Plant October 2012

$12.00

Volume 71, No. 07 October 2012

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NEW TECHNOLOGY SECTION

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HIGHLIGHTS Plan ahead for a 5S+1 program Vale clears the AER in Sudbury Business diagnostic for sluggish sales Shell digs deep to deal with CO2 Achieve peak cogeneration efficiency 12-10-05 10:56 AM

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Departments

>> Industry View

>> Bulletins D-BOX Technologies Inc., a Longueuil, Que. developer of motion technology for cinemas, has scored a third deal with Larry H. Miller Megaplex Theatres to equip six screens at four Utah locations with D-BOX MFX Systems. That’s for a total of 20 screens for Megaplex.

Calgary-based energy transporter Enbridge Inc. has received approval from the Alberta Energy Resources Conservation Board to construct the $1.4 billion Woodland Pipeline Extension Project.

It will involve building a 36-inchdiameter line approximately 385 kilometres from Enbridge’s Cheecham regional oil sands terminal to the mainline hub terminal at Edmonton. Initial capacity will be 400,000 barrels per day, expandable to 800,000 bpd.

Electrovaya Inc., a Toronto manufacturer of lithium battery technology, has acquired 71.6% of the shares of Miljobil Grenland AS (MBG), bringing its share to 78.1%. MBG, based in Porsgrunn, Norway, has invested about US$30 million in lithium ion battery technologies for a range of electric vehicle and other transportation applications.

Vancouver’s Ballard Power Systems has shipped the first 100 ElectraGen fuel cell power generation systems to Cascadiant Inc. and Inala Technologies, in Asia and South Africa. The fuel cell systems will be deployed to wireless communications networks for backup power.

New Flyer Industries Inc. has been awarded a contract by the New York City Transit Authority and the MTA Bus Co. to build 90 60-foot Xcelsior clean diesel buses. They’ll be manufactured at the company’s plant in St. Cloud, Minn.

LED Medical Diagnostics Inc., a Burnaby, BC manufacturer of the VELscope early-stage oral cancer detection device and DenMat Holdings LLC, a Los Angeles manufacturer of dentistry products and devices, have entered into strategic alliance to form an oral cancer-screening group.

Canada is the second most tax competitive country among 14 major global economies, after India, and it took the top spot among mature markets, according to KPMG’s 2012 tax study.

Vancouver (2), Toronto (5) and Montréal (6) ranked in the top 10 of the 55 major cities studied.

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CAW reaches deals with the Detroit Three

$210M turbo expander for Rimbey gas plant

Core features relate to bonuses, COL and pension benefits

Like other Detroit automakers, GM demanded lower labour costs.

TORONTO: The Canadian Auto Workers (CAW) union has come to terms with Detroit’s Three, ensuring car production in Canada will be free of labour strife for another four years.

Deals with Ford, Chrysler and General Motors follow the same core compensation arrangement, which includes $3,000 quality and productivity bonuses, and cost of living lump sum payments of $2,000 until 2015.

The automakers have also agreed to a 10-year hire grow-in program. New hires will start at $20.40, equal to 60% of the current base rate and grow to full compensation after 10 years, which is currently $34 an hour. The program reflects a concession made by the union to satisfy demands by automakers to cut labour costs.

Ford, which was the first to ratify, has the smallest Canadian footprint, but will create 600 jobs over the term of the agreement. It will add a third shift to its body, paint, and pre-trim departments and boost insourced work at its Oakville, Ont. assembly complex, accounting for 300 of those jobs.

PHOTO: GM

It could also introduce a new product at the plant, which would create an additional 300 positions.

GM has agreed to add a third shift at the Oshawa Flex assembly plant, which will create or maintain 900 jobs. Production will be extended on at least one shift for another year at the Consolidated Plant until June 2014. The automaker has also committed to new engine and transmission investments and production in St. Catharines, Ont. It’s commitments in Oshawa and St. Catharines involve additional capital spending of at least $675 million.

The deal reached with Chrysler Canada follows the pattern agreement agreed to by Ford and General Motors.

“We achieved the entire pattern intact,” said CAW president Ken Lewenza.

He said the agreement provides protection of current pension benefits for existing workers.

The CAW threatened strikes in early September after it claimed the automakers were making unprecedented demands for pension and wage cuts.

CALGARY: Keyera Corp. is investing $210 million in a turbo expander at its Rimbey gas plant in Alberta’s Pembina North region to step up ethane and natural gas recovery.

The natural gas processor based in Calgary said the project includes installation of a new 400 million cubic-feet-per-day turbo expander and construction of a 34 kilometre, six-inch diameter ethane pipeline to connect to the Alberta Ethane Gathering System.

The project will allow Keyera to recover more than 90% of the ethane at the Rimbey gas plant as it extracts up to 20,000 barrels per day.

Keyera will sell the ethane to a large, unidentified consumer in Alberta under a long-term sales agreement, and process gas for a large unidentified producer on a fee-for-service basis.

The company said the turbo expander will run in place of the existing lean oil NGL recovery system, but in the future “with relatively low additional capital investment,” there would be an opportunity to run both the lean oil system and the turbo expander unit. This would significantly increase the plant’s processing capacity.

Pending approvals, the construction phase is anticipated to begin in the fourth quarter, with start-up expected in late 2014.

The Rimbey gas plant is Keyera’s largest natural gas processing facility.

System cuts frac tank build time WINNIPEG: Westeel has developed an installation system that will help oil and gas operators build a frac tank for water man-

A bigger plant for Nu Flow OSHAWA, Ont.: Nu Flow Canada, a manufacturer of small diameter pipe linings, has relocated to a larger manufacturing and office site in Oshawa, Ont. The new location on Boundary Rd. South provides 21,000 square feet of manufacturing space, and 30,100 square feet of office and installation space.

The company made the move to accommodate growth.

Nu Flow manufactures, installs and distributes green repipe alternatives and no-dig solutions, including epoxy coatings and structural liners.

agement at drill sites in a day.

The Winnipeg-based manufacturer of steel storage units said its new speed plate technology allows operators to get their frac sites up and running fast without the use of cranes.

The re-usable and movable frac tanks are made with corrugated steel panels. The company says most sizes, including the tank and liner, can be delivered to a site in a single truckload.

The patent-pending system uses fewer bolts per panel seam but maintains structural integrity.

Westeel said it would initially launch the product in Western Canada and North Dakota, focusing on sales in the North American market.

The company is a division of Vicwest Corp., and operates five production facilities in Western Canada.

In-situ projects are located on lelases called “firebags.”

PHOTO: SUNCOR

Enbridge expands Suncor tankage $150 million for infrastructure at Athabasca terminal CALGARY: Enbridge Inc. is spending $150 million to expand infrastructure at its Athabasca Terminal to accommodate boosted production capacity at Suncor’s Firebag 3 and 4 developments.

The energy transporter will build a 350,000 barrel tank and additional infrastructure, including booster pumps, meters and make modifications to existing piping and manifolds.

Construction started in July and is to be complete by mid-2013.

Suncor has agreed to underpin the pipeline giant’s investment in the facility through long-term service agreements.

October 2012

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Industry View << Departments

Onex acquires KraussMaffei for $719M

Profitability index edges up 0.2%

TORONTO: Onex Corp. is acquiring KraussMaffei AG, a German manufacturer of plastic and rubber processing equipment for close to $719 million.

The company, based in Munich with plants in Germany, Switzerland, Slovakia and China, designs and manufactures machinery and systems for the injection moulding, extrusion and reaction process segments.

KraussMaffei has 4,000 employees and generated approximately $1.26 billion for the year ending in June serving customers in the automotive, packaging, medical and construction industries.

Onex Partners III, Torontobased Onex’s $4.7 billion private equity fund, will invest $340 million, of which Onex’s share is about $86 million as a limited partner in the fund.

In another transaction, a company owned by Onex and the Canada Pension Plan Investment Board is selling a non-core asset.

Tomkins, a London, UK-based engineering firm, is selling its Dexter Axle division in Elkhart, Ind. to an affiliate of The Sterling Group for $360 million.

Dexter Axle manufactures trailer axle, brake and suspension assemblies, and related replacement parts and components.

OTTAWA: Profitability showed a 0.2% rise in August and several manufacturing industries proved to be among the strong performers, according to the Conference Board of Canada’s Leading Indicator of Industry.

Despite the modest rise, the Ottawa-based research firm notes that’s the indicator’s largest gain since March 2011. At 103.2, the index is now where it was back in October 2011.

“Modest economic growth at home and a myriad of risks related to events abroad have The automotive industry shows positive profitability.

PHOTO: THINKSTOCK/ Stockbyte kept corporate profitability its lowest level in three years. from gaining any ground over the past year, and The telecommunications industry’s profitabilthat trend is expected to continue for at least the ity index fell for the third consecutive month in next few months,” said the Conference Board.

August, hitting to its lowest reading in more than Several manufacturing industries show posia year. tive profitability, including automotive and other Not surprising, the banking industry has posted transportation equipment, which have experi35 consecutive monthly gains in its profitability enced significant gains. index, dating back to September 2009, demonOne of the worst performers is computer and strating a definitive recovery from the 2008-2009 electronic product manufacturing, which saw its recession. index fall in 10 of the past 12 months, leaving it at

Coatings research program launched MONTREAL: Polytechnique Montréal and the Natural Sciences and Engineering Research Council of Canada (NSERC) have set up a chair at the school that will focus on nano-structured coatings.

The NSERC Multisectorial Industrial Research Chair in Coatings and Surface Engineering (MIC-CSE) will get a $5.35 million investment over five years from NSERC, and seven other partners, including Essilor, Hydro-Québec, Guardian Industries Corp., Pratt & Whitney Canada, Velan, JDS Uniphase and the Canadian Space Agency.

Research will focus on developing non-polluting manufacturing technologies for nanostructured coating materials to add successive layers of nanometre-thick films and thicker coating architectures using various materials (metals, ceramics, polymers, nanoparticles or others) on to flat surfaces and three-dimensional objects.

www.plant.ca

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Manufacturing makes a strong showing

Baytex buys leases for SAGD project CALGARY: Baytex Energy Corp. has acquired 46 sections of undeveloped oil sands leases in Cold Lake, Alta. for $120 million.

The Calgary-based company said the leases, near its heavy oil assets, offer potential for thermal and cold development.

The company has regulatory approval to build and operate a two-stage bitumen recovery operation using steam-assisted gravity drainage (SAGD).

A pilot SAGD project will be built in 2013, followed by a commercial 5,000 bbl/d plant in 2014.

Initial production in will begin in 2016.

Entrepreneurs are booming: CIBC TORONTO: More than 500,000 entrepreneurs are in the process of establishing their own businesses, boosting the pace at which Canadians will become their own bosses in the coming decade, according to a CIBC report.

“Small business friendly demographic trends are among those forces likely to support a net creation of 150,000 new Canadian businesses in the next 10 years,” says Benjamin Tal, CIBC’s deputy chief economist at CIBC. The report suggests: • Only 20% of new business owners are doing so because they can’t find a job.

• The 50 and over age group

Magna to buy German pump maker AURORA, Ont.: Magna International Inc. will add to its strength in automotive pumps with two transactions, one in Europe and one in Canada.

The global automotive supplier signed an agreement to acquire ixetic Verwaltungs GmbH, a German manufacturer of automotive vacuum, engine and transmission pumps, for $480 million.

The company, with two manufacturing facilities in Germany, and one in each of Bulgaria and China, had 2011 sales of approximately $380 million.

The transaction is to close in the fourth quarter of 2012, subject to European anti-trust approval.

Magna, through wholly owned subsidiary Magna Powertrain Inc., is also buying the 50% interest in STT Technologies Inc. owned by its joint venture partner SHW Automotive GmbH. STT Technologies, based in Concord, Ont., is a supplier to the North American market of transmission and engine related oil pumps.

Financial details were not released.

Automotive supplier Magna International is based in Aurora, Ont. and employs 115,000 people in 296 plants and 88 product development, engineering and sales centres in 26 countries.

is the fastest growing entrepreneurial segment, accounting for nearly 30% of start-ups.

• The self-employed are more educated – 33% have a university degree.

• 70% of new businesses are started by men, but women tend to be more successful.

• Educational services (up almost 65% since 2007) and health care are growing fastest (up almost 20%).

• BC leads the country with start-ups, representing 3.9% of the employed population.

The report notes half the revenues derived by businesses that have been around for two to five years are coming from outside Canada. Technology is increasingly leading to a higher level of cooperation between small business, self-employed and larger firms. Indeed, larger firms are calling upon the specific expertise of smaller enterprises to complete projects.

“Canadian small businesses are in a co-evolutionary relationship with corporate business in the economic landscape.

Large corporations need small business to reach local markets,” says Tal. He said the pace of growth in self-employment among immigrants has risen dramatically over the past two decades.

“Currently close to 20% of self-employed are immigrants, more than double the rate observed in the 1980s,” he said.

SMEs’ optimism rebounds in Sept.

TORONTO: Optimism among Canada’s SMEs rose in September for the first time since March, according to the Canadian Federation of Independent Business (CFIB).

The Toronto-based business association’s Business Barometer index increased two points to 62 from 60 in August, based on 918 respondents.

Manufacturers are feeling particularly confident with an index rating of 65.5, above the monthly average and an improvement from 62.8 in August.

Thirty-six per cent of business owners reported shortages of skilled labour as a constraint on their business.

Eighteen per cent of SMEs plan to hire full-time staff in the next three or four months compared to 12% who intend to cut back.

Orbite tech raises silica purity level

MONTREAL: Orbite Aluminae has developed a technology based on its hydrochloric acid leaching process that raises the purity of silica used in solar panels and other products.

The clean tech company based in Montreal said this development brings silica purity to the 99.9% (3N) level and provides a conceptual base to eventually reach purities of 99.999% (5N) to 99.99999% (7N).

Orbite describes its patent-protected process as crushing, then acid-leaching aluminous claystone found at its Grande-Vallée, Que. property. By using various temperatures and pH levels, the process selectively isolates the aluminum component and removes iron and other impurities.

Silica graded higher than 99.99% purity is used to manufacture photovoltaic cells for solar power and other high-technology products.

In 2009, metallurgical grade silica was selling for approximately $3 per kilogram and higher quality (5N-7N) for approximately $35 per kilogram.

The company estimates worldwide, metallurgical grade silica consumption was 1.37 billion metric tonnes in 2009 and 2.02 billion metric tonnes in 2010. Orbite said its high-purity alumina plant, to be completed by the end of 2012, is expected to produce silica of greater than 99.9% purity.

The company’s smelter-grade alumina (SGA) plant, projected to begin its first phase of operations in 2014, will have the potential to produce up to 1.2 million tonnes of silica ranging from 95% to more than 99.9% at maximum capacity.

