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Industry Update Issue100 76 February/March February 2014 $12.00 INC.GST INC.GST Issue 2018 $12.00
planning with a forward looking approach to industry capability by John Pollaers, Chairman of the Australian Advanced Manufacturing Council.
MEET THE TEAM PAGE 29
WELCOME TO THE GOLDEN EDITION
100 issues of Industry Update. 56 front page headlines. Thousands of pages, delivered to hundreds of thousands of desks across Australia. What a journey it’s been!
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PUBLISHER SCOTT FILBY
EDITOR LAURENCE MARCHINI
DON’T MISS OUT ON THE WRITE-OFF
WE ALL GET WHAT WE PAY FOR
As a small business owner myself, I have been surprised to find how poorly understood the Federal Government’s $20,000 instant asset write-off scheme is. And, as a result, small businesses have been putting off purchases simply because they don’t realise that they can claim almost immediately. The greatest misconception is that the allowance is $20,000 per company per year. Wrong: the $20,000 refers to the maximum value of each asset – and there is no limit to the number of claims that can be made in a year. We here at Industry Update have taken advantage of the scheme to upgrade several of our computers and expand our video production capabilities. Each of the asset purchases is valued at less than $20,000, and all are eligible for write-off this tax year. Another misconception is in the definition of a small business. This is simple. Any business with a turnover of less than $50 million is eligible. The third misconception is the duration of the scheme. And while the government has indeed been extending it each year, it would be foolish to assume that it will continue into the 2018/19 tax year. The scheme is designed to encourage the
sorts of investments that help small businesses to grow, and there are very few exclusions to the equipment that is covered. The time to invest is now, and to help encourage that investment, we’ll be running a special feature in the April issue of Industry Update magazine focusing on the types of equipment eligible for the scheme. And considering that for small businesses, cashflow is always an issue, the prospect of a speedy refund has additional appeal. It might be something as simple as a new computer for the office or a new mobile phone. Alternatively it might be something more productive like materials handling equipment. So long as it is for business use and it costs less than $20,000, it is eligible for the scheme. No doubt our regular advertisers will be keen to remind our readers just how far $20,000 can go by participating in our feature. I cannot go without saying a huge thankyou to every advertiser and reader that has made Industry Update a huge success! There are so many advertisers and I thank them all very much! Since our inception we still have many advertisers that are advertising today, including Nilfisk, SEW-Eurodrive, Treotham and Safetch - to mention just a few.
I like a bargain as much as the next person. But it can be all too easy to be swayed by an appealing price tag without taking true value into account. And I have been reminded of this several times this year alone.
Ross is most insistent that with any purchase we really should consider the “whole of life” costs, and explains why in the latest instalment of his Forklift Fundamentals series in Industry Update.
Take, for example, consumer electronics. When my son asked if he could have a new iPhone for Christmas (not the latest version), I naturally researched the market and came up with an Australian vendor on eBay selling the model he wanted at a very attractive price indeed.
So, it would be absolutely bizarre if governments were to fall for the same bargain blindness in their procurement, wouldn’t it? But we all know that they do.
Sad to say, within weeks of it arriving, faults started to appear – the touchscreen, the battery and so on. And it was only when we took it to the local Apple store that we found it to be a Japanese model that Apple Australia had no obligation to support. So much for the bargain! It seems strange to relate that companies can fall into the same trap. But they do. I was reminded of this while talking with long-time collaborator Ross Grassick of Lencrow Materials Handling, who knows of countless instances where forklift buyers have been swayed by the allure of a “bargain basement” forklift, only to find that the running costs are much higher than anticipated, and the reliability leaves a lot to be desired.
The latest lamentable manifestation of this has to be the Sydney Light Rail Project, the cost of which has already blown out from $1.6 billion to $2.1 billion, and is said to be running months behind schedule. This is made all the more annoying with the knowledge that neither the rails nor the rolling stock have been sourced locally. Interestingly, the NSW Government is threatening to penalise the Spanish consortium building the light rail an eyewatering $500,000 penalty for every day it's late. Who knows? Maybe that will make it a true bargain! And, talking of true bargains, such are the wonders of Australian consumer law that the vendor of my son’s iPhone was obliged to “refund, replace or repair” the defective product, which he did, complete with a free postal return and a prompt refund.
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THE FUTURE IS UNINTUITIVE
Common sense wisdom is an invaluable tool, but it’s not infallible, says Tony Pearce The future is changing fast, and what might initially seem to be perfectly reasonable often turns out to be completely and utterly wrong. Successful businesses must flexible and open to change, and there’s no better case study of this than the past few years: politically, socially, and technologically, very few things have been predictable by 'common sense'. The same qualities that have enabled Australian companies and initiatives to succeed in diverse areas (namely their broad skillsets and willingness to adapt) have also allowed them to survive unexpected hurdles, such as skyrocketing utility costs and supply chain disruptions. Common sense dictated that Australian manufacturing would shrink as large automotive manufacturers left the country; yet it has instead gone from strength to strength, seeing the longest uninterrupted period of growth in history and pulling in smaller manufacturers to fill the gap. Common sense indicated that
print couldn't compete with the reach and flexibility of the internet, but the last four years have seen us grow, defying expectations by providing engagement unmatched by the ephemeral nature of online content. And common sense told us that offshoring and automation were going to cut jobs in swathes, but collaborative robotics, onshoring, and an uptick in the rate of wage growth show quite the opposite. When it comes to power generation, South Australia came under fire for an over-reliance on renewables after state-wide outages at the end of 2012. Yet in the 20172018 financial year, despite an increase in renewable generation and clean storage, SA saw no major power incidents and exported 2.5 times as much energy as it imported. This time last year, skepticism remained high that Australia was likely to have a functional approach to developing its own space programme, but now? Not only are plans underway to remove our
If we rely solely on our intuition, we might as well be dabbling in divination.
reliance on other nation's launches and satellites, but our own startup companies are developing materials and propulsion techniques that could go global.
stubbourn creativity that has allowed us to hurdle these obstacles many predicted as inevitable, we might just earn that coveted title of an “innovation nation”.
If Australians can hang on to the
CONTENTS FROM THE EDITOR.......................... 8
MATERIALS HANDLING ............... 30
INDUSTRY POLITICS .....................12
Forklift Fundamentals - Part 4 .......... 42
SAFETY ............................................. 46
INDUSTRY PERSPECTIVE............. 20
SEW-Eurodrive’s Robert Merola sees plans coming to fruition...............22
INDUSTRIAL DOORS..................... 62
MEET THE TEAM ............................ 29
PUBLISHER SCOTT FILBY
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EDITOR LAURENCE MARCHINI
CREATIVE DIRECTOR MATTHEW LAM
firstname.lastname@example.org SUB EDITOR TONY PEARCE
NMW 2018 PREVIEW....................... 66
ENVIRONMENT/WASTE MANAGEMENT............................... 74 AUSTRALIAN MADE ...................... 78 Australian Made retractable reels in demand at home and abroad PRODUCT NEWS............................ 84 FUN AND GAMES ........................... 98
The rise and rise of Bluetooth............ 68
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• INDUSTRY POLITICS
COMBINING ADVANCED MANUFACTURING TECHNIQUES WITH SCIENCE AND INNOVATION
By Senator Michaelia Cash
For over 20 years, Industry Update magazine has been a valuable voice for Australia’s manufacturing sector, and I congratulate IU on reaching its 100th edition. This achievement is a timely milestone because Australia’s manufacturing sector is currently experiencing its longest consecutive run of expansion in over a decade. As readers of IU will know manufacturing is vital to Australians and our economy. The sector currently contributes $100 billion to the economy in value add, employs around 900,000 Australians and invests $4 billion in research and development—more than any other industry sector.
Transition and growth Australia’s manufacturing sector is enjoying a resurgence. Ai Group’s Australian Performance of Manufacturing Index grew by 2.5 points to 58.7 in January 2018, the 16th month and longest consecutive run of expansion in the manufacturing industry since 2005. Manufacturers’ business expectations are at the highest levels since mid-2003, driven by strong expectations for profits, selling prices, and capital investment. Manufacturing exports represent nearly 30 per cent of our total export value, second only to mining. Exports of Australian food, textiles, paper, petroleum, polymer, metals, transport equipment, machinery, furniture and publishing products have all increased over the past decade. The ability of many Australian manufacturers to change from traditional, heavy industrial processes to agile, flexible and knowledge-based manufacturing underpins this growth. There are plenty of examples of Australian manufacturing companies that have achieved global success as a result of changing the way they operate. Brisbane-based Smart Steel 12
Solutions (SSS) is one such example. Using leading edge technology, automation and robotics, the company has integrated the design, cutting and fabrication of its structural steel manufacturing processes. Not only does this system halve the manufacturing time for one tonne of steel, it has upskilled the company’s welders and boilermakers who now work in the design office alongside engineering staff. These efficiencies have allowed the company’s products to compete with imports and created several new highly skilled jobs. Opportunities for Australian manufacturing Over coming decades, Australia’s economy - and with it manufacturing - must continue to transform. Our economy must embrace the opportunities presented by globalisation and disruptive technologies – such as the Industrial Internet (or Industry 4.0). These changes bring great opportunities for our manufacturing sector, especially if it can embrace new technologies and
helping businesses and our economy to transform in response to these changes through an integrated set of initiatives and other policy settings. These include the Industry Growth Centres Initiative (including the Advanced Manufacturing Growth Centre), National Innovation and Science Agenda, Entrepreneurs’ Programme, Centre for Defence Industry Capability, CSIRO and Cooperative Research Centres. The $100 million Advanced Manufacturing Fund we announced in 2017 is already helping the sector create jobs, grow their businesses, improve productivity and perform on the global stage. The centrepiece of this package, the Advanced Manufacturing Growth Fund, worth nearly $47.5 million over two years, is helping industry and businesses continue to adjust to the changing landscape of manufacturing in Victoria and South Australia. In South Australia, the business ATi Implants Pty Ltd, received $1.5 million to establish a high-tech additive manufacturing process to produce dental implants.
For over 20 years, Industry Update magazine has been a valuable voice for Australia's manufacturing sector supply intermediate goods for niche markets in global supply chains that comprise some 70 per cent of global trade. There will be a greater emphasis on pre- and post-production activities in the manufacturing value chain activities that demand high skill jobs in R&D, design, engineering, marketing, sales and after-sales. Businesses will need to compete on value rather than price alone.
The role of government The Turnbull Government is
MiniFAB Pty Ltd, from Victoria, received close to $1.3 million, which it will use to upgrade its manufacturing facilities for the production of medical devices to be used for the emerging ‘organ on a chip’ technology.
Innovation in manufacturing In addition, the Advanced Manufacturing Growth Centre (AMGC) is helping industry to tap into our science and innovation capability to generate tangible benefits. The AMGC’s national network of collaboration hubs is driving industry-led R&D and
Senator Michaelia Cash is Acting Minister for Industry, Innovation and Science.
innovation with some of our top universities and CSIRO. Hubs include carbon fibre manufacturing, additive manufacturing and an Industry 4.0 ‘Test Lab’. Combining advanced manufacturing techniques with science and innovation helps industry to be more innovative, more competitive and more profitable. Take, for example, the partnership between Astor Industries and Dresden Optics. Through this partnership, Astor Industries has diversified its operations from automotive manufacturing to upcycling used beer keg lids, Lego and fishing nets to create spectacle frames that Dresden Optics is selling in stores across Sydney and Melbourne. This has created a new use for its existing technology and new opportunities for its existing workforce. This partnership has helped Dresden Optics grow too, creating new jobs and increasing its turnover from $450,000 to $1.2 million in just two years. In many ways, success stories like Astor and Dresden epitomise the future of Australian manufacturing. By embracing technological change and exploiting new ideas to their full potential, these businesses have innovated and reinvented themselves creating new and jobs new prosperity for Australians as a result. I again congratulate IU on its significant milestone. I am honoured to be the Minister for Jobs and Innovation and part of a government that is delivering on its commitment to strong economic and jobs growth.
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• INDUSTRY POLITICS
THE CHALLENGES AND HOPES FOR THE YEAR AHEAD IN MANUFACTURING
By Senator Kim Carr
An odd thing about public discussion of manufacturing in Australia is how often we have to remind people why it is important. Industry Update and its readers understand why manufacturing matters, of course, and I congratulate IU, as it celebrates its 100th edition, for its staunch defence of the sector. But in the wider media, manufacturing is all too often portrayed as a sector in inevitable decline. That is a fashionable view among sections of the commentariat, but it completely misunderstands the real economy. According to the ABS, manufacturing contributes 23 per cent of private-sector R&D - the biggest share of any sector of the economy. Without the diversity that comes from a strong manufacturing sector, the economy would constantly be buffeted by the boom-and-bust cycles of the commodities and property markets. And, most important of all, manufacturing creates jobs that sustain communities, and thereby underpins our democratic way of life.
...manufacturing creates jobs that sustain communities, and thereby underpins our democratic way of life. So the first challenge facing the sector is to keep making the case against the naysayers, and that is why politics, and policymaking, matter. It takes work to encourage people to invest in manufacturing, and especially to engage in innovative, advanced manufacturing that can secure a place in global value chains. It takes clarity of vision to remind people that innovation is not only, or even mostly, about start-up hype and gadgetry. Nor is it another name for disruption that inevitably leads to a loss of jobs. On the contrary, innovation is about
transforming traditional industries to create the jobs of the future. In articulating that vision, and in encouraging investment in manufacturing, government has an essential role. It is government that must ensure there are sufficient incentives for manufacturers to invest in R&D, and that they can obtain the knowledge and assistance – including access to finance – they need. And it is government that must be willing to intervene when soaring energy costs raise the prospect of many manufacturers moving offshore, as Australia’s gas crisis is doing now. All this requires stable and coherent policy, which is why the rapid churn of industry ministers and science ministers in the past five years has not helped to repair the innovation system. There is broad agreement that the system needs repair, and that this is a matter of urgency. Australia lacklustre performance in international innovation rankings speaks for itself. The 2017 Global Innovation Index ranked Australia 23rd out of 127 countries in research performance, but only 76th in effectively commercialising research. Since 2013 there have been numerous reports and reviews aimed at improving this performance. The most recent is Innovation and Science Australia’s 2030 Strategic Plan, released in January. Like its forerunners, the plan is a series of mostly disconnected measures. It recognises that a weakness of the innovation system is its fragmentation – the “system” is an array of institutions, agencies, programmes and overlapping jurisdictions – but offers no real solution to this problem. That is partly because the plan has been released while crucial Government decisions are unknown. We are still waiting on the Government’s response to the recommendations of the “Three Fs” review of the R&D Tax Incentive, the most important measure linking the tax and innovation systems.
One of the proposals in that review (and also supported by the 2030 Strategic Plan), a premium rate for collaboration between industry and research institutions, has the potential to lift investment in R&D dramatically. But it remains only a proposal. More broadly, the 2030 Strategic Plan struggles to set out the grand vision claimed in its title because the level of financial commitment to repairing the innovation system is also unknown.
The choice we must make is about what kinds of manufacturing we should do. The Abbott/Turnbull Government has cut $2 billion from science, research and innovation programmes – and removed the Science Minister from Cabinet. This is not how other countries with which we usually compare ourselves are approaching the reshaping of their own innovation systems. The UK and Germany, for example, are devising and implementing industry policies aimed at identifying and developing areas of competitive advantage, especially in manufacturing. Germany, in particular, accepts that investment in innovative advanced manufacturing is inseparable from investment in education, especially higher and vocational education, and in research conducted by universities and publicly funded research agencies. That is not what is happening here. The Germans have also demonstrated that it is possible to embrace new manufacturing technologies, including robotics, without generating massive job losses and social disruption. Germany’s manufacturing sector is still large – 24 per cent of the economy – and the German Government expects it to grow by another six per cent by 2020. (In Australia it has slipped below ten per cent.) In Germany, all this has been achieved while remaining a high-wage economy,
which the naysayers I mentioned earlier say we can’t do in Australia if our manufacturers are to be globally competitive. The naysayers were always wrong about that. And they are wrong in holding out a stunted vision of Australia’s economic future, in which we rely only on exporting commodities to the world. I have always maintained that we have no choice about whether to engage in manufacturing if we are to remain the prosperous, enlightened and egalitarian society we have always striven to be. The choice we must make is about what kinds of manufacturing we should do. It is a question posed with particular force in 2018, as the sector adjusts to the end of passenger car production, an industry that has always been a driver of innovation across the economy. Making the right choices for an advanced manufacturing future will require Government and industry working together, to devise and implement a comprehensive national innovation agenda. I assure the sector that in government, Labor will do what is necessary to build that future with you. We have started by setting a goal of committing 3 per cent of GDP to R&D by 2030. We have also announced a $1 billion Advanced Manufacturing Future Fund, to assist manufacturers – especially SMEs – who have difficulty obtaining finance from traditional sources. Despite the challenges, the resourcefulness and resilience that always sustained the sector in the past have never been lost. I am confident Australian manufacturing has a bright future. Senator Kim Carr is the Shadow Minister for Innovation, Industry, Science and Research.
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5x Online Auctions | Search: METALSA ALL AUCTIONS OPEN: Thursday, 1 March 2018 at 4:00pm (AEDT) AUCTIONS CLOSE From: Wednesday, 8 March 2018 at 3:00pm (AEDT) REASON FOR SALE: Cessation of Manufacturing | UNDER INSTRUCTIONS: Metalsa Australia Pty Ltd LOCATION: 5 Elma Road, Cheltenham VIC 3192 ENQUIRIES Tate Gilbert on +61 419 756 042 / +61 3 8726 9100 or email@example.com Logan Fenemor on +61 410 082 603 or firstname.lastname@example.org
LAPP AUSTRALIA LAUNCH IS VOTE OF CONFIDENCE FOR LOCAL INDUSTRY One of the world’s leading providers of branded cable and connector systems and integrated electrical and automation engineering solutions, Lapp, has set up a fully fledged subsidiary in Australia. Lapp Australia – headquartered in new 3100m2 premises at Eastern Creek, Sydney – will meet demand nationally for technologies used in future-focused areas of industry, such as automation, robotics, energy management, data distribution and intelligent manufacturing, buildings, infrastructure and process engineering. Lapp Australia General Manager Simon Pullinger says the new facility – which opened on 1st February 2018 – will bring new levels of service and choice to the Australian market, offering strong inventory of more than 1000 product lines onshore as well as direct access to more than 40,000 standard items from Lapp’s global ranges. “We are offering a one-stop shop for highly integrated, efficient and reliable systems which comply with the leading Australian, European and American compliance and quality standards, which are among the most demanding in the world. In addition to major Lapp brands of product – such as Olflex, Unitronic, Hitronic, Skintop, Silvin, Epic, Fleximark, and Etherline – Lapp Australia will focus strongly on world-class total solutions incorporating highly compatible components from the one source. This integrated approach will save customers time and money when assembling optimum solutions to their particular needs, while ensuring proven reliability in service,” says Pullinger.
rail and mobility systems, intelligent buildings and infrastructure, and the resources industry. Lapp Australia will work in close cooperation with its established key local Lapp distribution partner in Australia, Treotham Automation, which brings market-leading local expertise to its specialised markets. Lapp Australia will also extend its strong association with ECS New Zealand, a family-owned business, like Lapp, which has been a Lapp distributor for more than 30 years. ECS Investments is a 50 per cent shareholder in the new Lapp Australia business, with the other 50 per cent owned by Lapp Holding Asia. The existing online Lapp Express website, meanwhile, will continue to expand in both countries, complementing the new strengths delivered by Lapp Australia. Pullinger highlights Lapp’s investment in a new full subsidiary in Australia as a strong vote of confidence in local industry as it increasingly moves into the global industrial automation market, which is forecast to grow to an annual worth of US $350 billion (AU $460 billion) by 2024. “Lapp has delivered its resources, expertise and German top-quality standards to Australia at a time in the country’s industrial development when such support is most needed to prepare diverse industries for a future in which they will use technology to compete cost-efficiently.
“With Lapp’s 18 manufacturing locations on four continents and our industry partnerships, Lapp Australia will deliver outstanding access to internationally respected technology and innovation,” adds Pullinger.
“Lapp’s integrated approach to high technology solutions is also highly appropriate to world class Australian customers seeking the assurance of top quality products and systems that meet global compliance standards and are fully traceable back to the point of manufacture.”
The family-owned Lapp organisation is renowned globally for its levels of quality, innovation and for its commitment to ethical values and service, qualities which it will bring to key Australian markets, including: manufacturing and plant engineering, electrical engineering and energy systems, machine building and machine tools, food and beverage, automotive,
Lapp’s commitments to the markets it enters are always in-depth, long-term and backed by an uncompromising customer focus and dedication to client service. These values of Lapp globally have remained constant since its establishment by Oskar Lapp in 1959 and through its evolution into a global family of companies bound together with the same strong principles.
Pictured outside the new Australian HQ of Lapp at Eastern Creek in Sydney are Rod Calderon – Marketing and Office Manager; Indy Saggu – Customer Service Executive; Simon Pullinger - Lapp Australia General Manager; and Michael De Leon – Warehouse Supervisor
Pullinger says the new Eastern Creek facility provides a strong base for engineering, technical and product support staff, operating in a technology and distribution environment modelled on Lapp’s global facilities supplying more than 100 countries worldwide. These facilities provide fully tailored solutions, service and product backup that are easily accessible to engineers, designers and specifiers. Lapp Australia’s locally available stock, compatible products and systems and quick order turnaround times are designed to streamline the specifier’s job and to deliver optimum on-time results with outstanding ongoing reliability.
Lapp Group The family-owned Lapp Group is one of the world's leading digital automation and cable technology companies, with innovative products, systems and solutions advancing costefficiency, flexibility, quality and safety. Together, the founders Oskar and Ursula Ida Lapp created a family company with an international reputation and renown. As the founders of a unique industrial success story, they are an example for future generations, employees and friends. With hard work and enthusiasm and a clear view of the essential, and with perseverance, they are a model of focus, discipline and pioneering spirit - for the good of their customers and the future security of the company. When Oskar Lapp died of heart
disease in 1987, the company continued to be led in his spirit. Entrepreneurial foresight, an unwavering commitment to the company's interests and an absolute demand for quality are his legacy, which lives on to this day. His two sons, Andreas and Siegbert Lapp took over the management of the family business and have led the operation since then with their mother. From their childhood they have known the business and appreciated the meaning of responsible business behaviour. Lapp operates across a broad front of leading industries, including particularly automation, robotics and process engineering, manufacturing, automotive and transport systems, food and beverage, energy (including particularly renewable energy), machine building, bulk handling and conveyor applications; HVAC systems; process engineering in mining and mineral processing, oil and gas and agribusiness processes, including paper and packaging; metals and process engineering, rail systems, transport and industrial pump, motor and transmission applications. The Lapp brand is a byword for competence, quality and innovation all over the world. The high degree of continuity and stability guaranteed by the owning family, combined with an uncompromising customer focus, innovative strength and consistent branding, are a key part of this success.
Lapp Australia 1800 931 559 lappaustralia.com.au
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ICONIC TOOL BRAND LANDS IN AUSTRALIA After almost a century, the UK’s most iconic tool brand has arrived in Australia. Hartech Tools has been appointed the exclusive Australian wholesale distributor to launch and build Draper Tools in the Australian marketplace. Draper Tools was started in 1919 when the founder, Bert Draper, sold government surplus and tools in markets around the Kingston Upon Thames area. This led to the purchase of the original warehouse from which the Draper Tool Company as we know it today was born. Although Draper Tools began by selling its own brand, it was also a quality engineers’ merchant and tool wholesaler selling brands that
are well known today such as, Britool, King Dick, Elliott Lucas etc. Draper Tools continues to thrive on a mixture of inward investment, active support for the independent stockist, striving for operational efficiency and all underpinned by the golden rule since 1919 - guaranteed quality. Draper Tools is continuously reviewing and extending its product range across all industry sectors, which currently stands at around 18,000 items and growing. Although Hartech Tools is a newly formed company it has a combined industry experience of over 50 years within its sales and management team who have exceptional knowledge
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And the lime sector has the dubious honour of the highest CO2 intensity relative to turnover. Around 60% of the CO2 emissions from both cement and lime plants are released directly from the chemical reaction in the production process. Calix’s technology uses indirect heating, so the CO2 and furnace combustion gases do not mix. This re-engineering of the existing process captures almost pure CO2 released from the limestone without significant additional costs or increased energy use. Australian technology company, Calix, has secured EUR3.4 million in working capital from Efic to build the CO2 capture facility for the Low Emissions Intensity Lime and Cement (LEILAC) project in Belgium.
a European-Australian collaboration, and includes a consortium of some of the world’s largest cement, lime, and engineering companies, as well as leading research and environmental institutions.
