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Industry Update


Issue 76 February 2014 $12.00 INC.GST $12.00 INC.GST

Issue 110 October 2019




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The US manufacturing sector is in decline. The Institute of Supply Management's manufacturing index dropped to 47.8 in September, an unexpected fall from the already contracting figure of 49.1 recorded in August. Significantly, the figure is the lowest since June 2009 at the end of the Global Financial Crisis. The decline shows every sign of continuing. The ISM survey reported that US machinery manufacturers spoke of softening demand and reduced backlogs, while food, beverage and tobacco producers said Chinese tariffs are hurting their businesses. While the accelerating fall surprised analysts, even in the USA, there is near universal agreement on the main cause. "Global trade remains the most significant issue, as demonstrated by the contraction in new export orders that began in July 2019," said Timothy Fiore, Chair of the ISM's Manufacturing Business Survey Committee. The Trump administration’s trade war with China is now 15 months old, and it is manufacturing that has borne the brunt of the trade tariffs. Within the latest ISM data, export orders fell 2.3 points to a reading of 41.0 in September, the lowest since March 2009.

The news comes as an inconvenient truth to the US President, who came to power on a campaign to revitalise American manufacturing and bring back companies from off-shoring.

Our specialist bankers are just you are. Get in touch with us t Matthew Kelly

President Trump’s response to the news has been to blame the Federal Reserve for allowing the US dollar to become overvalued, Tweeting: “As I predicted, Jay Powell and the Federal Reserve have allowed the dollar to get so strong, especially relative to all other currencies, that our manufacturers are being negatively affected.”

Manufacturing & Wholesale

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Nonetheless, while the trade war continues, global trade is likely to suffer all round.

slowing economies and a disorderly Brexit could squeeze it even more.

The World Trade Organisation has now cut its forecast for growth in global trade this year by more than half and warns that further rounds of tariffs and retaliation,

The implications for Australian manufacturing are unclear. But it seems that manufacturers in the USA have most to lose.

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While viewing the rough cuts of the first of our documentary videos on workplace safety, I have been staggered by some of the statistics that the production team have gathered concerning workplace fatalities. And frankly they are still way too high. We do tend to think of today’s Australia as something of a “nanny knows best” society: one where you aren’t allowed to take the training wheels off your bicycle until you have logged 200 hours of supervised cycling. Safety checklists abound and site safety inductions become ever longer. Yet still we regularly read stories of negligence and even criminal activity concerning workplace health and safety. And the accident (and fatality) toll continues. Of course, it's all too easy to blame it on decades of the “she’ll be right” attitude to safety that typified the working environment of the last century – along with smoking and drinking on the job and building your own beach shack out of asbestos-laden fibro panels. However, if the safety culture of 20th century Australia was flawed, it’s fair to say that this century’s attitudes are a step in the right direction. Above all, the recognition that there

is such a thing as a safety culture within every company that sets the tone for the behaviour of the workforce is a massive step in the right direction. Likewise, it is essential that management not only “buys in” to the safety culture, but positively promotes it – regardless of the short-term effects on productivity. Clearly, there is no point in devising a safety checklist for personnel to go through before starting a task if ample time is not allowed for the safety checks to be performed. Australia’s industrial safety culture has certainly changed for the better over the past 20 years, and the majority of companies are doing the right thing in impressing the culture on their employees. But the accident statistics and the high-profile prosecutions do not lie. The culture is not universal. Even something seemingly as simple as proper workplace traffic management is not universally applied – and as our documentary video shows, the consequences of failure can be fatal. If it takes shock tactics to bring about change, then so be it. Because nobody should die at work.

These are strange days in which we live. So many of the great trading nations of the world have begun to “shut up shop” that the accepted global economic paradigms are beginning to have a very hollow ring. The post-WWII acceptance that free trade does more to bring nations together and to generate wealth and prosperity for all seems to have been thrown out the window. What has replaced it is a profound mistrust: one that says “this is unfair… we are clearly being ripped off by (insert name here)”. So whether it’s the US President complaining about unfair practices from China or a succession of UK politicians making imaginary cases for how the country would be better off if it didn’t have to deal fairly with the rest of Europe, nations have begun to look inwards.

become comparatively better at doing one of those things we thought was our own. At this point, you either adapt and improve – as Australia’s manufacturing industry has been doing for the past decade - or you throw your toys out of the pram and shout “unfair competition”. So what has this got to do with democracy? Well, as one who comes originally from one of the world’s supposed great democracies (with the mother of parliaments) I cannot go past the simple statistics that while the UK did vote in favour of Brexit by the slimmest of margins (51.9% to 48.1%), the turnout of voters was only 72.2%. Similarly, while a majority of the US electoral college voted for Trump over Clinton in 2016, just 60.1% of those eligible to vote did so.

The classical economists would talk about the law of comparative advantage. This is a very sensible concept. It says you do what you’re good at and you trade what you’re good at with others who are doing what they are good at.

That both these narrowly elected factions find themselves with the keys to dismantle free trade is worrying in the extreme.

Australia has been very successful in embracing this concept. We’re good at things like mineral resources, but not so good at (say) producing consumer electronics. So we trade.

Meanwhile, Australia’s government comes with a mandate from an election in which we all vote because we have to (OK, 90-95% of us do).

