning Prevents laser beam rasterizing. applications.

It supports extreme inner rotational speed variations by maintaining a shaft run-out of only +/- 0.010.

The result is a negligible jitter of less than ±0.1%, a key requirement in performance specifications for laser bar-code scanning machines used in production material handling applications.

The motor’s negligible shaft run-out characteristics prevent the laser beam from rasterizing.

BEI Kimco Magnetics, a Vista, Calif.based brand of Custom Sensors & Technologies (CST), says the motor incorporates a proprietary Hall commutati-

on4circuit that produces exacting switch points required by control electronics for rotor position sensing.

Precision ball bearings and a balanced rotor ensure reliable operation at speeds in excess of 11,000 rpm under continuous duty over the life of the system. www.beikimco.com www.plantmagazine.ca/rsc/ 33

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A minimum of 50 million operations.

Sensor for low-power apps Use Meder Electronic Inc.’s MK24 ultraminiature surface-mount reed sensors for low power applications, including portable electronic devices, contact sensors, position sensors, telecommunications switches and limit switches.

The 5- x 1.8- x 2.2-mm sensors have a long life: they should deliver a hit minimum of 50 million operations at 5 V, 5

POWER Big power for mini-apps MicroPower Direct’s MPB-20S provides power for miniature-sized applications.

The supplier of power conversion products based Six models with in Stoughton, Ma. says the open frame, 20-W AC/DC power a universal input. supplies handle process control systems, test and measurement instrumentation and board level power distribution systems.

Six standard models operate from a universal input of 85 to 264 VAC, providing tightly regulated single outputs of 3.3, 5, 9, 12, 15, or 24 VDC. Standard features include filtering to EN55022 Class B, input/output isolation of 3,000 VAC, and low leakage current. The MPB-20S series has an MTBF greater than 300 khrs. All models are approved to EN 60950. The series is certified to CE and is RoHS compliant.

The series is a pin mount design, fabricated on a compact 2- x 3.5-in. PC board that plugs into the user’s board. Each model is rated for operation over the wide ambient operating temperature range of 0 to 70 degrees C. www.micropowerdirect.com www.plantmagazine.ca/rsc/ 34

mA, 100 Hz. They’re made of a rugged over-moulded package containing the hermetically sealed reed switch and require no external power to operate making them suitable for lowpower applications in limited spaces.

Meder Electronic is a West Wareham, Ma.-based manufacturer of reed switches, sensors and relays. www.meder.com

Streamlines mill operations.

Sensors keep steel mills rolling Non-contacting LVDT position sensors from Macro Sensors keep steel rolling mill operations running smoothly resulting in less downtime.

They monitor the position of milling frames that support rollers during the hot rolling process to ensure frames don’t deform or shift, and the position of the rollers themselves.

Macro Sensors, a manufacturer based in Pennsauken, NJ, has built in long-term operation for use within the high temperature environment of steel rolling mills.

They’re sealed to IEC standard IP-68, rated to 85 degrees C and resist moisture as well as contamination from airborne particulates or other dirt and grime. www.macrosensors.com www.plantmagazine.ca/rsc/ 36

Monitor temperature wirelessly Monitor temperature, humidity, and barometric pressure in critical applications on the web with Newport Electronics’ zSeries sensors.

No software, just a web browser.

The compact wireless end devices mount discretely on the wall and transmit up to 300 unobstructed feet (92 m) to a coordinator connected directly to an ethernet network and the internet.

The system, which complies with IEEE 802.15.4 operating at 2.4 GHz, doesn’t need special software, just a web browser. The device triggers an alarm if variables go above or below a user-set point by e-mail to a single user or to a group distribution list, including text messages to internet-enabled cell phones and PDAs. Newport Electronics Inc. is a manufacturer of instrumentation in Santa Ana, Calif. www.newportus.com www.plantmagazine.ca/rsc/ 37

Detect gas leaks MSA’s portable ALTAIR 4X Multigas Detector driven by MSA XCell sensor technology delivers faster response time, increased stability and less than 60-second span calibration Better sensor life. time for oil and gas and manufacturing operations.