Efic, the Australian Government’s export credit agency, is a specialist financier that delivers simple and creative solutions for Australian exporters. Its aim is to assist Australian businesses by helping them to win business, grow internationally, and achieve export success.
According to Calix CFO Darren Charles, “As an Australian company developing technology with global applications, the support of government organisations such as Efic is critical in ensuring our success”.
Calix engineers and scientists are leading the LEILAC project, which is
The cement industry around the world accounts for as much as 7% of global CO2 emissions, making it one of the largest industrial contributors.
The technology is complementary with other carbon capture methods already developed in the power and cement sector, such as oxyfuel, and can make use of alternative fuels.
Newcastle City Council has signed a contract for the design, construction, operation and maintenance of a 5MW solar photovoltaic project as part of its plan to cut its emissions by 30% by 2020. The contract has been awarded to a joint venture between Carnegie Clean Energy subsidiary Energy Made Clean and Lendlease. The design phase will commence immediately with commissioning expected end of Q3 2018.
“The pilot plant will let cement and lime industries reduce their CO2 emissions dramatically without significant energy or capital penalty,” says Charles.
The solar farm will be located within the Summerhill Waste Management Centre in the Newcastle suburb of Wallsend. It will occupy a retired building and construction wastes landfill cell that has been capped with clay and turfed with grass.
Calix has previously won funding from both the UK (DECC) and EU (ASCENT Project) to develop its Endex reactor technology, which offers significant opportunities for energygeneration organisations seeking to reduce CO2 emissions.
It will be installed as a ground-mounted fixed-tilt system with the piling system optimised to suit the site topology and allow simple future addition of a battery storage system that could provide the council with electric fleet charging and demand response capabilities.
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AUSTRALIA VERSUS THE WORLD: WHAT’S YOUR POINT OF DIFFERENCE?
By Lindsay Wakefield
Ask most Australians and they will tell you that manufacturing in Australia is dead or dying. Ford, Toyota, Holden – all gone. Their suppliers – doors shut. Harley Davidson rides no more. We can’t even share a lift with other Australians as our bus manufacturers are closing down (Custom Bus in Sydney).
filtration process to produce milk with twice the protein and calcium of regular milk. An added advantage is the marketing cache gained by regional sourcing from farms around the small West Gippsland town of Rokeby. The market loves it and Rokeby Farms is thriving.
When I tell people that I am a manufacturer I receive looks akin to those that the poor, last Thylacine must have got as he paced his lonely cage in Tasmania.
Other dairy manufacturers such as a2 and Nudie have also experienced explosive growth by developing unique food technologies.
Yet for the past 16 months Australian manufacturing output has grown every month. How can this be? Shut down our biggest manufacturing sector and we still grow? Look a little closer and the patterns of success emerge. Our Australian environment is renowned for its vast diversity of flora and fauna. Despite a harsh and infertile land we are host to more unique species of flowers, plants and animals than almost any country in the world. And without stretching the analogy too much I believe there are parallels between Australian manufacturing and this abundance of species. To survive in Australia our animals developed unique abilities that enabled them to exist in regions too difficult for other competitors. They had to develop potent points of difference that gave them a competitive advantage. The same applies to Australian manufacturers and evidence suggests that we are doing just that. Rokeby farms is a dairy processing company that uses an innovative cold
It is possible to succeed in more traditional manufacturing industries if you understand your customers’ needs and your international competitors’ strengths and weaknesses. Analyse these and opportunity beckons. Look for these points of difference. Custom needs: Many engineered products require bespoke design to ensure they meet with local requirements or fit into a customer’s store or plant. Overseas competitors are often unwilling to adapt to Australian companies’ wishes. Find these products and customers and develop a flexible fast-moving local capacity to meet their requests. Time to market: 10 – 12 weeks on a boat is too long for many customers. Train your team to respond quickly and effectively to customers with short time lines and long international supply lines. Product innovation: Invest in technology and design original products with unique features and benefits. As long-term protection against a foreign product invasion this is frequently the
best weapon. Do it well and export opportunities may appear. Size: Many engineered products are bulky and expensive to ship. The cost advantage of cheap foreign labour quickly disappears. Complexity: Complex products usually require significant local support and expertise. The risk of buying from somebody in a different time zone and with poor English language skills can be too great. Become the local expert. Smart, flexible, willing to take risks:
that’s the blueprint for an Australian manufacturer in 2018. Find your point of difference and thrive. Lindsay Wakefield is MD of Australia's premier dock and lifting solutions company, Safetech. After graduating in medicine from Monash University in 1981, he cofounded Safetech in 1985 while continuing to practice medicine in Melbourne. In 1993 he retired from medical practice to become Managing Director. Today he also serves as a director of listed biotech company GTG.
Continued from cover
This is typified by the recent announcement of the continuation of the School Pathways Programme in South Australia and Western Australia. The programme is one of the Department of Defence’s key defence industry skilling and STEM initiatives. The Minister for Defence 20
Industry, Christopher Pyne said: “The Government will invest $3.6 million over three years for this programme in South Australia and Western Australia, helping to raise young people’s awareness of defence industry careers and encourage them to consider becoming part of the workforce behind the defence force.
“This will be also help support the development of a skilled workforce for the delivery of the continuous naval shipbuilding programme in South Australia and Western Australia.” This point is not lost on John Pollaers, who is also the Chair of the Australian Government’s Australian Industry and Skills Committee.
He concluded: “The Australian Advanced Manufacturing Council, representing the wider advanced manufacturing industry, strongly supports the integration of industry capability into defence planning and promotion of the high quality jobs that go with it."
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SEW-EURODRIVE’S ROBERT MEROLA SEES PLANS COMING TO FRUITION “We’re making great inroads,” he says, “considering we’re coming from a position as a component manufacturer and we’re trying to morph into the world of high-end automation.” “The company at large is committed to growing that end of the operation over the next three to five years and they’re making some very large commitments in resources and technologies in Germany, and the budgets that are being proposed are really blowing my mind.” “We’re looking at investments in the back rooms, in the production halls, in the products. Everything will dovetail together in the fullness of time.” Speaking locally, he says: “I think we are doing well in Australia – exceptionally well in the last 12-18 months in a mature market for a company that is 35 years old the growth has been very good.” “I think my target for being a $100 million company in Australia has probably shortened by a few years!” Robert Merola opens the company's new Far North Queensland service centre in Mackay
The last time Industry Update interviewed Robert Merola, the Australian boss of SEW-Eurodrive, the company was on the verge of realising some major plans. Almost two years on, those plans have come to fruition and the company is experiencing unprecedented growth, as he explained to Laurence Marchini. The company’s new $3 million Far North Queensland service centre in Mackay opened on time, despite the best efforts of Tropical Cyclone Debbie to devastate the area. “Our local manager was stranded for a few days and had to work from home – even with the power down,” says Merola. “But when he did eventually get there he was heartened to see that the building was still standing! Clearly a job well done by the builder.” Other developments have taken a little longer, such as the addition of SEW’s own state-of-the-art AGV system to improve the logistics at the company’s industrial gears facility in Melbourne. “This technology changes at such 22
a rapid rate,” says Merola. “With new battery technology and guidance systems coming in we decided that
“Where this comes in to play is when we are trying to sell something like a Movigear system,” he says, referring to
I think my target for being a $100 million company in Australia has probably shortened by a few years! we really did want to use the latest and greatest technologies and to demonstrate them to potential customers. So that’s only now fully coming to fruition.” Energy efficiency has always been a hot topic for SEW-Eurodrive. So what have been the implications of the recent increases in Australian energy prices? “We alone have invested between $300,000 and $400,000 so far in energy-efficient lighting and putting rooftop solar on our buildings,” says Merola. “We did have long-term contracts in place, but our power bills have tripled recently, and I dare say other companies would have experienced the same thing.” And this, he admits, is beginning to work to SEW-Eurodrive’s benefit.
the company’s Super Premium Efficient IE4 mechatronic drive system. “18 months ago when we were presenting customers with the case for energy efficient systems, the figures we gave them for the payback period were good, but they weren’t always compelling enough for companies to say ‘lets go ahead’.”
“I do try to be a little more conservative – I like the growth to be sustainable – I don’t like to see the sales graph with loads of peaks and troughs – I want a nice curve that’s always heading in the right direction.” The growth in the company’s turnover has seen SEW-Eurodrive particularly active in the recruitment market. “We’re at an all-time high up around 240 – that’s up 40 during the last 18 months,” says Merola. But while finding the right people has been relatively easy during this period, he is concerned that the labour market could soon be complicated by a revival in the resources sector.
“Now that power prices have trebled, the payback period is even quicker, so everybody is clamouring to get Movigears installed and start reaping the savings quicker.”
“With the mining recovery that’s been happening in the background I’m noticing the hourly rate for jobs like skilled fitters – particularly up in Far North Queensland – is starting to spiral upwards again, which doesn’t really bode well for companies like us trying to retain people,” he says.
One of Robert Merola’s avowed aims has been “to have SEW at the forefront of all things automation”. So, how does he think the company is progressing towards this?
“Companies can’t match (or afford to match) the rates that mining companies pay - I just hope it’s not another big bubble that’s starting to form again – but there are signs already
is already operating at full capacity, and we’re looking to expand it,” he says. “There will be several million dollars invested in the next few years in plant upgrades, new plants and service centres. We keep on investing in Australia because you need the backup and resources on the ground to provide the level of support for which we’re known.” Robert Merola has seen a lot of changes in the Australian manufacturing scene during his 35 years at SEWEurodrive, and that includes changes to the media serving it. Industry Update is a relative newcomer in comparison, but Merola is a fan.
The SEW-Eurodrive AGV system in action
of spiralling wage costs, especially in the skilled fitters area.”
saw the company organise its 20th annual fundraiser for the charity.
Robert Merola does have one regret about the past 18 months, though. Both he and the staff at SEW-Eurodrive have been long-time supporters of Wellways (formerly known as the Mental Illness Fellowship Victoria), and October 2017
The object was to take the overall total through the $2 million barrier, but the event fell agonisingly short of the magical figure at $1.95 million. “We had our best year for ages,” he says, “but just couldn’t hit the total.” There’s always
next year! So, what does the future hold for SEW-Eurodrive in Australia? In the short to medium term, Robert Merola is planning for more growth. “A lot of our foresight, for example that we invested into Mackay, has payed off very quickly. The load testing facility
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ARBON SET FOR BIG SHOW IN 2018 programmes. Says Lorenc: “It’s impossible to over-state the importance of planned maintenance. Equipment downtime can be the kiss of death for any logistics operation, and our planned maintenance programmes include an ongoing schedule of regular maintenance visits designed to keep equipment in top working order and address small problems before they become serious.” Arbon’s highly trained and certified technicians come prepared with fully stocked vans, so they can troubleshoot any piece of equipment – not just RiteHite.
Lee Lorenc is looking forward to showing people the full breadth of innovation in the Rite-Hite product range
There’s a big year ahead in 2018 for Arbon Equipment, the Australian sales and service arm of Rite-Hite, under the stewardship of General Manager Lee Lorenc. The company is set for major product announcements during the year as well as the opening of an allnew showroom and training facility at Laverton North in Melbourne’s west. Rite-Hite’s first claim to fame is as a manufacturer of loading dock equipment, including its innovative dock levellers and vehicle restraint systems. And this market remains a central focus for Arbon Equipment in Australia. As Lee Lorenc points out: “The company has always placed great emphasis on R&D, which has led to a continuous stream of revolutionary new products from Rite-Hite that we are lucky enough to be able to handle in Australia exclusively through Arbon.”
“I can see great opportunities this year in helping Australian companies in achieving a balance between the productivity and safety of their materials handling operations on the one hand and the efficient management of their facilities’ climate controls on the other.” Service is a key aspect of the Arbon Equipment operation in Australia, from its four bases in Melbourne, Sydney, Brisbane and Perth providing the expertise to meet the ever-changing needs of local customers – both at the loading dock, and inside the facility. The breadth of the service offering from Arbon is impressive, ranging from energy and safety assessments and planning and design services to repair services and preventive maintenance
Another key aspect of the Arbon Equipment service portfolio is product demonstrations – both on the customer’s site and at third party sites where prospective customers can see Rite-Hite equipment in operation. To this end, Lorenc is particularly keen to get the company’s new facility in Laverton North up to speed, and is progressing towards an open house on 11th May 2018 when he will be able to show off the showrooms and training facility. With the showroom occupying 450m2 of the 4500m2 facility, he will certainly have room to show off. “I’m looking forward to showing people the full breadth of innovation in the Rite-Hite product range,” he says. “And while 450 square metres might sound like a large area for a showroom, we’ve got a whole lot of products that we want to demonstrate.” The full size equipment displays will allow customers to see how the equipment works and to see it in operation.
“It’s particularly appropriate,” he adds, “that safety, security, productivity and energy efficiency are very much the watchwords that drive the Rite-Hite product philosophy.” “It’s no secret that Australian industry as a whole is currently experiencing something of a shock with increasing energy costs, which is leading many companies to re-examine the energy efficiency of their operations – both internally and externally.” 24
Arbon's new facility in Laverton North will host an open house on 11th May 2018
The training centre will also be a big plus, both in keeping Arbon’s highly skilled workforce up to speed on the full product range and extending this expertise to customers. The Arbon Equipment training portfolio also includes continuing education options that award credits from the Australian Institute of Architects. These courses can take the form of a one- or two-day intensive “flyin” course or shorter “lunch and learn” sessions covering dock safety, dock design or HVLS fans. Says Lorenc: “These AIA registered courses provide a wealth of valuable information in a short time. And the great thing is that companies can schedule them when it’s most convenient for their operations and employees, such as over lunch.” While the new facility will be a major milestone for Arbon Equipment during 2018, it is not the only thing that has Lee Lorenc looking ahead with anticipation. He cites the Rite-Hite mission statement of “improving industrial safety, security, and productivity worldwide through quality and innovation”. “While Rite-Hite continues to invest and innovate, we are excited about the future, and are really looking forward to introducing these innovations to the Australian market,” he concludes. Arbon Equipment 1800 1 ARBON (27266) arbon.com.au
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SPC SHOWS FAITH IN SOUTHERN CROSS COMPRESSED AIR TECHNOLOGY
The Southern Cross KHE 2-stage compressor
Following an extensive evaluation process, when SPC in Shepparton needed to increase the capacity of its compressed air systems, the company didn’t hesitate to go back to Southern Cross Compressors, its supplier since 2012 when SPC installed its first 250kW variable-speed KHE series air compressor. In fact the relationship between SPC and Southern Cross extends for many years prior to 2012. “The Southern Cross KHE 2-stage compressor continued to tick all of the boxes; capital cost, risk, total cost of ownership, after
The compressors provide extremely high-quality air to the processes at SPC
As energy costs became a key investment consideration the addition of a 220kW 2-stage compressor in January 2016 resulted in a significantly reduced power bill. The latest addition is another Southern Cross KHE series 250kW 2-stage variable-speed drive package to bring the total system compressed air power up to the 720kW needed to run the company’s expanding production lines. SPC is Australia’s largest and number one producer of premium packaged fruit. Its famous brands include SPC, Goulburn Valley, Ardmona, IXL, Perfect Fruit, SPC ProVital, and Taylor’s. Australians have trusted and loved these market-leading brands for 100 years.
not come into contact with the product, the air is considered safe for food processing. Mark Ferguson, CEO of Southern Cross Compressors Australia stated: “Large customers like SPC don’t keep faith by purchasing and installing your equipment unless they enjoy outstanding reliability and support. As SPC’s plant size and capacity has grown and their compressed air demands have increased, we at Southern Cross greatly appreciate the confidence in our product and our people to continue to supply and support their current and future needs.”
As well as these three large compressor packages, SPC also has a smaller 30kW, KHE VSD 13bar unit running a specialised packaging application and another 90kW KHE VSD unit providing air to another regional plant. This demonstrates the versatility of the SCCA range of air compressors that satisfy a broad spectrum of general and specialised applications throughout Australian industry. Southern Cross Compressors 1300 098 901 www.southerncrossaircompressors.com.au
Keen to save energy, SPC recognised the outstanding energy efficiency offered by the 2-stage package. Combined with a variable speed drive, these compressors have the ability to reduce energy consumption by as much as 50% compared to many fixed-speed equivalents. SPC celebrates its centenary in 2018
sales support, quality and lead time,” commented Lachlan Kerr, Reliability Manager with SPC. 26
Each compressor is integrated into the system through dedicated filtration and drying equipment to provide extremely high-quality air to the processes. Each compressor operates with a food-grade synthetic lubricant, and although the compressed air does
Each compressor is integrated into the system through dedicated filtration and drying equipment
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Industry Update's changed a lot over the years; it's been a long time since our first ever edition in 1995. While some things haven't changed (we're still #1), you might be surprised at what has. Join us in a nostalgia-tinged look back at the biggest leaps forward in Industry Update history.
ISSUE 1: WINTER 1995
This is where it all started. You might notice the front page looks a little different: no headline story, no big banner, and a very different layout. All of that came later. We started out simple, with product stories and advertorial making up the bulk of our content. We only released four editions per year, and our subscriber base looked quite different to how it does today. With just 8 pages of content and five core advertisers, the first ever Industry Update issue is hardly recognisable when compared to the hundred-page tome of news, case studies, and editorial that it has become. .
ISSUE 45: SUMMER 2008 Just over ten years later, Industry Update made some big changes. Momentum was building, and our audience was growing, but people were asking for more. Our audience wasn't happy with just four editions every year, and they wanted more content. We made the switch to a bi-monthly release, and have stuck to it ever since. In the ten years since the change, we've released often enough to have current, breaking stories, but at a pace that ensures editorial and design quality remains high. Our second change was the front-page headline, making us unique amongst trade magazines. "Showdown" was our first big front-page story, and it got people reading. Ever since, we've fronted every issue with a unique, newsworthy story that's delivered engaging content to our audience.
MEET THE TEAM
Behind every successful company is a team of people working hard to keep things running. Nothing happens by itself, and Industry Update is no exception. SCOTT FILBY - Founder and Director
LAURENCE MARCHINI - Editor
As founder, Director, and leading sales force behind Industry Update, he's the man that makes it all happen. After leaving Reed Publishing at 24 years old to start his own manufacturing magazine, he's seen it grow into the industry leader it is today.
Just about every word published by Industry Update has passed under the watchful eye of our editor, who takes great delight in finding the grammatical errors that others have inevitably missed.
MICHELLE ALCOCK - Finance & Accounts
GLYN SMITH - Advertising Sales Rep
When it comes down to it, every business runs on money. Michelle makes sure every dollar goes where it should, when it should.
Glyn is Industry Update’s resident smooth talker. We’re not saying he’s the sort to steal the shirt off your back and try to sell it back to you, but we’re not saying he wouldn’t, either.
NICOLE CHARLES - Administration
RHYS MCGOWAN - Executive Video Producer
Nicole has been with Industry Update Media for 3 years. While she remains humble, it would be fair to say that without Nicole as our office manager, a great many things at Industry Update would stop working.
Industry Update Video has been a roaring success, and Rhys has been behind the camera all the way, making sure everything from Tim Webster to forklifts is lit and framed correctly.
MATTHEW LAM - Designer
TRACY FILBY - Circulation & Data Manager
Everything needs to be put on the page, and a high-quality layout can be the difference between a good story and a great story. Matt makes sure IU looks as good as it does. He also makes sure we don’t use Comic Sans for anything.
Managing a great deal of data, Tracy holds knowledge of systems and sub-systems that operate more like art than science. If it breaks, she probably knows how to fix it.
LYN SLIGAR - Accounts Receivable
MILLY CAFFREY - Subscription and Copy Chasing
If you owe us money, chances are you’ve heard from Lyn. Polite, but firm and thorough, Lyn excells at making sure every contract is followed through.
Milly is the advertising coordinator at Industry Update. She's worked for the company since November 2016, gradually taking on more responsibilities.She also loves dogs - the little puppers and big woofers all have a place in her heart.
BEN KRAJANCIC - Online Content Assistant
TONY PEARCE - Sub-Editor
Ben is Industry Update's newest member, working dilligently to automate as much as he can. There are plenty of electronic systems that work quietly in the background, and he takes care of most of them.
As sub-editor, Tony makes words, and looks at words, and does absolutely nothing else, ever. This is as it should be.
ISSUE 72: JUNE 2013 With our ground-breaking "Beware" story, and a pagecount that made this issue our biggest ever, Issue 72 was an incredible edition: even more impressive that it marked our 18th birthday. With an eye-catching title like "Beware", Industry Update's investigation into the woefully under-regulated and dangerous world of welding safety had a lasting impact on the industry.
ISSUE 90: JUNE 2016 Our 21st birthday issue was cause for great celebration. It was once again headlined by a heavy-hitting industry story, and its page count made it our second-largest issue ever.
ISSUE 100: FEBRUARY 2018 And that brings us to today, and the magazine in your hands. The 100-page 100th issue: what a milestone! Here’s to another 100 issues...
It marked the beginning of an era of rapid expansion, one that saw old advertisers re-enter the fold as we proved to be a resilient force amongst the shifting world of print and online media.
INDUSTRYUPDATE.COM.AU INDUSTRYUPDATE.COM.AU 2929
• MATERIALS HANDLING
THREE BENEFITS OF MODERNISING A CRANE John Jackman explains that modernisation is a cost-effective way to extend the service life of a crane and update it with the latest technologies. Overhead, gantry and jib cranes are the workhorses of the manufacturing industry, and are major investments for manufacturing companies. From a few hundred kilos, right through to hundreds of tonnes in any factory, warehouse or facility, cranes are a safe, reliable and efficient way to lift and move just about anything. But as technology advances, and cranes experience natural wear, users face an interesting dilemma to keep production at optimum levels of safety, efficiency and reliability – upgrade to a new crane, or modernise the existing one? Replacing a crane is sometimes the only viable option, especially in situations where the existing crane is reaching the end of its design life, and the replacement cost is similar to the cost of modernisation. However, in many other cases, a crane modernisation may provide all the required benefits for a lower cost and with less downtime. Before committing to one or the other, it is advisable to consult with professionals who can assess the current situation and make appropriate recommendations. This article will look at the three main advantages of crane modernisation.
Modernisations preserve aspects of the existing asset that are in good condition (saving capital funds) and complement those aspects with the addition of selected new replacement components that enhance reliability and safety, adding current technologies. Common modernisations include the replacement of hoists, trolleys, operator cabs and controls to achieve increased capacity, speed, duty and load control.
Add the latest technology
A newly commissioned crane will have the latest and greatest technology, but each year newer and more advanced technologies are being researched and incorporated into cranes. After a crane has been in service for a number of years, it may still have fully functional components, such as rails, ropes or hoists, but it may not have the latest remote monitoring technology installed, for example. These sorts of situations are when a crane modernisation is an ideal solution.
Decommissioning an old crane and installing a new crane is a major undertaking, and even the most efficient replacements will involve some downtime. A modernisation, however, just adds the new technology to the existing crane, and can be completed in a much shorter
Before and after: this 1965-vintage hoist (left) was modernised in 2016 (right)
timeframe, meaning the crane can be back in service with minimal downtime.
Steps before modernisation Before determining what modernisations are needed on a crane, it is highly recommended that the crane undergo a thorough evaluation such as Konecranes’ Crane Reliability Study (CRS). In some cases, a major assessment will need to be undertaken, such as cases where it is a very old crane and there is no record of one being done recently. The major assessment is one way of ensuring the crane is standards compliant. The CRS is an engineering assessment that evaluates the current condition of a crane, provides a theoretical estimate of its remaining design life and provides recommendations for the next steps. Any of the structure or components excluded from the modernisation scope will still be assessed in compliance with Australian Standards, which provides
a complete and compliant solution on completion. Konecranes modernisations achieve outstanding results through a combination of consultancy, careful inspection, observation, and world-class experience and solutions. Konecranes’ capability to provide a life extension on existing assets is fiscally responsible and delivers a high return on investment. As the world’s largest crane organisation, with over 450,000 cranes and related pieces of equipment of all makes and models under maintenance worldwide, Konecranes has extensive experience in crane modernisations and inspections. John Jackman is Modernisation Manager at Konecranes Australia and New Zealand
Konecranes 1300 937 637 www.konecranes.com.au
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• MATERIALS HANDLING
BASELINE CONDITION ASSESSMENT HELPS OPTIMISE PNEUMATIC CONVEYOR PERFORMANCE
Millmerran Power Station is located south west of Toowoomba
As a key offering in its expert materials handling services, Kockums Bulk Systems offers a Baseline Condition Assessment (BCA) service to companies operating powder handling, packaging and vacuumassisted lifting equipment. The BCA provides plant owners with a complete assessment of the condition of their assets, together with the operating procedures, critical spares held, operator skill levels, preventive maintenance etc. This enables measures to be put in place to assist in bringing equipment back to top performance condition.