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Departments

>> Industry View >> Careers

A conceptual diagram of FSW of dissimilar metals. PHOTO: HONDA

Honda’s welding tech joins aluminum and steel First application: 2013 Accord made in North America

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TOKYO: Honda Motor Co. Ltd. has developed a technology for the continuous welding of steel and aluminum and has applied it for the first time to the subframe of a mass-production vehicle.

Honda says the technology will be used first on the North American version of the 2013 Accord before expanding the application to other models.

Friction stir welding (FSW) of dissimilar metals lowers vehicle body weight and improves fuel economy. The technology moves a rotating tool on the top of the aluminum that’s lapped over the steel with high pressure to deliver equal or better strength than conventional metal inert gas (MIG) welding.

Vehicle body weight is reduced by 25%, but this welding method also reduces electricity use by 50%. It also changes the structure of the subframe and the suspension’s mounting point, which increases the rigidity of the mounting point by 20%, contributing to the vehicle’s dynamic performance.

Honda has also developed a new application to mass-produce vehicles.

FSW requires the use of large equipment, but Honda developed a continuous welding system for a highly versatile industrial robot that also handles aluminum-to-aluminum welding for a fully aluminum subframe.

Honda also developed a non-destructive inspection system using a highly sensitive infrared camera and laser beam for in-line inspection of the bonding location for each unit.

Industrial R&D spending creeps up: StatsCan

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OTTAWA: Canadian businesses are anticipating expenditures of $15.5 billion on industrial R&D in 2012, edging up 0.9% from 2011, according to Statistics Canada.

Still, research and development spending remains below its 2007 peak of $16.8 billion.

The statistics agency says the recovery is being driven by growth in the manufacturing sector, up by $228 million (3.1%) to $7.6 billion. Manufacturers intend to invest $1.5 billion on communications equipment, up $129 million from 2011.

Overall, businesses in the services sector anticipate spending slightly less at $6.8 billion this year than in 2011 (down 0.2% or $12 million), with most of the decline in scientific research and development services (down $22 million or 1.3%).

Respondents to a survey said 61% of total spending will be concentrated in wages and salaries for R&D personnel, a level last seen in 2009 (60%).

Businesses say they will also dedicate 5% of their total industrial R&D expenditures to purchase land, buildings and equipment. The most recent peak in the importance of capital expenditures to total industrial R&D spending occurred in 2001 at 11%.

Since 2009, this ratio has been under 6%.

In 2010, industrial R&D spending continued predominately in Ontario ($6.8 billion) and Quebec ($4.7 billion). R&D spending in Quebec edged up 0.5% from 2009, while spending in Ontario declined by 4.2%. All other provinces except Manitoba (1.4%) saw decreases in industrial R&D spending from 2009.

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CRS Electronics Inc., a manufacturer of LED lighting in Welland, Ont., has appointed Michael Lam CFO, replacing interim CFO Paul Haber. Lam has been working as a consultant dealing with financial reporting and regulatory matters since 2009. Prior to that he was a senior manager at Deloitte & Touche LLP. Pacific Safety Products Inc., an Arnprior, Ont. manufacturer of body armour and products that provide protection from chemicals and biohazards, has appointed company board director Terry Vaudry CEO. He replaces Fraser Campbell who remains as the company’s interim chair.

Barb Peacock returns to the company as CFO following seven months as acting CFO for the National Aboriginal Health Organization. She was corporate controller at Pacific Safety Products from 2007 to 2011. Director Brad Field has resigned from the board.

Kane Biotech Inc., a Winnipeg-based biotechnology company that’s developing products for the prevention or removal of microbial biofilms, has appointed its president, Gord Froehlich, to the board of directors. Dr. Essam Hamza has resigned from the board for personal reasons. The company will license its products for manufacture.

Andres Tinajero joins Eurocontrol Technics Group Inc. as CFO. He has 15 years experience working in the financial field supporting a range of industries, including mining, not for profit, manufacturing and retail. The Toronto company acquires, develops and commercializes authentication, verification and energy security technologies through its Global Fluids International S.A. subsidiary.

John Pecman, the Competition Bureau official in charge of criminal matters, has been appointed interim commissioner. The term will last up to one year. Pecman has held several senior positions at the bureau during his 30-year career there. He replaces Melanie Aitken who left two years before her mandate was to end.

October 2012

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Departments

>> Economy WHOLESALE SALES DECREASE IN JULY

$ billions 52 50 48 44 42 40 38 36

RELIANCE ON US TRADE HIGHER: BMO Canadian businesses are becoming increasingly reliant on trade with the US while trade with other export markets such as Asia, Europe and Mexico remains relatively unchanged, according to the 2013 Business Outlook from BMO Bank of Montreal.

The report, conducted by Pollara, shows most of the businesses surveyed expect the Canadian and US economies to improve next year, but they’re pessimistic about prospects for Europe. Here are some highlights: • 39% of Canadian business owners say they are reliant on the US for trade, up 8% from last year.

Canadian businesses will resume “aggressively investing funds” that will be a key source of growth.

Despite recent volatility in the labour market, RBC said the economy has so far generated 20,000 jobs per month (as of August), which is above the average pace recorded last year, and consistent with the economy’s growth rate.

Exporters will also gain momentum as the global economy improves, but demand for imports will likely slow. RBC said the trade sector, which has only supported growth in one of the past 10 years, is positioned to boost growth by one-half percentage point this year and next.

Western Canada will lead growth rankings this year and next. Alberta tops the rankings for the second consecutive year, with Saskatchewan and Manitoba following closely. BC and Ontario will grow at rates just above the national average, while growth in the remaining provinces will be below that average.

• One in four large businesses plan to expand their operations into the US next year. Only 16% are reliant on Asian markets; 13% on Europe; and 8% on Mexico.

• Retail businesses showed the strongest degree of reliance at 49% followed by manufacturing (46%), business and financial (41%), agriculture (38%), services (28%), construction (22%).

• At 21%, Canadian manufacturing is the most reliant on EU trade.

“The US share of Canadian trade has dropped from over 80% near the end of the 1990s to approximately 68%, but has stabilized in recent years,” said Robert Kavcic, an economist with BMO Capital Markets. “The broader trend, however, is likely to remain one of trade diversification to countries outside the US.”

J 2007

number (thousands) 350

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J 2010

J 2011

J 2012

EI CLAIMS UNCHANGED

300

250

200

150

J

J

J 2007

2008

J 2009

J 2010

J 2011

2012

Employment Insurance benefits went to 508,000 people in July, virtually unchanged from June. Beneficiaries were up in Alberta and Ontario, but down in PEI and Quebec and status quo in the other provinces.

CAPACITY USE RISES

per cent 84

81.0

82 78.4

80 78

80.5

76 74 72

68

that’s a

J 2009

July’s wholesale sales fell 0.6% to $49.5 billion following a 0.3% decline in June. Among the seven subsectors, five representing 85% of total sales reported declines, including industrial machinery, equipment and supplies (-0.7%).

70

PReMIuM PRoduCtS And SeRVICeS thAt delIVeR effeCtIVe And fASt ReSultS

J 2008

SOURCE: STATISTICS CANADA

T

he second quarter was somewhat disappointing, according to an economic outlook by RBC Economics Research, but moderate growth is expected through 2013.

The latest Economic and Financial Market Outlook by the bank forecasts that Canada was caught up in a disappointing global trend in the second quarter, but monetary policy, continued business spending, supportive labour market conditions and an improving trade balance will lay the foundation for real GDP growth of 2.1% in 2012.

Craig Wright, RBC’s senior vice-president and chief economist, said the economy will likely pick up as temporary factors ebb and global growth prospects improve.

RBC expects inflation will remain “benign” and the Bank of Canada will gradually begin raising interest rates next year.

As the global economy improves, RBC forecasts

J

SOURCE: STATISTICS CANADA

Economy expands as risks wane: RBC

32

70.7 I

II III IV I 2008

II III IV I 2009

II III IV I 2010

II III IV I II 2011 2012

Canadian industries operated at 81% of their production capacity in the second quarter, up 0.5% from Q1. Manufacturing increased 0.5% to 81.6%. Transportation equipment and machinery contributed significantly to growth in capacity use.

$ billions 56 54 52 50 48 46 44 42 40 38 36 34 32 30 J J 2007

MANUFACTURING SALES DECREASE seasonally adjusted

Current dollars 2002 constant dollars J 2008

J 2009

J 2010

J 2011

SOURCE: STATISTICS CANADA

ECONOMIC DE VELOPMENTS AND TRENDS

Chained (2002) dollars Current dollars

34

SOURCE: STATISTICS CANADA

46

J 2012

Manufacturing sales fell 1.5% to $48.3 billion in July, the third decline in five months. Transportation equipment was responsible for much of the drop. Eleven of 21 industries representing 60% of total manufacturing reported lower sales.

October 2012

12-10-05 9:51 AM

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SOURCE: STATISTICS CANADA SOURCE: STATISTICS CANADA

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12-10-05 9:52 AM

Innovation

>> Robotics

Within

arm’s reach JACO boosts mobility for the wheelchair-bound disabled Kinova develops personal robotics for a worldwide market worth billions of dollars.

BY Matt Powell, Assistant Editor

T

wo young engineers from Montreal are ready to capitalize on a booming personal robotics industry with an innovative device called the JACO, which boosts the mobility of those confined to wheelchairs.

Kinova Robotics, founded in 2006 by longtime friends Charles Deguire and Louis-Joseph Caron L’Ecuyer, both 29, is making a name for itself developing personal robotics for research and the rehabilitation of people suffering from diseases such as paraplegia and muscular dystrophy.

“We’ve been friends for 12 years, we’ve done a lot of work together at school and floated the idea of starting our own business, but wanted to wait for the right opportunity,” says Caron L’Ecuyer, Kinova’s chief technology officer.

“The JACO was that opportunity.”

by dedicated control unit that also replaces the wheelchair’s control panel to create a completely integrated system that doesn’t require any extra on-board computers or interfaces.

“We’re doing for the upper body what the wheelchair does for the lower body,” says Caron L’Ecuyer. “The system is completely integrated so you don’t need to add anything to it. It’s modularity is the real innovation.”

The arm is made from lightweight tubular carbon fibre, weighing 5.7 kilograms, and three flexible plastic fingers handle payloads up to 1.5 kilograms. At 35 inches long, it’s completely silent and weatherproof, boosting the scope of JACO’s abilities.

The fingers expand to 4.7 inches and are made of flexible plastic so they won’t break while handling difficult-to-grab objects or when they’re bumped.

“Because the arm is so light, we’re able to lift more weight with the gripper,” says Caron L’Ecuyer.

Now enjoying a third-floor office space at Montreal’s INGO Innovation Centre, Kinova experienced a surge since introducing the JACO. The 3,000 square-foot space currently handles production of up to 100 JACO arms a year, a huge improvement from their humble beginning in the basement lab where Deguire and Caron L’Ecuyer were engineering students and part of a business incubator program at Ecole de Technologie Superieure (ETS).

Twenty-five per cent of Quebec’s engineers have degrees from ETS, according to the school’s website. Sixty-six per cent of its graduates, including Deguire and Caron L’Ecuyer, go on to work in small and medium enterprises.

What started as two young engineering graduates has now grown into a team of more than 20, most between the ages of 26 and 34. And they’re expecting more growth, hoping to boost Kinova’s workforce by another five employees.

Preparing for the boom CEO Deguire has three uncles suffering from muscular dystrophy. One of them, Jacques Forest, devised a makeshift mechanical arm capable of picking up objects, such as drinking glasses, and could open doors – both activities he wasn’t able to perform on his own.

“The arm was made from random materials such as bicycle brake wires and windshield wipers. It looked terrible but the concept was there. We grew off that,” says Caron L’Ecuyer.

Uncle Jacques passed away in 1993, but his legacy lives on in the mechanical arm named after him, perfected by his nephew and Caron L’Ecuyer, who spent five years developing the JACO in a stuffy downtown Montreal basement laboratory.

The six-axis manipulator arm with a three-fingered hand boosts mobility and makes daily tasks, such as eating and opening doors, easier. It attaches to a wheelchair and is controlled

Kinova’s JACO arm extending its reach.

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Promising growth is expected for the personal robotics market, too. According to the International Federation of Robotics, which oversees robotics markets in 15 countries, sales of robots for handicap assistance will grow to 4,600 units by 2015. At $50,000 a pop for a JACO arm, Kinova’s revenues could grow by $23 million by then even if it earns 10% of the market share.

“We’re readying for the boom,” says Caron L’Ecuyer. “We’re trying to position ourselves as a leader in manipulation technologies and personal robotics.”

And the Kinova team is hedging their bets. The company has also diversified with a research version of the device to help develop rehabilitation platforms for people suffering from diseases that limit mobility.

“The way we’ve designed the arm allows people on the research side to use it as a development platform for computer interfaces and mobile manipulation applications,” he says.

In early September, Kinova was awarded a $359,353 contract by the Canadian Innovation Commercialization Project (CICP) to introduce JACO arms into six rehabilitation centres across the country. The program is being jointly completed with the Ministry of Veterans Affairs Canada, and will gather data that demonstrates how the arm improves its users’ quality of life

October 2012

12-10-05 10:51 AM

>> Coatings

Advancing automotive tooling capability Research into new coatings is a costeffective way to improve performance and sustainability

By Stephen Veldhuis

T

here’s an old proverb that begins, “For want of a nail…” and ends with “…the Kingdom was lost,” which tells how a relatively small action can have major consequences. This proverb captures the complexity of manufacturing and the importance of tooling, which typically accounts for about 5% of a plant’s costs but also sets production rates, affects quality and determines the nature of the materials to be processed.

Tooling is often overlooked, yet its impact on productivity, quality and cost are significant. For example, making highperformance, lightweight engines without an enhanced tool to machine compacted graphite iron means a multimilliondollar automotive production cell stops repeatedly making production less efficient, thus adding cost. Higher production costs threaten jobs that could shift to other jurisdictions.

Researchers at McMaster University, the University of Windsor, Queens and Dalhousie are involved in a project supported by the AUTO21 Network of Centres of Excellence that includes identifying and developing advanced wear-resistant coatings for tooling.

In addition to lubricity, target properties of the nanostructured, physical vapour deposited coatings include hot hardness, enhanced fatigue fracture resistance, oxidation and corrosion resistance.

Environmental benefits

Kinova’s founders, Charles Deguire and Louis-Joseph Caron L’Ecuyer, invested five years in developing the JACO robotic arm.

and gauge associated economic benefits.

“This program is going to be a huge benefit because it’s not just putting money into our pockets. We’ll also learn how the arm benefits our customers and how we can improve it to suit specific needs in future designs,” says Caron L’Ecuyer.

And more robotics are coming – innovations developed thanks to JACO’s success. The company dedicates up to 40% of revenues to research and development.

While the partners are keeping their strategy confidential, the general plan is to stick with the healthcare market, the company’s core business. Caron L’Ecuyer says they would also like to develop a product that addresses the lower body.