The Cranberry Township, Penn. sensor manufacturer says the detector operates with only MSA XCell sensors for combustible gas, O2, H2S and CO and is compatible with ALTAIR 4 Galaxy Test Stand and optional MotionAlert and InstantAlert features. www.msanet.com www.plantmagazine.ca/rsc/ 38

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High-level x-ray contrast.

Safeguard contaminated food PolyMag XRD plastic additives from Eriez ensure food products containing broken pieces of plastic or rubber never reach consumers.

They impart x-ray contrast into foodcontacting plastic articles such as tote bins, paddles, pails, pallets, scoops, scrapper blades, shovels, conveyor buckets and chains, belting, gaskets, grommets and O-rings.

A co-polymer carrier resin is compatible with a range of polymers including polyethylene, polypropylene TPE. Eriez, a supplier of advanced technologies for magnetic, vibratory and inspection applications, is based in Erie, Pa. www.eriez.com www.plantmagazine.ca/rsc/ 39

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CIEN WELDING

Welding helmut makes the switch

Fibre laser markers.

High-speed marking and ingraving Miyachi Unitek Corp.’s 50 W LMF5000 ytterbium (Yb) fibre laser marker increases processing power for faster, deeper marks on materials such as aluminum, tool steels, copper, brass and graphite.

Use it for high speed marking, engraving and deep engraving of metals, thin sheet cutting and high speed surface texturing. The ultra-compact LMF5000 model maximizes integration flexibility.

Miyachi Unitek, a Monrovia, Calif.based manufacturer of welding equipment and systems, says the LMF5000 series features multi-language software support and advanced processing features, including pulse waveform control, selectable laser brightness and a range of spot and field sizes.

Multiple integration options accommodate standalone operation, full production automation or prototype development. www.miyachiunitek.com

The Tweco WeldSkill welding helmet from Thermadyne can make the switch from light to dark when TIG welding, even at 5A. It has four sensors for enhanced performance, operating in weld or grind mode and a large viewing area (10 x 4.3 cm), weighing in 0.5 kg.

And there’s no need for batteries: it’s solar powered.

When switching from light-to-dark, the helmut darkens in 33 microseconds, or 1/30,000th of a second, one of the fastest reaction times available (blinking takes 3/10th to 4/10th of a second).

When switching from dark-to-light, operators select from three switching speeds: short (0.25 to 0.35 s), medium (0.35 to 0.50 s) and long (0.50 to 0.80 s).

Sensitivity and delay knobs on the

Enhanced performance.

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Your safest, most efficient alternative to toxic solvent parts washing!

BIO-CIRCLE is a complete, cost-effective and hassle-free solution which: ✓ Cleans your parts without risks of health hazards ✓ Comes with a complete on-site maintenance CARE ServiceTM performed in 21 precise steps by our qualified technicians ✓ Is compliant with ISO 14000, ISO 18000, ACCP and Canadian food industry standards. ✓ Has been adopted by thousands of industrial facilities worldwide!

outside of the helmet shell allow adjustments while welding. When it’s set down, a recessed lens prevents the faceplate from touching the table, protecting it from scratches.

Thermadyne, based in St. Louis, Mo., is a global manufacturer of metal cutting and welding products and accessories. www.thermadyne.com www.plantmagazine.ca/rsc/ 41

INSTRUMENTATION Solenoid valves for air and liquids Use Dwyer Instruments’ compact, general service SBSV solenoid valves for air, gas, water and other liquid applications.

The 110 VAC twoway guided valves come in brass or Varied valve sizes and stainless steel with a flow rates. normally closed design but can be oriented in any position. Their NEMA-13 rated solenoid enclosures keep out debris.

Brass valves come assembled with an NBR seal and a maximum process temperature of 80 degrees C. Stainless steel valves come with a fluoroelastomer seal and a maximum process temperature of 120 degrees C. Sizes range from 1/8 to 2 in. NPT and orifices are from 3 to 50 mm.