Of course, where this whole concept can fall down is at the point where we find out that another nation has stolen our clothes, and has

We understand that world prosperity and even world peace is based on trade. Some, it seems, have forgotten those simple truths.


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DIGITAL DNA ANALYSIS PROTECTS CRITICAL OT INFRASTRUCTURE SYSTEMS As each new revolution has improved production efficiency and output in the manufacturing industry, it has come with the introduction of new threats and risks to critical systems. These advancements that provide a more robust delivery of critical infrastructure have also increased the risk of cyber-attacks, says Simon Masters of Logi-Tech. 80% of manufacturers will have adopted IIoT by 2021, adding more than 50 million connected devices to their infrastructure, dramatically increasing the attack surface. The global cost of cybercrime increased in 2018 to $13m, and 39% of all ransomware attacks targeted manufacturing companies resulting in the loss of hundreds of millions in revenue. Threats such as electrical outages and system downtime impact production and require backup infrastructures and the right protection to keep production lines running. Protection of critical infrastructure computer systems from malware and zeroday exploits is imperative for the success of the business.

The solution One of Logi-Tech’s key partners Digital Immunity has developed a unique

solution to help manufacturing companies remain productive and secure. It provides advanced cyber-threat prevention in operational technology with no impact to production or system performance. This solution requires no downtime, no signature updates, supports airgapped environments in manufacturing/ pharmaceuticals and critical IT removing the need for emergency patching. Digital Immunity works by using a patented digital DNA analysis of code executing in memory, at runtime – blocking any code that has a DNA different from that of the trusted code base. This function helps in identifying and preventing attacks that are disguised as legitimate code, tampered binaries and morphing malware or the introduction of foreign or malicious code, thus hardening mission critical operating systems and applications. Additionally, Digital Immunity’s Control Centre can mobilise your security team with real-time actionable alerts and forensics artefacts in context.

Revolutionary prevention The unique functionality of Digital Immunity is that it is easy to deploy on all

versions of Windows from XP SP1 through to Windows 10 and Server 2003 SP2 to Server 2019. And it consumes on average less than 1% CPU usage. Understanding that the availability of your OT environment is critical, Digital Immunity is deployed without the need of reboots or downtime, ensuring you don’t need to halt your production or modify your existing processes to accommodate a production deployment. This ease of installation ensures you will have rich local threat intelligence in the shortest possible time. Post installation Digital Immunity requires a low overhead for ongoing operations and reduces resource strain that is seen with many competing solutions.

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CONTENTS FROM THE PUBLISHER................... 2

MACHINERY.................................... 26

EMERGENCY LIGHTING................51

BUSINESS & FINANCE...................... 6


PRODUCTS...................................... 52

INDUSTRY POLITICS......................10

SAFETY.............................................. 36



MATERIALS HANDLING................ 40

COMMUNITY.................................. 60

MOTORS & DRIVES.........................18

WASTE & ENVIRONMENT............ 45

FUN & GAMES.................................. 62

WHITE PAPER How to select the right positioning sensor............................... 24





COOLING & FANS........................... 48














INDUSTRY UPDATE MEDIA PTY LTD Suite 403, Level 4, 116-118 Christie Street, St. Leonards NSW 2065 Phone: 02 9439 1288 Fax: 02 9439 3233 Email:

MANUFACTURING MAGAZINE All material in this publication is copyright to the publisher and/or its contributors. No material may be reproduced in part or in whole without the written consent from the Publisher. It is a condition of purchase or acceptance of this magazine that the Publisher does not assume any responsibility or liability for any loss or damage which may result from any inaccuracy or omission on this publication or from the use of the information in this publication or from the use of the information and illustrations contained herein and the Publisher makes no warranties, express or implied, with respect to any of the material contained herein.

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PROFITABLE AUSTRALIAN MATERIALS HANDLING COMPANY FOR SALE An opportunity has arisen to purchase a well-established Australian company with substantial experience, a strong reputation and ongoing contracts in materials handling, manufacturing and warehousing.

The company has built a strong reputation throughout Australia and the South Pacific for its solution-based design and high-quality manufacturing capabilities.

The technology-led company is profitable, and has a consistent annual turnover in the region of $5 million. There is a fully equipped design and manufacturing facility in Sydney with a highly skilled and motivated workforce.

In addition to its own manufacturing operation, the company has long standing supply agreements with European based manufacturers of high-quality specialised support equipment that enhance its value proposition.

There is a further technical sales office in Melbourne and an established sales operation covering all Australian cities and regions plus the South Pacific islands and PNG.

The company’s client list reads like a who’s who of Australian industry from manufacturers, national warehousing and logistics operators to food and beverage processors, and selected parts of the mining sector.

Having built the company to its current size and profitability, the existing directors are looking for fresh challenges in other fields. However, they are fully prepared to work through an agreed handover period to introduce the new management to the company’s technology, its customers and the market. The company would be a good

acquisition for an overseas company wanting to gain a foothold in the Australian materials handling market or for an existing Australian company looking to expand its range of products. In the first instance, interested parties should contact Scott Filby, Publisher of Industry Update, by email: scott@

ON THE UP: AUSTRALIAN MANUFACTURING GROWS AGAIN Positive signs continued for the manufacturing sector in September, with the Ai Group’s Performance of Manufacturing Index rising 1.6 points to 54.7, continuing a sustained run of growth only spoiled by a negative blip at the time of the federal election. The underlying data provide mostly positive signals, with employment up 6.2 points to 57.6 and new orders up 3.8 points to 57.1. However, production, sales and exports all eased to roughly parity, coming in at 49.8, sales 49.5 and 49.6, respectively.