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PHOTO: KINOVA ROBOTICS

When asked about R&D expenditures in the past, Caron L’Ecuyer offers a chuckle.

“We really don’t know how much we spent developing this thing,” he says. “It was just the two of us, so we were trying to get as much as we could for our buck.

We were also building the business as we were developing the product, which was a huge challenge.”

A year ago, the company was spending up to 90% of its revenues on R&D, but the struggle has paid off.

The JACO is now extending Kinova’s reach and setting the stage for additional innovations that will enable the disabled.

The research emphasizes the tribological, physical-chemical and mechanical characteristics of the coatings and involves close collaboration with Kobelco, a diversified Japanese corporation with operations in metals and machinery. Coatings tested under aggressive production conditions by industrial partners in some cases improve tool life by three to four times. The coating has also been combined with other surface treatments to address specific wear and performance issues.

One benefit of advanced coatings concerns the environment. The use of liquid lubricants and coolants would be reduced or eliminated.

Improved lubricity also aids in the production of parts with complex geometries and demanding surface quality requirements. Reducing the processing cost of lightweight and high-strength materials used in vehicles means fuel efficiency and performance improvements will be achieved at a cost that makes green choices more attractive to consumers while lowering the costs of processing recycled and bio-based materials.

Productivity would also improve. Tooling operating at higher temperatures would last longer, reducing changeovers and thus downtime, and less time would be spent monitoring processes.

Competitive pressure in the global automotive sector is intense. Every major automotive jurisdiction is pursuing cost improvements that often come down to pennies per part. Advanced tooling technology represents a significant opportunity for Canada’s automotive industry to gain a sustainable advantage.

Stephen Veldhuis is an associate professor at McMaster University, director of the McMaster Manufacturing Research Institute and an AUTO21 researcher in the areas of advanced tribology and coatings. Visit www.auto21.ca.

Comments? E-mail jterrett@plant.ca.

Comments? E-mail mpowell@plant.ca.

PLANT 13

12-10-05 10:51 AM

Management

>> Performance >> Pricing Strategy

Getting the price right

Common mistakes and what to do about them

BY MARK BORKOWSKI

B

Sales

SLUGGISH?

TRY A BUSINESS DIAGNOSTIC

Assessing the health of your operations helps to identify priorities that will generate the highest returns.

PHOTO: THINKSTOCK

Identify specific operational strengths and weaknesses to establish priorities for improvement.

BY GLENN FRASER AND CAROLINE COPEMAN

A

lready well into the second year of the strategic plan, the confectionery processor’s management team was perplexed that the company’s projected growth had stalled. They pored over sales statistics for weeks and despite long discussions about the reasons for the slump, were no closer to determining the root cause of the slowdown in sales growth.

Expansion was in the sights of the CEO, vice-president of sales and vicepresident of operations at an equipment manufacturing company with a capital nest egg and a surplus of capacity. Yet none could agree where to focus the attention needed to accelerate growth.

For a pasta manufacturer, input costs had been steadily increasing over the past year and the owner was becoming concerned about the impact on company profits.

Each of these management teams, faced with difficult decisions about the future of their operations, chose to conduct a business diagnostic as a first step. A diagnostic is particularly helpful when a company is experiencing an unplanned event, change or uncertainty and there’s no clear indication of why it’s happening. Planning for growth, merger, acquisition, divestiture or succession are also occasions when a diagnostic adds significant value.

The term “diagnostic” simply refers to

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the intent of the process to assess the health of an operation and to identify underlying causes of problems. With many manufacturers operating at less than optimal efficiency at the best of times, increasing effectiveness even marginally can have a big impact on profitability. A diagnostic identifies specific operational strengths and weaknesses, and establish priorities for improvement.

Also, when embarking on new projects, a diagnostic determines the endeavours that will potentially produce the highest returns when: • assessing the feasibility of a particular business strategy • determining how to increase capacity • interpreting profitability challenges • evaluating organizational structure • updating information technology or processes • exploring growth strategies • analyzing product and market opportunities • pinpointing research and development options • streamlining supply chain flow • assessing new, problematic or potential products/services • planning for the future

Focus on performance While a diagnostic focuses on specific performance areas (such as business strategy, processes, organizational design, supply chain), it’s generally most beneficial when the health of the entire organization is assessed because all areas are interrelated. While the specifics of the process vary from one company to another depending upon needs and circumstances, a typical approach involves steps similar to those used by our three manufacturers.

The first one usually involves reviewing

the strategic plan for insights regarding the company’s vision for the future and how it intends to get there. Key executives then complete a questionnaire to gather perspectives about the effectiveness of key business areas. This is followed by a review of several years worth of financial statements and ratios, an assessment of revenue, debt and the bottom line, and comparisons with industry benchmarks. Results are compiled in a diagnostic report for management that includes recommended actions for immediate and longer-term priorities.

The confectionery processor, equipment manufacturer and pasta maker determined the areas where they should focus, the root causes of some changes they were seeing and the approaches they should take to increase the probability of success and potential payout. The processor experiencing stalled growth launched an acquisition search. The equipment manufacturer that wanted to accelerate growth but lacked consensus among senior management determined the company’s core competencies, developed a new market acquisition strategy and secured new contracts in several growing markets. The pasta producer experiencing rising input costs embarked on a comprehensive cost management strategy.

Want your manufacturing company to be the picture of health? A business diagnostic just might be the best prescription.

Glenn Fraser (glenn.fraser@mnp.ca) is the leader of the GTA region Food & Ag processing practice of MNP (www.

MNP.ca); Caroline Copeman (caroline. copeman@mnp.ca) is a senior manager in the consulting practice.

usiness is challenging these days, especially when it comes to exporting while a strong loonie holds sway, but you can still improve margins.

Atenga Inc., which provides pricing advice to commercial and industrial companies worldwide, contends you can raise prices and improve sales volumes at the same time.

Dennis Brown, a partner at the Californiabased company, identifies 10 of the most common mistakes companies make and what to do about them: • Basing prices on costs. This invariably leads to prices that are either too high – or more often – too low. Base prices on customers’ perceptions of value.

• Basing prices on the marketplace. Find ways to differentiate products/services to create additional value for specific market segments.

• Attempting to achieve the same profit margin across different product lines. Profit is optimized when the price reflects the customer’s willingness to pay.

• Failing to segment customers. The value proposition for any product or service varies in different market segments. Reflect that difference.

• Holding prices at the same level for too long, ignoring changes in costs, competitive environment and customers’ preferences.

Get customers and sales forces used to frequent price changes.

• Incentivizing salespeople on revenue generated rather than on profits. Avoid volume-based sales incentives for pushing volume at the lowest possible price.

• Changing prices without forecasting competitors’ reactions. Know your competitors, predict their reactions and prepare for them.

• Using insufficient resources to manage pricing practices. Cost, sales volume and price are the three basic variables that drive profit.

• Hastily calling meetings to set the final price for new products or services. Establish internal procedures to optimize prices.

• Spending a disproportionate amount of time serving your least profitable customers. Eighty per cent of a company’s profits generally come from 20% of its customers.

Focus on the 20%.

Understanding what your customers value leads to better pricing, higher sales volumes and much better margins.

Mark Borkowski is president of Torontobased Mercantile Mergers & Acquisitions Corp., which specializes in the sale of privately held companies. Visit mercantilemergersacquisitions.com. E-mail Dennis Brown at dbrown@atengacorp.com.

Comments? E-mail jterrett@plant.ca.

Comments? E-mail jterrett@plant.ca.

October 2012

12-10-04 2:32 PM

Carbon Capture << Sustainability

Quest to capture

CO2

First CCS operation targets one-million tonnes a year

Energy giant’s $1.35 billion project will bury emissions from bitumen production two kilometres underground.

By Matt Powell, Assistant Editor

R

oyal Dutch Shell is preparing a place for those nasty carbon dioxide (CO2) emissions it produces at its Athabasca Oil Sands Project in Alberta to go, encouraged to do so by increasingly strict federal and provincial environmental requirements, and sweetened by a hefty government investment.

The energy giant plans to build Canada’s first carbon capture and storage (CCS) operation in Alberta at a projected price of $1.35 billion. The Quest project will cut CO2 emissions by more than 35% and capture more than a million tonnes of CO2 a year in a porous rock formation nestled two kilometres underground. Shell equates the sequestered CO2 with taking 175,000 cars off the road.

The Athabasca project, a joint venture owned by Shell (60%), Marathon Oil (20%) and Chevron (20%) produces 255,000 barrels of crude bitumen a day. As the majority owner, Shell will be the designer, builder and operator.

The federal government and Alberta have invested $865 million in the project. The province’s share is $745 million, which comes from a $2 billion fund to support CCS in the oil sands. Ottawa is investing another $120

Quest’s first injection well.

PHOTO: SHELL

million through its Clean Energy Fund.

Alberta embraces the project as key to reaching its carbon-cutting goals, but neither the province nor Ottawa are making carbon capture mandatory for oil sands operators. However, Quest’s business development manager says the project sets Shell’s feet firmly in the sand going forward. “[It] will allow us to meet regulatory reductions, but also exceed those reduction amounts in Alberta,” says Len Heckle.

Thanks to significant government involvement, he says it will help other oil sands operators with future CCS projects and to define emissions legislation down the road.

“We’ve got a major knowledge-sharing program with the governments, so we can pass along what we learn from this project into the next wave to make sure they’re as effective and efficient as they can be.”

Quest will capture CO2 from Shell’s bitumen processing operations at the Scotford Upgrader in Fort Saskatchewan, Alta., convert the emissions into a liquid form and transport them 80 kilometres through an underground pipeline. The CO2 will then be injected into a porous rock formation called the Basal Cambrian, two kilometres under layers of impermeable rock.

An amine solvent will be used to capture CO2 from the process stream. The gas is released from the amine when it’s heated, then dehydrated and compressed to reduce its volume by more than 400 times.

Fine-tuning the process to recover 98% pure CO2 from

>> Green Manufacturing

Cash in on waste diversion

Save on disposal costs by reducing what ends up in landfill

By Brett Wills

A

good way to kick off a sustainability drive is a zero waste to landfill program.

The general consensus is that diverting 90% of your waste is the minimum target. Manufacturers like to start with a zero waste to landfill program because progress can be easily measured; getting started is relatively simple, supporting resources are plentiful, and there are immediate initial cost savings (up to 25%) on waste disposal.

Here are five easy and proven steps to get you there: • Conduct a waste audit. This will establish your current state of waste diversion and identify opportunities to quickly increase diversion rates.

• Determine sorting requirements. Contact your waste hauler to determine the requirements for sorting different materials (comingled, separate bins for plastic, glass) then pick up some bins.

• Education. Staff, cleaners and visitors need to know what

materials and items go into each bin, why the organization is embarking on the program and the benefits to the company.

Reinforce messaging regularly.

• Set goals and measure progress. Establish a diversion rate within a defined time (90% by June 2013) and measure rates monthly. Typically, a waste hauler will provide monthly diversion rates as part of a value-added service.

• Launch and manage. Hold an official launch party supported by senior management to establish buy in. Manage the program through close analysis of diversion rates, daily waste walks to reiterate messaging and monthly audits of bins to ensure sorting is done properly.

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.

the upgrader’s hydrogen manufacturing units is the only new aspect of the Quest unit, thanks to Shell’s ADIP-X amine-based capture technology. This worldwide gas processing technique has been the standard for extracting hydrogen sulphide and CO2 from natural gas for more than 40 years.

Scotford’s upgrader adds hydrogen to heavy oil to break it down into a synthetic crude for processing into gasoline, a process that’s a major contributor to CO2 emissions.

While Quest is Shell’s first project to get the go-ahead in the oil sands, it’s not the only one. The company is also a 25% partner in Australia’s Gorgon natural gas liquefication project, operated by Chevron. That facility is expected to capture between three to four million tonnes of CO2 per year once it’s operational by 2015. In Norway, Shell is a partner in Test Centre Mongstad (TCM), the world’s largest CO2 capture research facility.

Shell’s Cansolv subsidiary also provides carbon capture technology to recover 90% of the CO2 from flue gases at a 150-megawatt turbine at a coal-fired power plant in Boundary Dam, Sask.

Mitigating costs Shell doesn’t expect to profit from Quest. The company will mitigate costs through government investments and will earn additional revenues from carbon credits for exceeding regulatory emissions requirements.

“Quest will definitely exceed the required limits set by the provincial and federal government, which will allow us to sell extra credits we earn from that,” he says. “But that’s really not the point of this project. We’re not doing this to profit from it. We’re taking a million tonnes of CO2 out of the atmosphere. That’s the direct benefit.”

The Harper government is on a quest of its own to make the oil sands less intrusive, although it won’t be easy to appease enviro-critics who oppose its development.

Environmental groups do offer some praise for CCS projects in the oil sands, but Chris Severson-Baker isn’t holding his breath over whether or not the projects will meet required emissions reduction goals.

“It’s a good strategic project for Alberta, it’s a good investment of public funds because this kind of project is going to have a significant role in the future when it comes to reducing greenhouse gases,” he says. “But it doesn’t do a whole lot to reduce the scale of emissions today,” says the executive director of the Alberta-based Pembina Institute.

He estimates the oil sands would have to see at least 30 CCS projects pop-up in the next five years for the technology to have the impact governments hope for.

Not making CCS mandatory for oil sands operators will also affect its development at other sites down the road.

“Until there’s solid policy in place, CCS won’t become a significant solution in terms of reducing emissions overall.”

Comments? E-mail jterrett@plant.ca.

Comments? E-mail mpowell@plant.ca.

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PLANT 15

12-10-05 9:53 AM

Sustainability

>> Emissions Reduction >> Clean Tech Recovering copper in China BioteQ Environmental Technologies Inc. is partnering with China’s largest copper mining company in a joint venture to build a $3.2 million water treatment plant.

The Vancouver clean-tech company said the additional treatment plant will be built at Jiangxi Copper Co.’s Dexing Mine site in southeastern China.

The plant, which addresses the mine’s need for greater water capacity, will apply BioteQ’s patented ChemSulphide process to selectively recover copper from mine drainage.

Up to 24,000 cubic meters of water will be treated daily (4.6 million cubic metres annually) to remove about 900,000 pounds of copper from the environment.

The copper concentrate will be sold to Jiangxi Copper Co.’s refinery at market prices.

UBC energizes with waste

Vale

Nickel smelting at Vale’s Sudbury, Ont. Copper Cliff operation.

PHOTO: VALE CANADA

clears the AER

Copper Cliff smelter gets a $2 billion retrofit The operation will turn sulphuric dioxide into a byproduct that will be sold for other industrial applications.

BY Matt Powell, Assistant Editor

V

ale has broken ground on a $2 billion emissions-busting project at its Sudbury, Ont. nickel smelter in an effort to meet increasingly demanding government emissions regulations. The move will reduce the Sudbury operation’s sulphuric dioxide (SO2) emissions by 70% from current levels, and cut dust and metals emissions by up to 40%.