Dywer Instruments Inc. is a Michigan City, Ind.-based manufacturer of controls and instrumentation for the HVAC, food processing and oil and gas industries. www.dwyer-inst.com www.plantmagazine.ca/rsc/ 42

Analyzer leverages IR spectroscopy The MINISCAN IRXpert from AMETEK Grabner Instruments is a portable multi-fuel analyzer for gasoline, diesel and biodiesel blends that incorporates the advantages of mid-IR and near-IR spectroscopy.

The MINISCAN IRXpert uses more than 12,000 data points from the infrared spectrum to determine the concentration of molecules in a sample.

AMETEK Grabner, a manufacturer of electronic instruments and electromechanical devices based in Austria, says the spectrum yields a “fingerprint” of more than 40 important fuel properties.

It performs compound analysis

according to international standards (ASTM D5845 for oxygenates, ASTM D6277 and EN 238 for benzene, and EN 14078 for biodiesel). Predictions for octane number, AKI and cetane number For gas, diesel and are based on ASTM biodiesel.

D2699, 2700, 613, ISO 5163, 5164; distillation on ASTM D86 and ISO 3405; and vapour pressure on ASTM D6378, D5191, D323 and EN 13016.

An integrated temperature-controlled density meter determines fuel density and comes fully configured and ready for testing.

There’s a full-colour touch screen for menu navigation and in-depth spectrum analysis. USB and ethernet interfaces provide quick data transfer, printing, LIMS integration, remote control and service. www.petrolab.com www.plantmagazine.ca/rsc/ 43

FLUID TECH SFE for R&D, process development The SFT-110WX benchtop supercritical fluid extractor (SFE) aids process development for successful scale-up to pilot or production equipment by precisely controlling temperature, pressure and flow rate.

Supercritical Fluid Technologies, a Newark, Del.-based Precise flow manufacturer of control.

SFE systems, has made the SFT-110XW for use in both research and process development applications.

An integrated micrometer delivers precise flow control and a completely removable oven lid plus a large side panel provide easy access to the high-pressure vessels.

An indicator light on the SFT-10 pump module alerts the user to proper operation of the Peltier pre-cooler, ensuring CO2 is maintained in the liquid state. An outlet from the restrictor prevents accidental damage to its tube when inserted into the collection container. Extraction vessels are up to 500 ml, single or dual configurations. www.supercriticalfluids.com www.plantmagazine.ca/rsc/ 44

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Low out-gassing gasket resin Dymax Corp.’s See-Cure GA-140-SC seals fuel cells, critical electronic assemblies and plastic assemblies.

This UV/visible light-curable, low out-gassing gasketing resin for applications requiring soft, tack-free, flexible gaskets is a silicone-free, one-part resin that doesn’t require mixing and can be dispenses into intricate and complex configurations.

The Torrington, Conn.-based manufacturer of solvent-free adhesives says it cures in seconds, conforms to intricate channels or recesses and it resists tearing when used for serviceable and limited-service applications designed for flat flanges, wide shallow grooves or flat surfaces. www.dymax.com www.plantmagazine.ca/rsc/ 45

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Products and Equipment << Technology Plantware

in place to eliminate data loss, and in extreme cases, the risk of fire caused by loose cables and arcing.

Isolators protect They’re rated for a temperature range connected equipment of -40 to 80 degree C. They proB&B Electronics Manufacturing vide Level 4 ESD protection Co. Inc. has expanded its fam(15 kV air, 8 kV contact) ily of USB isolators that as well as 4 kV isolation protect equipment from between the upstream and surges, spikes and electrodownstream USB ports. static discharges.