Encouragingly, of the sectors, it was machinery and equipment that registered the greatest gains, rising 2.5 points to 56.7, largely on the back of increased demand from the mining and defence sectors. However, the PMI report also points out that some manufacturers reported that a number of large infrastructure projects have begun to progress, after months of delays, increasing their tendering opportunities. The food and beverage sector

continues its steady growth (up 0.2 points to 59.2), and the report highlights ABS data that the sector not only accounted for 27% of manufacturing real valueadded output in the year to Q2 2019, it also accounted for 27% of manufacturing employment over the same period. Announcing the results, Ai Group Chief Executive Innes Willox said: "While sales and production were down in September, the lifts in employment and new orders are encouraging pointers for coming months – particularly as the

favourable impacts of income tax cuts, interest rate falls and the lower Australian dollar continue to build." However, the one dark cloud on the horizon is the continuing disparity between input prices and selling prices. The input price index rose to a year’s high of 71.9, while the selling prices index fell back to 48.9. Some of the manufacturers surveyed reported that increased import competition is restricting their ability to pass on input cost increases.

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ARE SOFT SKILLS THE ANSWER TO GETTING PAID ON TIME? Polite people don’t talk about money. As Kristin Wong wrote in her New York Times article How to talk about money, “...many of us grow up learning that money is one of a few topics — like politics, sex and religion — that you should avoid in polite company.” This social taboo adds an extra layer of complexity for accounts departments in small to medium enterprises when speaking to their creditors, and it is costing businesses dearly. “Late payments are taking their toll with nearly a third (31 per cent) of small business owners in Australia estimating their company currently has more than $20,000 in outstanding receivables,” according to Cec Busby in Cash flow issues putting almost half of Australia’s SMBs at risk. Cashflow is critical, nothing moves without it. ASIC states that poor cashflow is cited as a factor in 40% of business failures. Which means the important topic of cash flow needs to move further up the company agenda. So, how do we ask about something that isn’t socially acceptable to speak about? It's important that this interaction builds rather than strains relationships with customers. Yet, most companies leave this critical task to someone in the accounts department who: A) has never been properly trained to do the task, B) avoids the task in favour of other accounts duties, and

C) would rather clean out the office fridge than call someone and talk about an overdue invoice. Think about how credit control is conducted in your company. For most companies, credit control and accounts in general are not seen as part of the sales process or as customer engagement. They are often referred to as if they exist on a solitary island. We see credit control as a success-defining element of a customer-centric approach to customer service and sales. As Industry Update Publisher Scott Filby wrote in his article Why are we waiting? “Companies only grow by re-investing their profits, and they can’t do that until they get the money to which they are due.” Citing a survey by Xero of Australian businesses Scott wrote “Small to medium businesses are losing access to as much as $7 billion a year” thanks to Australia’s larger enterprises paying invoices late. Investment in people is as important if not more so than investment in the new shiny toys of automation and AI - and credit control is all about people. It is the human touch and the relationships built from the very first interaction with a customer that will determine that state of your cashflow. If you are only thinking about this when an invoice is 31 days overdue - it’s too late. Is it your own processes and mentality that are

teaching your customers to pay late? Equipping your staff with some essential soft skills and techniques can make a huge difference. Here are a few tips to help you: 1 Introduce your credit controller to your customer directly after a deal is signed. 2 Make credit control a legitimate and acceptable business activity rather than a hidden task. 3 Make sure the responsibility for account management is clear – and what is expected from all parties. 4 Give the accounts team authority to deal with the sales team. Too often sales override accounts leading to extended credit lines, which can be fatal if credit is over extended. (Remember, a sale is not a sale until the money is in the bank.) 5 Equip those responsible (this might even be you) with the skills required to do it right. This can include attitude and voice skills, negotiation skills to work through difficult situations, the ability to work with sales team, and simple techniques to approach the situation with confidence. 6 Incentivise team members who are a part of successful collections. 7 Stay on top of outstanding invoices and view the customers that pay late as an opportunity to re-evaluate your customer relationships. In short, it’s about taking responsibility for

all aspects of the business and the business relationships you and your company have. At the end of the day, customers will respect you and want to do further business with you if you are clear about expectations from the beginning. What separates a professional from an amateur? The professional gets paid. Sarah Jane Miatt is inspired daily by the power of people to thrive when equipped with excellent soft skills to think strategically, communicate their ideas and work collaboratively. Soft skills complement STEM skills by creating charismatic, influential leaders. Sarah sees the potential for a bright future for Australian manufacturing, and views embracing diversity (women, LGBTQIA+ people and differently abled) as a key part of this new post-industrial environment. Investing in soft skills enables us to compete on a global level in industry 4.0. Sarah gets a daily kick out of seeing the tangible results for her clients at the Australian Institute of Soft Skills (AISS) Training, from increased productivity to increasing cash flow to reducing staff turnover. It’s all about the ROI.