The Clean AER project (Atmospheric Emissions Reduction), which is currently the largest mining investment in the Sudbury area, will reduce Vale’s sulphur dioxide emissions to 45 kilotonnes by 2015, below the regulatory limit of 66 kilotonnes per year.

The project involves a complete retrofit of the Copper Cliff smelter’s converter aisle. Sulphur dioxide emissions that currently escape into the atmosphere through the super stack from converters will be captured in a new wet gas cleaning and acid plant.

The operation will turn the sulphuric dioxide into a gaseous bi-product that Vale will sell for various industrial applications, notably as a component in fertilizer production and raw steel treatment, says Brian MacNamara, Clean AER’s process engineering and commissioning manager.

“We already make a lot of this bi-product, but we will now have capacity to

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make more while cutting smelter emissions,” he says. “There are a lot of uses.

It’s a pretty big market.”

The project will also cut the smelter’s greenhouse gas emissions by up to 3.5 million cubic metres per year as the company moves to cut natural gas use.

“The goal of this project is to remove environmental regulations as a constraint to production,” says MacNamara.

“We’ve made a number of SO2 (sulphur dioxide) emissions reductions over the years – this is the final step towards meeting regulatory requirements we need to hit by 2015.”

Major local impact Vale says the project will also have a major economic impact on the local economy, suggesting it will employ at least 1,300 temporary workers during the construction phase. Ten per cent of construction projects have been awarded, at least half of those to local suppliers.

Aecon Group, a Toronto-based construction and infrastructure development firm, was awarded an $85 million contract to build reinforced concrete foundations, pipe rack foundations and perform site preparation work for the process plant.

The project will require 32,000 cubic metres of concrete, 44 kilometres of pipes, 235 kilometres of electric cable, and 15,500 tonnes of steel and ducting (enough to build the first quarter of New York’s Empire State Building).

Clean AER has been a long time coming. It’s already 10 years in the making and MacNamara has been involved for the last six.

“These projects that have billion dollar price-tags take a while to get going because of approval processes,” he says.

“We’ve got regulatory requirements to meet by 2015. We’re implementing this major project now to make sure we meet those requirements.”

He says the retrofitting will actually boost the company’s operation costs by $11 million when Clean AER is completed.

The mining and processing of nickel in Sudbury has gone on for more than 100 years, and it has been a major contributor to the local economy, both in jobs and investments. Vale expects to boost Sudbury’s retail spending by $74 million by 2015, according to an economic assessment the company commissioned by consulting firm KPMG. The Brazil-based mining giant, which has a market capitalization of $97 billion, employs more than 70,000 people at 18 subsidiaries worldwide. It has Canadian operations in Sudbury, Ont. and Thomson, Man. Together, they produce more than 20% of Canada’s copper, according to a report by Natural Resources Canada.

In 2010, Vale introduced a five-year, $10 billion investment plan to expand its Canadian operations. More than $3 billion is being spent on modernizing Vale’s Sudbury operations, including the Clean AER project. In late September, the first of four upgrader units arrived at the Sudbury smelter.

Meanwhile, Clean AER will help Vale clear the air as it meets regulatory requirements.

Nexterra Systems Corp., the University of British Columbia (UBC) and GE have completed an energy-from-renewable-waste heat and power system at the university’s Vancouver campus.

Nexterra, a Vancouver-based renewable energy company, describes it as the first commercial demonstration of a transformative system in North America, combining the company’s gasification and syngas conditioning technologies with a GE Jenbacher internal combustion engine to produce 2 megawatts of renewable electricity. The power will offset UBC’s existing energy consumption, which will be enough to light up about 1,500 homes.

The system will also generate 3 megawatts of thermal energy to displace up to 12% of UBC’s natural gas consumption, reducing greenhouse gas emissions by up to 5,000 tonnes per year.

Thermal cracking converts locally sourced wood into clean energy to deliver electrical efficiencies that are 25% higher than conventional methods of producing biomass-based electricity.

High energy lithium cell Electrovaya Inc. has released the next generation of its SuperPolymer technology, claiming it has one of the highest energy densities of commercial lithium batteries.

The Toronto-based developer and manufacturer of advanced batteries said the MN-eHP exceeds 200 Wh/kg, which it “believes” is one of the highest energy densities for a commercial lithium ion cell in a large prismatic design.

The cells use electrode materials such as graphite anodes and lithium metal mixed oxide cathodes. The company says the energy density is 50% to 70% higher than typical phosphate cells, 120% higher than lithium titanate cells and about 600% higher than lead acid batteries.

Because the cells require fewer materials for a given energy capacity, Electrovaya said they can be produced at a lower cost.

They also contain lower amounts of flammable electrolytes, making them safer.

Typical MN-HP cells are available in 30Ah to 40Ah format (110 to 150 Wh) and housed in a flat polymer pouch.

Comments? E-mail mpowell@plant.ca.

October 2012

12-10-05 9:54 AM

Zero Defects << Operations

>> Inside Maintenance

Outsourcing contracts

How to establish the best relationship

By Steve Gahbauer

C

The goal is to keep machines running, reduce costs and continuously improve quality.

PHOTO: THINKSTOCK/ David De Lossy

Making TPM pay

Achieve zero defects and workplace harmony Total productive maintenance involves everyone in the building and aims to eliminate equipment downtime.

By Steve Gahbauer

T

otal productive maintenance – TPM – is a manufacturing strategy that deals with equipment health and machine improvement by involving production operators, maintenance staff and top management. It’s a process that pays off handsomely, but it takes time, patience and interpersonal skills.

Developed by Seiichi Nakajima who first implemented it at Toyota plants in Japan, TPM is still used by many manufacturing and processing plants.

Its goals are the elimination of equipment losses, increased productivity, reduced costs, better product quality and the creation of a pleasant and cooperative work environment. TPM converges total employee involvement and state-of-theart maintenance technology to improve equipment capacity, machine use and uptime. Five fundamental functions are autonomous maintenance, equipment improvement, quality maintenance, reduction or elimination of unnecessary maintenance, and education and training.

Hailed in the beginning as an important wave of the future, TPM philosophy stands the test of time. Approaches and procedures have been modified based on experiences and results, but when it’s implemented properly the basic benefits still apply.

At the 9th Reinventing Maintenance conference in Mississauga, Ont., TPM as a business imperative was revisited by

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Jitender Singh, manager of engineering and facilities at Patheon Inc., a company with pharmaceutical development services that focus on meeting strategic needs for contract dosage form development and manufacturing worldwide.

He emphasized that TPM presents a structural and holistic approach to maintenance – an opportunity to look at operating systems, management structures, mindsets, capabilities and human behaviour. Everyone must be involved in setting goals for how to achieve lower

TPM’s eight pillars Set these to a zero target.

1. Focussed improvement. Continuous – even small steps of improvement.

2. Planned maintenance. Focus on increasing availability of equipment and reducing machine breakdowns.

3. Initial control. Establish a system to launch the production of new products and new equipment with minimum run-up time.

4. Education and training. Bring together workers who have skills for autonomous maintenance.

5. Autonomous maintenance. It means “maintaining one’s equipment by oneself.”

There are seven steps and activities.

6. Quality maintenance. Establish machine conditions that will not allow defects and control conditions required to sustain zero defects.

7. Office TPM. Make an efficient, working office that eliminates losses.

8. Safety, hygiene and environment. Create safe and healthy workplace where accidents do not occur, uncover and improve hazardous areas and conduct activities that preserve the environment.

Adapted from Seiichi Nakajima

costs and improve equipment health. It’s important to start small, evaluate results and take the next step.

When applying this one-step-at-a-time approach maintain a daily activity board, keep it up to date and in an accessible area. Huddle with the team each morning, follow up with weekly meetings and keep management informed.

Addressing people issues Although TPM focuses on equipment improvement, there are people issues, which were addressed by Liane Harris, a spokesperson for Machine Health Care, an ECS2 Group Inc. company specializing in predictive maintenance and corporate wellness.

Common workplace issues include stress, absenteeism, job burnout, harassment, bullying and substance abuse. The most vulnerable employees are the ones who are strongly motivated, dedicated and involved. Since they’re most important to TPM success, maintenance managers must pay special attention to them. Workplace stress can be managed, but awareness is key. Go with the flow and enjoy, said Harris.

Measure TPM success in small steps.

Set KPIs for safety, morale, planned versus unplanned maintenance, MTBF, MTTR and cost savings. Then celebrate achievements as they occur and award deserving individuals. That way TPM will help to achieve business goals.

Steve Gahbauer is an engineer and Toronto-based freelance writer, the former engineering editor of PLANT and a regular contributing editor. E-mail gahbauer@rogers.com.

ontracting out plant maintenance has been a long-standing industrial practice that has initiated heated debate concerning its merits, benefits and disadvantages.

There is no “one-fits-all” solution. Every plant has its own culture and peculiarities that need to be carefully evaluated before a decision is made to outsource.

Ben Stevens, owner of DataTrak Systems Inc. and former president of software designer OMDEC (Optimal Maintenance Decisions Inc.) who is an experienced maintenance professional, concludes outsourcing is a work in progress. But there are guidelines that will help with the decision-making process.

Start by understanding why you want to outsource and set criteria for determining which types of contracts best suit your needs and the equipment that should be included or excluded.

One contract type does not fit all circumstances. The one you select should deliver value for each of your criteria.

Most contractors want to deliver higher value, which increases the chances of a longer-term contract or a renewal. Therefore, converting from a “lump sum” or “fee for service” contract to something higher value and/or higher performance doesn’t have to wait for a new agreement to be signed. Stevens says the contractor needs to recognize that rewards will come for behaviour that increases your ability to deliver more value through improved maintenance practices.

Generally, he sees performance-based contracts as preferable to lump sum or fee for service. Performance-based will focus on achieving key indicators that are beneficial to both companies. On the other hand, lump sum and fee for service tend to do a poor job of delivering continuous improvement. That’s because the contractor is required to deliver selected maintenance tasks for a lump sum. Making more profit – always a prime business goal – leads to cutting costs, which often involves cutting corners on quality, skipping jobs that can’t be inspected, hiring less experienced labour, and using cheaper and lower-quality parts.

Of course, a contractor can also increase profits by being more efficient, but this rarely occurs in practice because it requires upfront investment in technology, procedural improvement and training.

Stevens says the best contracts encourage the contractor to propose new and better ways of doing maintenance that results in both parties making more money.

Steve Gahbauer is an engineer and Toronto-based freelance writer, the former engineering editor of PLANT and a regular contributing editor.

Comments? E-mail jterrett@plant.ca.

PLANT 17

12-10-05 9:55 AM

Operations

>> Think Lean

5S+1

More than just housekeeping Put a detailed plan and budget in place before establishing or enhancing the program in your workplace.

By Richard Kunst

E

ver considered how your 5S+1 program (the plus one covers safety) impacts employee attraction and retention; training and development; ease of employee assimilation; rapid onboarding of temporary employees; creating focus and commitment to process; and professional linkage of management vision and execution?

Within the next five years, many of your employees will be eligible for retirement. Since manufacturing isn’t exactly first choice among about-to-graduate students, having a professional work environment is a must.

Although 5S+1 is typically the first tool adopted by plants as part of the lean journey because of the visual impact, it’s often deployed with little or no definition and becomes just another housekeeping exercise. Materials and diverted labour costs can make it expensive to adopt.

Evolving from current state to worldclass ranges from $6 to $16 per square foot, which doesn’t take into consideration the cost incurred by employees putting down tape to mark aisles and shadow boxes.

You need to plan and budget before starting the journey or enhancing an existing program. Start by defining the following: • Budget. Don’t be cheap. It reflects the brand status of your company.

• Define colour codes (communication, quality, production, etc.).

• Define font type and size used for signage.

• Ban the use of duct tape.

Apply the methodology to your general areas with signage and location indicators. The break room or cafeteria are good places to start, but offices are also key. Tear down all of the existing signage. Start new. After 21 days folks are numb to their surroundings.

Once stuff is organized and colour coded people see the flow and they instinctively know where items are located.

5S+1 enables ease of employee assimilation. Finding your way through some plants is challenging, but when you go to a hospital, getting around is easy.

Need an x-ray? Follow the yellow lines.

Ultrasound, the blue lines.

The use of temporary employees will

What’s 5S+1?

It adds safety, addressing potential hazards and other key issues.

• Sorting • Standardizing • Straightening • Sustaining • Shining • Safety

>> Tech Tip

Maintaining motor health How to check for stator core loss

W

hen an electric motor is being rewound, the rotor has rubbed, or there is a question about the condition of a stator core, a core-loss test determines its suitability and the impact on the motor’s efficiency.

Testing reveals how specific applications There are two basic types of core loss. Hysteresis affect efficiency.

PHOTO: ZUREKS losses relate to the steel’s opposition to a changing magnetic field. This requires a change of core steel chemistry. If the steel changes colour, the hysteresis losses may increase.

Eddy current losses are based on the thickness of the steel plates that make up the core.

They’re perpendicular to the direction of the magnetic field. Shorted lamination and poor interlaminar insulation will cause the value to be high.

Core losses are measured in watts/pound or watts/kilogram by looping cables through the core and applying a calculated current while measuring watts. The core weight is often calculated if it can’t be weighed directly. The applied watts are divided by the weight. This determines the actual applied current based on the weight, geometry and magnetic properties of the steel. The range should fall between one and six watts/pound.

When suspect, subject the core to a hot spot test by saturating it magnetically. The stator temperature should rise a few degrees Celsius and a hot spot will be within 10 degrees C of the ambient temperature.

Create a clean, well-organized work environment that will attract professionals.

only increase. Getting them on board and productive requires a rigid 5S+1 program blurred into standard work.

5S+1 also creates focus and commitment. Walking five feet takes 2.5 seconds, 30 inches of reach is 0.6 seconds. Not much in a singular sequence, but the repeats soon add up to minutes and hours.

As you proceed through your sort, ensure items are categorized and identify where they need to be stored as follows: • Runners. Used every day. Access in under 30 seconds and no foot steps.

• Repeaters. Used occasionally. Access within two minutes or less.

• Strangers. Used rarely. Access within 15 minutes or less.

Every time an employee gets distracted retrieving an item, it will take them a minimum of 22 minutes to re-gain focus.

That’s a lot of lost productivity.

Finally 5S+1 provides professional linkage of management vision and execution. This is where employees tasked with implementing the program become very budget-conscious but spending a few pennies on tape is not real cost. It’s the labour used and the time it takes to learn a new skill. Don’t expect a welder to learn how to paint aisle lines on the floor. They probably won’t be straight.

Look at your organization and the type of image you wish to convey, then select your enablers accordingly. For example, don’t allow anyone to use tape for hanging a sign. It looks horrible. Same with duct tape, unless you are on the Red Green Show. It shows you are willing to compromise your significant investment with an unprofessional fix, like a manufacturer that recently commissioned a new $6.2 million line.