Downstream ports provide The one-port Ulinx full 500 mA power to connected UHR401 and two-port Ulinx devices. The high retention UHR402 USB isolators also proports hold cables so firmly that tect themselves thanks to their it requires 3.2 lb. of force to tough construction. They’re One- and two-port dislodge one. The Ulinx UHR401 made to withstand industrial USB isolators. and UHR402 are shipped with an externetworking hazards such as shock, drop, nal power supply that has US, EU, and vibration, electromagnetic interferUK blades. An optional locking barrel ence and temperature extremes. High plug can be purchased separately. retention ports hold USB cables firmly

Convert signals to IEC data WAGO Corp.’s IEC-compatible TeleControl PLC and four Linux-equipped I/O-IPCs conserve engineering resources by providing both control and smart grid integration. These WAGO-I/O-SYSTEM components support IEC 60870-5-101 (serial transmission), IEC 60870-5-104 (TCP/IP-based communication) and IEC 61850 (substation protection/control).

Programmable via CoDeSys 2.3, they convert signals from process/telecontrol apps via connected I/O into IEC-compliant data. This simplifies monitoring of supply networks/ transformers, integration of both pumped-storage and hydroelectric power plants into a control system, as well as WAGO IEC-compatible networking wind/solar farms. telecontroller.

The 32-bit 750-872 TeleControl PLC provides application protocols for data acquisition/control (Modbus TCP/RTU, Ethernet I/P) or management/diagnostics (http, BootP, FTP and more).

The 758-870 is available as a Linux 2.6 Master (Profibus DP or CANopen) or Slave (Profibus DP) – both with a 266 MHz Geode processor. The Linux-backed 758-875 I/O-IPC-G2 is available with a 1 GHz Celeron M processor as a Profibus DP or CANopen Master for extended application ranges. All 758 Series I/O-IPC-G2 Masters can double as a main PLC for industrial applications.

The Telecontrol components are compatible with the WAGO-I/O-SYSTEM’s 400+ digital, analogue, specialty and Ex-i-compliant modules for custom applications. Both the TeleController and I/O-IPC-G2 units pair with Ex-i-components to eliminate EX-barriers within hazardous control applications. They also provide capital asset management via WAGO’s Vibration Monitoring and 3-Phase Power Measurement I/O. WAGO is a supplier of spring pressure connection technology based in Germantown, Wis. www.wago.us www.plantmagazine.ca/rsc/ 48

B&B Electronics is a developer of rugged wireless and wired M2M connectivity solutions for harsh environments. www.bb-elec.com www.plantmagazine.ca/rsc/ 46

Module goes with the flow Emerson Process Management’s Ethernet/IP Module for Micro Motion Coriolis meters are for use in new or retrofit installations.

Access to the multivariable data allows for increased productivity and fast process insight with control system acAccess multivariable cess to flow, density, data. temperature and many other parameters.

Installable in less than 30 minutes, the module mounts in the control cabinet, eliminating ethernet cabling running out to the field. The module web browser provides network access to a powerful configuration and diagnostic interface for a full range of remote activities.

This includes smart meter verification, which determines Coriolis meter performance without stopping the process or interrupting the flow.

The new module accesses a growing number of EtherNet/IP plant-wide networks and adds to the range of communication interface options available with Micro Motion Coriolis flowmeters. These include DeviceNet, Profibus DP, Modbus, Foundation fieldbus and Profibus PA in addition to the traditional interfaces of 4-20 mA frequency and HART. The DIN-Rail-mountable module is ODVA-certified. Its software allows easy configuration of the flowmeter via the plant network.

Emerson Process Management is a manufacturer of industrial technology based in St. Louis, Mo. www.micromotion.com

Improve conveyor operation with industrial brush for sealing, guiding, positioning and static control

• Conveyor and material handling • Packaging lines • Machine tooling • Protecting hydraulic mechanisms

Custom industrial brushes in a variety of sizes and configurations For more than 25 years, Sealeze has manufactured the widest variety of custom brush products designed to meet your application needs. Our experienced Sales Representatives, in-house engineering staff and design services are available to help you find the right brush solution for your application.