SMALL BUSINESSES EXPECTING GROWTH, BUT FACE BARRIERS According to the latest Westpac Small Business Report in collaboration with Deloitte, Australian small businesses are looking forward to financial growth in the next 12 months because of improved economic and political certainty after recent tough conditions. However, many are reluctant to hire staff due to too many policies and procedures. 
Although small businesses are matching the wider economy in growth terms, they are falling behind in increasing their workforces, with 31 per cent of respondents employing fewer people than 12 months ago. 
 The most common hurdles to hiring are financial (38 per cent), only needing help occasionally (28 per cent), and wages and penalty rates (24 per cent), suggesting that more support is needed across industry and government to help businesses break down employment barriers. 
 “Many small businesses faced tough conditions over the last six months with a slowing



economy and tightening margin pressure. However, there is some light at the end of the tunnel which can help boost employment,” Westpac General Manager of SME Banking Ganesh Chandrasekkar says. 
“Given recent RBA interest rate cuts, a boost in infrastructure spending and a better-looking housing market, many small businesses say they are optimistic about the coming 12 months. 
“One way to boost confidence back into the market is to remove the complexities and challenges small businesses face when it comes to hiring. If every employing small business took on one additional staff member, that is 900,000 jobs. Even if we could create a fraction of that amount by removing employment barriers, it would make a big difference.” To supplement household income, one third of small businesses have taken on a second job or ‘side hustle’, revealing that their most common fear is having no financial security. This is particularly

common among non-employing businesses (41 per cent), female small business owners (40 per cent compared to 25 per cent of males) and industries feeling more exposed in the current environment such as agriculture (52 per cent) and the arts (45 per cent). Many small businesses are taking advantage of the gig economy to embrace on-demand solutions that provide flexibility and easier access to casual employees, and it’s growing quickly, increasing 68 per cent in revenue terms in one year in NSW. However, 20 per cent of small business owners have no income other than their business and 15 per cent would lose equity in their home if their business were to fail. The average small business household gets 63 per cent of its income from the business. “This places an extraordinary amount of pressure on business owners, their families and employees, for the business to perform,”

Chandrasekkar says. “With over half of Australian small business owners using their personal savings to establish their business, this can have a deep impact on their mental and financial wellbeing. “At Westpac we approve 93 per cent of lending requests received. Despite this, two in three business owners do not request funding, leaving many small businesses cash-strapped. Before taking on a side hustle or putting undue stress on yourself, know that Westpac is here to help with $30 billion ready to lend to small businesses for the right investments.” From the beginning of 2020, Westpac is expanding its unsecured lending offer to help more small businesses access funds to manage growth and cash flow when they need it most. It’s estimated an extra $10 billion will be available in unsecured, conditionally approved limits, without the need to put up other assets as security.


As fired up about manufacturing as you are Our specialist bankers are just as passionate about the manufacturing industry as you are. Get in touch with us to see how we could help fire up your business. Matthew Kelly Manufacturing & Wholesale

Head of Manufacturing & Wholesale 0412 265 197

ŠSt.George Bank - A Division of Westpac Banking Corporation ABN 33 007 457 141 AFSL and Australian credit licence 233714.



By Hon Karen Andrews MP

Australia will always be a manufacturing nation. It’s become a bit of a go-to phrase for me recently but I want people to know the sector’s continued success is important to me and to the Prime Minister. Growing our manufacturing industries is a key part of the Morrison Government’s plan to deliver 1.25 million new jobs over the next five years. To achieve this, we need to continue to develop our core and emerging manufacturing industries, and investing in new technologies is central to this mission. We must keep pace with the latest technology and skills to remain competitive, building on our strengths to further cement our position in the

global marketplace. Business must take the lead, but the government has a vital role to play as an enabler. That is why in September I launched the $160 million Manufacturing Modernisation Fund. The fund includes $50 million from government and will be matched by at least $110 million from industry. The fund will provide grants to small and medium manufacturing businesses so they can invest in capital equipment and new technologies to modernise and employ more Australians, particularly those in regional and outer-suburban areas.

as 3D printing, robotics, artificial intelligence and nanotechnologies. The fund will also support businesses to upskill workers to maximise the benefits of new technologies.

It will cofund investments in transformative technologies such

The Manufacturing Modernisation Fund includes:



• $20 million for matched grants of between $50,000 and $100,000 for smaller scale technology and efficiency investments.

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In the discussions I have had with the industry and technology communities in recent months it is clear government and industry agree that we need to harness the power of

The Manufacturing Modernisation Fund is open to applications until 31st October 2019. • $30 million for larger-scale grants of $100,000 to $1 million, on a three to one funding basis, to support transformative investments in technologies and processes.

Demonstration Unit Available Contact Tente Castors & Wheels for further information 1300 836 831

CSIRO’s Australian National Outlook 2019 report has predicted that the manufacturing sector could contribute 25.6 per cent in additional GDP growth between now and 2060, the largest contribution from an industry sector.

We expect the fund to support around 350 businesses over the course of its lifetime and have a positive impact on the economy through increasing the competitiveness of Australian manufacturing businesses and ensuring manufacturing jobs. Manufacturing is vitally important to Australia. It creates value across the economy through its demand for research and development, design and engineering services, production, logistics and after-sales services.

technology to grow our economy. Combined with other government initiatives like the $100 million Advanced Manufacturing Fund, the Advanced Manufacturing Growth Centre, the Entrepreneurs’ Programme, and the $40 million Innovative Manufacturing Cooperative Research Centre, we are walking the walk when it comes to manufacturing. It’s essential to ensuring ‘Australia will always be a manufacturing nation’ remains more than a slogan.