What did we find? Duct tape. Ugggh.

Richard Kunst is president and CEO of Cambridge, Ont.-based Kunst Solutions Corp., which publishes the “Lean Thoughts” e-newsletter and helps companies become more agile, develop evolutionary management and implement lean solutions. Visit www. kunstsolutions.com. E-mail rkunst@ kunstartofsolutions.com.

Source: Motor Diagnostics Health Newsletter, Success by Design.

PHOTO: THINKSTOCK

>> Audits

How to pinpoint energy opportunities

Lassonde tallies savings from gas and compressed air

L

assonde Beverages Canada in Toronto has achieved remarkable energy savings in its production and maintenance departments thanks to its decision to conduct audits.

“We are on a path of continuous improvement through employee education and training, and the reduction of energy consumption and waste production,” says Daniel Marcoux, the plant’s manager.

Lassonde, a manufacturer of juices and drinks, employs about 120 people at its 8,400 square-metre production facility with a 6,500 square-metre warehouse. The company worked with the Guelph Food Technology Centre to develop key performance indicators and a sustainability plan, with special emphasis on maintenance. It also had a waste and energy audit conducted by Agviro Inc., a gas audit by Enbridge, and a compressed air audit

by C.E.D. Compressed Air Inc. As a result, 22 energy and six environmental efficiency opportunities were identified.

The plant previously operated two large 300- and 200-hp boilers, which accounted for 90% of its natural gas consumption at a cost of about $450,000 annually. Using information from the Enbridge audit, steam trap leaks and economizers were repaired, condensate lines were insulated, new controllers were installed, natural gas pressure was lowered, and one boiler was shut down. Steam and condensate lines were also insulated for annual energy savings of almost 300,000 kWh per year.

After the compressed air audit, the company installed four new 7-bar air compressors with internal cooling. Marcoux also notes that most of the 52 identified air leaks have been sealed, and with proper balancing the company shut down one 75-hp compressor for annual electricity cost savings of $34,000.

The company is now investigating the feasibility of replacing piping to make compressed air use more efficient and to lower air pressure. — Steve Gahbauer

Comments? E-mail jterrett@plant.ca.

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October 2012

12-10-04 2:34 PM

Global Ranking << Trends

We’re less

competitive Canada drops to 14th globally A World Economic Forum report notes our less favourable research and innovation factors.

By Joe Terrett, EDITOR

A

s the competitiveness gap widens in Europe, Canada’s global position has also slipped from 12th to 14th, according to an annual competitiveness ranking by the World Economic Forum, an independent global organization based in Geneva.

The Global Competitiveness Report 2012-2013 shows Switzerland topping the rankings for the fourth straight year, with the US in seventh place and Canada residing in the top 20.

Canada continues to place near the top of the 144 countries measured in the report thanks to “highly efficient” markets with high rankings for goods (13), labour (4), financial (11), well functioning and transparent institutions (11) and excellent infrastructure (13). However, this year’s ranking was dragged down by a “less favourable assessment” of research institutions and the government’s role in promoting innovation through procurement practices.

Human resources ranks highly (seventh for health and primary education, fifteenth for higher education and training), but higher education, ranked eighth two years ago, is on a downward trend.

The Conference Board of Canada, which helped manage the distribution

Canada is still in the game competitvely but it has dropped five places in global ranking since 2009.

PHOTO: THINKSTOCK

of surveys here, noted the nation has dropped five places since 2009.

“Canada is a developed economy and … at a stage where its capacity to innovate successfully determines its overall success. Businesses must be able to compete on the basis of developing new or improved products, services, models and processes,” says Daniel Muzyka, president and CEO of the Ottawa-based think tank.

He contends Canada is not taking full advantage of its strong economic fundamentals, well-educated workforce and efficient markets to build higher valueadded products and services.

“Too often, Canada fails to commercialize its good ideas into marketable products and services or capture the value from growth,” he says, suggesting all levels of government, businesses and educational institutions need to do more.

One of the obstacles is a lack of metrics for innovation, says Doug Watt, a director

>> Human Resources

Attracting key employees is a struggle Global survey also found they are highly stressed

C

ompanies worldwide continue to struggle with attracting and retaining high-potential and skilled employees needed to increase their global competitiveness, according to a new report.

A global survey of 1,605 companies conducted by global professional services company Towers Watson also found that employees are experiencing high levels of stress, a trend many employers expect to continue for the next three years.

Close to two-thirds (61%) of Canadian respondents cite problems attracting critical-skill employees while 40% are having difficulty attracting high-potential talent and roughly 35% are finding it hard to attract top-performers, and more than 30% have difficulty retaining them.

The survey reveals a mismatch between what employers are offering and what employees are looking for. Canadian employees, including top talent, are more focused on competitive base pay and job security, while employers are emphasizing other items such as challenging work and the organization’s reputation as a good employer.

The study also found that Canadian employees continue to experience high levels of stress at work. Close to half (47%) of Canadian respondents indicate employees often experience excessive pressure in their job and 65% report employees have been working more hours than normal during the past three years.

Fifty-three per cent expect to maintain this trend for the next three years.

of research at the Conference Board.

“A lot of companies look at metrics as investment in research and patents so we’re (Conference Board) looking at developing business innovation metrics such as brand innovation, customer satisfaction, understanding of the market.”

Innovations Among the emerging market economies, China is down three places to 29 but leads the BRIC group. Brazil is at 48 and the only country to improve its ranking. South Africa (52), India (59) and Russia (67) showed small declines.

The US slipped two more places to seventh, its fourth consecutive decline.

The report notes a low public trust of politicians and a perceived lack of government efficiency among business leaders, but the US continues to be a major global innovator and its markets “work efficiently.”

Switzerland and countries in Northern Europe have been consolidating their strong competitive positions since the financial and economic downturn in 2008, says the report. However, countries in Southern Europe, such as Portugal (49), Spain (36), Italy (42) and Greece (96) continue to suffer from macroeconomic imbalances, poor access to financing, rigid labour markets and an innovation deficit.

Filling out the top 10 are Singapore (2), Finland (3) having overtaken Sweden (4), The Netherlands (5), Germany (6), the UK (8), Hong Kong (9) and Japan (10).

Overall, Canada is still doing well, says Watt. Efficiency enhancers in goods, labour markets, financial and technology use are all ranked highly. “[Countries] at the top of the rankings leverage those qualities to be more innovative,” he says. “Right now we’re treading water. If we do that for too long, we’ll sink.”

>> Exporting

Coherent strategy needed for Asia More participation in Asian institutions: ADF

I

f Canada wants to secure its place in Asia, it will require comprehensive engagement that extends beyond a commercially focused, and bilateral-centred approach, according to a taskforce report published by the Asia Pacific Foundation of Canada.

ADF cites Canada’s contact with various Asian organizations as key to building trade relationships.

Canada is a member of APEC, and talking to the Association of Southeast Asian Nations (ASEAN) and the ASEAN Regional Forum (ARF).

It also participates in non-official forums such as the Pacific Economic Cooperation Council (PECC) and the Shangri-La Dialogue. Canada is not a member of the ASEAN Defence Ministers’ Meeting ++ or the East Asia Summit.

Final approval is pending to join the Transpacific Partnership (TPP) trade negotiations but ADF said Canada has not concluded a single free trade agreement with any Asian country.

“Some might question the value of Canada joining process-filled forums in Asia, but keep in mind that the rules of engagement in Asia are different,” said Don Campbell, a co-author of the report. “Being active participants at these tables is critical to building long-term trust with Asian counterparts. This is ultimately vital to Canada’s long-term prosperity.”

Securing Canada’s Place in Asia: Institutions, Means and Mechanisms offers the following recommendations: • Establish a coordinating unit with access to senior government officials on Canada’s participation in Asia and convene on a regular basis with non-government stakeholders.

• Formalize and sustain a bilateral dialogue with the US focused on Asia.

• Strengthen existing bilateral dialogues with strategic Asian partners including China, Japan, India, South Korea and Indonesia.

• Seek early admission into the East Asia Summit.

• Volunteer to chair and host APEC in 2017.

• Seek admission into the ASEAN Defence Ministers Meeting ++.

• Consider appointing a Canadian Ambassador dedicated to ASEAN. • Conclude as a matter of urgency a FTA with South Korea.

• Pursue as a top priority comprehensive economic partnership negotiations with Japan.

• Move towards a trade agreement with China.

• Conclude trade negotiations with India.

• Secure final approval for participation in the TPP negotiations.

The Vancouver-based Asia Pacific Foundation of Canada is a not-for-profit, independent resource for Canadians on contemporary Asia and Canada-Asia relations.

Co-authors of the report include Don Campbell, senior strategy advisor to Davis LLP; Paul Evans, professor of Asian international relations at UBC; and Pierre Lortie, senior business advisor at Fraser Milner Casgrain LLP.

Comments? E-mail jterrett@plant.ca.

www.plant.ca

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PLANT 19

12-10-05 10:52 AM

Trends

>> US Election

Mr. President

2012

HOW ROMNEY AND OBAMA CONNECT WITH CANADIAN INDUSTRY Nov 6. will determine how Canada intersects with its biggest ally over the next four years.

BY MATT POWELL, ASSISTANT EDITOR

T

he US presidential election is quickly approaching as the land of the free and home of the brave ponders Democrat Barack Obama and Republican Mitt Romney.

Nov. 6 will be a big day for Canada too. The winner will impact Canada/US relations in such areas as energy, natural resource development, manufacturing and trade.

So, who is better for Canada?

Both are good, according to John Kriton, a political science professor at the University of Toronto, but “Obama is better.”

And Canada/US relations will be much better when the election is concluded, he adds.

“Then we can get back to business and stop the partisan political squawking that’s typical to elections.”

Here are three industry-related areas where Canadian interests intersect with the presidential nominees.

Loonie The Canadian dollar is hovering on or near parity with the US greenback. If Obama is re-elected, that’s unlikely to change.

His tapping of the Federal Reserve boosted the value of Canadian commodities, artificially inflating the cost of exports.

Exports between Canada and the US barely topped $330 billion in 2011 according to Statistics Canada, a significant drop from pre-recession days when exports were $370 billion (2008).

Peter Hall, chief economist at Export Development Canada, notes many factors have affected Canada’s relatively flat trade growth with the US since 2000, among them China and other emerging markets.

“But there’s been a strong rebound in growth since the recession, which shows not all is dead. We’ve recouped a lot of what we lost in 2009.”

Romney has vowed to cut budgets to raise the value of the US dollar, which would gain on the loonie and bring prices down to boost Canada’s export volumes.

Falling commodity prices would soften the loonie, bringing it into the 91 cent range by 2017.

“Commodity prices are inflated in the US because they’re going through a period of adjustment. Banks and corporations are sitting on massive amounts of cash, but once that settles down, prices will drop and make the value of the loonie more manageable.”

Trade Obama is a star in Canada. A recent Angus Reid poll suggests 65% of Canadians would vote for him; only 9% for Romney. But that doesn’t mean he’s good for business.

20 PLANT

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Obama is emphasizing manufacturing and bringing back jobs that have migrated overseas. Since Canadian manufacturers’ fortunes are directly tied to the prosperity of their US counterparts, that should be a plus for Canada. But there’s also a hint of protectionism in the air with renewed interest in the Buy American Act. “It’s a minor annoyance,” says Kirton. “But Canada’s been dealing with Buy American for a long time. It’s nothing new.”

However, US states are offering manufacturers hefty incentives to boost business south of the border, particularly in almost union-free jurisdictions, which will draw investment away from Canada. ElectroMotive’s move from London, Ont. to Illinois to make locomotives comes to mind.

Foreign companies are showing interest in Alberta’s oil sands, particularly China (see Nexen). But China’s interest in Canadian oil may fray trade with the US. If elected, Romney has promised to declare China a currency manipulator, which could be a problem for oil sands producers, especially as ownership diversifies. For example, a Republican government could take issue with buying oil from Chinese-owned companies in Canada.

Hall, however, doesn’t see any need to worry.

“The stuff’s here, it’s not going anywhere. That gives Canada the upper hand when it comes to oil trade.”

Energy Obama nixed TransCanada Corp.’s Keystone XL pipeline plans earlier this year until after November’s election. He’s concerned about environmental factors associated with the project, and there’s still no guarantee the pipeline will be approved without significant changes to TransCanada’s plans.

Romney says he would approve the pipeline within 100 days of the election, but there are plenty of roadblocks to bypass.

The Canadian Energy Research Institute (CERI) says cancelling Keystone would cost the Canadian economy more than $630 billion in additional GDP over the next 25 years. Alberta would miss out on $95 billion in royalties.

While 2008 was about Obama’s call for change, Nov. 6 will determine whether or not US voters are still on board.

Of course, we’ll reserve judgment in the interest of objectivity regarding who we think is best for Canada, but if you wish to weigh in, e-mail us with your thoughts.

Comments? E-mail mpowell@plant.ca.

>> Productivity

Slow growth the real drag on performance: Deloitte Companies not investing enough in their businesses

W

hen it comes to productivity performance, it’s not about size or sector composition, according to a new report from Deloitte.

Disputing decades of speculation that it is size and sector composition that restricts performance, the consulting firm’s report, The Future of Productivity: Clear choices for a competitive Canada, identifies the real drag as the inability of Canadian companies to sustain growth over the longer term.

Among the chief reasons is the reluctance of Canadian companies to invest Since 2000, US in growth, and government policies that encourage companies to remain small. manufacturing has Among the key findings, firms that export outperform non-exporters, but grown six times faster fewer than 3% of Canadian firms export.

And Canadian businesses spend at only 65.2% the US rate on machinery than in Canada. and equipment, while investment in information and communication technology (ICT) is at 66% in manufacturing and 80% in financial services.

The report found that Canada’s productivity lags the US in all areas, regardless of a company size, sector, business type or location. And the competitiveness gap has widened in mining, oil and gas, and financial services, but it’s particularly wide in manufacturing. Since 2000, it has grown six times faster than in Canada.

Deloitte notes productivity growth in Canadian manufacturing averaged 0.88% between 2000 and 2008, well below the 3.3% rate of growth in the US. And a survey of US firms from 1998 to 2008 showed that rapidly growing firms are more productive. In Canada, for instance, 4.9% of firms account for 43% of all job growth.

Deloitte advocates bolder investment in measures that boost productivity and seek out opportunities for growth domestically and internationally. It also calls on governments to create the right conditions for growth by eliminating barriers to trade, encouraging competition and foreign direct investment; and adjusting Canada’s immigration system to deal with an aging population and looming skills shortage.

The report notes Canada needs to develop new trading partners to lessen its dependence on the US, and increase the transparency of the foreign direct investment review process. This would encourage more foreign companies to invest in Canada, which would force Canadian businesses to invest and innovate to remain competitive.