800.787.7325

e-mail: industrial@sealeze.com www.sealeze.com

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STONE TUCKER INSTRUMENTS INC. MBX Bristle Blaster

Chlor Test

PCWI High Voltage Holiday Tester

• Universal gauge body – all PosiTector 6000 SPG and DPM probes, easily converts from a dew point meter to a coating thickness gauge or surface profile gauge • No software required - Browse gauge readings and charts using your computer's file explorer, or upload to PosiTector.net • Two models - Standard and Advanced. Standard models now have more features • An ergonomic design that's rugged and weatherproof

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CIEN PLANTWARE

Hubs minimize fieldbus hand wiring

Servo drive extends integrated motion

The UNO-3072A and UNO-3074A wallmount industrial PCs with Intel Atom D510 processors from Advantech are just the thing for machine automation and warehouse tasks.

They feature 2 GB DDR2 RAM with an integrated RAID 0/1 controller for two 2.5-in. SATA HDDs and an external SATA port for additional storage. Both work in temperatures ranging from -10 to 60 degrees C and have shock and vibration absorbers for data storage security.

Advantech, a supplier of eAutomation technologies based in Cincinnatti, says the UNO-3072A and UNO-3074A are designed with two Intel gigabit Fulfills EtherCAT and ethernet ports to real-time OS requirements. fulfill EtherCAT and Real-Time OS requirements; 4 x external USB 2.0 ports and 1 x internal USB port, VGA display, I/O programmable LED indicators, isolated DI/DO, and 2/4 x PCI slots for versatile peripherals. The 2 x RS-232/422/485 serial ports support any baud rate for applications that require specific baud rates. www.advantech.com/ea

MTL Instruments’ F300 Megablock wiring hubs for fieldbus apps minimize hand wiring so individual devices are added to and removed from segment without disrupting For hazardous network communications. applications.

They’re used in Zone 2 and Division 2 hazardous areas where high-energy trunks are powered by a range of fieldbus power supplies.

A pluggable Trunk In/Out connector allows replacement of a Megablock without breaking the connection to other devices on the segment. The F97 terminator mounts in the Trunk Out connection to provide termination when the Megablock is located at the end of the segment. It can be removed when the segment is extended to ensure correct termination.

A green power LED on each unit indicates whether at least 10 V of DC power is present. Pluggable surge protection components for the fieldbus trunk and individual spurs are available, reducing the cost of providing surge protection.

MTL, a unit of Cooper Crouse-Hinds, is a supplier of electronic instrumentation and protection equipment based in Syracuse, NY. www.mtl-inst.com

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The Allen-Bradley Kinetix 350 single-axis EtherNet/IP servo drive from Rockwell Automation delivers high-performance motion control on EtherNet/IP. Rockwell Automation, a global supplier of automation technology in Milwaukee, Wis., says the drive lowers the cost of deploying integrated motion on low-axis machines found in applications such as: indexing tables, process skids, case packers, erectors and packaging.

When used with the Allen-Bradley CompactLogix 5370 programmable automation controllers and the Allen-Bradley PanelView Plus human-machine interfaces, the drive provides entry into Rockwell’s integrated architecture, which scales from 200-10,000 I/O, giving machine build- Kinetix 350 on EtherNet/IP. ers the portability to migrate existing machine designs into new, higher-end machine designs and vice versa. The Kinetix 350 on EtherNet/ IP also helps machine builders reuse code to reduce their design, installation and commissioning time.

It’s equipped with safe, torque-off functionality that allows tasks such as machine setup, cleaning, removal of jams and other maintenance to be done without shutting down.

The Kinetix 350 servo drive has a 400W to 3-kW power range to meet a wide array of global machine requirements, including support for 120-VAC input. www.ab.com/motion

Super storage for automation

Mounts on a DIN rail.

Converters monitor current CTC signal converters from NK Technologies make it possible to monitor current in applications where it’s impossible to install a one-piece sensor.

Operators use an existing standard 5-A secondary CT or low voltage (0.333 VAC) ProteCT current transformer with non-contact ranges as low as 0-5 A over a conductor to produce a standard 4-20 mA two-wire, loop-powered signal.

With DIN rail mounting and a 24 VDC loop-powered supply, the CTC snaps in easily and requires no calibration because the primary current transformer ratio provides the scaling required without any installer intervention.