The flyash produced from burning the coal used at Millmerran is of high quality, and the classified product is used predominantly in concrete and cement manufacture in SE Queensland.
One recent highly successful BCA has led to substantial performance improvements in a pneumatic conveying system operated by Independent Flyash Brokers in Queensland. The flyash conveying system was supplied by Kockums in 2008 and installed at Millmerran Power Station, located south west of Toowoomba.
The original pneumatic conveying vessels (PCVs) were designed to exceed the output from the classifier, transferring the quality ash to the
the equipment to increase the transfer rate in the same equipment. This had not yet been required, but with potential upgrade considerations, it
The ash from the power station is conveyed to the IFB raw ash bin, from which it is fed to a Metso C102 centrifugal classifier to separate the cement-grade ash. The residual coarse ash is conveyed to a reject silo for landfill. The classified ash is then ‘dense phase’ conveyed off the power station site to remote load-out silos up to 380m distance, for collection by road tankers. IFB also has the option to bypass the classifier – allowing for unclassified (run of station) flyash to be conveyed to the load out silos for specific customers.
load out silos at 85t/h. However, to incorporate future developments, a second operational sequence of continuous conveying was built into
A centrifugal classifier separates the cement-grade ash
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The classified ash is conveyed to remote load-out silos for collection by road tankers
was tested at the time of the BCA.
to the original performance.”
IFB Operations Manager Peter Dennis called in Kockums to perform a BCA with a view to improving current performance and attaining a higher rate of product throughput than the original design had required.
Shortly after the BCA visit, IFB purchased a fourth 4m3 PCV to convey reject flyash.
As part of the BCA, the Kockums specialists together with IFB maintenance personnel replaced aeration cloths on the 4m3 capacity PCVs and tuned the system to return to “as commissioned” state. They optimised the cycle times by altering airflow rate and pressure of operation, by adjusting the appropriate control valves. The original PLC program required no upgrade during this process. Significant savings were made on the air volume used, such that when running unclassified ash to the load out silos, one of the two ash conveying compressors was able to return to standby mode, even during the continuous conveying tests, which showed a potential achievable continuous throughput rate around 135t/h. According to Kockums CEO Francois Steyn: “Peter Dennis was pleased at the outcome, which confirmed that his team’s approach to preventive maintenance of the equipment easily enabled the return
According to Peter Dennis: “The fourth KT400 vessel is working well. The vessel arrived on time and the installation went very smoothly. The electrical connection is particularly simple. The cabinet on the vessel is prewired before delivery requiring only a 10A 240V feed and an Ethernet cable across to our PLC.” “This fourth vessel gives us the plant redundancy we need, to allow for production to continue when the other reject vessel is offline.” “Following on from the BCA, it is our intention to enter into a partner agreement for Kockums to perform annual check-ups on our equipment to maintain optimum performance,” concludes Dennis.
Kockums Bulk Systems 03 9457 8200 www.kockumsbulk.com.au
Demonstration Unit Available Contact Tente Castors & Wheels for further information 1300 836 831 - E-Drive Flex system can be retrofitted to most trolleys - Increase manpower efficiency by saving effort - Used a a 5th wheel to improve direction stability - Retractable wheel system ensures easy manouverability - Reduces potential injuries for staff – neck, back, shoulder and wrist pain - Infinite speed control (forward and reverse) - Egonomic handle design with system and battery charge LED indicators
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• MATERIALS HANDLING
LOAD LIMITER TAKES SIMPLE APPROACH TO CRANE SAFETY It is often held up as an engineering truth that simplest is best. And while improvements to any technology almost invariably produce improved solutions to engineering problems while making them more complex, there are still many applications where the old maxim still holds true. In cases where the simple design does the job just as well, it brings with it the added benefits of lower cost of ownership and easy maintenance. Take, for example, a load limiter used to ensure the safety of crane lifting operations. While Australian Standard AS 1418 dictates that a load limiter is desirable, it does not dictate the design. And over the years several new designs have appeared. Some involve the spinning of a centrifugal clutch, some work by sensing how much current is drawn by the motor and disengage the hoist when the current draw indicates excessive force, and others involve sophisticated electronics to measure the load. In comparison, the Liftco load limiter design has stood the test of time, with the best part of 30 years of continuous service. The design is elegant in its
simplicity. The crane cable is threaded through a hole in a piston mounted in a C-shaped frame. As the load on the cable increases, the piston is pulled out of its cylinder, working against a precisely calibrated spring resistance. When the load exceeds the set resistance, the piston triggers a heavyduty microswitch, sending shutdown signal to the crane controller. When used on any gantry crane, a suitably specified and calibrated Liftco load limiter gives the operator the confidence that the crane is not attempting to lift too great a load – a load that could damage the crane motor and its structure and potentially cause a serious safety breach. Units are available with load limits from 200kg to 15t. (So the range covers multi-fall gantry cranes up to 120t capacity, using one load limiter per cable.) In each case they are supplied ready for use, and can easily be calibrated to different values on-site with the adjustment of a simple lock nut. As for refinements to the design over the years, there is now the option of a second microswitch set to a slightly lower value to provide an additional alarm signal before the load limit is reached.
And Liftco has added the option of an equally simple underload limiter that can be used to prevent damage to both the load and the crane mechanism during lowering operations. It works by monitoring the tension in each cable and is triggered if one or more cables goes slack, indicating that the load has become unbalanced by an obstruction or snag during the lowering operation. The South African made Liftco load limiter is sold and supported
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throughout Australia by Liftco Industrial Supplies from its newly opened headquarters in Wollongong. And, such is the robust simplicity of the design, the company boasts that 99% of maintenance can be conducted on the spot. Liftco Industrial Supplies 02 9829 4411 www.liftco.com.au
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• MATERIALS HANDLING
ROUGH-TERRAIN FORKLIFT PROVIDES AN IMPROVED VIEW Manitou reckons it has reinvented the rough-terrain forklift. The company’s new MC18 truck is a compact unit with an overall width of 1450mm, allowing it to manoeuvre into restricted spaces. The MC18 truck provides optimum visibility for operators during handling operations with its panoramic glazed roof with no metal structure. The roof comprises a lamination of two tempered glass sheets separated by a plastic film, which protects the operator from falling objects and meets the requirements of
ISO 6055 (FOPS) safety standards. The cab features a novel "doubleskin" cover combining a tough, rigid section and a flexible insulated section, reducing the cabin noise level to just 79dB (compared with the market average of 86dB). The MC18 has a ground clearance of 300mm, which is reckoned to be the highest for a compact truck, giving it more versatility on all types of ground, and improving obstacle clearance. The truck can also be switched between
two- and four-wheel drive without interrupting operation.
speed of 25km/h while also reducing fuel consumption by 12.5%.
The four-wheel drive mode provides maximum driveability and traction, but by switching to two-wheel drive the truck can reach its maximum
Manitou Australia 02 9517 3174 www.manitou.com
MOBILE SCREW CONVEYOR KEEPS TRANSFERS FREE FROM DUST The latest Flexicon mobile flexible screw conveyor has a multipurpose hood that enables the dust-free transfer of material discharged from bulk bags and/or manually dumped from handheld sacks into elevated process equipment or storage vessels. The conveyor is mounted on a frame with locking castors, and so is easy to move around a plant. And, rather than include the heavy frame components typically used to support bulk bags, it is designed to use with a forklift or plant hoist to suspend the bag
above the unit during operation. An iris valve on top of the dust hood allows variable control of flow through the bulk bag spout. A bag support tray and hinged door enable the manual addition of minor ingredients from handheld sacks. The flexible screw conveyor is suitable for both free-flowing and nonfree-flowing bulk materials, including products that pack, cake, smear, seize or fluidise, with no separation of blends. There are mounting flanges at the
discharge end of the conveyor support boom to allow the integration of a metal detector below the conveyor outlet. All material contact surfaces are stainless steel finished to sanitary or industrial standards with the exception of the conveyor's polymer outer tube. The mobile frame is constructed
Flexicon Corporation (Australia) 1300 353942 www.flexicon.com.au
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• MATERIALS HANDLING
NOVEL TRANSFER CHUTE DESIGN CUTS MAINTENANCE IN HARSH ENVIRONMENTS Chute Technology has developed a novel design for long-life coal chutes and bins that eliminate clogging, excessive wear and costly breakdowns in corrosive mining environments. The new minerals processing technology, designed using discrete element modelling (DEM) techniques, combines space-age ceramic tile abrasion linings and replaceable high impact wear elements made from chromium carbide overlays, to reduce maintenance and increase wear life. Chute Technology Partner Tom Woods says the first examples of the new materials handling technology are already being manufactured for use in a major Hunter Valley mine. The client was looking for a long-term solution to clogging, high wear and production interruptions occurring as old chutes
were removed, and new ones installed under its rotary breaker and main scalping screens. “Some of the old materials handling technology used at different mines has been wearing out in months instead of years as they mine through wet and rocky material,” says Woods. “The chutes’ constant failure and replacement is disrupting production continually in a number of locations, which require a long-term solution to the problems resulting from high material impacts and high abrasion factors within their production chain.” Using DEM technologies proven in coal and ore applications throughout Australia, Chute Technology was able to model and translate into reality an optimum configuration that minimises impact and abrasion zones and smooths
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ROPE AND CHAIN CRANES AND HOISTS: • Helps reduce the risk of accidents • Protects against overloading of Crane and supporting structures • Quick and easy installation and available for all capacity cranes • Available preset or easily calibrated on site • Helps reduce maintenance costs • Minimizes down time • Automatic reset by reducing the load CONDUCTOR BAR • Available in steel and copper • Quickly and easily installed • Supports required only every 1.5m • Also available in a compact cluster range
White ceramic tiles feature in areas most exposed to abrasion
the flow of material. The new design eliminates some common impact and abrasion zones, while placing additional impact and wear protection in other zones most subjected to maintenance issues. Ceramic tiles are used in areas most exposed to abrasion, using the same extremely hard and thermal shockresistant material employed by NASA on spacecraft and increasingly in highperformance commercial and military aircraft. High-strength chromium carbide steels are used in areas most affected by impact. To further reinforce the new materials handling technologies’ lowmaintenance credentials, the chutes and bins’ entire bodies are manufactured from 3CR12 corrosion resistant metal for long life. “The end result of the new smooth flowing designs and the strategically placed impact and wear materials is a product that is engineered for virtually no blockages and no maintenance for extended periods of years, in many cases in excess of the life of the mines
in which they are located,” says Tom Woods. “The additional cost of the long-life technology is more than offset by the gains in production and improvements in safety resulting from the curtailment of labourintensive blockages and infrastructure replacement.” The new materials handling technologies are not only applicable to wet and sticky coal and ores, but also to other materials handling inputs prone to create wear and expensive blockages and maintenance, with attendant production costs and OH&S risks and costs. The design fundamentals have already been proven in practice, with DEM analysis techniques applied to both mines and coal loading facilities. And the wear and impact materials are premium products that have also demonstrated their qualities in the toughest applications. Chute Technology 1300 833 140 www.chutetechnology.com.au
SIDE PULL PREVENTERS/ROPE GUIDE PROTECTOR Prevents side pulling and protects rope guides and drums on most multi-fall Cranes and Hoists. • Prevent dragging of loads • Helps reduce down time.
Liftco Industrial Supplies Pty Ltd
Freecall: 1800 LIFTCO (543826) Email: firstname.lastname@example.org Web: www.liftco.com.au
Chute Technology Partner Tom Woods with the first of the new coal chute designs
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• MATERIALS HANDLING
FORKLIFT FUNDAMENTALS PART 4: WHAT IS CHEAP IS NOT ALWAYS VALUE Ross Grassick argues that true value can only be judged by considering whole of life costs. There are many products today that are marketed on price, and it is all too easy to be fooled into believing that when a piece of equipment is cheap it is good value. Forklifts are definitely among the products that fall in this category. When you purchase a forklift or other materials handling equipment it is only natural to look for a bargain. You will doubtless be influenced by where the equipment is made and whether it looks good. However, rather than basing the final decision on the purchase price, the real question you should be asking is “What are the whole of life costs?” or “Do the savings in the purchase price offset the running costs?”. Let’s look at what makes up the “whole of life costs” and in turn look at the value angle of those costs. Fuel is the single largest everyday cost of an internal combustion forklift, yet few people consider fuel efficiency in their purchasing decisions. However, the difference can be a lot more than you think. For example, the latest
electronic injection engines offer up to 10% less fuel usage. To put this in perspective, if you use three cylinders of LPG per week over five years that comes to a total of 780 cylinders. A 10% fuel saving would save the cost of 78 cylinders of LPG.
It looks good and comes from a reputable manufacturer, but what are the
The next biggest cost is tyres. There are many factors that contribute to tyre costs, but for this exercise we will look at tyres on a new purchase. The questions to ask are whether the tyres supplied with the unit are of a well known brand and whether they are supported by a warranty in Australia. Low cost tyres are exactly that: they are built to a cost. The quality brand name tyre will generally deliver double the performance and twice the lifetime. In most cases, maintenance costs are less than tyres and fuel over a fiveyear cycle. The preventive maintenance recommended is similar across most brands, yet there are many owners that
A quality tyre will deliver up to twice the life of a cheap one
think they are saving money by not having these services carried out. Preventive maintenance avoids damage to other components by replacing wearing parts before they fail. This misguided cost-cutting idea will cost time as well as money in the long run. In maintenance the biggest problem is time lost due to poor availability of spare parts. You need to know that the supplier of the equipment both carries the parts in stock to suit the units you are buying and is also backed by the manufacturer. The reality is that the unit could be out of service for 5-10 days if parts need to be imported - and even longer if the wrong ones are sent.
Preventive maintenance avoids damage to other components
The last cost is that of disposal at the end of use. And the basic fact is that well known and well supported brands always have a higher residual sale value.
In summary, when you next look to purchase a new forklift don’t just stop at the price. You need to look more deeply at the savings the forklift can offer over its whole lifetime. Support is a key factor in this: how long has the seller been in business, and do they offer after-sales service? Do they carry spare parts for the model you are buying, do they deal direct with the factory, and can they offer the warranty? Check that the warranty covers both parts and labour, check the term of the warranty, and check what is covered. Most of all, the value of the purchase should be measured over the full term of ownership - not just on the day of purchase. Lencrow Materials Handling 1300 536 276 www.lencrow.com.au
r e th e g o T s n o ti lu o S Piecing
For More Information Visit
www.kockumsbulk.com.au Call 03 9457 8200 to speak to your local representative
Multi Purpose Access System
• MATERIALS HANDLING
FLEXIBLE DRIVE SYSTEM GETS TROLLEYS ON THE MOVE
Advantage Dual rib grip Choice of heights Premium - Australian Made Range of accessories / compatibility Lightest weight scaffold on the market
Tente has developed a novel solution for adding motive power to trolleys. The E-Drive Flex system can be retrofitted to most trolleys to provide starting assistance or as a permanent drive. Suitable for almost any trolley or equipment fitted with castors, the E-Drive Flex comprises a single motorised wheel, a control box, a remote control, a battery and a charger. The system reduces the effort required to get heavy loads moving, improving manoeuvrability and operator safety. When activated, the wheel is lowered to the ground to provide motive power. Once the load is in motion, the
wheel can be raised and switched off to enable the trolley to freewheel, or it can be kept down and powered to provide continuous assistance. If the battery runs out of charge, a manual lever is provided to raise the wheel so that the trolley remains mobile. The ergonomically designed handle incorporates system and battery charge LED indicators, together with infinitely variable speed control (both forwards and reverse). Tente Castors & Wheels 1300 836 831 tentecastorsandwheels.com.au
PERMANENT MAGNET LIFTERS PROMISE PERFORMANCE AND SAFETY
For more information or to arrange delivery call us now
1300 10 20 80 or visit instantaccess.com.au
Offering the reliability of ball bearings on the activation shaft, nickel plating on internal components and patented neutral-crown technology, Tecnomagnete MaxX magnetic lifters are designed to ensure that all the magnetic field is concentrated at the lifting face. Available from Serpent & Dove Applied Magnetics, these lifters come with a five-year warranty, reflecting the company’s confidence that MaxX lifters embody the best and safest permanent lifting magnet technology available. MaxX magnetic lifters are available with lifting capacities from 125 to 2000kg, and there are special models for thinner gauge steels or for vertical lifting.
Serpent & Dove - Applied Magnetics 02 9971 7577 www.serpent-dove.com
MATERIALS HANDLING •
SIMPLEST VALVE ACTUATORS OPEN THE GATE TO AUTOMATION AND PRODUCTION EFFICIENCY James Maslin suggests that when it comes to valve actuators the simplest solution is often the best. Rapid and reliable actuation of gate valves is becoming more and more critical to liquid and gas handling applications as industries face the twin demands of production automation and pressure to produce without production interruptions for maintenance. Gate valves, also known as sluice valves, are one of the most widely used types of valves in industrial applications, where they typically operate either fully open or fully closed, being used in pipelines as isolating valves rather than control or regulating valves. Their compact simplicity, low pressure loss, bidirectional versatility and ability to handle full flows where particles cannot cluster has led to widespread use in process engineering applications throughout industries such as food and beverage, agribusiness, manufacturing, mining and mineral processing, liquid-solid separation, filtration, materials handling, water and waste water and waste-to-energy projects. Typically gate valves are manually or (occasionally) hydraulically actuated, but where faster or remote actuation is required, they usually rely on conventional pneumatic actuation using a cylinder with rods and seals. However, an alternative means of actuation is available to process engineers charged with designing pipeline and reticulation systems that
respond to the needs of automation and uninterrupted production demands. These flexible-wall, bellows-type Airstroke actuators - manufactured by Firestone and distributed throughout Australia by Air Springs Supply - are, in essence, tough, fabric-reinforced rubber balloons of different shapes engineered to perform different tasks. The simple single, double and triple-convoluted airbags operate without seals, shafts or internal moving parts to provide ultra-reliable actuation alternatives for materials handling technology exposed to grime, debris and waste, which can disrupt the seals and shafts of convention pneumatic and hydraulic cylinders. Reliability engineered into their DNA Structurally they are identical to the enormously durable and reliable Firestone air springs used as OEM equipment in the suspensions of huge trucks and semi-trailers. This proven reliability under some of the worst conditions imaginable – like being continuously battered on Outback roads at extreme ambient temperatures – is what makes Airstrokes so tough. It’s engineered into their DNA. The globally proven Airstroke range comprises single, double and triple convoluted models with strokes up to 300mm. They suit applications requiring clean actuators that don’t need lubrication, but which can also cope effortlessly with dirt and grime.
THE TOTAL MATERIALS
A big plus in some applications is that Airstrokes can stroke through a radius without a clevis, thus eliminating both complexity and cost when engineers need to actuate through an angle. Their ability to soak up shock without damage while delivering high-repetition strokes means they are also highly applicable to engineering applications ranging from stamping and clamping to pumps and conveyors. Airstrokes are readily available through Air Springs Supply’s national distribution network, and, in comparison to equivalent technology, are relatively inexpensive. And they can easily tolerate heavy loads, without lubrication or maintenance. When used in linear motion control applications, where high precision is not a critical parameter, these actuators offer high force and speed, which is difficult to find in any other actuator, except more complex and expensive types. Airstrokes operate using air pressures delivered by standard compressed air systems found in nearly every factory, workshop and production plant. Apart from being readily available, compressed air can also be channelled and routed from one place to another. Pneumatic actuators are inherently safe. Because of the use of air, they are not flammable and are not susceptible to short circuit, in contrast with electric actuators. These types of actuators also constitute a clean technology because
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they are less prone to contamination. Because they use air, which is free from harmful chemicals, pneumatic systems are well known in the food, beverage and pharmaceutical industries. Airstroke actuators do not overheat upon excessive use, and are thus suitable for many uses in applications that require longer cycles of use. And they can easily sustain constant pressures, which is an outstanding advantage compared with other types of actuators. With easy installation and maintenance, Airstroke pneumatic actuators can be extremely viable and economical alternatives. James Maslin is National Sales and Marketing Manager for Air Springs Supply. Air Springs Supply 02 8877 5500 www.airsprings.com.au
N I V E R S A RY
www.lencrowforklifts.com.au | 1300 536 276 (Australia wide) INDUSTRYUPDATE.COM.AU
ACCESS ALL AREAS - COMPLIANCE IS KEY TO SAFE WORK AT HEIGHT
Systems Scaffold Quick Deck allowed easy access to the Nepean Rail Bridge
Instant Access Australia & New Zealand is a specialist provider of access equipment including aluminium scaffold, mobile towers, elevated working platforms, swing stages and access solutions. The company was the first in Australia to offer aluminium mobile scaffold and throughout its 50 year history it has continued to develop costeffective aluminium access solutions. Instant Access operates a quality system to AS/NZS ISO 9001:2008(2015). National Sales Manager Alex Delnido adds: “We operate and maintain a quality management system complying with AS/NZS ISO 9001:2008. The system covers design, manufacture, sales, servicing and hire operations. All of our products comply with applicable regulatory requirements and Australian/ New Zealand Standards.” Workplace Health and Safety (WHS) is of paramount importance, and Delnido is proud that Instant Access is an organisation committed to safe working practices. “We are currently working towards AS/NZS 4801 compliance and certification management system,” he says, “and, as an organisation operating in a number of jurisdictions we are committed to complying with differing WHS requirements.” Instant Access is one of Australia’s leading access solutions suppliers and manufacturers, and has achieved this position by providing its customers with quality cost-effective solutions across a number of product categories: 46
Aluminium mobile towers are produced in compliance with AS/NZS 1576.3-1995 for applications in construction and internal finishing as well as specialist painting, plastering and carpentry. Fibreglass mobile towers are produced in compliance with AS 1931.1 and AS 1931.2 plus AS/NZS 1576.3-1995. These find applications in nonconductive electrical trades, in corrosive environments and in clean-room noncontamination environments. Modular aluminium scaffolding systems are produced in compliance with AS/NZS 1576.3-1995. These have wide ranging applications in maintenance, repair and overhaul (mro), civil and turnkey engineering, and building construction. Aluminium Spandeck is produced in compliance with BS 6399.1-1996 and BS 5395.3-1995 for use in applications such as walkway bridges, work platforms and staging/roofing systems.
Modular aluminium scaffold is adaptable to many tasks
keep up with industry standards. And, as part of its expert service offering, the company's dedicated customer service representatives are on hand to advise on any technical or operational issues, and its team of technicians are on call 24 hours a day. The company stocks an extensive range of spare parts to help it to respond promptly to customer needs, and its conveniently located branches offer a repair service for most types of access equipment. Instant Access also has purpose-built paint bays provide a complete spray painting service on any equipment. Challenging applications With its wide range of standard
products and applications expertise, Instant Access prides itself on finding solutions to the most difficult challenges. The company's Major Projects Division aims to be the supplier of choice in the provision of engineered access solutions for complex access situations with a focus on safety, innovation and project management. The company's experience includes but is not limited to: under-bridge, wharf and conveyor access; rail corridor access; barge, work boat and marine access solutions; blasting and painting access solutions; aviation access design; scaffold, rigging and project management solutions; and shoring and support systems design. Instant Access 1300 10 20 80 www.instantaccess.com.au
Instant Access also offers training, both on- and off-site, to suit customer requirements. The training programmes have been devised to meet the various safety needs of building trades and general industry, ensuring the correct and safe use of access equipment. Each of the courses has been developed to meet with relevant industry codes and regulations and WHS requirements. However, compliance and safety is not a “once only” phenomenon, and Instant Access insists that strict service maintenance inspections take place prior to every delivery. The company's technicians continually undertake extensive training to
Aluminium mobile towers offer easy access for maintenance
THE NEW CODE OF PRACTICE REVOLUTIONISING WORKPLACE TRAFFIC MANAGEMENT
The interaction between pedestrians and vehicles in the workplace presents a major WH&S hazard. Until now there has been very little legislation relating to the subject.
this, the British Standards Institution (BSI) recently published the first official code of practice for safety barriers used in traffic management for workplace environments.
Safe Work Australia has published a general guide on traffic management, together with specific guides for aspects such as warehousing. However, while these guides do help to identify the hazards, they do not define or mandate the use of any specific type of barrier.
The code of practice, PAS 13:2017, was sponsored by safety barrier specialist A-Safe, which led an expert steering committee made up of some of the world’s biggest blue-chip companies: Nestle, DHL, Jaguar Land Rover, Allianz, and Mars, to name a few.
This problem is not unique to Australia. In the UK, incidents involving pedestrians and vehicles in the workplace cause 50 deaths and more than 5000 injuries annually. Worldwide, 317 million workplace accidents occur each year, with 2.3 million people losing their lives. That’s 6300 every day.