“

”

October 2012

12-10-05 9:57 AM

Energy Efficiency << Technology

>> Supply Lines

A 50,000 square-foot facility.

NEW PROVINCIAL PLANT Provincial Partitions has completed the move to a new head office and main manufacturing plant in Mississauga, Ont. The 50,000 square-foot facility on Creekbank Rd. has added three new 16- x 16-ft. drive-in doors to accommodate the movement of materials and prefab, factory-built structures.

The modular structure company will continue to manufacture its System 40 demountable partition system at its 30,000 square-foot Campobello plant until the transition is complete.

LIMITED EDITION TOOL SET

Use a thermal imager to spot temperature variations.

PHOTO: FLUKE

COGENERATION

PARTNERSHIP OF CONVEYANCE

HOW TO ACHIEVE PEAK EFFICIENCY Apply measurement and maintenance in three key areas to get the most value from combined heat and power.

BY COLIN PLASTOW

C

ogeneration puts heat captured from industrial processes back to work by making steam that drives a turbine generator or heats other parts of a plant. Heat recovery is important because it increases energy efficiency by 30% or more.

No wonder sophisticated cogeneration solutions are now available in a range of sizes, but even the best of them require regular maintenance to ensure peak efficiency.

Measurements and maintenance

www.plant.ca

21-23-PLNT.1.indd 21

should focus on the following areas: 1. Enhancing heat recovery. Anything that allows heat to escape from a heat recovery system reduces efficiency.

Insufficient or damaged insulation and failed steam traps are two areas that merit close attention.

Start with a careful visual inspection with a thermal imager, performed annually and after any maintenance that requires the removal of insulation.

In a typical cogeneration system, heat from exhaust gases is used to preheat water that is fed to a boiler. Steam from the boiler is then piped through the facility for heating or other purposes.

Trap failures are common yet hard to spot. There are two failure modes: open and closed. In the closed mode (plugged), water that has condensed in steam pipes is trapped, reducing heat transfer and thus efficiency. But the water can also become entrained in the steam flow, form-

Gray Tools has launched a “Limited Edition” red toolbox set to mark its 100th anniversary.

The sets with 11-drawer cabinet and nine-drawer top chest each come engraved with a commemorative anniversary logo, a special serial number marking each tool’s uniqueness and a thank-you card from the Brampton, Ont. manufacturer’s chair Alex Gray.

Gray Tools now has five tool sets marking the anniversary.

ing a “water hammer” that will damage or destroy equipment as it pounds away like the tool of the same name.

Open mode (leaking) allows steam to vent from the distribution system into the condensate return system. A single open trap wastes thousands of dollars worth of steam a year.

To check for proper operation, know the steam system you’re working on, the type of steam trap you’re investigating and the tools you’re using to do the investigation. Examine the trap for obvious signs of trouble. Traps that have not been serviced for years may have failure rates as high as 30%.

A thermal imager typically displays objects of different temperature with colours (bluish for cool, reddish for warm).

Open mode shows high temperatures on both sides of the trap, because it’s venting steam straight through and into the

Advanced Motion & Controls Ltd. has entered into a distribution and integration partnership with conveyor system manufacturer Hytrol Conveyor Co. in Jonesboro, Ariz.

The Barrie, Ont. distributor of automation products will handle concept to long-term support of all new and existing Hytrol conveyor products.

$26.3M US NAVY DEAL FLIR Systems Inc. won a $26.3 million contract from Defense Logistics Agency (DLA) Aviation for advanced imaging systems and related electronics for installation on US Navy equipment. Work will be performed out of FLIR’s facility in Wilsonville, Ore.

$37.3M FOR EFT Nederman Group has completed its $37.3 million acquisition of Environmental Filtration Technologies (EFT).

The Swedish manufacturer of air filtration products said the acquisition strengthens its position in North America and Australia in mining, chemicals and steel.

EFT, based in Charlotte, NC, employs 385 people with annual sales of $125 million.

Continued on page 22

PLANT 21

12-10-05 9:58 AM

CIEN

Increase energy Pumps efficiency by 30% Continued from page 21

condensate return system.

An ultrasonic detector reduces the high-frequency sounds of steam flow to frequencies audible by the human ear. It also shows sound intensity on a display to detect leaks.

Conduct steam trap surveys at intervals determined by the system pressure. Technicians often test several dozen traps per day.

Other leak locations include bypass valves, tubes, air and exhaust systems.

2. Optimize mechanical systems and equipment. Vibration analysis measures the frequency and intensity of vibrations caused by wear, misalignment, looseness and other mechanical problems.

It will find the cause of overheated mechanical parts that have been detected with a thermal imager.

Examine rotating mechanical equipment to identify abnormally high temperatures. Focus on signs of overheating on motor end bells, which can indicate possible bearing or alignment problems.

The pumps, compressors and motors that make up a cogeneration system are subject to bearing wear, misalignment, balance, looseness and other mechanical problems. Measuring and analyzing the vibration signature of the machine and identifying abnormalities provide equipment condition information during operation. Detecting a bearing failure on the circulating water pump for a heat recovery boiler prevents unscheduled downtime. Reduced downtime translates to increased plant availability.

3. Improving electrical systems. Electrical inefficiencies can be present in both the electrical generation and distribution system, and in electrical equipment that operates as part of the cogeneration system.

If the generator of the cogeneration facility is supplying a large number of inductive loads (for example, motors and transformers), it may be running at a poor power factor. Adding power factor correction capacitors makes power available to do useful work in the distribution system.

If the generator is supplying nonlinear loads (for example, VFDs, UPS systems or copy machines), then undesirable harmonic currents may be flowing in the system. They can produce excessive heat in wiring and equipment, causing operational problems with other controls. Such inefficiencies need to be monitored and controlled.

Conduct a power quality survey of both the cogeneration unit and the electrical system it supplies to identify existing and potential problems, including harmonics and distortion of the voltage and current waveforms.

Use a data logger to record the behaviour of the electrical system over time. This is valuable because many power quality problems, such as transients and voltage sags, occur only briefly. Failure to maintain the electrical system within specified parameters creates excessive heat that causes controls to operate improperly and reduces the efficiency of electrical production.

Individual maintenance issues, such as missing insulation, a leaking mechanical seal, a failed-open steam trap, or an overheating transformer, can seem minuscule compared to overall energy production of the cogeneration process, but constant attention to problems will pay big benefits over time.

Colin Plastow is an industrial product manager for Fluke Electronics Canada. E-mail colin.plastow@ fluke.com.

Comments? E-mail jterrett@plant.ca.

BOOST PUMP PRESSURE MOVITEC high-pressure in-line pumps from KSB Pumps Inc. provide the pressure boost needed for industrial applications involving water supply/treatment, hot and cold water recirculation, condensate transport, boiler feed and desalination systems based on reverse osmosis.

They come in a range of sizes (up to a 90mm pipe diameter) and feature heads of up to 249 metres and flow rates as high as 90 cm/h.

Inlet and outlet nozzles are in line and the same size so the pumps install easily in piping systems.

Stainless steel hydraulic elements ensure long service life and high pumping efficiency.

KSB, based in Mississauga, Ont., sells pumps and valves manufactured by KSB Group, based in Germany. www.ksb.ca Easy installation.

www.plantmagazine.ca/rsc/ 1

ACCURATE PUMPING FOR CERAMIC SLIP In the ceramics industry, slip consistency must be maintained at correct levels for production efficiency and product quality. But the abrasive nature of the slip is a challenge for most pump types.

Bredel’s SPX handles abrasive, corrosive or viscous fluids without damaging the working parts of the pump. Peristaltic hose pumps are virtually maintenance free with no impellers, liners or mechanical seals to replace, no Virtually no check valves to clog and no rotors and stators to wear out. maintenance.

The SPX hose pump runs dry safely works 24/7.

Bredel is a brand of the Watson-Marlow Pump Group with US operations in Wilmington, Mass. www.wmpg.com www.plantmagazine.ca/rsc/ 2

21-23-PLNT.1.indd 22

HIGH-PRESSURE, NO EXTERNAL COOLING BATH Thermoelectric technology ensures Supercritical Fluid Technologies Inc.’s self-contained SFT-10 liquid carbon dioxide pump achieves high pressure without an external cooling bath.

The pump pressurizes carbon dioxide up to 10,000 psi (69 MPa) at flow rates from 0.01 to 24.0 ml/ min. for supercritical fluid extraction, fluid reaction chemistry and chromatography.

Dual sapphire syringe pump technology achieves high pressures rapidly and the Peltier chiller maintains a low enough temperature at the pump heads to ensure the carbon dioxide remains liquid.

The standard operating mode is “constant pressure” where the pump will maintain a pressure set point and there’s an optional constant flow mode, from 0.01 to 24.0 ml/min.

The pump comes as a stand alone or as part of SFT-100/SFT-100XW supercritical fluid extractors.

Supercritical Fluid Technologies is a Newark, Del. manufacturer of bench top and small scale pilot equipment. www.supercriticalfluids.com www.plantmagazine.ca/rsc/ 3

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Hamilton puts the "HEAVY" in heavy duty! With superior features like precision tapered thrust bearings and CNCmachined raceways, Hamilton's Forged Steel Casters will out perform and outlast other comparable casters.

And, most are stocked for 24-48 hour PRONTO® shipment.

For the best heavy duty casters, backed by the best delivery and the industry's first and only three-year product warranty....

HEAVY DUTY FLAP VALVE MAG DRIVE CENTRIFUGAL

Call Toll Free National 1-888-845-7867 www.vikingpumpcanada.com cinfo@idexcorp.com

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22 PLANT

Pressurizes CO2.

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Products and Equipment << Technology

HIGH-EFFICIENCY AIR FLOW

DOWN-HOLE APPLICATION EXTENDED Moyno HTD660 pumps handle high-temperature applications such as steam-assisted gravity drainage (SAGD) and cyclic steam stimulation in the oil and gas industry that prevents operators from using downhole progressing cavity pumps.

It has a metal-to-metal rotor and stator (that does not include elastomer) and withstands downhole temperatures to 350 degrees C (600 degrees F). Tolerances between the metal-to-metal rotor/stator clearance are closely controlled. Low levels of vibration compare to Progessing conventional downhole PCPs. cavity pump.

Use HTD660s for hot oil encountered during thermal recovery methods such SAGD and cyclic steam stimulation.

Moyno Inc. is a pump manufacturer based in Springfield, Ohio and is a unit of Robbins & Myers Inc., which handles Canadian distribution through its Calgary office. www.moyno.com

Versa-Matic’s Model E40 1 ½-in. high-flow, bolted metallic pumps include its Elima-Matic high efficiency air valve system.

The Mansfield, Ohio manufacturer of air-operated double diaphragm pumps says the E40 delivers 123 gpm, a 43% increase it claims as an improvement over other pumps.

The pump is distributed by York Fluid Controls in Brampton, Ont. www.yorkfluid.com

Long-life diaphragms.

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DISCHARGES FLUID AT 2:1 FLUID/AIR PRESSURE Wilden’s HX400S high-pressure air-operated double-diaphragm pump transfers viscous, solid-laden slurries at high discharge pressures using a liquid chamber rather than external boosters or amplifiers. This allows generating at a 2:1 ratio of discharge fluid to air inlet pressure, for a discharge fluid pressure of up to 250 psig (17.2 bar).

Available with 1 1/2-in. (38-mm) inlet and discharge connections, it’s outfitted with a Pro-Flo X air distribution system.

A state-of-the-art efficiency management system allows operators to dial in the actual parameters regardless of the application demands or pump size.

Other features include an advanced, bolted construction; DIN or 300-lb.

ANSI flanged connections; lubefree operation; 62 gpm (235 l/min) maximum flow rate; 125 psig (8.6 bar) maximum air inlet pressure; and 250 psig (17.2 bar) maximum discharge pressure.

LIQUID HANDLERS REPLACE SYRINGE PUMPS

Wilden Pump and Engineering Co. makes pumps in Grand Terrace, Calif. www.psgdover.com

Valco’s Cheminert M6 and M50 liquid handling pumps replace syringe pumps to eliminate refill cycles and changes.

This new generation of pumps for liquids and/or gases produce a bidirectional, pulseless flow with a range of over six orders of magnitude (5 nl/min to 5 ml/min for the M6; 1 µl/min to 25 ml/min for the M50).

As positive displacement pumps they’re self-priming and tolerate any gas that may find its way into the fluid lines. There is no separate fill cycle and the capacity is unlimited.

RS-232 and RS-485 communication protocols are incorporated into the microprocessor-driven controller. (USB interface requires Bidirectional pulseless flow. an adapter.) Software controls flow rates, flow direction and metered volumes.

VICI Valco Instruments Co. Inc. is a manufacturer of injectors, valves and actuators with a Canadian sales office in Brockville, Ont. www.vici.com

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No external boosters.

Rely on Reelcraft Made in USA

Now You’re Torquing!

®

SALES • SERVICE • RENTALS • CALIBRATION • CERTIFICATION

www.torquetools.com X•Ar EXOSKELETAL ARM Introducing the X•Ar Exoskeletal arm that attaches to your arm and provides dynamic support throughout your natural range of motion. Now used in the Medical Industry, in the Physical Therapy department, which has been quite successful.

Outstanding Acid and Chemical Resistance

Series 7000

New!

Epoxy Resin EP21AR • High strength adhesive/coating • Superior insulation • 100% reactive

Compact dual pedestal hose reels

Triple tap receptacle

p Series L4000 Series DP5000 and DP7000

p

Heavy duty power and light cord reels 154 Hobart Street, Hackensack, NJ 07601 USA +1.201.343.8983 • main@masterbond.com

www.masterbond.com www.plantmagazine.ca/rsc/ 113

www.plant.ca

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NON-MAGNETIC TORQUE WRENCH McCann Equipment also introduces the first ever Non-Magnetic Torque Wrench, which is proving invaluable for medical equipment, notably in the MRI field such as scanner maintenance, a torque wrench is required to check the bolts used with the gradient power supply cables. This non-magnetic tool is an important advance for both health & safety and asset protection, because using standard steel tools close to high powered magnets can be difficult and hazardous.

www.reelcraft.com | 800-444-3134

info@torquetools.com | www.torquetools.com | 1-800-663-6344 (MTL) | 1-800-287-5714 (TOR)

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CIEN TEST & MEASUREMENT

The sealed polypropylene lens protects the LED and electronics from impact and acid migration. Terminals Monitor battery cell are sealed to prevent corrosion. electrolyte levels The light is reverse polarity proFlow-Rite’s Eagle Eye tected and has three self-resetting advanced electrolyte fuses. An optional remote level indicator monimounts a light on the tors and displays the side of the battery status of battery cell when the monitor is electrolyte levels, obstructed. includes a trimmable Flow-Rite Controls probe and doesn’t Ltd., based in Byron require calibration.