The secondary of a standard 5-A current transformer is connected to the input terminals of the CTC device, the CTC secondary is connected to a nominal 24 volt DC supply and then to the PLC or panel meter input. The converter then produces 4 mA when there is no current through the primary CT, and 20 mA when the CT has full range current present.

NK Technologies is a San Jose, Calif. supplier of current sensing, ground fault detection and power monitoring products. www.nktechnologies.com www.plantmagazine.ca/rsc/ 51

Wireless switch with turbo roamer

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Weidmuller’s WLAN wireless connectivity device provides an access point, bridge or client using Power-over-Ethernet (PoE) or redundant power supply connections.

It’s IEEE 802.11a/b/g compatible in both Avoid wireless the 2.4 GHz or 5.8 GHz signal loss. bands and has a Turbo Roaming feature that allows mobile clients to quickly switch between wireless cells without signal loss.

Several zones are easily specified per radio cell (multi SSID) and different VLANs assigned.

The Richmond, Va.-based power transmission, data and signal control provider offers WPA/WPA2 encryption and RADIUS server authentication (IEEE 802.1X) services to prevent unauthorized wireless network access.

The module, encased in a metal housing, snaps onto the TS35 mounting rail or a rack mount kit option.

IEEE 802.11a/b/g wireless AP/Bridge/ Client WLAN models are available for both the European and North American markets, with an extended operating temperature range from -40 to 75 degrees C. www.weidmuller.com

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Open Ethernet network.

Real-time performance ADVANCED Motion Control’s EtherCAT, an open ethernet-based network standard for real-time performance and topology flexibility, gives motion control precision a boost.

The DZE & DZS series of servo drives for EtherCAT-enabled control networks fit in the palm of your hand and provide precise motion control at a reduced cost when applied in a multiple networked axes system.

Demultiplexed Motion (DMX) technology connects up to 3 DZS drives (subnodes) to a single DZE (node) on an EtherCAT network for up to 4 axes of servo motion.

Removing the cost of additional EtherCAT nodes greatly reduces overall system cost. DxM technology handles all sub-node activity through one node, making master tasks simpler in multi-axis systems.

The Camarillo, Calif.-based company manufactures high power density servo drives. http://www.a-m-c.com

April 2012

12-04-10 11:02 AM

Industrial Literature Reviews CIEN

>> Events Lean 101 CME – Innovation Insights May 3, Brampton, Ont. The five steps to lean thinking, how to use value stream mapping, takt time and visual factory, hosted by Taro Pharmaceuticals Inc. May 3. Call (800) 999-4129. Visit www. innovationinsights.com.

MMTS SME May 14-16, Montreal The Montreal Manufacturing Technology Show (MMTS) presented by the Society of Manufacturing Engineers (SME) for Quebec manufacturers will feature the “Interactive Practical Education Component” – educational sessions held next to equipment exhibits. Visit www.mmts.ca.

Ultrasound World VIII UE Systems May 14-17, Clearwater Beach, Fla. The Ultrasound World technology forum features presentations and short courses by users of ultrasound technology covering a wide range of topics for condition monitoring and energy conservation. Visit http://209.200.118.95/ resources/ultrasound-world-viii-conference.aspx.

Better Physical Asset Management: Initiatives that Work C-MORE May 28-June 1, Toronto This course offered by the Centre for Maintenance Optimization & Reliability Engineering (C-MORE) at the University of Toronto will help you upgrade your asset management practices with proven approaches that have shown measurable pay-offs. Visit ihttp://cmore.mie.utoronto.ca. Click on Events (on the right).

2012 CME National Lean Conference CME June 4-7, Winnipeg Thought leaders and practitioners share their insights and perspectives on continuous improvement, hosted by Canadian Manufacturers & Exporters (CME). Download the details at http://mb.cme-mec.ca, Upcoming Events.