The resulting document is the final word on safety barrier practice and workplace traffic management procedure, globally. It covers everything from defining minimum requirements for barrier tests and pass/fail criteria for barrier survival and fixings integrity, to assessing the kinetic energy of impacts and implementing appropriate force resistance.
Alarming statistics like this need to be addressed. As a step towards tackling
THE TOTAL MATERIALS
PAS 13:2017 contains industryleading guidance in both the use and design of safety barriers in workplace environments. It is essential reading for anyone working in health and safety in workplace environments.
“It’s also a solid reference point for manufacturers and distributors of safety barriers, and remains vendor neutral, communicating a nonbiased message to the audience, so the content can be used by anyone.”
James Smith is co-owner and director of A-Safe. He says: “The PAS is a reference point for anyone with responsibility for facility design, traffic management, segregation and workplace health and safety; and shares best practice on the application and use of safety barriers. It encourages readers to think about the role of safety barriers as a priority, not an afterthought or retrofit.
The PAS 13:2017 code of practice is available from BSI Publications.
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A-Safe Australasia 02 9625 8927 www.asafe.com
N I V E R S A RY
www.lencrowforklifts.com.au | 1300 536 276 (Australia wide) INDUSTRYUPDATE.COM.AU
SAFETY FIRST WITH INDUSTRY LEADERS, INNOVATORS AND PIONEERS share innovations in safety technology, knowledge and protocols. Marie Kinsella, CEO of the International Exhibition and Conference Group, the specialist company behind the event is thrilled to bring an incredible variety of safety innovators, all under the one roof.
On 23rd and 24th May 2018, Melbourne Convention and Exhibition Centre will host Australia’s biggest and brightest minds in health and safety for the inaugural Workplace Health & Safety Show 2018, a new event showcasing the cutting edge of the safety world. An unmissable event bringing together like-minded manufacturers, organisations and businesses who recognise and value the importance of workplace health and safety, the show will collectively pool and
“The Workplace Health and Safety show is an excellent opportunity to share the latest in safety gear and tech, and connect with like-minded individuals across a massive range of industries,” says Kinsella, who is keen to remind us that industries like manufacturing rely heavily on smoothrunning safety practices, and keeping up to date is one of the best ways to stay on top of your game. “It’s no secret that great safety practices are one of the cornerstones of successful business, so it’s vital for businesses to stay informed,” says Kinsella.
The show will include stalls from companies with real potential in manufacturing safety, with a mix of bright new innovators (Elide and its famous Fire Extinguishing Ball) and industry leaders (Swinburne Professional – the University’s health and safety training department), and plenty more. The Workplace Health & Safety Show is the official exhibition of #Safetyscape, a programme of events, workshops, forums, seminars and conferences backed the highly respected Australia Safety Institute of Australia and headed by leading industry professionals from a multitude of industries in the health and safety community. Whether you’re a company looking to get your brand out there, a visitor looking for the latest and greatest in the safety industry, or just have a keen interest in staying safe in the workplace, the Workplace Health & Safety Show will have you covered.
Businesses, organisations, and manufacturers are encouraged to register and get amongst this exciting event housing top professionals from not only including manufacturing, but also building and construction, mining, hospitals, transport and more. The Workplace Health & Safety Show 2018 www.whsshow.com.au
BUY DIRECT & SAVE! On-line sales: www.floorsafe.com.au Email: firstname.lastname@example.org Phone: 1300 717 769
AUSTRALIA’S LARGEST SUPPLIER OF QUALITY SAFETY PRODUCTS
ALUMINUM STAIR NOSINGS
FIRbREGLASS STAIR NOSINGS
CARbORUNDUM STAIR NOSINGS
SAFETY TREAD NOSINGS
RUbbER STAIR NOSINGS
TACTILE 300 x 600 PADS
ANTI-SLIP FOR TILES
PEEL & STICK TACTILE PADS & PAVERS
BUMPER GUARD PROVIDES HAZARD WARNING AND PROTECTION IN ONE range of products, with an extensive choice of shapes and design options, including magnetic and fluorescent types. All products are made from highly resilient polyurethane foam that is designed to take the hardest knocks and impacts. Knuffi is the benchmark that others have tried to imitate but have never equalled in terms of performance, quality, value for money and longevity that converts to a maximum return on investment.
Available now from Roobuck, Knuffi is a world-class German-made warning and bumper guard protection system that improves safety in a wide range of industrial applications, both
indoors and outdoors. Knuffi has been in operation for more than 40 years, and its laboratory has developed a high-specification
Knuffi is the preferred choice of safety professionals who recognise its benefits as a new and key tool in achieving a "zero harm" strategy; and providing the peace of mind of longterm performance. Roobuck (Australia) has been granted master wholesaler status for Australia, New Zealand, SW Pacific, Papua New Guinea and
Mongolia. The company is seeking new customers and resellers in these regions who have a serious and proactive interest in taking advantage of the Knuffi offering. Roobuck 02 9938 1550 www.roobuck.com.au
WORKWEAR EXPANDS PPE PORTFOLIO RS Components has expanded its PPE clothing portfolio with the addition of more than 500 new items to its RS Pro range and more than 100 garments from the popular workwear brand, Snickers. The new RS Pro high-quality range has been developed to offer maximum performance combined with maximum cost effectiveness. It includes trousers, tee-shirts, polos, sweatshirts, fleeces, waistcoats,
THE TOTAL MATERIALS
jackets, shoes, boots, gloves and hats.
The new Snickers workwear includes three styles of trousers, three types of gloves, kneepads, polo shirts and hoodies. These are available from RS in all popular sizes and some in a variety of colours.
These new introductions extend and complement the existing Personal Protective Equipment and Site Safety portfolio from RS.
These new garments and accessories join the existing RS PPE portfolio, which includes products from Dickies, Scruffs
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RS Components 1300 656636 au.rs-online.com
N I V E R S A RY
www.lencrowforklifts.com.au | 1300 536 276 (Australia wide) INDUSTRYUPDATE.COM.AU
MEEKE ENGINEERING EXPANSION BRINGS ALL ENGINEERING SERVICES UNDER ONE ROOF capacity has now been complemented by a CNC vertical machining centre (VMC) – a brand-new YCM TV 158B – which has a unique feature. The patented T-base structural design is one of the many innovations developed by YCM. Its overhang-free table movement is fashioned from sturdy Meehanite cast iron to ensure dynamic levelling accuracy, machining rigidity, and long-term durability. The long travel of the x-axis is on the top of the base, where the saddle moves along the full stroke; the cross y-axis saddle supports the worktable. The T-base rigid structure has full stroke support, and does not have overhang problems, thereby guaranteeing dynamic levelling accuracy. The design also offers a small machine footprint, and the TV series of VMCs has the most efficient chip disposal system in its class. Meeting the future
Meeke Engineering General Manager Satish Sawant and workshop Forman Derrick Vuong
In 1989, the two founders of a Sydney company – Ivan Meeke, now retired, and Joe Di Giulio, the present Managing Director – saw that the industrial sector had a shortage of good-quality engineering workshops. With the ambition of growing quickly to meet the needs of a vibrant marketplace, the partners launched Meeke Engineering. According to General Manager, Satish Sawant: “In the 1980s, there was a need for a high-class jobbing workshop, and that was what we were set up to provide.” “Today, our customers at home and abroad need much more. We provide the diversity they need – machining, fabrication, assembly, testing, and painting – all at the same location.” Sawant, who has a degree in production engineering, continues: “Our Wetherill Park workshops in Sydney’s industrial heartland provide a lot more than just production capacity. “ “Senior staff members frequently interact with customers to devise knowledge-based solutions to specific 50
problems, often going on to design and engineer a prototype – even before the chips start to fly.” He explains that the company regularly provides hydraulic cylinders and refurbishing, complex welding jobs, specialised CNC machining, and quick turnarounds when required.
will drive further growth during the next decade: greater accuracy, shorter delivery times, and reasonable prices. In part, this is why the company’s existing production capability and
Meeke Engineering sees CNC as being very important, considering the continuing shortage of skills in conventional machining, highlighting the key role played by CNC in guaranteeing the consistent quality and accuracy of jobs.
Typical challenges include centre barrels and impellers for the mining industry, gearbox cases for the gear industry, moulds for the rubber mould industry, rollers for the conveyor industry, and hydraulic cylinders for the earthmoving industry. “In our workshops, we have the expertise and experience to produce everything from a batch of tiny components to a complete system that has been designed, manufactured, assembled, and tested under an ISO 9001:2015 accredited QA regime,” says Sawant. Customer expectations Meeke Engineering has grown in line with the needs of its customers, and the management team has identified three trends that, together,
The TV series of VMCs has the most efficient chip disposal system in its class
Meeke Engineering offers complex CNC machining
According to Satish Sawant: “We have found that the latest controls are fairly easy to understand and operate and, together with on the job training, they have helped us overcome the skills shortage, increase our precision, and expand our daily throughput.” Throughout Australia, YCM machine tools are sold, serviced, and supported by Sydney-based 600 Machine Tools, a member of the global machinery manufacturer and distributor, 600 Group, which was founded during Queen Victoria’s reign.
... they have helped us overcome the skills shortage... Asia-Pacific Managing Director, Cliff Purser, comments: “I am not in the least surprised that such a technology-driven manufacturer as Meeke Engineering, has chosen to extend its capacity and capability with a VMC designed and manufactured by YCM.” “An ISO-9001 accredited manufacturer, YCM was founded in 1954 and has built a worldwide reputation for technological innovation. Its latest model – a ‘smart’ multi-tasking mill/tum machining centre – won the Supreme Excellence Award of the Taiwan Machine Tools Industry 2017.” He adds: “The TV 158B is a popular
choice for workshops in Australia, because its standard gearhead spindle provides up to 6000 rpm speed with 48kg-m (347.19 lb-ft) torque. “The 10,000 rpm spindle is deployed with IDD spindle design and oil-air lubrication to reduce the deformation caused by heat, ensure the accuracy, and extend the life of the spindle,” adds Purser. Not just for control freaks Sales Manager of 600 Machine Tools, Steve Drummond, says: “In recent years, we have supplied several machine tools to Meeke Engineering, including two from YCM.” “The third YCM machine we have configured for Mr Sawant and his team is a ‘best in class’ VMC that is capable of producing complex components at high speed.” “However, despite the sophistication of the TV 158B, the latest Fanuc MXP200FB control ensures that operators can approach this machine with confidence, due to its ease of use and simplicity of operation.” With regard to manual operation, he adds: “Even if you haven’t used a milling machine since your schooldays, you could walk up to a YCM machining centre now and start cutting metal.” 600 Machine Tools 02 9674 4738 www.600machinery.com.au
INDUSTRYUPDATE.COM.AU MTIQualos_Measurement 2015 IndUpd.indd 1
onsistency of cut, combined with very low operating he perfect way to take your business to the next level.
ue of its own, opening up possibilities for companies tart-ups through to full production, 3-shift
o-focus cutting head, IPG laser source, Siemens ss-relieved fully annealed frame it really is a cut above
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PLE TO USE
ED CUT SPE TI
C M E A C UR A RE
FIBRE LASER PROVIDES A COMPETITIVE EDGE
Jon Flynn founded Wildcat Industries around 10 years ago
The acquisition of a Yawei HLE fibre laser from Applied Machinery has enabled Wildcat Industries to improve its production processes and become more competitive. Following many years working in the sheet metal industry, Jon Flynn founded Wildcat Industries around 10 years ago. Based in Dandenong, Victoria and now employing 20 people, the business has four distinct divisions: high tolerance sheet metal work, architectural facade work, the manufacture of high tech wood and gas flue systems and more recently Wildcat wood-fired pizza ovens. While the architectural division services clients right across Australia, the sheet metal work is predominantly Melbourne based.
part of my business; the service, support and warranty are very important for me and Applied excel in this area. So the decision to buy a Yawei fibre laser from Applied Machinery was both a logical and easy one.”
The Yawei has enabled us to redesign products to make them perform and look better and produce parts of a much higher quality. And the decision has paid off.
Flynn already had extensive experience of dealing with Applied Machinery, and reckons that he had virtually bought every single piece of equipment to date from the company.
“The Yawei has enabled us to redesign products to make them perform and look better and produce parts of a much higher quality. Plus of course, given the speed and accuracy of the fibre laser we are saving huge amounts of time; you can just do so much more with it. You don’t get any burn marks or blemishes on the material either,” Flynn adds.
He says: “The Applied Machinery people look after me as though they are
“The Yawei has been an absolute game changer for me; I really can’t stress that
enough. It’s allowed us to replace one of the turret punch presses and also replace the plasma. Crucially this enabled us to bring all our laser cutting in-house,” he continues.
The Yawei HLE is constructed using high quality components, such as a 2kW IPG fibre laser source, a Swiss Raytools cutting head and a German Beckoff CNC control system plus a rigid, robust frame. “The Yawei has also made me more competitive in the marketplace,” adds Flynn. “There’s no tooling setup for short runs, we can forecast more accurately and cut more out of a sheet resulting in further cost efficiencies. Plus we can now cut a wider choice of material including titanium
and stainless steel.” The Yawei fibre laser has also given Jon Flynn the confidence to quote for work that he wouldn’t have previously targeted, thereby expanding his business. One new customer picked up as a direct result of having the fibre laser is expected to provide a significant lift in work over the next 5 years. “Quite simply the Yawei HLE has far exceeded my expectations,” says Flynn. “It really is that good. Yes, there are cheaper models out there but none of those have the quality, robustness and longevity that I am looking for; many also don’t meet Australian standards. Let’s face it, you get what you pay for. “The way things are going I can definitely see a need for a second fibre laser in the future,” he concludes.
Applied Machinery 03 9706 8066 www.appliedmachinery.com.au
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Industrial Modular INcludes Drawer Dividers
PTB-20 Parts Bin
PTB-32 Parts Bin
PTB-24C Parts Bin
PTB-48C Parts Bin
PTB-48CD Parts Bin
$180 ex GST
$230 ex GST
$210 ex GST
$330 ex GST
$470 ex GST
586 x 222 x 350mm 10kg capacity per shelf
943 x 465.4 x 2030mm 100kg capacity per shelf
$410 ex GST
466 x 222 x 642mm 60 plastic bins
898 x 465.4 x 2030mm 100kg capacity per shelf
$320 ex GST
444 x 222 x 642mm 60 clear-front plastic bins
586 x 222 x 937mm 48 plastic bins
MSR-16 Shelves + Buckets
$770 ex GST
$680 ex GST
16 x BK-420 Plastic Bins
16 x BK-420 Plastic Bins
ustryUpdate Congratulations Ind
edition on your 100th neryhouse
From the team at Hare &
586 x 270 x 970mm 48 plastic bins
MSR-24 Shelves + Buckets
MSR-24E Extension Pack
$820.45 ex GST
$730 ex GST
16 x BK-210 Plastic Bins 8 x BK-420 Plastic Bins
16 x BK-210 Plastic Bins 8 x BK-420 Plastic Bins
POSSIBILITIES DESIGN YOUR OWN Available from
www.machineryhouse.com.au Specifications & Prices are subject to change without notification.
STORAGE SOLUTIONS PTB-30CHD Parts Bin
LP-900P Industrial Louvre Panels + Buckets
880 x 400 x 880mm 30 plastic bins
900 x 456 x 20mm Includes walls panel + 43 bins
$590 ex GST
$290 ex GST
MSR-32 Shelves + Buckets
MSR-32E Extension Pack
$870 ex GST
$780 ex GST
32 x BK-210 Plastic Bins
SR-22 Mobile Storage Bin Rack
SR-36 Mobile Storage Bin Rack
SR-72 Mobile Storage Bin Rack
$230 ex GST
$400 ex GST
$720 ex GST
880 x 410 x 950mm 22 plastic bins
MSR-33 Shelves + Buckets
32 x BK-210 Plastic Bins
15 x BK-164 Plastic Bins 12 x BK-210 Plastic Bins 6 x BK-420 Plastic Bins
$950 ex GST
880 x 410 x 1705mm 36 plastic bins
MSR-33E Extension Pack
15 x BK-164 Plastic Bins 12 x BK-210 Plastic Bins 6 x BK-420 Plastic Bins
1740 x 410 x 1705mm 72 plastic bins
MSR-65 Shelves + Buckets
MSR-65E Extension Pack
$1,250 ex GST
$1,160 ex GST
65 x BK-164 Plastic Bins
65 x BK-164 Plastic Bins
$860 ex GST
MSR-FR Modular Shelving Frame
$220 ex GST
BK-164 164 x 375 x 105mm
BK-420 420 x 375 x 178mm
$12 ex GST
$20 ex GST
$16 ex GST
MSR-FRE Frame Extension
MSR-SH Modular Shelves x 2
$130 ex GST
$80 ex GST
MELBOURNE 1 Fowler Rd Dandenong
625 Boundary Rd Coopers Plains
11 Valentine Street Kewdale
Ph: (02) 9890 9111
Ph: (03) 9212 4422
Ph: (07) 3274 4222
Ph: (08) 9373 9999
1/2 Windsor Rd Northmead
BK-210 210 x 375 x 178mm
PLASMA CUTTER LEADS START TO FINISH CAPABILITIES “The optimised work flow and range of production facilities available on the one site means even the most complex jobs can be handled efficiently and expeditiously, without elements of the work having to be sent off-site with the attendant delays and potential lack of uniformity of quality standards,” says Tom Woods. “We are also able to fully utilise the skills base of our staff team, which we have built up over 50 years and three generations of family ownership. We have a tremendous asset in our staff loyalty, great staff skills and our investment in comprehensively equipping ourselves to handle complete projects on-site.” Tom Woods with the new plasma cutting technology at the Tomago site
New high-definition plasma cutting technology has been introduced by the TW Woods Group to optimise efficiency and quality in the production of chutes, bins, loaders, tanks, silos and other materials handling and metal fabrication tasks involved in creating long-life low-maintenance products. The new Lincoln Spirit 400 machine – now operating in the company’s 400m2 plate processing facility – was specified to deliver industry-best standards of cut quality on standard and specialty steels, including stainless steels and heavy-duty chromium carbide protective plates up to 60mm thick. TW Woods Managing Director Tom Woods says high-quality wearand impact-resistant materials are now in high demand as coal and mineral processing plants place new emphasis on long-life product that avoids delays and breakdowns as mines step up production. The same quality, traceability and accountability standards are being required by private and state organisations involved in the energy, marine, oil and gas and defence sectors, where safety and durability are paramount. The investment in state-of-the-art plasma cutting technology has also been complemented by the installation of a new 6 x 15m, 5m-high Truflow spray booth and bake oven to deliver best quality protective finishes for customers in industries including defence, energy, manufacturing, mining, minerals processing, materials handling, metals, process engineering and water and
waste water. Truflow technology – the same type used by industry leaders including Siemens, Bombardier and Veolia – is used by TW Woods to apply quality finishes ranging from camouflage patterns for defence projects, to protective coatings for mining, energy and bulk handling equipment used in aggressive, marine, chemical and mining environments. The new investments are part of an ongoing multi-million-dollar expansion of TW Woods’ two-hectare facility to expand the range of tasks it handles on the one site from start to finish, enabling it to maintain strict quality control and to meet tight deadlines. Production efficiency and quality control when producing such designs is further enhanced at the TW Woods plant by the integration of its plate processing area containing the new Spirit 400 machine with an 800m2 paint and blasting facility incorporating a sand blast chamber with 10m-high ceiling to handle large jobs. This facility feeds directly to a state-of-the-art 720m2 industrial paint shop with 12m entry door to handle major projects such as coal and ore train load-out facilities, complex piping, recirculation tanks, shaker screens, storage bins, hoppers, silos, chutes, ductwork, bridgework, steel structures, tanks and mobile water tankers. The paint shop is immediately adjacent to the new Truflow facility, in which painted products can receive specialised finishes, all on the one site.
Materials handling system efficiencies are further enhanced by innovative designs from TW Woods partner engineering group Chute Technology, which uses advanced engineering technologies, including discrete element modelling, to optimise and translate into reality materials handling configurations that minimise problems such as impact and abrasion zones and which smooth the flow of material within such systems. “We are finding that quality- and safety-conscious clients are requiring increasingly higher standards of design, construction, finish and quality control to ensure the best lifespans and least maintenance achievable in their industries. Companies and utilities are increasingly aware of the high costs of lost production and safety hazards involved in systems that are prone to wear and breakage. Failure-prone systems can entail high labour costs and
The new Truflow paint finish facility
significant hazards involved in having to continually clear stoppages and install new materials handling facilities to tight production deadlines.” Housed on the company’s twohectare site with Hunter River frontage, the new facilities complement 4000m2 of workshop area in which the company undertakes medium to heavy steel fabrication, plate rolling and pressing and manufacturing of materials handling equipment including chromium carbide clad plate hardened steel products. The company’s services (including specialised shaping, fabrication and welding technology for metals including carbon steel, stainless steel and aluminium) are used by organisations such as Delta Energy, Incitec Pivot, water and waste water authorities, Integra Coal, Laing O’Rourke, Xstrata and surface and underground mining companies throughout Australia including iron ore producers in the Pilbara and coal companies in Queensland. The company has also become a valued supplier to the water treatment and materials handling industry because of its expanded capacity to process specialised metals and manufacture complex shapes required for specialpurpose tanks, silos and pressure vessels.
TW Woods Group 02 4964 8300 www.twwoods.com.au
COMPACT ROBOT ARM TAKES CONTROLLER ONBOARD Unveiled by igus at the recent SPS IPC Drives event in Nuremberg, the latest addition to the robolink family is available now from Treotham Automation. The latest addition to the range is a more compact device with the control system integrated into the base of the gripper arm, removing the need for a permanent PC connection. Available as either a 4- or 5-axis robot, the latest generation igus robolink incorporates a control unit from Commonplace Robotics. This saves space and makes the robot arm even better suited to flexible automation processes. The modular control system can be programmed using Joint, Linear, DigitalOut, Loop, or If-Then-Else commands. Further components, such as image processing systems, can be integrated via plugins. The software is supplied on CD and can be run on any Windows-capable computer during
commissioning. Further I/Os enable the control system communicate with other controllers. The robolink is ideal for cost-effective automation of simple processes, such as order picking, feeding, quality assurance, assembly tasks or image processing applications. And as it is a modular system, it can be easily adapted to a wide variety of applications. All robolink arms can be designed, configured and ordered online using a wide range of gears, motors and connector modules, grippers and lifting vacuums. The design software can also be run on a tablet, allowing users to view a visual simulation of the movement of the arm. Treotham Automation 1300 65 75 64 www.treotham.com.au
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LOCAL AUTOMATION TECHNOLOGY BOOSTS RAIL BEARING REFURBISHMENT An Australian-designed and -built automated journal bearing polishing machine from Schaeffler Australia is benefitting rail customers by cutting job turnaround times while optimising output quality and service life. The novel automated machine has been introduced by Bearing Engineering Services, a division of Schaeffler Australia, to deliver superior raceway finishes and extended service life in railway journal bearings used by passenger and freight rail customers, including government and private industry customers such as mining companies. The BES automated journal bearing polishing machine is capable of handling all metric and AAR sizes, and is a first for the Australian bearing reconditioning industry. It has been commissioned
at BES’ plant in Auburn, Sydney, and is working out very well in service, according to the company’s Railway and Reconditioning Manager, Enzo Cavalli. “The turnover time savings are invaluable and the quality boost is also a major benefit for customers wanting to get the longest life and greatest reliability out of their rolling stock,” says Cavalli. The new machine, designed in-house and built by local contractors, enables BES to deliver bearing raceway quality levels closer to that of new. As a result, it increases whole-of-lifespan efficiencies for BES clients, including those in light and heavy passenger rail, as well as freight and heavy haul operations throughout Australia, New Zealand and the Asia-Pacific region. BES customers also extensively cover heavy haulage rail including iron
Enzo Cavalli and Schaeffler Australia’s John Tawadros with the automated journal bearing polishing machine
ore, coal and other mining industries, bulk handling, sugar, transport terminal and port loading infrastructure users of railway equipment.
The BES automated bearing polisher
Not only does the new automated technology provide a superior raceway finish compared with traditional manual polishing methods, it enables improved quality control through greater accuracy and consistency. For customers, the improved service life reduces bearing lifecycle costs. And for staff, workplace health and safety is improved thanks to reduced manual handling, fewer repetitive manual operations, and
improved dust and contamination controls and collection. The introduction of the automated machine into the BES production and refurbishment facilities has enabled highly trained and skilled staff to spend more time focused on the critical areas of the reconditioning process that deliver higher value and better returns to clients.
Schaeffler Australia 02 8977 1000 www.schaeffler.com.au
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Arbon Equipment Pty Ltd. is the exclusive Australian distributor for Rite-HiteÂŽ, a leading global manufacturer of loading dock and industrial facility equipment. Arbon has four locations across Australia offering material handling systems and preventative maintenance programs designed for maximum safety, security and productivity. Together, our products and professional sales representatives and service technicians, make Arbon a reliable, local partner for your business. Count on Arbon for dependable service, extensive experience and quality products for your industrial facility. At Arbon, our people are here for your people. .