Centre, Mich., manuThe light measures electrolyte levels factures fluid control without drawing a direct current from devices for lead acid the cell, instead using capacitive sensing batteries, boats and technology found in electronics such as laboratory use. touch screen monitors and cell phones. www.flow-rite.com It also eliminates any potential corroProtects against sion between the plates and the probe. acid migration. www.plantmagazine.ca/rsc/ 8

Dual stylus.

More versatile contour measuring Mitutoyo’s CV-4500 contour measuring system amps up the accuracy and widens its range with a magnetic arm holder that makes changes quick and easy.

The dual stylus measures more parts and features in upward and downward directions without changing the arm’s

orientation that allows measurements on internal diameters and part thicknesses.

The 10~50 mN programmable force eases measurement of thin profile workpieces.

The system’s range is 100 mm with accuracy of ± (0.8+ 0.01H |) and resolution of 0.05 µm for the X-axis, and 60 mm with accuracy of ± (0.8+ 0.02H) and resolution of 0.04 µm for the Z1-axis.

Maximum measuring speed is 80 mm/s (X-axis) and 30 mm/s (Z1-axis).

Mitutoyo is a developer of measurement and inspection technologies with a Canadian office in Mississauga, Ont. www.mitutoyo.ca www.plantmagazine.ca/rsc/ 9

Manage trace concentrations.

System tests gas mixtures KIN-TEK’s AutoBlend system, managed by six independently controlled channels using permeation or diffusion tubes, adds trace concentration components to matrix gas for sensor testing and catalyst sensitivity research.

Each channel contains up to eight compounds in disposable tubes. Two additional dynamic headspace modules add higher concentrations of common mixtures, or low volatility substances to the test mixture. An optional humidification module adds humidity to the final mixture.

The multi-channel, computer controlled gas blending system covers a wide concentration range from high parts-per-million to low parts-per-billion thanks to a secondary dilution feature.

KIN-TEK Laboratories Inc., based in La Marque, Tex., develops gas calibration and testing systems for industrial applications. www.kin-tek.com www.plantmagazine.ca/rsc/ 10

Stores 512 readings.

A multimeter for benchtop measurement essentials B&K Precision’s 5492B digital multimeter delivers essential benchtop measurements with 120,000-count display resolution and 0.01% basic VDC accuracy.

Those essential measurements include DC voltage and true RMS AC voltage, DC current and true RMS AC current, two- and four-wire resistance, continuity, diode test, frequency, and period. Builtin math functions such as Rel, Max/Min, dBm, dB, %, limits, and Mx+B are also included.

An internal buffer stores up to 512 readings at a rate of up to 57 per second.

Buffer storage operation and retrieval www.plantmagazine.ca/rsc/ 116

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Products and Equipment << Technology is completed from the front panel or via remote command.

Advanced options on the front and rear panel allow manual triggering of a measurement from a key press. It sends a bus trigger via remote control, or by inputting an external trigger signal. A VM Comp output terminal tells you when the measurement is complete.

Programmable via SCPI commands, the 5492B comes standard with USB and RS232 interfaces, and a built-in GPIB interface option (model 5492BGPIB) covers labs and system integrators.

B&K Precision Corp. makes test and measurement instruments in Yorba Linda, Calif. www.bkprecision.com www.plantmagazine.ca/rsc/ 11

SAFETY DeTecT fLAMes froM A DisTANce

5,000-psi range.

or 0-10 VDC and with electrical connections of either a DIN 175301-803C L-connector or a two-meter integral shielded cable.

AutomationDirect is a supplier of automation components based in Cumming, Ga. www.automationdirect.com

Sierra Monitor Corp.’s 3600-I Triple IR (IR3) detects fuel and gas fires at long distances while avoiding false alarms. Indeed it’s capable of detecting a one square-foot (0.1 square metre) gasoline pan fire at 215 ft. (65 m) in less than five seconds.

Durable and weather resistant, the flame detector includes a heated window that eliminates condensation and icing.

Sensitivity selection ensures no zone crossover detection, while multiple output options maximize flexibility and compatibility. It also includes HART protocol for maintenance and asset management and is RS-485 and Modbus compatible.

Sierra Monitor Corp., based in Milpitas, Calif., manufactures hazardous gas and flame detection systems for industrial applications. www.sierramonitor.com Heated window. www.plantmagazine.ca/rsc/ 14

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eAse PreveNTive PoWer MAiNTeNANce The MG300 RMS multimeter from Extech Instruments makes insulation testing a more routine part of predictive maintenance with faster troubleshooting and repairs.

It includes a built-in insulation resistance tester and wireless datastreaming functions Wirelessly for remote monitoring streams data. and datalogging.

Rugged and waterproof, the IP67-rated combination meter includes a digital insulation resistance tester (or megohmmeter) with four test voltages for measuring resistance up to 4 GΩ with 0.001 MΩ resolution. The full-function, RMS digital multimeter covers duty cycle measurements and provides milliamp readings for analogue 4-20 mA current loops in industrial analogue process controls.

CAT-IV-rated wireless datastreaming ensures safer troubleshooting and maintenance of dangerous moving equipment and one-person operation of remote safety switches.

The meter includes a remote USB receiver, Windows-compatible software, test leads with alligator clips, a Type K bead wire temperature probe with adapter, carrying case, and six AA batteries.

Extech Instruments is a developer of handheld test and measurement tools based in Nashua, NH. www.extech.com

The old definition of uniform no longer works for companies who need to reflect their uniqueness in what their people wear to work.

Today’s uniform has to be an extension of the brand, while comfortably fitting each individual who wears it—and invariably an off-the-shelf solution is not a solution.

That’s why Imagewear’s custom uniform program fits so many companies, so well.

We’ll provide the appropriate fabrics, custom tailoring, expert embellishment and procurement strategy that fit the uniqueness of your organization, your people and the way you work, down to the ground.

Find out more about how we can customize uniforms that work better for you, from initial design through to program management, contact us today at 1-877-675-1513.

Custom design. Because we never forget that there’s a YOU in Uniform.

www.plantmagazine.ca/rsc/ 12

MeAsure Pressure of NoN-coNDeNsiNg gAses Manage pressure measurement applications with ProSense SPT25 pressure transmitters from AutomationDirect for air and non-condensing, non-corrosive gases.

The all-stainless steel welded thin-film sensing element provides fast response time. With a pressure sensing range from vacuum to 5,000 psi, the transmitters resist vibration, shock and EMI/RFI, but are accurate over a wide compensated temperature range.

Models include a 1/4 in. NPT male threaded process connection and are available with linear outputs of 4-20 mA

www.plant.ca

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CIEN position signal is required.

Balluff manufactures sensors in Neuhausen, Germany. It has a Canadian office in Mississauga, Ont. www.balluff.com/micropulse

SENSORS

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Low-light indicator uses solar power Mitutoyo’s ID-S Solar ABS digimatic indicator combines the convenience of ABS origin memory with solar power.

It functions at light levels as low 40 lux thanks to a super capacitor that maintains a power reserve up to three and a half hours for applications where even lower light levels are encountered.

Magnets boost performance.

Transducers ease field maintenance The rapid replacement module (RRM) option on Balluff’s Micropulse Generation 7 linear position transducers allows quick field changeovers without removing pressure tubes from hydraulic cylinders.

The transducer electronics and sensing element are replaced as a single unit, keeping the hydraulic seal intact.

Because the pressure tube stays put, oil spillage and environmental containment procedures aren’t necessary.There’s no need to bleed the hydraulic system and there’s no danger of debris entering the hydraulic port. Non-contact magnetostrictive technology keeps performance consistent in applications where absolute

The ABS measuring system restores the most recent origin position, eliminating the need to reset the origin at poweron. Data-hold and data-output functions are included for better management of measurement results.

The measuring range is 0.5 in. (12.7mm) with selectable resolution of 0.0005 in./0.01 mm or 0.00005 in./0.001 mm.

The unit also supports output to measurement data applications such as MeasurLink, Mitutoyo’s statisticalprocessing and process-control program that displays real-time measurement results for SPC applications.

Mitutoyo is a developer of measurement and inspection technologies. It has Canadian operations in Mississauga, Ont. www.mitutoyo.ca

and take advantage of gigabit ethernet technology that transmits data over standard CAT-5e and CAT-6 cables for distances up to 100 m. www.teledynedalsa.com www.plantmagazine.ca/rsc/ 17

PACKAGING

Wraps up to 80 trays per minute.

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Speed-up wrapping operations

VISION

ABS origin memory.

See images up to 29 fps.

MATERIALS HANDLING Rotary stages boost throughput Aerotech’s CCS series rotary stages with integrated captured collet chucks provide automated material handling capability for a wide range of materials and applications.

The chucks accept C-, D- or Levin-style collets and come in sizes supporting tube diameters from 0.1 to 27 mm for applications requiring high-precision gripping of tubular material.

The work-piece advances without manual realignment to compensate for axial tube motion during clamp/unclamp cycles. Axial motion is significantly reduced to eliminate part re-registration by moving the taper around the collet.

Aerotech, a manufacturer of positioning stages, drive and control systems based in Pittsburgh, Pa., says mounting features support customer supplied wet-cutting accessories. The stages also tolerate moderate fluid leakage into the aperture to prevent encoder contamination and collet-chuck failure. www.aerotech.com www.plantmagazine.ca/rsc/ 19 Chucks support 27 mm diameters.

Better quality colour inspection Boost inspection operations with Teledyne DALSA’s Genie TS camera, which has been updated to include three colour models and integrates the company’s CMOS imaging sensor technology to capture pictures at speeds up to 29 fps.

Teledyne DALSA, a manufacturer of digital imaging products based in Waterloo, Ont., describes the higher colour quality as increasingly important for inspection in the food processing and automotive industries.

The cameras are based on the AIA (Automated Imaging Association) standard

Standard-Knapp’s 296TS continuum tray/ shrink system wraps up to 80 trays per minute.

The system includes a graphic operator interface, while its advanced diagnostic program automatically directs to a fault screen if there’s a problem. It also provides automatically scheduled maintenance alerts.

The stainless steel-framed system features easy “walk-by” maintenance thanks to transparent guarding that makes the system’s parts clearly visible. An on-demand film wrapping wand is controlled by a servo motor and sensor, and runs only when needed.

Standard-Knapp, a manufacturer of packaging machinery based in Portland, Conn., outfits the film bed with a clamshell that opens and is removable for periodic maintenance.

Servo-driven Zero-Gap infeed integrates geometry and sensors to ensure there’s a continuous supply of containers to downstream lanes and grouping sections. www.standard-knapp.com www.plantmagazine.ca/rsc/ 18

MOTION CONTROL

For challenging applications.

™

Couplings deliver high torque Zero-Max’s CD couplings with a peak torque of 78,000 Nm handle high torsional stiffness (up to 419,000 Nm/DEG) and load capacity for large and challenging power train applications.

Continuous torque is 39,000 Nm with an angular misalignment capacity of 1.5 degrees, axial misalignment of 6.5 mm and parallel misalignment of 0.24 mm.

The hub is made from 1045 HR steel with fasteners made of titanium 6AL4V grade 5 materials. A composite centre disc ensures performance at peak torques in hostile environments.

The company, a manufacturer of motion control products based in Plymouth, Minn., says the couplings tolerate temperatures between -70 and 250 degrees C. www.zero-max.com

METAL DETECTABLE PLASTIC COMPONENTS TUBE

ACTUATOR

CAP

LPS® Laboratories has revolutionized food safety for manufacturers with the release of six NSF® H1 food grade lubricants with patent-pending DETEX™ metal detectable plastic components.

LPS LABORATORIES • An Illinois Tool Works Company

TEL: (800) 241-8334 or (770) 243-8800 • Website: LPS® is a registered trademark of Illinois Tool Works

MRO Ad 1-12.indd 1

26 PLANT

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www.lpslabs.com

Scan QR code to watch DETEX™ Demo Video or go to www.lpslabs.com/LPS_ProductVideos.html

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October 2012

12-10-05 9:59 AM

Products and Equipment << Technology METAL WORKING

For CNC milling machines.

TOOL SETTING

BY RADIO Renishaw’s RMI-Q multiple probe radio transmission system eases integration in cable-free environments for machining centres and CNC milling machines with a single receiver for tool setting and spindle-mounted touch probe installations.

It activates the spindle-mounted touch probe or table-mounted tool setting probe to provide a visual indicator when the device is activated. A 2.4 Ghz frequency hopping spread spectrum (FHSS) ensures uninterrupted operation in busy radio environments, especially for applications where line-of-sight is obscured.

Renishaw is a producer of motion control and precision machining components based in Gloucestershire, UK. Renishaw (Canada) Ltd. has a sales office in Mississauga, Ont. www.renishaw.com www.plantmagazine.ca/rsc/ 21

Inserts enhance stability.

SHOULDER MILLS REMOVE MORE MATERIAL Blaxx shoulder mills from Walter USA remove large volumes of metal with precision. Wear and corrosion resistant, they come in diameters starting at 25 mm.

The F5041 and F5141 mills have highly precise indexable insert pockets that position inserts accurately and securely.

The tools are also fitted with tangential inserts that enhance tool stability.

Four cutting edges per insert reduce horsepower consumption. Controlled runout concentricity, and 90 degree perpendicularity ensure high degrees of accuracy, while cutting depths up to 12 mm are possible with a larger LNHU1306 indexable insert.

Since insert pockets and chip clearances demand less material, smaller tool diameters are achievable with higher density capabilities than other mill designs. Higher density enables up to 30% higher feed rates.

Walter USA, based in Waukesha, Wis., manufactures cutting tools for milling and drilling applications. www.walter-tools.com/us www.plantmagazine.ca/rsc/ 22

METAL FLUIDS HANDLE THE HEAT MAG’s CYCLO COOL 4000 and 4100 metalworking fluids are formulated for machining proprietary stainless and heat-treated steels used in forgings for hydraulic fracturing (fracking) pump parts and similar equipment used in the oil and gas industry.

The fluids are formulated for extreme high-heat applications, such as deep-hole drilling, tapping and hogging tough-to-cut metals. But they also work on aluminum, bronze, brass and copper, containing a combination of extreme pressure additives, esters and mineral oil for physical lubricity.

by a foil shield layer for improved performance over single layer cables.

Cables come in 100-ft. coils and 500- or 1,000-ft. rolls.

AutomationDirect is a supplier of automation products based in Atlanta, Ga. www.automationdirect.com www.plantmagazine.ca/rsc/ 24

24-bit resolution.

ENCODER IS VIBRATION RESISTANT TO 30 G CVM42H CANopen multi-turn encoders from Pepperl+Fuchs feature a stainless steel housing, flange and shaft to deliver 24-bit resolution in harsh environments where there are high mechanical stresses in mobile equipment, crane, steel production and wind turbine applications.