Carbon Economy Summit CMO June 6, Toronto Presented by CanadianManufacturing.com for manufacturing, environmental and government leaders, this forum focuses on environmental, financial and risk management performance in the low-carbon era. Sessions will cover upcoming carbon regulations and standards; climate change strategies for business; revenue growth opportunities; legal and marketing compliance; and sustainable transportation, manufacturing and supply chains. Visit www.carboneconomysummit.ca.

PTDA Canadian Conference PTDA June 7-9, Victoria, BC The Power Transmission Distributors Association (PTDA) present a program for Canadian power transmission/ motion control professionals that includes an industrial showcase, market briefs and speaker sessions that cover the Canadian economy, clean energy and changing demographics. Visit www.ptda.org/CanadianConference.

IMTS AMT Sept. 10-15, Chicago The International Manufacturing Technology Show (IMTS) sponsored by the Association For Manufacturing Technology (AMT) will feature more than 1,100 exhibitors showcasing the latest in manufacturing technology. Visit http://www.imts.com/show/info.html.

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DILBERT™ CONTROLCAT NEW HORIZONS®

MOST POPULAR VACUUM CUPe

The DILBERT™ CONTROLCAT NEW HORIZONS® in Temperature, Pressure, Flow and More Version No. 28 contains over 150 full colour pages of state-of-the-art products separated into seven sections: Automation, Sanitary, Temperature, Electric Heaters, Wireless/Data Acquisition, Pressure/Strain/Force, and Flow/Level/Environmental. www.omega.ca/literature/controlcat28/ OMEGA www.plantmagazine.ca/rsc/ 121

Vi-Cas Manufacturing’s new 16-page, full colour brochure details the company’s most popular vacuum cups.

In addition to dimensional information (including lip diameter, height and mounting holes), the new literature shows photos of each cup to guarantee accuracy. Vacuum cups and accessories are used extensively in all types of packaging and labeling operations. www.vi-cas.com Vi-Cas Manufacturing www.plantmagazine.ca/rsc/ 124

FORCE AND TORQUE MEASUREMENT CATALOGUE

INDUSTRIAL EXHAUST FANS, IMMEDIATE DELIVERY

Imada, Inc. offers a new force and torque measurement catalogue. Products include: mechanical and digital force gauges, manual and motorized test stands, special attachments, digital torque screwdrivers, wrenches, testers and calibrators, hardness testers for rubber and plastic, LED stroboscopes and handheld tachometer. Dealer inquiries invited. www.imada.com Imada, Inc. www.plantmagazine.ca/rsc/ 122

N.R. Murphy carries a large inventory of industrial Exhaust Fans in a vast range of sizes.

The most popular versions are fully built and ready to ship.

When an unusual requirement turns up, they have the experience and manufacturing capacity to quickly modify or build a new fan. Free catalogue, includes N.R. Murphy's line of fans, specifications and guidelines. www.nrmurphy.com N.R. Murphy www.plantmagazine.ca/rsc/ 125

The most comprehensive catalog in the timing belt industry!

A GUIDE TO PWM FLOW CONTROL

BRECOflex CO., L.L.C. is proud to offer its 184 page, B212 polyurethane timing belt catalog. This catalogue focuses on the wide range of belting products and gives detailed, technical information.

For a free copy of the B212 or other catalogues, samples, and technical support call (732) 460-9500 or visit www.brecoflex.com today!

BRECOflex CO., L.L.C. www.plantmagazine.ca/rsc/ 123

A Guide to Pulse Width Modulated (PWM) Flow Control takes an in-depth look at PWM flow control, explains its value in spray operations and includes case studies that illustrate the benefits in coating, lubricating and dispensing applications. www.spray.com Spraying Systems Co. www.plantmagazine.ca/rsc/ 126

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112 . . . . . .

115 . . . . . .