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HIGH-SPEED DOORS HELP MAINTAIN CLIMATE CONTROL Ever increasing energy costs are causing many companies to re-evaluate the climate-control requirements of their premises, and that includes taking account of the types of doors used – particularly on larger openings. There are many different types door on the market that can be used for large openings. However, the longer the time that any large area door is open (or partially open), the more air is exchanged between the indoor and outdoor environments. And in buildings with high frequency of traffic through the doorway, it is inevitable that any slow action type of door will regularly be left in the open position for longer than necessary. This can significantly increase the costs associated with heating the building in winter and cooling it during summer – especially in applications where the indoor climate is critical to processing operations or product storage. The simple solution is to install an Efaflex High Speed door available from DMF. These fast-acting doors offer an effective and reliable alternative to standard roller shutters or sectional type doors. The premium Germanmanufactured range includes spiral,
roll up and folding door designs, and these can be used for indoor or external applications in all types of facilities, including warehouses, production facilities and stores. With opening and closing velocities in the region of 1-2m/s (depending on size and model), Efaflex doors minimise the time the door is open and therefore help maintain climate control for temperature-sensitive areas, reducing draughts in the workplace, reducing the ingress of weather and/or dust and fumes, and keeping vermin and birdlife out. The fast cycle time also improves premises security, with little chance of unauthorised people gaining access while the door is closing. The Efaflex range includes door blades manufactured from a range of different materials. All types feature industry-leading wind resistance, and thermally insulated types are available that provide outstanding heat insulation of between 0.66 and 1.52W/m2K, depending on the size of the door, further improving climate control. One important factor to consider when choosing a high-speed door is reliability, and the number of cycles between servicing. Whereas a slowacting roller door might be subject to three or four open/shut cycles per day, a
Fast and reliable, the Efaflex high speed door is a premium solution
fast-acting high-speed door will often be subject to 500 or more cycles per day. The various models of Efaflex high speed doors are rated for between 150,000 and 250,000 cycles per year (with appropriate maintenance). One critical design feature is that the door blade does not roll onto itself, but is tracked around a spiral design system. This results in very smooth and quiet operation, and results in very little wear. Efaflex holds the original patent for this design, which now also comes with an “oval spiral” option, and even a flat tracking design that is ideal for applications where there is low lintel space. Each Efaflex high-speed door is driven by an electronic control system, combining a PLC with encoder positioning and frequency inverter drive control. This control system enables a wide range of programmable features so that the operation of the doors can be customised to each application. A safety light curtain is synchronised to the door blade position, and is highly reactive to anything that intrudes into
the closing space. Additional safety features include optional motion sensors that cover the immediate surrounds of the doorway, and flexible bottom rails for smaller doors with high pedestrian throughput. A wide range of activation methods can be specified for each door, depending on the exact requirements of the application. These include pushbuttons, remote controls and swipe cards. Induction floor loops and various forms of active or passive motion sensors are popular options for warehousing and logistics applications. As the exclusive Australian agent for Efaflex products, DMF International is uniquely positioned to offer these high quality high-speed doors to local customers. With trained partners Australia-wide, DMF can provide solid backup service, including maintenance support, with spare parts stocked in Sydney and Melbourne. DMF International 1800 281170 www.dmf.com.au
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THE REVOLUTION IN THE DELIVERY OF TRADE MEDIA IS HERE - INDUSTRY UPDATE VIDEOS
Industry Update has been promising a revolution in manufacturing media, and now it’s here.
Industry Update Video is now live on our website at www.industryupdate.com.au While many companies have already embraced the medium of video to promote their products and to demonstrate them in action, until now, no Australian manufacturing media organisation has taken this approach to video. Our 6pm TV news style format with a national and credible journalist at the helm is one of the secrets to the success of Industry Update Videos. MattScott is the production name of Industry Update Videos and will become as well known throughout the country as Industry Update. Industry Update Video is hosted by Tim Webster, one of Australia’s most trusted and credible •
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MTI See-Thru Insulated Traffic Doors provide a rugged lowmaintenance solution to maintaining climate control between different internal temperature zones. The strongly built 44mm-thick traffic doors are made with a rigid PVC framework, a high-impact ABS plastic skin, internal foam insulation and a full perimeter rubber gasket. Their high-quality construction gives them high values of insulation, and the semi-ridged rubber sealing system ensures that drafts and energy loss are kept to a minimum.
bumpers or flat impact panels that help cushion the impact of forklifts and pallet trucks. MTI See-Thru Insulated Traffic Doors operate smoothly, require little maintenance and are built to survive in even the toughest applications. MTI See-Thru 1300 135 539 www.mtiqualos.com.au
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• NMW PREVIEW
REGISTRATIONS OPEN FOR NATIONAL MANUFACTURING WEEK 2018
Thousands of visitors, exhibitors, and speakers from around the world are expected to attend National Manufacturing Week (NMW), to be held from 9th to 11th May 2018 at the Sydney Showground. With registrations now open, the free-toattend event will offer unrivalled access to world-class speakers and renowned exhibitors, discussing the latest in industry trends and innovations over three days. Themed ‘Where Innovation Meets Opportunity’ to represent the leads, lessons, and partnerships formed at the event each year, the programme will centre on and explore the impact of digital transformation, innovative design and business management on the manufacturing industry. This year’s speaker programme features a leading-edge series of seminars, showcases, workshops and networking sessions. The event will host 40 presenters including Dresden Optics’ Founder Bruce Jeffreys, Plastfix’s CEO Mario Dimovsk, Apollo Kitchens’ Managing Director Peter Bader, AusIndustry’s Director of Accelerating Commercialisation Larry Lopez, and SSS Manufacturing’s CEO Chris Brugeaud. The exhibition area will also showcase more than 150 exhibitors from leading companies from around the world and will be divided into 12 product
zones: Advanced Materials, Additive Manufacturing, Automation and Robotics, Electrical, Engineering, the Industrial Internet of Things (IIoT), Machine Tools, Packaging and Plastics, Industrial Safety, Supply Chain and Logistics, Warehousing and Materials Handling, and Welding Technology. Leading companies will exhibit the latest technology in manufacturing each day in the exhibition area, and will be presented by 3M, Alfex CNC, Atom, ECI Solutions, Farley Laserlab, HG, Konica Minolta, Millsom Hoists, Supagas, NHP, Nikon, Renishaw, Techni Waterjet, and WAGO. NMW 2018 is expected to attract thousands of visitors, exhibitors and speakers from more than 20 countries around the world. “National Manufacturing Week is Australia’s only fully integrated annual manufacturing exhibition, and provides an unrivalled opportunity for delegates to network, collaborate and learn from one another,” said 2018 Exhibition Director Robby Clark. “Last year was one of our record events in Melbourne, with more than 10,000 visitors coming through the doors. We are ready for another great NMW in Sydney this year, with a number of highquality speakers and exhibitors already confirmed.”
This year NMW will be continuing with the successful Business Matching Programme, which provides visitors a personalised itinerary of meetings and content sessions that match their specific needs and maximises their time onsite. Major industry partners and sponsors for NMW 2018 include the Australian Manufacturing Growth Centre, SafeWork NSW, and Welding Technology Institute of Australia. Partnership opportunities are still open, with more information available on the NMW 2018 website. NMW 2018 will again be co-located with the Safety First Conference & Expo,
and Inside 3D Printing Conference & Expo. NMW 2018 is free-to-attend and provides a unique opportunity to extend knowledge and training. National Manufacturing Week will run from 9th to 11th May 2018 at the Sydney Showground, Sydney Olympic Park. To register for NMW 2018, visit www. nationalmanufacturingweek.com.au.
9 â€“ 11 May 2018 Sydney Showground
WHERE INNOVATION MEETS OPPORTUNITY 150+
ATTENDEES OVER 3 DAYS*
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THE RISE AND RISE OF BLUETOOTH Laurence Marchini looks at the evolution of one of the world’s most successful wireless technologies. If there ever was an electronic technology that falls into the “overachieving” category, it would have to be Bluetooth. In less than 25 years, this wireless phenomenon has grown from a neat little trick for synchronising data between your phone and your PC to become an integral part of the IoT. Indeed, today Bluetooth capabilities can be found in all manner of industrial equipment, from sensors to machine controllers, enabling to all-pervasive smartphone to be used for programming, data acquisition and other “proper” engineering tasks. So, how did it become such an integral part of the landscape? The early proponents of the concept would doubtless say that it was always going to happen. Arising from the initial work at mobile phone maker Ericsson during the early 1990s, the wireless technology really came to the fore with the foundation of the Bluetooth Special Interest Group (or SIG) in 1998. Importantly, the five companies that were the founder members of the Bluetooth SIG - Ericsson, Intel, Nokia, IBM, and Toshiba – effectively had the market covered between them, from mobile phones to personal computing and including the all-important silicon manufacturers.
The plan for world domination was simple: the technology had to be easy to use across all platforms, the hardware had to consume minimal power and the silicon had to be so cheap (tens of cents a piece) that there were no cost barriers to integration in all levels of equipment. The third of these criteria was perhaps the easiest to achieve. In one of those “if you build it we will come” moments, Bluetooth succeeded in capturing the imagination of hardware manufacturers around the world, and that in itself created the manufacturing volumes required to bring the costs down. The speed of acceptance by the electronics industry was impressive: by the end of 1998, the SIG had grown to 400 members – long before the first products hit the market. However, when those first products did begin to trickle onto the market there was little indication that this was going to be the phenomenon it would become. The first Bluetooth enabled mobiles and headsets did not hit the market until 2000, and it was a further two years before the technology was used in many of the applications considered commonplace today. However, by 2003 Bluetooth had well and truly captured the imagination of the gadget-buying public, with weekly shipments of products topping a million, and then three million the following year. The real key to the continuing success of Bluetooth became the evolution of the standard. Short-range low-bandwidth connections between handsets and earpieces and between PCs and peripherals are one thing. But, what about applications that need a little more range, a little more bandwidth? The timeline for the evolution of the standard has been rapid. Version 2.0 Enhanced Data Rate (EDR) appeared in 2004, and 2009 saw both the first high-speed version (Version 3.0HS) and, crucially, Bluetooth Low Energy technology standardised for Version 4.0.
The Bluetooth logo is made up of the initials of Harald Bluetooth written in Scandinavian runes
The Ericsson T36 lays claim to be the first mobile phone to have built-in Bluetooth
Bluetooth 4.0 can be considered the real game-changer for sensor-based applications, thanks to its Low Energy
Headsets were an early success for Bluetooth, even if the designs were a little clunky
technology. This new generation of Bluetooth technology placed less emphasis on maintaining a constant stream of information. Instead, it was designed for applications sending smaller packets of data as required and then putting the connection to sleep during periods of non-use.
A step further, and sensor manufacturers are making it possible for users to calibrate, set up and debug sensors at a safe distance using smartphones and tablets connecting via Bluetooth.
This solved two key Bluetooth challenges by reducing battery drain and removing the need for constant pairing and repairing of connected devices. In 2013, Bluetooth 4.1 effectively set the stage for the Internet of Things, and the following year the SIG introduced Bluetooth 4.2, with further enhancements for IP connectivity, privacy and speed. Today, many of the industrial uses of Bluetooth are simple wire-replacement applications, for example linking portable test equipment with computers for file transfers, and these operate happily using legacy short range versions of Bluetooth such as V2.0 + EDR.
The Bluetooth wireless headset for the PlayStation 3 games console
One example here is Vega, which has offered Bluetooth as a communications option on its plics modular instrument platform, and now builds Bluetooth connectivity directly into its latest sensors such as the low-cost Vegapuls WL S 61 radar level measurement sensor. But it is in the field of smart sensors that Bluetooth will find its full industrial growth potential, and the key to this will be the latest revision of the standard – Bluetooth 5. This latest evolution of Bluetooth Low Energy is the first to embrace the concept of mesh networking, completing the journey of the technology from simple pairing (or 1:1 links) to full many-to-many (or m:m) communications. Crucially, in a mesh network, all communications paths are intertwined, with each node also operating as a relay for messages from all other nodes. So suddenly, the short communications range of Bluetooth ceases to be an issue. An entire factory of sensors can be networked to a central (or distributed) control centre.
And those sensors don’t just have to be on machines. Indoor positioning and location services and enterprise wearables powered by Bluetooth can help manufacturing companies improve material management, human resources and process flow. While there are other low-power wireless communications technologies that support mesh topologies – such as ZigBee – Bluetooth Mesh has the additional advantage of compatibility with standard smartphone, tablet and PC equipment. So, if Bluetooth Mesh is going to become the communications medium of choice for the Industrial Internet of Things, just how ubiquitous could it become? Not surprisingly, now in its 20th year, the Bluetooth SIG reckons this will be the next big thing. Citing data from ABI Research, it is predicting a tenfold annual growth of Bluetooth smart industry devices up to 2022 and that overall, close to 4 billion Bluetooth devices will be shipped this year alone.
The Vegapuls WL S 61 entry-level radar sensor was the first from VEGA to come with Bluetooth wireless connectivity as standard
OPEN-SOURCE ROBOTICS NOW OPEN TO ALL… AT AN ATTRACTIVE PRICE POINT in a cosmetics company where it is put into action handling fragile glass components. In order to make the transition into a robot-equipped workplace, laboratory or classroom even easier, RS has created new robotic ‘bundles’, each of which comprises the parts required to build an igus Robolink D robotic arm – one with a 1kg capacity and another with a 4kg capacity and longer reach.
Massimo Temporelli demonstrates robotics principles
Robotic solutions are no longer the domain of the large multinational. Paolo Carnovale explains how any firm, college or organisation can now access their potential thanks to new learning initiatives and product bundles from RS Components.
With Industry 4.0, the so-called Smart Factory and the Internet of things (IoT) currently occupying the limelight in the engineering world, it is easy to forget the substantial effect that previous ‘industrial revolutions’ have had on engineering and manufacturing. Arguably, the advent of numerical control (NC) and – even more so – computer numerical control (CNC), brought about the biggest change in contemporary manufacturing operations, leading to the widespread adoption of automated and robotic solutions. Indeed, by linking computers with control solutions and the manufacturing ‘coal face’, companies now have easy access to the Big Data that is underpinning this latest round of industry buzzwords. It is hard to imagine any production line or laboratory not having some form of automation in their midst, but robotics have not quite had the same level of saturation, primarily due to the ease at which simple, cost-effective solutions can be developed and deployed. But this is set to change, thanks to a new initiative from RS. Underpinning the new initiative is a selection of tutorials hosted within the DesignSpark section of the RS website, which take visitors through all the steps necessary to build a fully working and programmable robotic arm. Part one 70
shows the user how they can deploy open-source resources and controllers to develop a robotic arm capable of being used in sophisticated industrial automation applications. By selecting an open source design and associated code from Ruc Fablab (http://www.ruc.dk/fablab) and combining it with an Arduino-based PLC from Industrial Shields, Massimo Temporelli, President and co-Founder of The Fablab demonstrates in a video how the first steps can be taken on the road to a fully featured robotic solution. The tutorial page also includes numerous design file downloads and lists all the other components used in the build, including the servo motors, the power supply and the wiring – all of which are available from RS. In part two, Temporelli takes the robot to a real industrial environment to demonstrate its capabilities and potential for real-world industrial applications. Part three takes the concept even further with the deployment of an igus Robolink D industrial mechanical arm.
The kits include four articulated joints, ready assembled with NEMA stepper motors; two pressed-steel connection arms; a connecting component for the base motor to the arm; a robot base unit with Harting connectors and an assembly kit, which contains mechanical and electrical and assembly componentry, fixtures and fittings. By using popular industrial formats for the connectors, users have an incredible freedom of choice regarding onwards connectivity and integration with wider systems. Indeed, every single part needed to create a complete robotic system is available from RS. Users can also develop the robots further beyond their kit form, by purchasing additional components from the Robolink D range. Although robots were originally conceived to replace human workers, most of their benefits now arise from the way they complement the human workforce. By undertaking repetitive and laborious manual tasks, robots free up their much more ‘costly’ human peers to undertake more value-adding work that makes better use of their time and capabilities. These new robotic bundles also offer
Using the same open-source processor Temporelli develops an even more capable solution, backed by the capabilities of the igus components, which are based on existing industryproven hardware and materials. Although the principle is the same, some of the components have changed from step one, but once again these are listed on the tutorial’s page. As before, a video is available to take the user through all the primary steps. The final episode of the DesignSpark tutorial, sees the finished robot in action
RS has created new robotic “bundles”
an attractive entry point for any smaller establishment, which may operate on a lower budget and they will bring the efficiency and reliability of robotic solutions to a far wider audience. Not only will users benefit from the functional capabilities of robotic solutions, but the bundles also offers significant cost savings versus buying the individual parts separately. Both robot variants will deliver up to four axes and four degrees of freedom and are ideal for use in applications including R&D departments, educational establishments, laboratories and smallto medium-sized industrial factories; anywhere where a reliable, precise, affordable and flexible collaborative bench robotic arm is needed. Paolo Carnovale is Head of Industrial Product Marketing at RS Components.
RS Components 1300 656636 au.rs-online.com
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AIR KNIFE ELIMINATES STATIC The new Exair Gen4 Super Ion air knife eliminates static electricity at low inlet pressures, reducing compressed air use, increasing production throughput and saving money. It can be used to remove static charges from plastics, webs, sheet stock and other product surfaces where tearing, jamming or hazardous shocks are a problem.
a “breeze” to a “blast” to gently wipe or forcefully blow away debris.
Novel design features include armouring on the high-voltage cable to protect against abrasion and cuts, an integrated earth connection and electromagnetic shielding.
The Gen4 Super Ion air knife product line includes devices from 76mm in length right up to 2.74m long. The electrical ion source is shock-free and there is no radioactive element.
The Gen4 Super Ion air knife incorporates Exair’s Super air knife that reduces compressed air use by inducing surrounding airflow at a ratio of 40:1. This “amplified” airflow carries the ions to the target, helping to eliminate static charges in less than a half second. The air volume and velocity are infinitely controllable from
Applications include surface cleaning, neutralising plastics, bag opening, printing machinery, packaging operations and elimination of painful static electricity shocks. Compressed Air Australia 1300 787 688 www.caasafety.com.au
Available now from RS Components, the testo 160 IAQ is an indoor air quality data logger with integrated sensors for temperature, humidity, CO2 and atmospheric pressure. The compact Wi-Fi equipped unit has a wide range of uses, including industrial applications such as food and beverage production, and in laboratories. As a Wi-Fi networked appliance, data acquired by the logger is accessible at any time from any browser-enabled device such as a smartphone, tablet or computer. Users can also gain free access to the testo cloud - a central data repository where the 160 IAQ can send data. Housed in an IP20 rated enclosure measuring just 84 x 117 x 32mm, the logger is easy to conceal, for example in a packing case. It has a large internal memory, with a capacity of 40,000 measurement values. The 160 IAQ runs from standard
alkaline batteries, which should last for approximately 12 months. In addition, the unit can be powered via an external USB power supply with batteries used for emergency power backup. The testo 160 IAQ Wi-Fi data logger is available now in Australia from RS Components RS Components 1300 656636 au.rs-online.com
CONNECTORS HANDLE MORE CURRENT Mouser Electronics is now offering easy access to the Amphe-PD series connection system from Amphenol Industrial. Designed to connect wireto-wire, wire-to-board, and busbar terminations, the Amphe-PD series distributes higher currents with less heat than similar-sized connectors. The connectors use Amphenol’s
Radsok technology, which enables higher current handling, lower temperature rise, less resistance and lower mating forces. The Radsok terminal features a stamped hyperbolic contact with multiple beams that provide high reliability, optimal current carrying performance, and a longer cycle life in a small footprint.
Amphe-PD connectors are available from Mouser in a two-position, 3.6mm Radsok rated at 70A, or a two-position 5.7mm version capable of carrying 120A continuously. The series handles higher currents without wasting valuable space, offering a compact solution for data applications that require small, yet powerful connectors.
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INDUSTRIAL SPECIFICATIONS FOR M23 CONNECTOR Treotham Automation has a new right-angled M23 connector from Hummel that is extremely robust, easy to mount and Speedtec-compatible, making it ideal for industrial environments. All locking and fastening screws are easily accessible. Clearly visible marking facilitates plugging the connector in, even in cramped and inaccessible working conditions. Contacts, pins and sockets remain unchanged, and so the new M23 panel connector fits seamlessly into the
modular Hummel connector system. All casing designs in the product family can be combined with numerous contact inserts. The pin and socket inserts are also interchangeable in any casing shape. Familiar crimping tools can also be used with the new connector. The new M23 panel connector is available as a signal, power and hybrid connector, each with different locking systems. In addition to the screw cap version, there is a Twilock quick-release
connector version and one that is connector-compatible with the Speedtec locking system. The connector has a compact design and can also be rotated at an angle of up to 300. The panel connector is equipped with a mounting flange in two sizes. The connector is rated for operating temperatures between -40 and +125°C and complies with sealing classes IP67 and IP69K in a locked state
Treotham Automation 1300 65 75 64 www.treotham.com.au
DEVELOPMENT KIT IS QUICK START FOR PRESSURE MEASUREMENT A new development kit from RS Components allows designers to check out Honeywell pressure sensors without having to write code in advance. The Honeywell SEK001 sensor board allows developers to start testing and prototyping right away.
Arduino Uno (Rev3) microcontroller board. The sensor can be mounted directly on the SEK001 board, or connected via leads (enabling the sensor to be tested in adverse environments), or in a prototype product for proof-ofconcept testing.
Ideal for sensor demonstration, testing and evaluation purposes, the SEK001 is essentially an Arduino shield board that interfaces the chosen sensor to an
The kit combines the evaluation board with five jumpers that are preconfigured to evaluate the onboard Honeywell HSC differential pressure sensor. The SEK001
also has sockets to receive Honeywell's TruStability HSC and SSC series pressure sensors, which come with either I2C or SPI digital outputs, as well as the new TruStability RSC series of high resolution pressure sensors. Free-to-download Honeywell software controls the Arduino Uno board and takes readings from the sensor under evaluation. Sensor measurements can be displayed on a PC and saved for further analysis.
The Honeywell SEK001 Arduino shield sensor evaluation kit is available now from RS Components. RS Components 1300 656636 au.rs-online.com
MICRO-SIZED CONTROLLER IS BIG ON FEATURES Available now from Control Logic, the Panasonic FP0H is a micro-sized PLC that occupies just 42mm of DIN-rail space, providing onboard data logging and flexible connectivity at an entry-level price. The unit can be expanded up to 384 digital and analogue I/Os using Panasonic’s FP0H and FP0R expansion hardware. It offers two channels of
network connectivity for industrial protocols such as Ethernet I/P and Modbus, as well as various serial options. Other key features include data logging to SD card, unlimited PID, a timer, a counter and free access to thousands of preconfigured function blocks through Panasonic’s FPWIN Pro7 software using all five IEC61131-3 languages and allowing hardware-free
simulation. Configuration and commissioning time is reduced using a positional control wizard for hard computational setup for counting, and two-axis x-y linear interpolation. Control Logic 1800 557 705 www.control-logic.com.au
ULTRA-MINIATURE LOAD CELLS Solution for limited space •
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• ENVIRONMENT/WASTE MANAGEMENT
TWO-STAGE WASTEWATER TREATMENT IS FIT FOR LORD HOWE ISLAND
Lord Howe Island is 600km due east of mainland Port Macquarie
Australian company CST Wastewater Solutions has put together an environmentally friendly and costefficient wastewater treatment system for smaller, remote and ecologically sensitive community, municipal, agribusiness and industrial applications throughout the AsiaPacific region. The two-stage system uses a combination of coarse and fine screening and advanced dry compaction technology to produce a more hygienic and more compact solids output that is easier to handle and transport. The system itself is economical and compact and uses less energy and water compared with alternative systems. The new system, which uses the world’s best technology in an Australianengineered package, has been selected for use by the Island Board of World-Heritage listed Lord Howe Island after extensive testing to determine the best solution for the management and disposal of waste generated on the island. The existing waste management facility for the island, which lies 900km off the east coast of Australia, sorts various waste streams including food waste, paper and cardboard, green waste, recyclable materials re-usable materials and general waste. Septic waste
from residential and commercial system is also treated at this facility, drawn from about 220 waste water systems on the island, 25 of which are commercial operations. Currently pump-outs are delivered to the facility via a 1800 litre wastewater tanker. “CST Wastewater Solutions was tasked to review a ‘best fit’ sludge dewatering system for the septic waste, because the current infrastructure is becoming outdated and the existing drying beds are to be decommissioned,” said CST Wastewater Solutions Chemical Engineer and Managing Director Michael Bambridge. Bambridge and his brother Peter worked extensively with the Lord Howe Island Board’s Project Manager to find an optimal solution that combined outstanding environmental performance with equally strong OHS performance – and which has a much smaller footprint than the drying rack system previously used. “The extensive work done by Peter with the Lord Howe Island Board Project Manager inspired us to take a fresh look at the type of environmental solutions on offer to communities and industries in environmentally sensitive locations throughout the Asia-Pacific,” said Michael Bambridge. CST proposed a two-stage system.