The Twinsburgh, Ohio manufacturer of

automation products notes they handle axial and radial shaft load capacity to 270 N, they’re vibration resistant to 30 g and shock resistant to 300 g, and operate at temperatures between -40 to 85 degrees C. www.pepperl-fuchs.us www.plantmagazine.ca/rsc/ 25

FINISHING FINISHING DISCS CUT WASTE

For oil and gas applications.

CYCLO COOL 4000 is a heavy-duty cutting fluid that contains extreme pressure additives, esters and mineral oil for physical lubricity. The company recommends it for machining fracking pumps and other severe-duty applications.

CYCLO COOL 4100 is a low-foaming coolant formulated with a blend of sulphurized and chlorinated extreme pressure additives for heavy machining and grinding of ferrous and non-ferrous material, including titanium. It provides stability for applications where hard water build-up presents a problem.

MAG is a developer of machine tools and systems lubricants based in Sterling Heights, Mich. It’s Canadian head office is in Mississauga, Ont. www.mag-ias.com www.plantmagazine.ca/rsc/ 23

ENDURO-FLEX finishing discs from Walter Surface Technologies have been redesigned to include a flap with a cloth and abrasive composition.

Backing is trimmable to increase the disc’s longevity and Removes achieve a more consistent surface finish while removing more material. more material.

A 5-in. disc with Grit 40 removes up to 2,500 g over its lifespan, which the company says is comparable with other discs and different grit sizes.

Walter Surface Technologies, a manufacturer of surface treatment technologies based in Montreal, notes the disc’s longevity lowers costs by reducing changeovers and waste. www.walter.com www.plantmagazine.ca/rsc/ 26

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

AUTOMATION 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.

Reduces electrical noise sensitivity.

✓ Has been adopted by thousands of industrial facilities worldwide!

CABLES BOOST INDUSTRIAL COMMUNICATIONS Automation Direct’s low-capacitance data cables reduce electrical noise sensitivity.

Impedances are specific for RS-232/422 and RS-485 communication applications in industrial environments.

The 24 AWG tinned copper conductors are constructed as twisted pairs to reduce electrical noise sensitivity and come in one, two, or three-pair colourcoded versions. Polyethylene insulation provides high insulation resistance and the tough PVC jacket is rugged enough to handle industrial conditions.

Protection from radiated or conducted electromagnetic interference is provided

Let us help you save time and money, with safety in mind.

Book your on-site FREE demo!

1-888-592-5837 biocircle.com

walter.com

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www.plant.ca

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CIEN PLANTWARE

Seamless upgrade.

SMART TRANSITION TO LED BACKLIT LCD ERG’s Smart Bridge module resolves many of the problems associated with LCD changeovers using your system’s existing input power signals and converting the analogue dimming signal used for the

inverter into a PWM signal for the LED driver. This powers the LED backlight driver without additional modifications.

Remove the inverter, plug in the footprint-compatible module and connect the input cable from the existing power supply or controller to the Smart Bridge. The module converts the signals and mates directly to the LCD via a small harness, powering the new backlight driver correctly.

The standard version (SBD4212F) is a pass-through with integrated PWM dimming and operates from a typical 12 V signal. The DC-DC converter with integrated PWM dimming (SBDCD4213F) is designed for applications requiring a step-up conversion from 5 V to 12 V. The third version is a DC-DC converter without dimming (SBDC4227F).

The Endicott Research Group (ERG), a supplier of drop-in replacement LED drive modules is based in Endicott, NY. www.ergpower.com www.plantmagazine.ca/rsc/ 27

CALCULATOR TARGETS PUMP COSTS What does a pump cost over its lifetime?

Use Met-Pro Global Pump Solutions’ online calculator to get an estimate for one or more pumps.

Input your data including initial pump costs, installation costs and annual recurring costs such as maintenance.

The calculator takes into account energy costs and generates an analysis, including a pie chart.

Generate results by visiting www.mpgps.com/products/pump-life-cycle-

Estimate lifetime costs.

cost-calculator.

Met-Pro Global Pump Solutions-Fybroc is a supplier of pump technologies based in Telford, Pa. www.mp-gps.com www.plantmagazine.ca/rsc/ 28

Open architecture.

CONTROLLERS AMP UP PERFORMANCE

OctOber 23–25, 2012

|

Advantech has cranked up performance levels with two open-architecture embedded controllers.

The high-end, high-performance UNO2184G is for applications requiring a lot of graphical processing power, while the UNO-2174G is a mid-end controller for faster performance without 3D capabilities.

The UNO-2184G comes with a high performance Intel Core i7-2655LE processor and the UNO-2174G comes with an Intel Celeron 847E. Both models support up to 16 G DDR3 RAM (with 4 G/8 G RAM onboard or built-in), a dedicated Intel HD graphics processor, and they’re fanless, operating in temperatures as low as -10 degrees C and as high as 60 degrees C. Advantech’s Industrial Automation Group based in Cincinnati develops automation technology. www.advantech.com/ea.

edmOntOn, AlbertA

Make your link in Canada’s oilsands supply chain.

www.plantmagazine.ca/rsc/ 29

The Canadian oilsands is now one of the largest industrial engineering projects in the world, with over $2 trillion in expected spending over the next 25 years. Thousands of workers and companies are positioning to support the oilsands, a movement that is quickly reshaping the Canadian economy.

The 2012 National Buyer/Seller Forum is the ideal context for your company to:

• Connect with potential buyers • Network with upcoming supply-chain players • Display and promote your products and services • Develop your oilsands strategy

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HD VIDEO ON TCP/IP NETWORKS Matrox Graphics Inc.’s Maevex H.264-based encoder/decoder technology distributes video and audio such as digital signage, collaborative video walls, security and surveillance over standard TCP/IP networks.

The technology offers one-to-one unicast or one-to-many multicast extensions of H.264 encoded video via standard wired (CATx) and/or wireless (Wi-Fi) connectivity at 1,080p (60 Hz).

It leverages standard CAT5, CAT5e, CAT6, CAT7 cabling and standard networking infrastructure and wi-fi technologies, features a command and control software to remotely manage the distribution network, includes user defined fine-tuning of codec and network bit rate, and uses a solid-state, energy-efficient design for high MTBF and long product life cycles.

Matrox is a developer of display graphics technology based in Montreal. www.matrox.com www.plantmagazine.ca/rsc/ 30

28 PLANT

October 2012

12-07-25 10:43 AM

12-10-05 10:49 AM

Industrial Literature Reviews CIEN Free Spray Optimization Handbook Learn how to improve spray performance in cleaning, coating, cooling, drying/blowoff and more with Optimizing Your Spray System, Technical Manual 410A from Spraying Systems Co. Handbook includes information on how to detect and solve spray nozzle problems, how to establish a nozzle maintenance program and the benefits of automated spray control. www.spray.com Spraying Systems Co. www.plantmagazine.ca/rsc/ 121

Canadian Distributor Wanted For Imada Force and Torque Instruments 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. www.imada.com Imada Force and Torque Instruments www.plantmagazine.ca/rsc/ 122

CLAMPS, TOOLING COMPONENTS Newly updated, this 688page catalogue, in print or online, features photos and specifications of clamps, pins, hoist rings, knobs, threaded inserts, spring-loaded devices, supports, locators, toggle clamps, modular fixturing, drill jigbushings and power workholding. www.carrlane.com Carr Lane Mfg. Co. www.plantmagazine.ca/rsc/ 123

>> Events Physical Asset Management Certificate Program C-MORE Nov. 5-9, Toronto Nov. 12-14, Toronto Centre for Maintenance Optimization & Reliability presents this certificate course to help maintenance pros better manage their plant assets. Visit http://cmore.mie.utoronto.ca, Educational Programs.

ACCESSORIES – AIR AND DUST HANDLING SYSTEMS This fully illustrated, 8-page catalogue features a wide variety of accessories including: stamped and rolled angle rings, blast gates, galvanized spiral duct, diverters, clean outs, nozzles, duct silencers, rotary air locks and exhaust fans. www.nrmurphy.com N.R. Murphy Ltd. www.plantmagazine.ca/rsc/ 124

CATALOGUE SHOWCASES INDUSTRY-LEADING CASTERS

VAC-U-MAX is a premier manufacturer of industrial vacuum cleaning systems for production lines and other dust-intensive areas. With a VAC-U-MAX heavy-duty industrial vacuum cleaning system on site, both your capital equipment and your employees will be safer and cleaner. www.vac-u-max.com VAC-U-MAX www.plantmagazine.ca/rsc/ 125

Platinum Edition Catalogue No. 300 features 130 pages of enhanced product layouts, detailed illustrations, rich graphics, user-friendly charts, and numerous colourful photographs all intended to simplify the selection process for buyers and specifiers. www.HamiltonCaster.com Hamilton Caster www.plantmagazine.ca/rsc/ 128

HIGH PRECISION TIMING BELTS WITH BACK COVERS

OMEGA Introduces FREE LITERATURE Spotlight on omega.ca®

BRECOflex offers high precision timing belts with a wide variety of backings. A heated chemical bonding process assures a strong seal to the belt. All backings provide excellent wear resistance and resilience. They come with a full range of accessories including pulleys, clamps, tensioners and slider beds. www.brecoflex.com BRECOflex www.plantmagazine.ca/rsc/ 126

CME Trade Summit CME – Manitoba Nov. 20, Winnipeg A trade event for SMEs presented by Canadian Manufacturers & Exporters (CME), Manitoba division, features speakers, practitioners and services for the support of international sales and growth plans. Visit www.cme-mec. ca/english/events/events.html.

FABTECH 2012 SME Nov. 12-14, Las Vegas, Nev. The society of Manufacturing Engineers (SME) showcases metal forming, fabricating, welding and finishing technologies. Visit www.fabtechexpo.com.

MainTrain Toronto PEMAC Nov. 19-22, Toronto The Plant Engineering and Maintenance Association of Canada (PEMAC) hosts this learning, training and networking conference for Canada’s asset management professionals. Visit www.maintrain.ca.

Investment Symposium CAPP Dec. 10-12, Toronto The Canadian Association of Petroleum Producers (CAPP) will bring together senior executives from more than 50 oil and gas producing companies and investors. Visit www.capp.ca.

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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/ 127

Industrial Vacuum Cleaning Systems from VAC-U-MAX

CAM Summit APMA Nov. 29, Toronto The Automotive Parts Manufacturers’ Association (APMA) Canadian Automotive Manufacturing Summit features Canadian CEOs and senior executives who will share opinions, discuss the issues facing the industry, and outline a course for a profitable future. Link to Calendar at www.apma.ca.

www.plant.ca

MOST POPULAR VACUUM CUPS

Contains over 50 full colour pages of the latest state-of-the art products from Omega.

Products include a variety of thermocouples, wire, RTD and thermistors, meters, infrared transmitter, pressure products, flow meters, pH and conductivity products, data acquisition and data Logging, recorders, heaters and automation products. Your one stop shop for process measurement and control products. www.omega.ca OMEGA www.plantmagazine.ca/rsc/ 129

Index of Advertisers RS#

Advertiser

Page #

130................................... AME............................................................... 30 120................................... Buyer/Seller Forum.......................................... 28 106................................... Canadian Linen................................................. 9 116................................... Design/Manufacturing show............................. 24 104................................... Exair................................................................. 7 109................................... Flir................................................................. 11 102................................... Gorbel.............................................................. 6 112................................... Hamilton Caster............................................... 22 117................................... Imagewear...................................................... 25 101................................... IPEX.............................................................. IFC 107................................... Kunst............................................................. 10 103................................... Lapp................................................................. 6 118................................... LPS................................................................ 26 108,113............................ Masterbond............................................... 10, 23 115................................... McCann Equipment . ....................................... 23 131................................... OPA............................................................... IBC 114................................... Reelcraft......................................................... 23 105................................... Schneider......................................................... 8 132-134............................ Spraying Systems..........................................OBC 111................................... Viking Pump.................................................... 22 119................................... Walter Surface Technologies............................. 27

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“Thanks to the new system upgrades, we’re seeing significant savings in energy use.”

Douglas Dittburner Energy Manager, Cadbury

Saving energy makes sense – business sense.

Get up to 70% off project costs, including: • Engineering studies • On-site energy manager • Key system upgrades

Energy efficiency incentives from your local electric utility are available for industrial plants like yours. Whether you’re in the food and beverage, automotive or plastics and packaging industry, you may be covered for up to 70% of your project costs, including engineering studies and process and systems upgrades to help lower operating costs. Big or small, every Ontario business can benefit from energy efficiency.

• Monitoring and targeting

Contact your local electric utility or visit saveonenergy.ca/industrial

Subject to additional terms and conditions found at saveonenergy.ca. Subject to change without notice.

A mark of the Province of Ontario protected under Canadian trade-mark law. Used under licence.

OM Official Marks of the Ontario Power Authority.

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MoToR-DRIveN TaNk CleaNeRS PRovIDe HIgH-IMPaCT, DePeNDable CleaNINg of TaNkS uP To 80' (24.4 M) IN DIa. TankJet AA290 and AA190 tank cleaners use air or electric motors to drive high-impact solid stream nozzles and reliably clean tanks day in and day out. Motors are positioned outside the tank for long wear life. Plus, motor performance can easily be monitored through plant control systems. tankjet.com/tj290

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ObstructiOns

in tanks t causing cleaning challenges?

cut cleaning

time by 75

%

TaNkJeT 75 offeRS CoMPleTe, CoST-effeCTIve CleaNINg of TaNkS uP To 30' (9.1 M) IN DIa. Ideal for cleaning process tanks of all types, TankJet 75 tank cleaners use solid stream nozzles rotating in multiple axes to provide 360° coverage. Available with two or four nozzles, these units feature a simple self-cleaning design, long-lasting performance and easy maintenance.

Superior Spray. SeriouS reSultS.

tankjet.com/tj75

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A food ingredients producer had workers manually cleaning tanks with ribbon blades. Cleaning the tanks between batches took an hour or more and the results were inconsistent.

fRee TaNk CleaNINg evaluaTIoNS

The use of two TankJet® 75 tank cleaners solved the problem. The units are

One of our local tank cleaning experts will visit your plant and evaluate your current cleaning methods. You will receive suggestions on how to clean tanks more thoroughly, reduce water and chemical use and return tanks to service more quickly.

A payback analysis on recommended equipment will also be provided.

surfaces including the ribbon blades. The powerful impact of the water jets

tankjet.com/evaluation www.plantmagazine.ca/rsc/ 134

mounted in opposite corners of the tank to ensure thorough cleaning of all ensures repeatable results with every cleaning cycle.

The results: • Cleaning time reduced to 20 minutes • Production increased by three batches per day • Labor expense reduced by $25,000 per year

Learn more about this application and dozens more at spray.com/results

Unmatched Global Engineering, Manufacturing and Technical Support Nozzles | Control Systems | Headers & Injectors | Research & Testing 1.800.95.SPRAY

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