Berg Chilling Systems inc. . . . . . . . . . . . . . . . . . . . . . . . . 9 Carr Lane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 DV Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Exair Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Flir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IBC/18 Fluid Metering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Gordon R. Williams Corp. . . . . . . . . . . . . . . . . . . . . . . . . 5 Hannay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Health and Safety Ontario . . . . . . . . . . . . . . . . . . . . . . . 23 Imagewear . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24/25 Master Bond Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Sealeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 SEW Eurodrive . . . . . . . . . . . . . . . . . . . . . . . . . . . . IFC SME - Society of Manufacturing Engineers Canada . . . . . . . . . . . . 8 Spraying Systems Co. . . . . . . . . . . . . . . . . . . . . . . . . OBC Stone Tucker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Union Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Vac-u-max . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Vi-Cas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Viking Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Walter surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 PLANT 29

12-04-12 1:50 PM

Departments

>> Postscript

Alternate energy sources: still a dream

By Jock Finlayson

T

he annual global energy outlook released by the Paris-based International Energy Agency (IEA) is a timely, if sobering, reminder of the enduring place of fossil fuels in the overall energy mix.

Energy demand and supply patterns change slowly. Despite the earnest wishes of politicians and environmentalists, shifting away from existing carbonintensive energy systems will take generations, not years.

oil demand is expected to increase by 15 million barrels “toWorld reach 99 million barrels per day by 2035… ” According to the IEA, even if governments around the world fully deliver on commitments to reduce greenhouse gas emissions and phase out fossil fuel subsidies, energy demand will rise by 36% between 2008 and 2035, almost entirely as a result of economic growth and rising incomes in emerging markets.

Fossil fuels will account for more than half of the increase in energy use to 2035, with oil remaining the single, dominant

(although diminishing) source of energy.

World oil demand is expected to increase by 15 million barrels, reaching 99 million barrels per day by 2035.

According to the IEA’s projections, coal-fired electricity generation continues to expand on a global basis in emerging markets, especially China and India, even as reliance on coal decreases in Europe, the US, Canada and other developed economies. New coal-fired capacity

to be added in China alone between 2008 and 2035 will exceed the total combined capacity of US, the EU and Japan.

The IEA also shines a spotlight on the growing importance of natural gas in the energy equation. While consumption actually fell in 2009 as the global economic downturn took its toll on demand, use of natural gas is poised to climb 44% by 2035, outpacing growth in demand for all other fossil fuels.

Natural gas is a low-cost, abundant energy source that’s the least carbonintensive fossil fuel, and gas-fired power plants can be built close to population centres relatively quickly. The EIA projects natural gas consumption will grow the fastest in China, but the fuel is also becoming more popular in many other markets, including North America.

Adopting renewables What about all the various renewable, carbon-free energy sources? The IEA hopes renewables will supply one third of the world’s electricity needs by 2035, up from one fifth today. Hydro and wind will lead, although solar, geothermal and bio-mass will also play bigger roles in the future. But there is less scope to adopt renewables outside of the power sector, certainly over the short to medium term.

The IEA believes renewables might meet 8% of global demand for road transport by 2035, compared to 3% now; and maybe 16% of industrial and building heat production, compared to about 10% today.

All of this underscores the immense challenges involved in shifting energy systems away from existing fuel sources and infrastructure, a point long emphasized by Canadian scholar Vaclav Smil, who wrote in 2009: “It took 45 years for the US to raise its crude oil use to 20% of the total energy supply; natural gas needed 65 years to do the same. As for electricity generation, coal produced 66% of the total in 1950 and still 49% in 2007 – wind-driven generation now produces 1.5% and solar photovoltaic a fraction of that. Whatever the eventual solution…the new requisite infrastructures are unlikely to be completed in the next few years.”

Even with taxpayer-financed subsidies, government-imposed rules mandating higher fuel efficiency and progressively greater use of renewables, it’s hard to see how carbon-free energy can be expanded on the scale necessary to make a significant difference to the global energy supply mix in the next decade.

The reality is the world’s energy system in 2020 is apt to look very similar to the one that exists today.

Jock Finlayson is executive vice-president of the Business Council of British Columbia. This column is distributed

by Troy Media in Calgary. Visit www. troymedia.com.

Comments? E-mail jterrett@plant.ca.

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