The Hon Karen Andrews MP is Minister for Industry, Science and Technology.




By Brendan O'Connor

The latest data from the Australian Bureau of Statistics paint a fairly sombre reflection of the Australian manufacturing industry, begging the question: what is the Morrison Government’s plan to help manufacturers to grow and become globally competitive?

Monthly Business Survey for August 2019, with a decline in business conditions across industries.

Each day that passes, it is becoming more apparent that either there isn’t a plan or if there is, it’s not working.

The Liberals’ lack of an economic plan is leaving Australia, and particularly manufacturing, dangerously exposed to turbulence in the global economy.

The data for the August quarter reveal a record low number of Australians holding a job in the manufacturing industry and a record low number of people employed full time in the manufacturing industry, down 100,000 in 12 months. This, from an industry with a history of decent full-time jobs, is concerning. There are some bright spots, with the Ai Group’s, Performance of Manufacturing Index for September showing strength in the food and beverages, and machinery and equipment sectors of the industry. However, for the past six years, I have been struck by an abundance of rhetoric but an absence of urgency from this government to strengthen industry conditions. Just last month, Labor reignited calls for the Minister for Industry, Science and Technology, Karen Andrews, to act and stop local vitamins and mineral supplement manufacturers being stripped of their ability to use the iconic Australia Made logo. The government’s inaction on this issue has threatened an industry worth $5 billion to the Australian economy and put close to 30,000 jobs at risk. It was only following pressure from industry and Labor that the government presented an interim regulatory change; however, no details have been made public on a timeline for properly fixing this issue. The grim manufacturing statistics I mentioned are not specific to the manufacturing industry, in fact there are slowing economic conditions nationally – a struggling jobs market and low wages growth. More than 1.8 million Australians are underemployed and there are at least three unemployed Australians for every job vacancy. Business confidence and conditions have deteriorated under the Morrison Government, according to the NAB


The RBA cut interest rates again to 0.75 per cent in an attempt to drive down the unemployment rate.

Australia has a future as an advanced manufacturing nation with capacity for major growth. An advanced economy needs an advanced, innovative and highly skilled industrial base. This requires strategic leadership from government as well as a partnership with business and workers. It doesn’t require a reduced investment in research and development, which impacts Australia’s capacity for innovation, economic diversity and new jobs. We are witnessing the continuation of an overall downward trend in R&D under this Government’s watch. Business R&D spend has hit 0.9 per cent of GDP, falling below 1 per cent of GDP in the previous data (2015-16).

Local Projects, Local jobs plan that would see more government procurement and investment in major projects spent on local businesses and local jobs, to name a few. We also committed to lifting research and development investment to 3 per cent of GDP per annum by 2030, to ensure manufacturing has the best scientific and research expertise available. Australia’s manufacturing industry is facing challenges, but what it needs is a government willing to back them. Not one that says we can’t afford a manufacturing industry. As the new Shadow Minister for Industry and Employment, I want Australia to be a successful advanced manufacturing nation. Lifting skills to ensure the workforce is prepared for the jobs of the future is crucial to future employment security and

better wages. It requires bipartisanship and collaboration, none of which can be achieved without leadership, a plan, and vision from the current government. There is no doubt in my mind that a strong, diverse and agile manufacturing sector is critical to Australia’s future.

Brendan O'Connor is Shadow Minister for Industry and Employment.



As a recent Australian Institute of Company Directors report noted, Australia’s total gross domestic spending on R&D is currently ranked 21st within the OECD and that while the global trend is for national business expenditure on R&D to grow, Australia’s has fallen. As such, Australia’s investment levels below countries such as South Korea, Israel, Sweden, Denmark, Finland, Iceland, Norway and Singapore. Research and development is fundamental to Australia’s future industries. That’s why Labor set a goal of increasing the share of gross domestic product devoted to research and development to the last election. If the Morrison Government was serious about helping manufacturers to grow, become competitive globally and develop new technologies they would be investing in R&D. Labor took a comprehensive plan to support local manufacturing firms and jobs to the last election. While all of our policies are under review, it is worth remembering some key initiatives, such as the $1 billion Advanced Manufacturing Future Fund, the Australian Investment Guarantee, the


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HYDRAULICS ON THE CREST OF A WAVE highly applicable to the Emirates Team New Zealand team, which will be doing everything it can to stay in front during the America’s Cup.