The first stage is a CST screen extractor with coarse screening at 6.0mm up front to remove plastic, rags and other disposals typically found in community, commercial and industrial wastewater treatment plants.
Wastewater Solutions for compact dewatering applications ranging from food processing, food waste, grease trap and waste oil through to municipal wastewater sludge, livestock manure and agribusiness processes.
The second stage uses CST’s new KDS separator technology for fine screening and dewatering of the fines. The clog-free automatic liquid-to-solid waste separator is being introduced to the Asia-Pacific by CST
The KDS system was developed in Japan, a country that is highly focused on food and water purity. CST Wastewater Technologies engineers KDS’ latest technologies into Australian-engineered packages specified to
The new clog-free automatic liquid-to-solid KDS separator
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applications throughout the Asia-Pacific, including coastal, remote and ecologically sensitive areas. It is more hygienic and produces an output that is twice as light and half the cost to transport for disposal compared to other systems. It is also extremely compact, energy efficient and uses minimal water.”
Designed for efficiency, sustainability and conservation of resources in smallto- medium applications, the energyefficient KDS separator consumes as little as 0.06kWh of electricity and uses no wash water. Compared with alternative technologies it saves on power, space and money.
The KDS separator produces hygienic and easily handled output
achieve best results in individual locations, such as Lord Howe Island. “CST completed successful trials on Lord Howe Island under the supervision of the Board’s Project Manager, obtaining impressive results from the pilot plant KDS separator, with high screening capture and effective dewatering of the fines from the wastewater delivered by the tanker servicing the community,” said Bambridge.
“The KDS separator uses a fraction of the power of a centrifuge and involves no water usage during operation, unlike a belt press or a screw press. For a relatively low investment cost, it offers a high-performance alternative for example to sludge drying beds and geobags,” says Bambridge. The KDS technology can also be used for thickening of dissolved air flotation sludge – a very common application throughout wastewater operations – in which role it achieves solids capture of 97% thickened sludge at a dryness of 17%. Waste activated sludge dryness levels are typically 15-25%.
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• ENVIRONMENT/WASTE MANAGEMENT
A NEW GREAT WALL OF CHINA: DISASTER OR OPPORTUNITY TO RETHINK WASTE WITHIN AUSTRALIA?
By Samantha Cross
There has been much in the news lately concerning the Chinese National Sword and resulting bans on waste imports. To get it straight - China has not stopped imports of all recyclables, it stopped importing the highly contaminated mixed recycling streams that are generally gathered from our kerbside collections. The methodology has been to set contamination targets so low that they cannot currently be met by most mainstream recyclers worldwide. And this could effectively reduce exports to China by up to 85%. One of the reasons is that China is increasingly looking at its own doorstep, where recycling is rather uncommon. By reducing imports, it hopes to stimulate its own national recycling efforts. However, in the short term Chinese manufacturers are hit just as hard as the overseas waste industry, as they desperately try and find sufficient materials in the short term to keep their plastics manufacturing facilities open. China will still accept clean loads of HDPE, LDPE, PP etc, but not all scrambled up in a single stream. Take a look at one of the “easier to recycle” items – the plastic drink bottle. This is most likely a PET bottle, with a PP lid, sometimes with vinyl or composite paper/LDPE/aluminium seals and a vinyl sticker that’s glued to the bottle. Now think of the processes required to separate these materials so they can be sorted back into four or five or six 76
different material streams. Currently, most material recycling facilities (MRFs) that receive kerbside recycling sort the main categories like aluminium, steel, PET, PP, cardboard/ paper and glass. However, except for the metal streams, they all have significant portions of other materials mixed in with them, mainly due to the way they are manufactured in the first place.
Waste only becomes waste when there is no more use for it. In response to the Chinese National Sword and the restrictions now in place, some MRFs have started to stockpile and wait for better times. These times may not come. This again will impact households and businesses and could prove disastrous for the kerbside recycling collections. There is a need for action, to create resilience and to reinvigorate local remanufacturing capacity and stimulate local market demand. So, what can we do now? Rather than lamenting over the lost cheap export solutions, we should embrace the change as opportunity to invigorate and invest in local innovation and recycle and remanufacture of our own waste materials. The National Sword is a global issue creating the impetus to review local manufacturing opportunities within Australia.
Local manufacturers should look at their current business processes and investigate where they can incorporate recycled materials into their processes rather than using virgin materials. This may represent an opportunity to reduce current input costs or develop new product lines. Waste only becomes waste when there is no more use for it. If you are a manufacturer based in NSW, the NSW EPA currently offers funding under its Waste Less Recycle More programmes. Funding in other state jurisdictions is also helping businesses participate in the circular economy and reducing materials ending up in landfill. There are also funding programmes for new and enhanced recycling infrastructure and small equipment rebates that assist businesses to recycle or to provide cleaner recycling stream and increased opportunities for landfill diversion. Cross Connections Director, Samantha Cross, has been involved in creating connections and helping businesses progress circular economy projects since the late 1990s. Although the term circular economy may be relatively new for some, keeping resources in the productive economy is not new and continues to make good business sense. Businesses who rethink waste and connect and collaborate with key stakeholders, have greater opportunity to participate in the circular economy and achieve improved economic, social
and environmental outcomes. The Plastic Police Programme is an example of a micro circular economy model being developed by Cross Connections in the Hunter Region and is but one example of how businesses can participate in the circular economy. As a manufacturer you may have the interest and the capacity to collaborate and receive collected materials for reprocessing, to develop an innovative new product or receive material as an input into an existing product currently
The National Sword is a global issue creating the impetus to review local manufacturing opportunities within Australia. being manufactured, replacing virgin materials in the process. If Australia businesses recycled, reprocessed and reused their own waste rather than dumping and exporting it, thousands of new jobs could be created, and dependence on international markets reduced. Cross Connections is a NSW based business committed to progressing the development of the circular economy in Australia. Anyone interested to find out more can contact info@crossconnections. com.au.
ENVIRONMENT/WASTE MANAGEMENT •
SURFACE MOUNTED AERATOR REPLACES SUBMERSIBLE SYSTEM AT TANNERY A tannery in Belgium has upgraded its wastewater treatment system with two venturi aerators “driven” by a single Gorman-Rupp pump. The exercise has been a great success, delivering improved performance and reduced maintenance. The tannery had previously been running two 7kW submersible aerators and two 2.5kW submersible mixers, but the installation was problematic as poor mixing and low levels of transferred oxygen resulted in unacceptable levels of odour from the process. So the tannery management consulted the local GormanRupp distributor, Hydro +, to review the application. Two Venturi-Aeration VA-500 units were selected to deliver the correct amount of oxygen transfer for the application, and a single Gorman-Rupp T6A60S-B was selected to provide the flow and pressure to these “static” mixer/aerators. A venturi aerator was positioned at either end of the tank for the best mixing effect, and because the Gorman-Rupp pump is self-priming, it
could be mounted beside the basin. A venturi aerator draws atmospheric air into its mixing chamber when wastewater is passed through it at high velocity. This velocity breaks up biological matter as well as causing a venturi effect, introducing as much as 2.2-times the volume of air per volume of water. And because all the equipment (the pump and the aeration units) is located outside the basin or lagoon, servicing is quicker, easier and safer for operators, reducing maintenance costs. The new tannery installation has achieved much higher oxygen transfer, better mixing and a reduction in downtime. After the first 12 months of operation, the only maintenance required was an oil change. More information on Gorman-Rupp VenturiAeration systems can be obtained from authorised
Australian distributor, Hydro Innovations. Hydro Innovations 02 9898 1800 www.hydroinnovations.com.au
Venturi-Aerator and Gorman-Rupp pump being set up to replace existing systems.
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HydroInnovations.com.au 02 9898 1800 email@example.com
• Safer than devices located inside basins • Greatly reduced maintenance cost
• AUSTRALIAN MADE
AUSTRALIAN MADE RETRACTABLE REELS IN DEMAND AT HOME & ABROAD The retractable reel has become a common sight in Australia, in both domestic and working environments. Typically used for hoses and the like, the retractable reel is not only a tidy storage solution, it also improves safety by minimising the length of hose exposed and thereby reducing the trip hazard. One Australian company that takes the retractable reel very seriously is Melbourne-based AK Reels. Dubbed “the reel innovators”, the company has applied its retractable reel design to a growing range of commercial, industrial, domestic and leisure applications, with the result that its Australian made reels are currently used in 13 countries worldwide. Interestingly, it is not a hose that is the company’s best-selling product. That accolade goes to the company’s retractable safety barrier tape reel, which is used around the world in industries and areas where traffic management and safety are required. These range from mining to manufacturing and from airports to warehouses. AK Reels Director John Jones is in no doubt why the retractable safety barrier tape reel has been so successful in a market where many cheaper imports are available. “We find people are demanding quality products that are going to last,” he says, “which might mean paying a little more in the first place, but, in the long run it’s cheaper than buying the whole product over and over again.” Unlike the cheaper imported plastic tapes, which can break easily and are often single-use, AK Reels’ tape is made out of heavy duty woven nylon webbing material, which is similar in strength to a car seatbelt. “The imported products can be hard to handle and might work for a day or two, while our Australian made retractable tape reel might last you a decade,” says Jones. Such has been the demand for the safety tapes that AK reels has expanded the range so it now offers a suite of webbing tape solutions for all industries and areas where traffic management and safety are required. The compact BC300 has the same range of tapes as the bigger RC reels and is generally used for factory
John Jones is proud of the reputation his company’s products have achieved
According to John Jones: “We’ve developed a reputation for high quality niche products, and local manufacturing is critical in ensuring quality control.” And AK Reels continues to innovate. For example, the new magnetic brackets have also opened up portability options for all the reels that have traditionally been fixed in place. Air hose reels, water reels or any of the RC range can now be fitted with the heavy-duty magnetic brackets. AK Reels' retractable safety barrier tape reel
doorways and delivery areas. The BC reels adds 5,10 and 15m coverage in a lighter more compact 3.5kg case. This complements the RC3000 Heavy Duty series, which covers 15-25m expanses. The much smaller still KC300 series of cassette wall mounted barrier tapes is for indoor uses only and will extend up to
Not only are the mounting brackets magnetised but the catches too have powerful magnets to hold the tape in place where solid metal fixtures are available. In warehouses the magnetic cassette and BC reels mount easily on racking systems to control loading and unloading of stock.
…people are demanding quality products that are going to last. 10m in distance. The longer length of the cassettes gives more options where shorter distances need to be sectioned off without having to buy several different size cassettes. All of the safety barrier reels are now available with neodymium magnetic brackets. These are the strongest manmade magnets available and ensure the reels perform at their best. This innovation has expanded the uses of the reels by making them completely portable - ideal for trucking companies making deliveries where limited cordoning opportunities are available.
Service vehicles in mining sites require safety barriers around tyre changing areas in the field. The magnetic reels have solved this problem and maintained safety requirements. AK Reels also manufactures a large range of highly durable retractable hose reels for industrial and domestic applications – all made to suit particular purposes and to withstand variations in temperature and conditions. These range from hot wash hose reels for the food industry to drinking water hose reels for recreational vehicles using food-grade plastic hoses. Other industrial hose reels cover welding gases, chemicals, oil and pneumatics.
The innovation extends to the domestic scene with the release of the company’s Designer garden reels, available in a choice of colours to match the customer’s outdoor colour scheme. The hoses used in the Designer garden reels are also new. “We believe it was the first woven and knitted hose line for outdoor use made in Australia,” says Jones. “This hose is by far the most advanced of its type in the Australian market and exhibits superior kink resistance to standard hoses.” John Jones is quick to acknowledge the advantages of signing up with the Australian Made Campaign: “The Australian Made logo helps us to readily communicate our reputation for quality to new customers because manufacturing standards in Australia are so high,” he says. He admits: “We’ve had our ups and downs over the years – as the Australian dollar has had its ups and downs – but through the dedication of our staff we’ve managed to pull through, and we’re very proud of the reputation our products have achieved.” AK Reels 03 9460 4455 www.akreels.com.au
• MACHINE BUILDING
RUGGED ACTUATORS HELP PARAPLEGIC MOTORCYCLIST RIDE AGAIN
James Powell is back on the road with the help of a Thomson Electrak HD actuator
When James Powell was repairing actuators on aircraft landing gear as an aeronautical engineer, he never thought that he’d someday be using them to help him regain his passion for motorcycling. However, after a riding accident in 2009 left him wheelchair bound for life, his professional background played an instrumental role in getting him back on the road. Powell doesn’t remember much about the accident itself. “I was on my way to work, and the next thing I knew, I was waking up in the hospital, unable to walk,” he said. Determined not to let this disability limit his enjoyment of life, Powell learned to do everything from driving a car equipped with hand controls to wheelchair bungee jumping and bodybuilding (he is a six-time champ within Australia). But riding -particularly on two wheels - was a major source of gratification and freedom missing for him. “I used to enjoy unlimited access to the outback, forests and beaches,” he said. “I wanted to be with my friends, riding through the bush country again. My only option was a four-wheeled quad bike, but that is quite restrictive.” Quad bikes are not allowed full registration in Australia, even as transportation for disabled individuals. Riders must provide authorities with exact times and dates for every ride as well as proof that they have permission from the owner of the property on which they plan to ride. Powell spent four years trying to petition authorities for exceptions with no luck, then began researching quad
alternatives with hopes of getting back on two wheels. Engineering a design plan As motorcycle controls are on the handlebars, operating this type of vehicle would not pose a problem, but because Powell had no use of his legs, stabilising the bike during a stop would present a major challenge. His research revealed some stabilising wheels available on the market, primarily to lend confidence to beginner riders, but none provided the reliability and sturdiness he would need for the bush and the outback. Channelling his engineering days, Powell concluded that building a custom system was his best option, and knew that the secret to his success would lie in selecting the right actuator to drive the lowering and raising of stabilising wheels. These wheels do meet the disability modification requirements for motorcycles, and so would be subject to fewer restrictions than quad bikes. “I needed something that was lightweight, and I wasn’t going to get that with a hydraulic pump system, which would be too bulky for use on a motorcycle,” said Powell. “Plus, I couldn’t find anything that would have been fast enough or strong enough. I needed something that could deploy rapidly. It also had to be robust enough to lift my weight and serve me for a long time. I also looked into pneumatic systems, but even though they are quick acting, they did not have the strength I was looking for.”
The stabiliser is only used when the bike stops
The smart solution After a few false starts with systems using dual actuators, Powell took the advice of a local automotive technology distributor who suggested that heavyduty electromechanical linear actuators from Thomson Industries would be best suited for the rugged conditions he would encounter. “I started with a list of several actuators that would have been sufficient for my basic needs and compared their spec sheets for weight, speed, current draw etc,” he said. “The Thomson actuator was slightly heavier than the others, but its IP rating and strength proved to have the robustness I needed.” Powell designed his stabiliser using a Thomson Electrak HD actuator. This ballscrew-type actuator is known for its high power, longer stroke, onboard electronics and unmatched ruggedness. It has an ingress protection rating of IP69, which means it is highly resistant to mud, inclement weather, dust and other extreme conditions.
The onboard electronics of the Thomson actuator also enabled him to customise the controls. An encoder built into the actuator tracks its position and relays it to a small computer that Powell built to read the signals and display them on the handlebars, enabling him to control the actuator. Once the bike is rolling, he simply raises the stabilisers, and when he is ready to stop, lowers the wheels - much like a pilot would deploy aircraft landing gear. “The Thomson actuators were very easy to work with,” he said. “I had built the overall mounting structure from scratch to accommodate it, so mounting was just a matter of tightening two bolts and connecting a couple of wires.” The modified motorcycle is now fully tested and in steady operation, and Powell is enjoying his rediscovered freedom to ride - and stop - whenever and wherever he pleases. Thomson Industries 02 6917 5048 www.thomsonlinear.com
The actuator and carriage system attach to the back of the bike with only two bolts
AUSTRALIAN MADE •
CYLINDER SECURITY DEVICE HAS INTERNATIONAL APPEAL It may well have been developed with a very Australian application in mind, but the Australian Made BottleChock from VisionSafe is rapidly becoming an international success.
Available in galvanised or stainless steel, this exclusive Australian designed product grips around and keeps in full contact with the cylinder, restricting both horizontal and vertical movement.
The BottleChock is purpose designed to keep cylinders of all types secure, and is ideal for gas cylinders, oxygen tanks, fire extinguishers and oil drums. It can be used in fixed installations, such as securing a fire extinguisher to a wall, or in mobile applications, keeping loads safe in working vehicles – and particularly in utes.
The flexible design makes it easy to "snap" cylinders into place, and the cylinders can be easily changed with one pull buckle and strap.
“Bottlechock is registered as an Australian Made product and we are very proud of that,” says VisionSafe Managing Director Dean Roberts. Virtually all of the components are manufactured in Australia and the product is assembled at VisionSafe’s headquarters in Perth.
Each Bottlechock comes ready to install with an easy fit kit, with top and bottom fittings included. Sizes range from small (100-145mm), to medium (160-230mm), and large (245-375mm). There are also kits that can hold up to four cylinders in separate, individual chocks contained in a single bracket.
And this success is not limited to Australia. “We’ve been exporting to New Zealand and the UK for some years,” says Dean Roberts, “and we’re just about to break into to the US market.” VisionSafe 08 9295 0624 www.visionsafe.com.au
The Bottlechock is used in many different industry sectors. It has proved particularly popular in the mining industry, and has also been successful in manufacturing, agriculture, construction, health and defence.
The easy way to secure cylinders, drums and more on...
FOR MORE INFORMATION CONTACT VISIONSafe Phone (08) 9295 0624 Email firstname.lastname@example.org Web www.visionsafe.com.au
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• Vehicles • Walls • Boats • Labs • Floors • Trolleys and lots more!
• MANUFACTURING INNOVATION
INNOVATION DRIVES AUSTRALIAN MANUFACTURING GROWTH
By Milly Caffrey
In the 1960s, as much as a quarter of Australia’s workforce was employed in the manufacturing sector, and the industry fuelled 25% of the nation’s economy, according to the Productivity Commission. Half a century on, the closure of Toyota, Ford and then General Motors in October 2017 seemed to signal the ultimate demise of manufacturing in Australia. Manufacturing output and employment have both fallen steadily since the mid-1980s, and the ABS confirms that the top five sectors for share of employment are now all in the service sector, a phenomenon not unique to Australia. However, Elisabetta Magnani, Professor of Economics at Macquarie University, highlights the opposite phenomenon in neighboring superpower China. Over the past four decades China has seen its industrial structure evolve rapidly from lowlabour-cost manufacturing, to become a global power in the production of chemicals, electronics, ships and aircraft. Professor Magnani points out that meanwhile in Australia, the manufacturing sector has been weakened by an overreliance on the mining sector during the mining boom, a failure to translate this profit into
sustainable investment and a reluctance to engage with a forward-looking active industrial policy. However, there is evidence to suggest that the death of manufacturing in Australia has been overstated. Dr Keith Mclean, Manufacturing Director for CSIRO, believes that although Australia experiences disadvantages such as high labour costs, geographical remoteness and a small domestic market, these are becoming less important as globalisation, digitalisation and the increased demand for more bespoke and complex solutions takes hold. “The figures over the past 16 months have shown Australian manufacturing is expanding,” says Dr Mclean. “We’re seeing growth in a sector that already provides direct jobs for 860,000 people and tens of thousands more in support industries.” Dr McLean views innovation and ingenuity as crucial factors in the growth of Australia’s manufacturing sector. “Innovation is the key and it’s where Australians excel – from the stump jump plough, to bionic ears and CSIRO’s own WiFi. This means manufacturing in Australia is an opportunity not a weakness.”
He points to one NSW company, Romar Engineering, as a pertinent example of this. Once mainly an auto parts supplier, the company has evolved dramatically since its founding in 1968, reinventing itself as a provider of high-quality and commercially scalable manufacturing solutions to a wide range of industries including aerospace, defence and the medical sector. Romar Engineering is expert in silicone and rubber manufacturing, as well as tiny precision parts for complex machines and huge metal parts for mining and defence equipment. It has an expansive manufacturing site in Sefton, in Sydney’s west, and also a facility in Singapore. And while China has transformed into a manufacturing giant, this Australian company is confident that it can compete because its level of skill is so high. “Australian manufacturing companies must face the perception that to get good value, businesses feel they have to go overseas,” says Romar Engineering CEO Alan Lipman. “We challenge this by providing beautifully designed and consistently high quality products, which means in many cases the end-to-end cost to the client is reduced compared to going overseas because the manufacturing process is simplified and defects are avoided.” Romar Engineering is unique in having a highly sophisticated Class 8 clean room, built to manufacture regulated parts. The growth of the business has also seen it partner with CSIRO to become the first company in the Southern Hemisphere to use the DMG Mori Lasertec 65 for highly advanced additive manufacturing. The company already supplies manufacturing solutions to Asia and the USA and plans to continue exploring global markets through digital storytelling and promotion. While Romar Engineering now has international reach, it is very much the SMEs that are driving the growth of the manufacturing sector in Australia and make up the vast majority of businesses.
The DMG Mori Lasertec 65 gives Romar Engineering an edge
The Tiny House Company founded in 2016, is one such business. Carpenter
Romar Engineering CEO Alan Lipman challenges perceptions on manufacturing
Greg Thornton and architects Lara Noble and Andrew Carte design and manufacture homes based on the ethos of the worldwide tiny house movement; simple and affordable living. The dwellings are 18 square metres and come with solar capacity, a composting toilet and a grey water plant. Thornton explains that the idea for The Tiny House Company came when he travelled with Noble and Carte to Portland in the USA and the group saw scope to do things in Australia. “The market for tiny houses had been going for 10 years in America and the movement had grown to a big size without taking off yet in Australia,” says Thornton. “We saw a market for tiny houses here as an infill housing option (houses constructed on vacant lots) and we were inspired by the energy and interest in the United States.” The company’s manufacturing site is 300m2, and a tiny house takes approximately 10-12 weeks to build with a team of four people. Thornton describes the main challenges of manufacturing the tiny houses in Australia as getting councils on board, as the idea is so new that policies often have not been developed around how the placement of houses is regulated. As well as acceptance being a challenge, there are other questions relating to the homeowners’ grant and finding land to put the house on. Despite these challenges, tiny houses are a timely and appropriate response to Australia’s housing affordability crisis, which is predicted to continue for another 40 years, according to the Committee for Economic Development of Australia. The mortgage-free tiny houses range from about $59,000 to $79,000 and are
MANUFACTURING INNOVATION •
built on wheels, so they are relocatable. In addition, these dwellings benefit the environment by using far less resources to build and promoting energy conservation through lower electricity consumption. The Tiny House Company has plans for future growth with a new prototype going to the Brisbane Homeshow in September. Its success, along with that of Romar Engineering, confirms the view of the US Consumer Technology Association, which earlier this year evaluated that out of 38 countries, Australia ranked third in the world as an Innovation Champion, behind only Finland and the UK. With the Turnbull government’s recent focus on reshaping Australia as a manufacturing and technology powerhouse, our position at the top of the list is welcome news, signaling that the country is on the right trajectory to regain our position as an innovation nation. The Tiny House Company manufactures… tiny houses
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DIESEL-POWERED PRESSURE CLEANER IS A QUIET ACHIEVER The latest model of high-pressure water cleaner from Spitwater uses a “silent” diesel engine to provide industrial-grade cleaning performance in applications where noise might be a problem. Designed and built at Spitwater’s Albury manufacturing plant, the Model SW15200DES Silent Diesel delivers 15L/min hot or cold water flow at 200bar pressure in a selfcontained, portable machine. Like all Spitwater machines, the new unit is based on a threeceramic-piston brass-head pump from Interpump, chosen for its compatibility with Australian water conditions. The pump is directly coupled to a 9.6kW Hatz Model 1D81C Silent Pack diesel engine, geared so that the pump operates at a constant 1800rpm. The single-cylinder diesel engine is air cooled, with a vertical cylinder,
and uses a direct-injection multihole nozzle. The flywheel fan and charging alternator are integrated with the flywheel so there are no V-belts. It is encased into a noiseproof sheet-metal capsule, complete with a twin exhaust silencer system. The engine incorporates electric start with overcranking protection, and generates a noise figure of just 62.8dB(A) at 7m, which makes it highly suitable (for example) for cleaning outdoor surface areas in densely populated areas. Like all Spitwater models of this type, the Model SW15200DES Silent Diesel has a large water cooling tank that tank acts like a radiator in a car and is designed to allow full, 100% water bypass. This system offers real protection from temperature fluctuations in the pump. It also features a 12V-activated diesel burner system with Spitwater’s
own-manufactured horizontally mounted, half-inch diameter, 45m-long heating coil for hot water production. These heating coils offer cleaner burning, less sooting and a longer service life than alternative designs. The unit offers adjustable-rate chemical dispensing from its 10L chemical tank, and is supplied ready to go with 10m of heavy-duty doublewire-braided high-pressure hose and
a high-quality heavy-duty 340bar gun. A wide range of accessories is available. Spitwater high-pressure water cleaners are built tough for tough Australian working conditions and will remove heavy dirt with ease.\ Spitwater 1300 SPITWATER www.spitwater.com.au
BEARING HEATERS ARE FASTER AND SAFER FOR MOUNTING AND MAINTENANCE bearings in a wide range of industrial machinery. They can also be used to heat clutches, gears, and other ferromagnetic components quickly and safely.