25 years of sailing innovation By its very nature, the America’s Cup is a secretive business, but behind the curtains, Hydraulink has worked in partnership with Emirates Team New Zealand for the past 25 years and five campaigns – following the 1995 watershed victory in San Diego. Hydraulink has been at the coalface of hydraulic design and advice, from the monohulls to foiling catamarans and back again to the current AC75 class, which is the most stringent test of the company’s bespoke hydraulic hose assemblies and fittings connecting all the hydraulic systems on board. The recent move to foiling class catamarans in San Francisco then Bermuda has showcased on a global stage the new hydraulic technology and its capability to push the limits of speed, pressure and safety. The powerful hydraulics that have powered Hydraulink’s customers’ machinery for years are about to step onto the glamorous stage of the greatest yachting show on earth. In a hydraulic odyssey every bit as technical and challenging as engineering hydraulics for the most complicated industrial machinery, the Hydraulinksupplied Emirates Team New Zealand yacht has been officially launched this September, as it prepares for the 36th America’s Cup in 2021. In one of the world’s most complex and advanced sports engineering projects, Emirates Team New Zealand will be aiming to defend the 36th America’s Cup with its ‘yacht of the future’ designed for enhanced speeds, control and precision. For the upcoming 36th America’s Cup taking place on Auckland’s Waitemata Harbour, Hydraulink’s 25-year Official Supplier partnership with Emirates Team New Zealand will continue – this time with the most advanced hydraulic systems to-date. “Emirates Team New Zealand’s new AC75 class features huge advances on anything that has gone before. For



example, the boat will use a world-first cantilever system whereby no keel is needed. The foils arms are raised and lowered using a battery powered power pack replenishing an accumulator which provides instant pressure to raise and lower the foil arms in around 3 seconds,” says Hydraulink Director and yachting enthusiast, Lee Short. “The other hydraulic systems on the boat for adjusting the sailing functions are all run on a different hydraulic circuit powered by the several on-board crew members called ‘grinders’. Their role is to operate manual pedestal winches (called ‘coffee grinders’) that power the pumps that provide the pressure for all other systems. It is a physically demanding role with a significant impact on a racing yacht's overall performance,” says Short.

Pushing the limits again September’s early morning unveiling at Emirates Team New Zealand’s Viaduct base was a sneak peek for the public at the sleek body of the new foiling monohull and its four metre foil arms with attached foil wings, which have dramatically changed the America’s Cup in 2021.

“The world saw from previous Cups in San Francisco, and then in Bermuda in 2017, what’s possible on the water with catamarans, and for the upcoming showcase Emirates Team New Zealand and Hydraulink are once again at the cutting-edge of America’s Cup innovation with the new AC75 class,” says Short. The presentation of Te Aihe or ‘Dolphin’ as Emirates Team New Zealand’s flagship boat was the moment to highlight the work of over 100,000 man-hours from a team of 65 in the design and build department. The boat and its foil wings, which will help the boat to lift out of the water, are a testament to Kiwi innovation, constantly pushing the limit of technology.

The foil cant system (FCS) is the driving force of the new AC75 class. This FCS is standard on each boat and identical sets of Hydraulink fittings and hose assemblies have been supplied to every team to operate this complex system. Each set of hose assemblies is constructed, tested and certified by Hydraulink using its brand-new test rig capable of pressures up to 4000bar. Hydraulink is also supplying Emirates Team New Zealand exclusively with its other independent systems on board as the boats prepare to hit the Waitemata sailing at 50 knots (90kmph) in March 2021.

“Hydraulink’s innovation, drive and cutting-edge technology is well respected throughout industry worldwide. With the increased emphasis on complex hydraulic systems, Hydraulink is relishing the opportunity to once again be racing against world technology leaders,” says Short.

With design pressures up to 500bar, these boats simply won’t sail if their hydraulics don’t operate efficiently. Hydraulink’s successful partnership with Emirates Team New Zealand has led America's Cup Events to use Hydraulink’s hoses and fittings for each team’s foil cant system for the 36th America’s Cup.

The name Te Aihe (Dolphin) is based on the Maori proverb: "As the dolphin soars through the seas so does a leader sew people together”. The proverb is

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STORAGE BATTERY MANUFACTURER IS A TRUE AMBITIOUS AUSSIE million worth of energy storage systems expected to be manufactured at the company’s Darra facility in Queensland over the next four years, RedEarth is on track to achieving its goal of becoming one of Australia’s leading energy storage providers. RedEarth cofounder and CEO Charles Walker says the Australian Made certification marks an exciting milestone: “As Australians adapt to the new electricity paradigm (we call it “Electricity 2.0”) and rooftop solar continues to boom, we are proud to provide a genuinely Australian product, which are superior on both quality and price. “With foreign products currently dominating the Australian energy storage market, we are pleased to be delivering an Australian Made alternative that supports the domestic economy,” he adds.

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RENEWABLES AND ENERGY EFFICIENCY SHOW UP NEXT YEAR IN SYDNEY The Clean Energy Council has teamed up with Reed Exhibitions Australia to launch a new industry exhibition focusing on the latest renewable energy and energy efficiency technology. The Energy Next show will be held for the first time on 14th and 15th July 2020 at the International Convention Centre Sydney alongside the Clean Energy Council’s annual Australian Clean Energy Summit. Energy Next will showcase the latest renewable energy and energy efficiency solutions from lighting to insulation products, energy monitoring and metering, energy storage, solar and wind energy, distribution networks, project development and low-carbon transport. Seminars, practical workshops and networking functions will also be held on the exhibition floor, providing visitors the opportunity to learn more about the transformational energy solutions to solve their renewable energy challenges.

Kane Thornton, Chief Executive of the Clean Energy Council, says the show will compliment the Australian Clean Energy Summit as a leading industry hub for clean and renewable energy industry engagement. “Announcing the inaugural edition of Energy Next for 2020 is incredibly exciting, especially following the completion of another highly successful Australian Clean Energy Summit at the end of July. “The colocation of Energy Next with next year’s event will generate even further conversations and connections to improve clean energy generation and adoption. “We are proud to be partnering with Reed Exhibitions Australia to offer NSW based organisations a clean energy event, which is timely due to the unprecedented boom in wind and solar projects and New South Wales’ target of zero net emissions by 2050.”

According to Robby Clark, Exhibition Director at Reed Exhibitions Australia: “Energy Next will support the Clean Energy Council’s Australian Clean Energy Summit from 2020, to support clean energy adoption and energy efficiency improvement in New South Wales, which is particularly relevant with over 600 multinational companies and 90 renewable projects valued at $20 billion in the pipeline within the state. “The event will be relevant for

installers, manufacturers, distributors and suppliers across utilities, energy management, energy storage, onsite renewables, off-grid applications and smart grids by offering access to the leading innovative solutions and approaches to enhance their clean energy usage.” Energy Next 02 9422 8921

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ENERGY EVENT TO FEATURE LEADERS AND STARTUPS This year’s All-Energy Australia event is set to feature the largest exhibition in its history, with more than 290 industry leaders and innovative startups to showcase their transformative energy solutions. Under the theme “Advancing Australia’s transition to a clean energy future”, the event will also feature a conference with 200 speakers across seven streams. The industry event has been strategically developed to support and educate professionals working or investing in the renewables sector, having attracted more than 8500 local and international industry visitors in 2018. “The clean and renewable energy sector continues to grow from strength to strength, as Australia continues to increase integration and reliance on these energy sources,” says Robby Clark, Exhibition Director at Reed Exhibitions Australia. “With the industry spurring Australia’s progression to zero emissions, we are excited to be able to offer visitors access to the latest innovative clean and renewable energy solutions, on our largest exhibition floor to date,” he adds. A number of international energy suppliers will feature on the exhibition floor at All-Energy Australia 2019, including Growatt, a leading global PV manufacturer that produces a range of smart energy storage solutions for on-grid and off-grid applications, and SMA, a global photovoltaic system technology specialist. Rex Wang, Product Manager at Growatt, explains: “As the number one residential solar inverter brand in China, Growatt is excited by the opportunity to showcase our range of solar energy solutions, from inverters to energy storage solutions for on-grid and off-grid applications, at All-Energy Australia 2019. “At the event, Growatt will be launching our new battery-ready X series residential inverter, the MIN 2500-6000 TL-XH. This inverter has a battery interface that easily integrates into an existing storage system to eliminate retrofit costs and is a perfect option for homeowners, looking to convert their rooftop PV systems into solar storage systems in the future.” John Susa, Executive Vice-President of Global Sales & Service, SMA Solar Technology adds: “We are excited to introduce our latest SMA Energy Systems for home, business and large-scale at the upcoming All-Energy Australia 2019. For large-scale segment, we will launch the most powerful PV inverter, the


brand new 1500V DC-coupled Sunny Central UP, which enables significant cost reductions on transportation, installation, commissioning and service as well as operation costs of PV power plants. “We also bring the new SMA Sunny Tripower Storage 60, the new battery inverter for business applications together with SMA Energy Storage-Business to the Australia market as the perfect solution for commercial and industrial storage solutions. SMA is committed to powering Australia by leveraging its German Engineering with SMA 360-degree Business Support to contribute to both our customers’ success and a sustainable green future.” Many local and international exhibitors both will be displaying their energy market solutions, from virtual power plants to embedded networks, solar batteries and solar energy storage solutions. According to Patrick Matweew, Chief Executive Officer, Redback Technologies, his company’s presence at All-Energy Australia will focus on showcasing its advanced energy solutions: "We're excited to show our next generation of advanced energy solutions at this year's All-Energy Australia. Redback is offering a whole new suite of data-enabled products and features that create value for a wide variety of customers in the energy markets including consumers.

Marketing Director Daniel Mahoney says: “At Social Energy, we’ve had Australia as a critical market on our roadmap for dynamic energy storage for a number of years. Now off the back of taking over 50% market share in the UK of the solar coupled storage industry, we’re extremely excited to be launching our operations in Australia, alongside our partner Duracell, exclusively at All-Energy Australia. “The 23rd October will mark our official launch in the Australian market, with a world-leading management team already in place for Social Energy Australia. We will be showcasing the Duracell Energy Bank v2, connected to our domestic VPP platform, capable of cutting customers’ electricity bills by up to 70%. “Our launch celebrations continue with a night-time event on the 23rd with a special appearance from our shareholder and brand ambassador Shane Warne. We look forward to seeing many faces from the industry and revealing the future of energy storage and electric vehicle

charging throughout AEA.” All-Energy Australia will be held from 23rd and 24th October 2019 at the Melbourne Convention & Exhibition Centre. Free registration is available at:

“Our team will be demonstrating the capabilities of the Redback Energy Platform, which includes Virtual Power Plants, Embedded Networks, network safety and much more." James McLaren, Managing Director at startup Newton Aqua, describes his company as an innovative clean technology company that specialises in the generation of renewable energy and the desalination of water. “We are especially pleased to be participating at our first All-Energy Australia Exhibition and Conference,” he says. “This exhibition is an excellent opportunity to showcase our unique technologies to industry, potential customers and the general public. It is our mission to apply our innovative renewable technologies to supply the world with clean, reliable and affordable water and energy.” In addition to the numerous product and brand launches featuring at All-Energy Australia 2019, Social Energy will launch its Australian presence, having been founded in the UK seven years ago and achieving the largest market share for solar systems installed in the UK since June.