The latest generation of FAG Heater devices from Schaeffler are suitable for use on rolling bearings weighing up to 1.6t for mounting and maintenance operations. A broad range of bearing sizes – from bores of
15mm through to outside diameters up to 2m – can be heated using the new range, which includes both tabletop units and floor-standing units. These heating devices are used in installation and maintenance of
The new range of heaters feature Delta-T control, using two sensors to continuously measure the temperature difference between the inner and outer side of the component being heated during the heating process. This helps to prevent damage caused by preloading in the workpiece as the device’s output is reduced shortly before a preset maximum temperature difference is reached. This gives the heavier outer ring enough time to expand to the required extent. This also makes Delta-T control a safer solution for heating rolling bearings. The heating process can also be started with a time delay via remote control in order to provide increased
safety for the mounting personnel.” The new heaters boast efficiency values of up to 0.9. This reduces the heating time and energy consumption, which in turn means lower operating costs. The microprocessor-controlled heating process is 30 to 50% faster than previous versions. The heaters are controlled via a user-friendly menu that is available in more than 20 languages. Using the intuitive touchscreen, the user can select from four different heating methods. The system additionally allows the heating process to be documented, favourites lists to be created, and heating curves to be graphically illustrated.
Schaeffler Australia 02 8977 1000 www.schaeffler.com.au
HYBRID SAFETY MODULES ENABLE DECENTRALISED AUTOMATION Turck has expanded its range of hybrid safety modules that combine safety I/O and general-purpose I/O in a single, rugged, on-machine, remote I/O device with the release of the CIP Safety Hybrid Safety Block I/O module. These hybrid safety modules can be adapted to the signal requirements of the installation through the use of configurable I/O points and by leveraging the flexibility of IO-Link. On the safety side, each module has two safety inputs for connecting safety sensors, such as light curtains or emergency stop buttons. Two further safety channels can be used as either inputs or outputs. The general-purpose (non-safety related) side has four configurable I/Os, each capable of switching up to 2A when used as outputs. Two IO-Link master ports are also available, which offer an additional 32 points of configurable
discrete I/O when used with Turck IO-Link hubs. As well as operating as remote safety I/Os, the hybrid safety modules can be operated as stand-alone safety controllers for local safe I/O. This allows the implementation of safety functions without the need for a dedicated safety PLC while still providing safety diagnostics and general purpose I/O data to a higher level non-safety PLC. The modules are available with high levels of ingress protection (up to IP69K), allowing their use in the most demanding environments and enabling decentralised automation without the need for additional control cabinets. Turck Australia 1300 132 566 www.turck.com.au
SAFETY CONTROLLER MONITORS MULTIPLE FUNCTIONS Available in Australia from Treotham Automation, the Reer Mosaic is a versatile safety controller that can reliably monitor multiple safety functions within a single machine or across a plant. The modular controller can manage safety sensors and signals such as light curtains, photocells, laser scanners, emergency stops, electromechanical switches, guardlock safety door switches, magnetic switches, RFID switches, safety mats and edges, two-hands controls, hand grip switches, encoders and proximity sensors for safety speed control. The Mosaic safety controller is configurable and scalable with a highly efficient entry level option. By reducing the number of devices and wiring used, the costs and overall size
PREVENTION INFORMATION SUPPORT MELBOURNE CONVENTION & EXHIBITION CENTRE
of the project are also minimised. The lower number of electromechanical components needed also means a better performance level and therefore a higher safety level. The Mosaic comes with lifetime free software updates complete with validation, monitoring and simulation features. Treotham Automation 1300 65 75 64 www.treotham.com.au
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SAFETY CONTROLLERS ARE MADE FOR PRESSES Leuze electronic has developed a new series of safety controls especially for use on eccentric and hydraulic presses. The new MSI 400 safety controls feature a compact design and are designed in accordance with the requirements of the EN 692 standard for mechanical presses and the EN 693 standard for hydraulic presses. The new devices contain tailored and certified function modules for press control and protection, and are
particularly suitable for use on small and medium-sized presses. The predefined press function modules, simulation function and log generator make programming and configuration quick and easy. They enable monitoring of the press procedure and can be used to implement various different operating modes (single stroke, automatic, cyclic, setup mode).
Safety devices such as two-hand switches, footswitches, E-stops and operating mode selector switches and safety sensors can all be easily integrated. Leuze electronic 1300 538 933 www.leuze.com.au
EFFECTIVE LED SIGNALLING SERVO SPECIALISTS SORT PROBLEMS AUSTRALIA-WIDE FOR HAZARDOUS LOCATIONS Available now from Mechtric, the new D2xB1LD2 beacon from E2S Warning Signals is UL1638 approved for private mode fire applications and general signalling duties. It is available in a choice of red or grey enclosure colours with field replaceable UV stable polycarbonate lens colour filters, fieldreplaceable without needing to access the enclosure and fitted with a stainlesssteel guard as standard.
DataFactory has a fully equipped electronic lab
Imagine you are running a sophisticated manufacturing centre, and a complex CNC machine powered by servodrives is its mainstay. One day, in the middle of an urgent job, one of the drives packs up. At first, the solution seems obvious: all you need to do is contact the agent. But when you do you find that the agent doesn’t have a qualified technician on hand, the servodrive became obsolete five years ago, nobody keeps any spare drives, the replacement drive suggested by the agent is not compatible with your system, and you need the services of an integration specialist.
And they are the people who solve these problems. It takes a combination of deep knowledge and experience to repair or retrofit a sophisticated servodrive at short notice. It helps that DataFactory engineers have designed a few servodrives in their time. And they have commissioned and serviced a great many more in their careers. It also helps that they are well versed in a number of the programming languages and communications protocols that are at the core of today’s control systems. And they have a fully equipped electronic lab at their disposal.
The integration specialist is currently in Japan, but will be back in Australia in a couple of weeks. And the whole exercise will cost a small fortune.
So, the next time you have a problem, perhaps you should give them a call. It might save you a small fortune.
Sound familiar? According to the engineers at DataFactory, this is more commonplace than you might imagine.
DataFactory 03 9874 7737 datafactory.com.au
Candela ratings of 73.4cd to UL1638 for private mode fire and 180cd for general signalling applications ensure that the D2xB1LD2 is the most effective LED signalling solution available for hazardous locations. An array of high power Cree LEDs provides minimal inrush and operating current and optimises visibility in all directions. The beacon has five flashing modes: 1Hz, 1.3Hz, 2Hz, double strike and triple strike with an effective output of up to 180cd for warning applications. It also has selectable high power and low power steady modes with outputs up to 87cd for status signalling. DC voltage versions feature three remotely selectable stages, enabling different flash rates to be allocated to different processes or alarm conditions from one device. With UL/cUL approval for Class I Div 2, Class II Div 2 and Class I Zone 2/22 as well as being IECEx and ATEX certified for Zone 2 and 22 applications, the D2x family of warning signals can be installed almost anywhere in the world. The marine grade LM6 aluminium enclosure has a chromate and powder
coated finish for maximum corrosion protection and conforms to NEMA Type 4/4X/3R/13 and EN60529 IP66 protection standards. Pluggable duplicate (four wire) terminations mean quick installation and enable multiple units to be looped or daisy-chained without requiring additional junction boxes. Integrated monitoring diodes and user-configurable end of line options ensure compatibility with supervised control panels. The D2xCDLD2 combination device features the D2xB1LD2 with a D2xS1 116dB(A), 64 tone UL464 alarm horn integrated into a single enclosure to create the most effective solution for audible and visual signalling, reducing cabling and installation costs. Mechtric 1800 252 995 www.mechtric.com.au
EXTENSION PROTOCOL SIMPLIFIES PLC I/O EXPANSION
PROFESSIONAL CONNECTORS ARE COSTEFFECTIVE ALTERNATIVES
Turck has developed a novel protocol that enables high-density networking with I/O resource constrained PLCs. The Backplane Ethernet Extension Protocol (BEEP) can be used to network up to 33 devices and link them to a PLC on a single connection using a single IP address. The first device in the I/O network is set as the BEEP master using the device webserver. The BEEP master can then scan the entire network and create a new data map that includes all the downstream devices, with all device configuration options saved in the master. BEEP enables easy I/O network reconfiguration as it supports drop-in device replacement. So long as the network was set up using BEEP, a technician can simply replace a slave device with a new device to keep the system online. The BEEP master will automatically recognise the new device,
IP69K and so are ideal for use in the food and beverage industry. These connectors combine plastic housings with stainlesssteel coupling nuts, providing resistance to chemicals and oil.
assign it an IP address, and download the parameters to it. BEEP technology has already been integrated into many of Turckâ€™s multiprotocol digital block I/O modules, including the BL Compact pushbutton station, the TBEN-L and TBEN-S digital stations, and several variants of the FEN20 module. And, as BEEP is compatible with all standard Ethernet components it requires no special equipment. Turck 1300 132 566 www.turck.com.au
RS Components has expanded its RS Pro range of connection devices with a number of additions that are well suited to general industrial, instrumentation, and medical applications, as well as being suitable for harsh environments. The additions include IP68 waterproof connectors featuring robust plastic shells, and with cable and panel mount options that are available in 13, 17 and 21mm panel cutout types. Also new are washdown-rated M8 and M12 connectors that are sealed to
All products in the RS Pro portfolio are designed as cost-effective direct replacements for branded off-the-shelf products. Other additions to the RS Pro interconnection range include: a series of halogen-free cordsets suitable for both office and industrial applications; and white DC-power connectors for medical and consumer applications. Also new are ranges of male and female pluggable PCB terminal blocks in a range of pitches, which are approved to UL and VDE standards RS Components 1300 656636 au.rs-online.com
MAINTENANCE-FREE 3D ELECTRIC TORQUE WRENCHES GAIN SLIDING PRINTED GRIPPERS FOR FLEXIBLE PACKAGING REACTION ARMS Heinrich, Enerpac Territory Manager – Western Australia. “The new sliding reaction arm is ideal for using to react the tool of a neighbouring bolt or nut head, especially where the centres vary. The black handle locks the socket position with a simple clockwise quarter turn of the hand. To unlock and slide again simply quarter turn anticlockwise by hand,” he adds.
Enerpac has released sliding reaction arms that enhance the safety, flexibility and efficiency of its ETW electric torque wrenches in difficult torque tightening applications. The reaction arms – one that fits the nationally distributed ETW1000, 2000 and 3000, and a second that fits the ETW6000 – are suited to applications such as replacing mill liners on mining and bulk handling sites; track, road and rail undercarriage, wheel and shovel maintenance; turbine bolts, tower segments and turbine casings; and pipe flanges, valves, manway covers and pressure vessels. “The new sliding reaction arm has been designed for applications where the distance to an adjacent reaction point or bolt centre are widely spaced and uneven making it difficult to utilise standard reaction arms,” says Bert
“A major benefit of this tool accessory is safety. The two sockets mounted on the sliding reaction arm engage with the bolt or nut heads, meaning there is no pinch point injury possible between the operator’s hand and the tool or workpiece.” “The other main benefit is its infinite variability. It can be customised to suit different bolt centre lengths and centres, making the tool safer and more efficient in a huge range of applications.” The ETW has high-speed continuous rotation, which allows it to perform its tasks faster than manual methods. It is built with a low-friction planetary gearbox to minimise wear and extend uptime. The user can input a nominal torque value followed by a specific angle of rotation Enerpac Australia 02 8717 7200 www.enerpac.com.au
Grippers used in the packaging industry have traditionally been made from metal. However, these devices are generally limited to a single task, and sized for a specific product – for example for fitting the lid to a particular size of glass jar. If production should switch to a different product, the sourcing of a suitable gripper could prove a production bottleneck. However, it is now possible to produce robust and lightweight plastic grippers using 3D printing with igus tribo-filaments, and Treotham reckons that the whole process is 85% cheaper and 70% faster than producing the equivalent metal part. Treotham has been offering tribologically optimised igus 3D print filaments for 3D printing since 2015. So
long as the CAD data are available, it is easy to fabricate a gripper using an additive process with self-lubricating iglidur high-performance plastics that are optimised for wear and friction. Plastic grippers are not only seven times lighter than metal grippers, they are also much more cost effective. Treotham also offers five other igus filaments for the printing of wearresistant parts for a wide variety of applications. Compared with standard materials such as polylactide, these high-performance plastics are up to 50 times more wear-resistant and can be processed on all standard 3D printers. Treotham Automation 1300 65 75 64 www.treotham.com.au
BACKPACK VACUUM OFFERS A BOOST OF TURBO POWER Nilfisk has developed a novel battery powered backpack vacuum cleaner that combines fast charging time with a boost function for heavy-duty cleaning. In recent years the professional cleaning industry has seen an increase in battery driven vacuums, offering increased mobility for operators and improved safety for all concerned with no cables to provide trip hazards. Nilfisk Australia Product Manager Greg Jones likens the trend to that in the power tools industry, where battery power has almost become the norm, saying: “We have for the past years worked with a vision of creating that same freedom for people in the cleaning industry – but without compromising the performance and functionality of the vacs.” Enter the Nilfisk GD 5 Battery – a lightweight backpack model free of cords that is especially useful for room to room cleaning and cleaning in demanding spaces like inside lifts - or up and down staircases.
Says Jones: “Many of the earlier battery driven vacs had long charging times and insufficient power for heavy duty – or even deep – cleaning. We believe that we have solved these issues with Nilfisk GD 5 Battery.”
Then unit features a dual-speed motor (normal and boost) to improve productivity, and provides up to 60 minutes runtime on a single charge of its 36V lithium battery. Charging is quick, bringing the battery to 90% in 40 minutes so that switching between
two batteries in the vac and the charger enables non-stop cleaning. Nilfisk 1300 556 710 www.nilfisk.com.au
THE SAFETY PARTNERSHIP: CULTURE AND PROTECTION Reports have shown that a worker dies every 15 seconds from a workrelated accident or disease – that’s a total of 2.3 million people around the world every year. The economic, social, and legal impact of accidents makes worker safety a top priority for commercial and industrial employers around the world. Studies have shown that building an enduring culture of safety can be the most cost-effective and proven accident-prevention process. Creating and internalising this culture is the most successful way to minimise costly injuries and maintain a safer, more productive and engaged workforce. Defining a culture of safety Building a safety culture is a new philosophy of preventing injury in the workplace. Safety is no longer something defined and enforced by management; rather, it becomes the right and responsibility of each and every employee. When workers embrace safety standards and better safety behaviours, they can regulate
their own safety much more effectively and consistently. The key elements for establishing and supporting a sustainable culture of safety consist of the following: • Demonstrating transformational safety leadership at the managerial level. • Serving as a guide to how employees should behave in the workplace. • Focusing education and training on behavioural issues. • Choosing safety equipment employees prefer and want to wear and use. • Establishing an analytic and diagnostic infrastructure that provides essential information. • Using technology and services that help coordinate and simplify the right kind of data to create and manage an informed culture of safety. • Setting measurable goals and providing feedback focused on positive behaviour.
• Appointing safety ambassadors to accelerate culture change. In summary, a culture of safety exists when safety is everyone’s priority and workers make safe choices on their own. The bottom line By building an enduring culture of safety, safety managers empower their workers to embrace safety standards and practice better behaviours.
In successful cultures, workers regulate their own safety much more effectively and consistently, become partners in the transformation of their worksite into safer environments, and instinctively make safer choices on their own - for the safety and protection of themselves and their co-workers. Honeywell Industrial Safety www.honeywellsafety.com
COMPACT SENSORS PERFORM FOR CONVEYORS AND PACKAGING Leuze electronic has expanded its Global Beam family with a compact range of standard sensors in IP67 housings. The new 15 series is designed for the reliable detection of objects in industrial environments, and is particularly suited to standard automation tasks in applications such as conveyor systems, materials flow or secondary packaging in which large operating ranges are required.
The SR 15 sensors have a cubic design. They feature an extremely bright light spot and an easily accessible potentiometer that make installation quick and easy, even in spaceconstrained installations. The 15 series is available with a range of different operating methods, which expands its applications flexibility to cater for special requirements such as
SLIM PSU SAVES SPACE AND COSTS Available now from Control Logic, the PIC240.241D is the latest addition to the Puls Piano series of DIN-rail power supplies. The 24V, 10A PSU has a universal 100-240V input, and comes with a DC-OK signal relay contact as standard. Saving space in cabinets and machine designs, the slimline supply is just 49mm wide. It boasts an impressive efficiency level of 94.8% and a lifetime of 74,000 hours. Terminals are robust and its low power losses enable new cost-saving design principles featuring a slim
detecting glossy objects and reflective surfaces. The high function reserve (or operating margin) enables the sensors to operate reliably even under extreme conditions, reducing the risk of system downtime. For end users the new series represents an economical solution with a good price/performance ratio.
Leuze electronic 1300 538 933 www.leuze.com.au
PROFESSIONAL TOOLKITS ARE FIT FOR INDUSTRIAL APPLICATIONS
single-board design and high-quality polycarbonate housing. Control Logic 1800 557 705 www.control-logic.com.au
RS Components has introduced a new wider range of toolkits, each designed to support a specific set of requirements, such as maintenance, machine safety, transportation and utilities. The new RS Pro toolkit series includes offerings for general electronics applications and kits for maintenance engineers, technicians, mechanics and electricians. There are also specialist kits for automotive and high-voltage electrical applications, as well as sets of precision pliers. Each RS Pro application-specific toolkit has been put together as an ideal starting point, providing engineers and technicians with all the basic tools for a particular industry application. However, they are also likely to prove popular as replacement toolkits for experienced users. The full range includes: 13- and 32-piece electronics toolkits; 28-, 29-, 32- and 36-piece kits for electricians;
41- and 82-piece kits for mechanics; 25and 81-piece kits for technicians; 15- and 85-piece field-service kits; a 95-piece automotive toolkit; a 13-piece maintenance toolkit; a two-piece general-purpose measuring set; and two four-piece sets of pliers, including a premium precision set. The top-of-the-range 95-piece automotive kit comes in a portable tool chest and includes hammers, wrench sets, punches, sockets, ratchets, extension bars, pliers, cutters and screwdrivers. The 36-piece VDE/1000V toolkit for electricians is another highlight. This has been designed for engineers and technicians working on or around live circuits. In addition to electrical tools such as cable strippers and voltage testers, the kit includes VDE-certified screwdrivers and pliers that are individually tested for safe use up to 1000V AC. The new toolkits are the latest additions to the RS Pro range of more than 50,000 products engineered for manufacturing and industrial environments. All RS Pro products are produced to industrial quality standards, undergo rigorous testing in the RS lab, and are backed by the RS Seal of Approval. RS Components 1300 656636 au.rs-online.com
HYBRID CABLES FOR THE IMPORTANCE OF A CORRECTLY SIZED AIR RECEIVER ENERGY CHAINS SIMPLIFY MACHINE DESIGN Air receivers are generally one of the most underrated items of plant in a compressed air system. However, by providing compressed air storage and acting as a buffer between the compressor and the air reticulation system, a correctly sized air receiver can significantly lower energy and maintenance costs. A correctly sized vessel has the effect of limiting the load/unload cycles (or stop/start cycles) of the compressor. This reduces the risk of excessive wear and tear on the control system and the drive motor. The vessel volume directly impacts the off-load cycle time and overall energy costs for partly loaded compressors. Cycling compressors vent their internal pressure when ‘off load’ to reduce absorbed power. If the off-load time is too short then the compressor never really fully unloads which results in higher overall energy usage. The compressor off-load time is a function of storage volume, pressure settings and plant demand. Even a variable-speed-drive compressor needs an adequate storage volume to ensure a clean signal to the control system to ensure steady system pressure. Air receivers offer the added benefit of separating liquid condensate that is entrained in the compressed air. By reducing the air velocity through the vessel to below 0.6m/s, moisture droplets will fall out under gravity and the fluid can be easily drained away using a good quality
machine builders. The single cable takes up less space in the energy chain, and it also allows designers to simplify interconnection by using a single hybrid connector for the entire system.
automatic drain valve. This reduces the moisture load on corresponding filters and dryer, improving their life and efficiency. It is important to appreciate that an air receiver cannot provide more air for the plant than the compressor/s can deliver. However, in some circumstances an engineered air receiver can accommodate a high demand over a short time frame, potentially avoiding the need to invest in a larger compressor. In applications where air is used in short bursts, such as tyre fitting and the like, a larger air receiver is often the right solution, and can result in significantly lower investment and running costs. It is clear that the energy saving benefit of extra storage capacity far outweighs the additional cost of the vessel, and all compressed air systems can benefit by having the right size air receiver regardless of the size and type. Southern Cross Compressors 1300 098 901 www.southerncrosscompressors.com.au
BEARING DEALS EXPAND POWER TRANSMISSION LINEUP target a wide range of industrial applications, including production lines and conveyor systems.
RS Components has expanded its mechanical power transmission portfolio with the addition of components from two of the world’s largest manufacturers of bearings and other components for power transmission systems. Schaeffler and Timken products now available from RS include ball bearings, roller bearings, sprockets, belts, pulleys, and many other parts necessary to build up or maintain different kinds of motioncontrol applications. The components
Treotham Automation is offering a new series of hybrid cables specifically for use in energy chains. The igus CFBUS.PUR.H01 series cables combine Ethernet or Profinet elements with power cores in a single cable with an oil-resistant PUR outer jacket that makes them ideal for moving applications in machine tools and other demanding environments. There are a number of advantages to this hybrid cable approach for
Treotham can supply the full range of igus hybrid cables, which currently comprises 1354 different designs. These include the CFBUS.PUR.H01.049 with CAT6 and the CFBUS.PUR.H01.060 with Profinet in addition to versions with Profibus and fibre optic elements. To enable global use, the whole cable family has UL and NFPA approvals and meets the requirements of EAC and CTP.
Treotham Automation 1300 65 75 64 www.treotham.com.au
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Protoblast Company has been designing and manufacturing to suit customer’s needsand since 1975. Protoblast Company has individual been designing manufacturing to suit Protoblast Company has been designing and manufacturing customer’s individual needs since 1975. • Abrasive Recovery Systems • Airless Blast Machinesto suit individual needs since 1975. • customer’s Section Blast Machines Dust Collectors • Abrasive Recovery Systems • •Airless Blast Machines • Abrasive Recovery Systems • Airless Blast Machines Machines • Dust Collectors The best way •toSection prepareBlast a surface for a coating is by using the abrasive • Section Blast Machines • Dust Collectors blasting process. Whether you need to blast castings, concrete blocks, The best way to prepare a surface for a coating is by using the abrasive screws, surfboards or steel work... The best way to prepare a surface for a coating is by using the abrasive blasting process. Whether you need to blast castings, concrete blocks, blasting process. Whether need to blast castings, concrete blocks, screws, surfboards or steelyou work... Protoblast has the experience screws, surfboards or steel work... to design and supply has equipment that is fast,toefficient, Protoblast the experience design improves your product saves you Protoblast has the experience toefficient, design and supply equipment thatand is fast, money... year after year. and supply equipment that is fast, efficient, improves your product and saves you improves your and saves you money... year afterproduct year. money... year after year.
The RS power transmission portfolio now includes more than 400 products from Schaeffler, largely roller bearings and ball bearings from the company’s INA and FAG branded ranges. There are also more than 200 new products from Timken, mostly comprising tapered roller bearings with race widths from 7.93 to 42.86mm. The Schaeffler and Timken bearing ranges are available now from RS in the Asia-Pacific region.
P.O. Box 157 Picton NSW 2571 P. 1800 772 320 Inter. +61 2 4677 2320 P.O. Box 157 Picton NSW 2571 E. email@example.com P. 1800 Inter. +612571 2 4677 2320 P.O. Box772 157320 Picton NSW E. firstname.lastname@example.org P. 1800 772 320 Inter. +61 2 4677 2320 E. email@example.com
RS Components 1300 656636 au.rs-online.com
www.protoblast.com.au www.protoblast.com.au www.protoblast.com.au
TELESCOPIC LADDERS FEATURE IN NEW ONLINE TOOL STORE Warequip Solutions has set up a new online store to showcase its latest range of telescopic ladders together with the Plano Europe Technics range of tool storage and tool safety products.
The ladders and platforms are made of durable aluminium with hard-wearing glass-fibre-reinforced plastic fittings. There are three models in the range, all meeting Australian Standards (AS/NZ 1892).
Worksafetools.com.au is the first store in Australia to release the world famous Telesteps telescopic ladder range, with the first shipment due to arrive during January 2018. The novel Swedish designed ladders are easy to adapt to the desired length for the task in hand. And the telescopic design makes them ideal for use in confined spaces.
The complementary Plano Europe Technics range includes tool stops, toolboxes, tool holders, tool bags, accessory pouches and much more. These professional tool kits are innovative in their design as well as functional and comfortable.
Work Safe Tools 1800 337 711 WorkSafeTools.com.au
SOLAR-POWERED OFF-ROADER IS TOUGH TEST FOR SERVO CABLES The goal of the project is to break the record of an Australian team for the fastest crossing of the Simpson Desert with a solar-powered land vehicle. This means a distance of 360 kilometres along the "French line" from Purni Bore to Birdsville. Attached to the roof of the SolarBuggy are 2.5 square metres of solar cells. The team has less than 4 days, 21 hours and 23 minutes to accomplish their project.
Since the beginning of 2016, a team of 16 students from the University of Bochum in Germany have been developing and constructing a solar-powered off-road vehicle, the SolarBuggy. The current model, dubbed "Froggee", is set to cross the Australian desert in the spring of 2018, aiming to set a new world record in the process. The buggy has been constructed using chainflex servo cables from igus, which are ideally suited for the thermal and mechanical loads that will be experienced.
Against this background, all components in the SolarBuggy have to cope with the toughest demands and at the same time have a low weight. This is especially true for the chainflex cables that are installed. They are used to connect the motor controllers to the electric motors, for driving the vehicle and for the internal wiring of the contactors. The combination of low weight and small diameter as well as maximum mechanical durability is the
The SpecialiSTS in elecTronic DriveS for over 30 yearS • Repairing/retrofitting of electronic AC, DC and servo drives • Repairing of complex electronic boards, including obsolete boards that are no longer supported by vendors • Design and construction of multi-drive systems • Board-certified engineers • Professional Control Systems Integrators • Laboratory & Clean Room • Large Stocks of Spare Parts • 30 Years experience • Australia wide service
Call us on 03 9874 7737 www.datafactory.com.au
The servo cables in the SolarBuggy have a special conductor design that features high current carrying capacity and withstands the mechanical loads due to motion and vibration, so that there are no interruptions to the power supply. "The cables are shielded, provide DC and AC voltage and have a high electromagnetic resistance to external influences," explains Kay Bollerhof of the SolarBuggy team. "As they are very tough, they are ideally suited to thermal and mechanical stress in Australia," he continues. Treotham offers the igus chainflex servo cables with or without an inner jacket. Depending on the type, they are flame-retardant, coolant-resistant and oil-resistant, remain flexible at low temperatures, and were originally designed for use in energy chains. Tested under real conditions in the in-house igus laboratory, they ensure a maximum service life and guaranteed operational reliability. In the case of the SolarBuggy, the CF270.UL.350.01.D servo cables used can cope with bend radii down to 7.5x their diameter, and so can fit in the smallest installation spaces. Thanks to a PUR outer jacket, they are oil-resistant, halogen-free, silicone-free and flame-retardant.
Siemens continues to develop its Sirius range of industrial control products, and RS Components is providing support for Australian users looking to migrate to the latest generation of devices. The latest units offer higher power ratings and increased functionality in the same form factor as the previous series. They comprise full range of control panel products, from simple load feeders to units that switch, protect, start and monitor motors up to 250kW and 400V. The Sirius system simplifies panel building, with reduced effort both for modular interconnection and panel wiring. The flexible in-feed system uses screw-type and spring-loaded connections, enabling easy assembly with no tools required. The latest series of modules are fully compatible with the new IE3 and IE4 generations of motors, and there is a novel range of snap-on function modules, such as communication units. Also new are current-monitoring relays for the upgraded S00, S0 and S2 units, which can be directly integrated onto the load feeders. As well as supporting users in migrating to the new generation of Sirius devices, RS will be stocking both the oldand new-generation Sirius products to make the migration process as smooth as possible, as products are phased out over the next few months. All Siemens Sirius system units meet all relevant worldwide standards and approvals for deployment in any market including safety applications and specialised environments such as the railway and shipbuilding sectors.
• 24 hour turnaround available
strength of the igus cables.
INDUSTRIAL CONTROL MIGRATES TO THE NEXT GENERATION
Treotham Automation 1300 65 75 64 www.treotham.com.au
RS Components 1300 656636 au.rs-online.com
SENSORS COMBINE TO MEASURE PAINT COLOURS IN REAL TIME
MicroEpsilon has come up with a novel time- and space-saving colour measurement system for liquid paint that can be directly integrated into the paint production process. Traditional methods for measuring the colour of liquid paint have involved painting a test area and only performing the measurement once the sample has dried-off to achieve reliable measurement results. This is time-consuming in itself. But if the results are unsatisfactory, the container has to be remixed and blended - or even trashed. The new measurement setup available from Bestech Australia combines the colorControl ACS7000 high-speed inline photospectrometer and the optoNCDT 1420 laser triangulation sensor, to enable real-time and high-precision colour measurement of liquid paint directly in the production process. And, as there is no need to wait for any drying time, the new method
ADAPTABLE CONTROLLER OPENS ACCESS TO THE IIOT level languages and model-based code. And different developers can work independently on the same project using different programming languages and their development tools of choice, thereby speeding application development. Open source software and apps can also be incorporated.
significantly improves production efficiency. The key to the measurement process is the combination of the two sensors. The measurement of the spectral distribution of the light reflected from the paint is greatly influenced by the measuring distance: even a change of 0.05mm will change the measurement results. By adding the laser triangulation sensor to monitor the measurement distance, the measurement system can adjust the distance of the colour sensor from the object to guarantee consistent measurement accuracy. As both sensors are particularly compact devices, the integrated measurement system saves space as well as time. Bestech Australia 03 9540 5100 www.bestech.com.au
Phoenix Contact has unveiled its open control platform, which it reckons both simplifies the task of controlling industrial processes and answers the challenges of the world of IIoT. The companyâ€™s PLCnext Technology is described as an enhancement to classical IEC 61131-compliant PLC programming that makes it possible to program controllers using high-level language. The result, according to Phoenix Contact guarantees PLClike real-time performance and data consistency while working with high-
The first hardware platform to be released is the PLCnext Control, which is claimed to combine the robustness and security of a classic PLC with the openness and flexibility of the world of smart devices. The new controller is adaptable and capable of expanding to accommodate future technologies. It features open interfaces and a direct cloud connection to expand connectivity to new levels. The hardware combines a high-performance CPU with high levels of mass storage in a small housing. Phoenix Contact 1300 786 411 www.phoenixcontact.com.au
SIMPLE, SAFE, PRODUCTIVE SYNC GRIP PULLERS
PLUG-IN TERMINAL BLOCKS SIMPLIFY SYSTEM BUILDS structures as well as for making quick and safe connections inside panels or installation ducts. Dual crossconnections and same cross-connectors can be used on both terminals and sockets, and optional locking mechanisms protect against vibration. The Klemsan StoP (spring to pin) series of plug-in terminal blocks from Control Logic offer an easy way for system builders to connect signal and power circuits using plugs and sockets. StoP series units can be used to couple terminals without any DIN rail fixing to fix energy breakdowns quickly, making tests faster and safer. The versatile connection terminals can be used on DIN rails as well as other rail terminals with different sized
Removing sockets from terminals is extremely simple by pushing the clip upwards, with easy access to wires using a screwdriver to open the spring cage. New line Sync Grip Pullers Our new line of pullers make your job easier and safer. With jaws that synchronously open and close, positioning is simpler and helps prevent misalignment.
The unique pin lock mechanism prevents misconnection by matching the correct plugs and sockets. All terminal blocks are easily identified using strip labels or marking tags. Control Logic 1800 557 705 www.control-logic.com.au
TERMINALS PROMISE COSTEFFECTIVE MACHINE CONTROL Available now from Rockwell Automation, the Allen-Bradley PanelView 5310 family of graphic terminals are ideal for smaller applications using up to 50 HMI screens. The terminals are available now in 7, 9 and 12in display sizes, and a 6in display option will be available shortly. Sharing many of the benefits of the larger PanelView 5500 the PanelView 5310 family help make design, operations and maintenance tasks more efficient. For example, engineers can now reuse controller alarms without creating HMI tags, which can help them reduce configuration time. They can also use the enhanced integration to create high-speed jog buttons in place of hard-wired switches. These auto-diagnosing buttons can interact with the controller at I/O speeds to help reduce downtime and improve productivity.
VNC connectivity allows operators to remotely monitor operations via a smartphone, tablet or personal computer. Historical-trending and data-logging features also allow operators to easily troubleshoot issues directly on the panel. Engineers can load projects onto the PanelView 5310 graphic terminals directly from removable media to quickly recover information and perform updates without needing the Studio 5000 View Designer application. Rockwell Automation 1800 762 593 www.rockwellautomation.com
WALK BEHIND SCRUBBERS TAKE ON MORE INTELLIGENCE Tennant has brought its latest generation of automatic walk-behind scrubbers to the Australian market with the release of the T500 and T500e models, together with a novel web-based fleet management system that helps users to clean more intelligently and efficiently. Featuring the company’s new SmartFill automatic battery watering system, the T500 series answers one of the most common complaints from heavy-duty users – battery maintenance. The new system removes the need for the operator to manually check, open and fill flooded batteries, reducing the maintenance task considerably. Other innovations in the T500 series include a new 700mm orbital cleaning head option that is claimed to effectively remove floor finish without using expensive detergents. It also features Tennant’s ecH2O NanoClean technology to reduce its environmental impact compared with daily chemical cleaning. The new Iris Asset Manager provides full visibility of the user’s fleet with a wide variety of reporting and monitoring capabilities including the delivery of key
performance metrics and intelligent insights to increase productivity. It also allows users to view an analysis of costs to clean, allowing them to make informed decisions regarding where and how to reduce costs. It also monitors battery usage and enables users to optimise battery charging operations and maintenance to extend the life of the battery, thereby reducing operational expenses and downtime. Josh Hastings is Marketing Manager for Tennant Australia. He says: “The T500 line continues to deliver Tennant reliability and exceptional performance that our customers have come to expect across the ANZ market.” Tennant 1800 226 843 au.tennantco.com
EXECUTIVE SAFETY FOOTWEAR COMBINES SMART STYLE WITH COMFORT The Oliver PB 38 Executive is a dual-purpose footwear range that looks smart in an office environment, and provides safety protection and outstanding comfort features out on site. There are three choices: the standard black derby shoe, a black zip sided ankle boot and a black elastic sided boot - each providing the wearer lightweight, stylish footwear with premium water-resistant soft-touch leather uppers and a full leather lining. Users can experience leading comfort in safety footwear all day long, whether they are onsite or in the boardroom. The contemporary styling is matched by the proven Oliver combination of the PB dual-density polyurethane sole, which provides
excellent slip, crack and split resistance, as well as having a heat resistance to 130C, accompanied by a lightweight shock absorbing PU midsole with a hard-wearing outsole for a variety of working conditions and industries, including manufacturing, hospitality, logistics and architecture. Protection of the foot against drop or impact events is afforded by the NATUREform steel safety toecap with its wider profile for added comfort. All three choices in the Oliver PB 38 Executive range comply with all relevant AS/NZS and relevant EN and ASTM International footwear quality standards. Up until April 30th, Oliver offering the chance to win one of 10 De’Longhi Espresso coffee machines, when you
] The three Oliver PB 38 range choices will meet all types of workplace aspects from administration to industrial, supervisory or hospitality roles where long hours on the feet or the need to walk around plant sites where full safety protection is key. Picture shows black zip side boot.
purchase a pair of boots from the Executive range. Simply purchase from participating retailers, and enter at www. oliver.com.au. (T&Cs apply.)
Oliver Footwear 1300 126 687 www.oliver.com.au
LED LIGHTING OFFERS PRACTICAL APPROACH TO ENERGY SAVINGS The ENSA range of energy-saving LED lighting products and accessories is available from Cornick, offering practical energy efficiency solutions, designed for fast installation, reduced power consumption and improved lighting performance.
floodlights and canopy lighting.
ENSA products incorporate the latest in LED lighting technology to ensure each light offers optimal effi ciency, light quality and service life.
There are also a wide range of lamps, including LED tubes, downlights and panel lights for commercial, office and residential applications.
The range includes industrial grade fixtures, such as highbays, street lighting,
Specialised products include battery-backed LED lights for
Highbay lighting for demanding industrial and commercial environments combines high-performance highreliability Samsung LEDs with novel aluminium heatsinks for optimal heat dissipation.
emergency lighting and intelligent lighting sensors that further increase the potential for energy saving. These intelligent sensor units offer a choice of 5.8GHz microwave or passive infra-red movement sensors that are only activated when ambient light levels fall below a set limit. Once activated, the motion sensors switch on the connected light when motion is detected, and turn it off after a programmable delay has elapsed.
Available in Cooling Capacities of 320W - 1500W
Available in Cooling Capacities of 320W - 4000W
Slim Line Series
NEW STOCK AVAILABLE
In industrial applications such as warehousing, ENSA intelligent sensor units can be combined with any of the company’s energy-efficient LED highbay units to significantly reduce power consumption while maintaining security and plant safety by ensuring that illumination is available when required. Cornick 1300 307 067 www.cornick.com.au
NEW STOCK AVAILABLE
ENCLOSURE CABINET PRECISION COOLING Seifert Systems - Precision air conditioning for process control cabinet applications. Designed to keep your electronics cool and operating at optimum performance. Seifert air conditioning incorporates filter less technology. No need to change filter mats means less maintenance and less down time. Cooling capacities range from 200W to 4kW. Seifert also offer heat exchangers, heaters and fan systems - complete thermal solutions. A 105 Lewis Rd, Wantirna South VIC 3152
T +61 3 9801 1906 / F +61 3 9887 0845
AIR TOOLS TARGET PROFESSIONAL USERS RS Components has added more than 70 new air tools and accessories to its RS Pro equipment range. New tools include air impact wrenches, drills, saws, ratchets, grinders, sanders and polishers. Accessories include sockets, chisel sets, saw blades, keyless chucks, grinding wheels and sanding discs. All the tools are lightweight and robust, making them suitable for
both production and maintenance applications. They have been designed to improve the speed and ease of work activities while minimising noise and vibration output. Ergonomic grips and lightweight bodies reduce fatigue during prolonged everyday use.
hammer type air ratchets; 3in cutting discs; saw blades; and a 10mm keyless chuck. Impact sockets are available in a large range of options, including eight- and 18-piece kits. The range also includes a five-piece chisel set and various sander and polisher sets.
Highlights of the new air tool range include: air impact wrenches such as the 0.5in stubby and turbo variants; lump-
Further information is available from the dedicated RS plant maintenance website. The new RS Pro air tools are
available now in Australia. RS Components 1300 656636 au.rs-online.com
REDUNDANCY MODULE BOOSTS POWER SUPPLY RELIABILITY The latest addition to the Puls Piano range of DIN-rail power supplies from Control Logic is a cost-effective diode redundancy module that can be used to increase system reliability by integrating 1+1 or N+1 redundancy. The PIRD20.241 module can be used
in either a 2x10A or 1x20A configuration for safe decoupling of parallel-connected power supplies for quick integration into the system. The input voltage can be between 9 and 35V with both constant current and hiccup overload power supply behaviour accepted.
The module features a wide operating temperature range of -40 to +55ºC without derating and a narrow width of only 39mm. These factors combine to enable its integration in a wide range of application areas that can benefit from the Puls brand characteristics of high efficiency,
absolute reliability and long life. Control Logic 1800 557 705 www.control-logic.com.au
INNOVATIVE HIRE SPECIALIST TOOLS UP HYDRAULICS NSW equipment hire specialist Hire Express has chosen Enerpac tools to comprehensively stock the hydraulic lifting and bolting sections of its business. Blacktown-based Hire Express is a relatively new player in the industry and differentiates itself in the hire market by providing full technical and compliance data for its equipment online, accessible via QR codes on the equipment. The data include service histories, risk assessments, operator manuals, registration and insurance. Hire Express Managing Director Allen Besseling has more than 30 years’ experience
in the hire industry, including three years as CEO of a long-established national hire company. When it came to hydraulic lifting cylinders and bolting tools for his new business, he immediately thought of Enerpac.
Companies that make smaller components, accessories and parts often design them specifically for use with Enerpac tools, as these are the benchmarks of safety and reliability,” he adds.
“Enerpac is a strong and trusted company with a history of safe, high-quality products, backed by a reliable brand and strong traceability of product. I’ve had a long association with Enerpac and have always been impressed by their products and quality customer service,” says Besseling.
To date, Hire Express has used Enerpac tools on projects as diverse as bridge extension and mine-site cable termination, as well as simpler lifting and bolting tasks.
“In our industry, the word cylinder is practically synonymous with Enerpac.
“Another major advantage is Enerpac’s comprehensive range. They have cylinders for lifting hundreds of kilos, right up to a thousand tonnes, as well as bolting tools for every task,” says Besseling.
Enerpac Australia 02 8717 7200 www.enerpac.com.au
Screw Compressors For full range scan QR code or go to
pneutechgroup.com.au/iu Call 1800 763 883 for all of your compressed air needs.
The Wenglor P1MM001 is a reflex light barrier that can reliably detect objects at distances up to 500mm without using a reflector. The sensor needs nothing more than a suitably defined background as a reference, and this could be something like the side panel of a conveyor system. The device has an intelligent function for dynamic readjustment of the switching threshold. This offsets external influences such as contamination and temperature fluctuations, ensuring precise switching performance and less idle time. The use of visible red light makes the
sensors easy to align, and they are easy to set up for any application by simply pressing the teach-in key. The measuring process even detects transparent objects made of glass, PET and sheet materials. And in the beverage industry these sensors can be used to monitor the presence of bottles throughout the entire product lifecycle. Treotham Automation 1300 65 75 64 www.treotham.com.au
IP SURVEILLANCE GOES BEYOND SECURITY Billed as the premier IP surveillance solution for enterprise and commercial applications, the VIP Vision range of IP CCTV systems is available in Australia from Cornick. Whereas traditional CCTV systems were developed for basic security purposes - to deter, detect and record evidence of criminal activity – IP surveillance systems can achieve far more than the security of assets and employees. The VIP Vision range comprises cutting edge products that combine high quality, high performance and high reliability. Systems are based on a choice of network video recorders capable of managing up to 128 channels of video, offering professional video surveillance solutions for small projects through to large commercial, public sector and government level applications. The range of cameras is impressive, with fixed- and motorised-lens cameras
MORE RANGE FOR LASER TRIANGULATION SENSOR The optoNCDT 1750 laser triangulation sensor is now available from Bestech Australia with extended measurement ranges of 500 and 750mm. This is a major addition to the existing 2-200mm measurement range, offering superior performance to its predecessor, the ILD1700.
from 2 to 8Mpixel and a new 12Mpixel option providing better than UHD resolution. For all-round visibility, there is a range of pan-tilt-zoom dome cameras as well as 180 and 360-degree panoramic and fisheye cameras. There is also an extensive range of accessories, including video wall controllers, brackets and adapters, central management software and PoE accessories that help ensure surveillance network integrity. Cornick 1300 307 067 www.cornick.com.au
The 1750 laser triangulation sensor offers extremely high resolution and low linearity deviation thanks to an enhanced algorithm. The sensor also has an RTSC (real-time surface compensation) feature and performs accurate measurement independent of material properties, saving time by ensuring easy commissioning. The new optoNCDT1750 is now compatible with the C-Box/2A controller, replacing the CSP-2008 universal controller, adding the flexibility to interface with analogue and digital outputs. With its fast measurement rate of 7.5kHz, this sensor is suitable for
automated online monitoring in wide range of industries, such as electronics production, packaging, automotive, and machine building. Bestech Australia 03 9540 5100 www.bestech.com.au
Save on cost, not on clean with Nilfisk’s innovative floorcare range
The Nilfisk floorcare range has been designed with your everyday cleaning costs in mind. Whether it’s a large warehouse space or a small convenience store, we have identified the source of some of the most common cleaning expenses and created smart solutions that reduce consumption and noise levels, while making equipment cleaning faster and easier to use. Optimising your time, budget and labour resources – so you can save on cost, not on clean. Find out more at nilfisk.com.au or call 1300 556 710.
THEY SAID IT...
1. What is the densest naturally occurring element, with a density of 22.59g/cm3?
The best industry and political quotes of the past and present:
2 Who was the first Australian to compete at the Olympic Games? 3 … and who was the first medallist? 4 Which US filmmaker, writer, actor, comedian and musician was born Allan Stewart Konigsberg on 1st December 1935? 5 Which team has won the most Premier League titles in England with 13? 6 Which city lies further north: New York or Barcelona? 7 Where in Australia is the Big Potato 8 Who made the first circuit of Australia by air (in 1927)? 9 … and where was he trying to get to when his plane disappeared in 1935? 10 How much is infinity plus one?
15-17 May 2018, Sydney International Convention Centre
NATIONAL DIESEL DIRT AND TURF EXPO 13-15 April 2018, Panthers Penrith, NSW www.dieseldirtandturf.com.au
“What is the difference between a taxidermist and a tax-collector? The taxidermist only takes your skin. ” Mark Twain “One of the key problems today is that politics is such a disgrace, good people don't go into government.” Donald Trump “There can be neither today without yesterday nor tomorrow without today.” Kim Jong-un “Any product that needs a manual to work is broken" Elon Musk
WASTE 2018 CONFERENCE
1. Accepting that at the North Pole it is impossible to look north and at the South Pole it is impossible to look south, where in the world would you be if you couldn’t look east or west? 2. You are in the center of on an island that is a kilometre long and half a kilometre wide. The vegetation is very dry from a long drought. Suddenly it catches fire at one end of the island, and a strong wind is blowing it towards you, burning the whole width of the island. There's no beach, only steep cliffs, and the sea is full of sharks. How can you survive?
3. A man is standing in line at a bus stop with his newly purchased fishing rod. When it's his turn to board the bus, the driver measures his fishing pole and informs him that he can't bring it on board. The maximum length of items allowed on the bus is 4 feet and the fishing pole is 5 feet long The man goes back to the store to return the fishing rod but fortunately the sales clerk is clever and proposes a simple solution that will allow the man to bring his fishing rod on the bus. The man returns to the bus with the same fishing rod and this time the driver allows him to board. The man did not bend, break, cut, collapse, or alter the fishing rod. So what did he do?
whsshow.com.au CEMAT AUSTRALIA
ARBS AIR CONDITIONING, REFRIGERATION AND BUILDING SERVICES EXHIBITION
SECURITY EXHIBITION & CONFERENCE
8-10 May 2018, Sydney International Convention Centre arbs.com.au NATIONAL MANUFACTURING WEEK 9-11 May 2018, Sydney Showgrounds www.nationalmanufacturingweek.com.au
25-27 July 2018, Melbourne Convention & Exhibition Centre securityexpo.com.au ALL-ENERGY AUSTRALIA 3-4 October 2018, Melbourne Convention & Exhibition Centre www.all-energy.com.au
SAFETY FIRST CONFERENCE AND EXPO
WASTE EXPO AUSTRALIA
9-11 May 2018, Sydney Showgrounds
3-4 October 2018, Melbourne Convention & Exhibition Centre www.wasteexpoaustralia.com.au
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3. The man bought a 3 x 4 foot box at the store and placed the fishing rod inside it diagonally. The length of the box (as per the standard way in which it is measured) 2. Set fire to the other half of the island then walk behind the fire on to the burnt ground. 1. At the centre of the earth. Lateral Thinking ANSWERS
1 Osmium, 2 Edwin Flack (Athens, 1896) 3 Flack won gold in the 800m and the 1500m and a bronze at tennis 4 Woody Allen 5 Manchester United 6 Barcelona 7 Robertson NSW 8 Sir Charles Kingsford Smith 9 Singapore 10 Infinity Teabreak Trivia did not exceed the 4 feet maximum so he was allowed to bring it on the bus.
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Published on Mar 2, 2018