THE SWEET TASTE OF SUCCESS actually use that power for another axis.” This means that if one axis is slowing down or putting power back into the DC bus, other axes can use that power. With effective project planning, this makes it possible to have a smaller power section than the collective sum of the control axes, if all axes are not motoring simultaneously, offering a significant savings from an OEM perspective. Aside from the smarter power solutions, and compact design platform, the Movidrive Modular also provides performance enhancements with motor resolution of 65Kpulse/rev, which has proved to offer exceptional motor performance. Another important aspect for implementing this hardware was the integrated safe circuit with level PLe performance.

When a US candy manufacturer needed a specific machine to make soft gummy candies it once again turned to JH Tester, an Australian company that had been providing it with machine control solutions for more than 10 years.

kinematic models that cover a broad range of mechanical configurations. Data are stored via a data exchange function on a memory card in the MOVI-C controller.

Located in the western suburbs of Sydney, JH Tester Industrial Automation has been in operation for over 35 years. Family-owned and operated, the company was started in 1980 by John Tester providing technical service and support to the textile industry.

“We’ve had a very close relationship with SEW ever since they entered the variable-speed drive market in Australia – around 30 years ago. The quality and reliability of their products and services make them an obvious choice for us,” says Tester.

Over 20 years ago, JH Tester switched its focus to the design and manufacture of automated systems for a variety of sectors, including manufacturing, food and beverage, building, mining, infrastructure, and water processing.

The Movisuite software package offers a powerful but flexible programming package that provides planning, commissioning, operation and diagnostics software, electronic control and monitoring devices, mechanical drives and gearmotors in an all-in-one solution. All components can be fully integrated into most automation concepts, fieldbus topologies and network standards.

All drive functions of the motion control topology are available in the module automation topology. In addition to the graphical editors for the drive functions, automation tasks associated with the higher-level master controller can also be implemented in part or in full using the programming system in the MOVI-C controller.

“Our specific strength is motion and motion control – anything that has servo controls is our sweet spot,” says Tester. “And we also have strengths in PLCs and HMIs. We pride ourselves on providing innovative simple automation solutions to often complex challenges in the manufacturing sector.”

Four modules – one solution Designed and built in Australia, the confectionary machine features 18 MOVI-C Movidrive Modular axes controlled by the SEW Eurodrive MOVI-C Controller motion platform.



The MOVI-C Controller motion platform receives setpoints for single-axis or coordinated motions, and determines the motion path for the connected application axis, thereby taking care of tasks such as phase-synchronous operation, an electronic cam function or kinematics. Predefined software modules are used to implement the motion control drive function quickly and reliably with the aid of graphical editors. There are more than 50

Tester says: “The all-in-one integrated features of the MOVI-C motion package made it an obvious choice for the project.” “Because it is a highly integrated solution, the MOVI-C was perfectly suited for this specific confection machine application, the heart of which was the motion platform that our internal software design engineer developed,” says Tester. “The MOVI-C is a neat package – it is a compact practical solution. Because of the Movidrive Modular dual-axis control mounted in one hardware platform, you don’t need vast cabinet space to house it. Moreover, it reduces the switchgear and auxiliary components required.” And, he says, it is also highly energy efficient. “It shares a common powerbase, which means that if any axis is in regeneration, or generating power, I can

The simplicity of the MOVI-C Movisuite software package allowed easy integration for the entire hardware package. “It also has only one platform to program for the 18 axes – it uses a common master virtual encoder to coordinate many axis, making it highly coordinated,” says Tester. “The end product, in this example the confection machine, is therefore highly user-friendly and meets our standard for creating simple solutions to complex challenges.” Tester adds that the MOVI-C application enables particularly high rates of productivity, with the confection machine capable of producing as much as 2.5 tonnes of candy per hour. The centrally coordinated multiple electronic cam curves enable multiple axis synchronisation for a virtual axis. “Because it is a highly integrated automated solution, we have very precise cam arrangements. While, normally, you’ll see clients using mechanical cams, we are using electronic cams to more effectively tie axes together,” he says. “And the cams can be changed on-the-fly, which allows configuration of the machine while it is actually working. It means that we can change and modify the cam while the motor is running, modify the time unit of the machine and modify the lathe profile of the pumps during operation. These things are ordinarily very difficult to do while a machine is in motion. So on-the-fly updating of cams is a big advantage in this package.” If there are issues with the drive, they can be swapped for others, while the SEW MOVI-C controller can download the parameters in the drive and reconfigure a drive with a minimum of disturbance.



Using the latest technology integrated into the MOVI-C product range has provided many advantages for JH Tester. “We were ahead of the market using such innovative new technologies. We have had a close relationship with SEW for a long time now, and they’re a great company to work with,” says Tester. “As we develop new solutions with their products, we are now piloting many advanced and cutting-edge industrial automation solutions with SEW. So, it is a very fruitful relationship that works very well for both of us.” The MOVI-C’s Ethernet connectivity also means that JH Tester can also deliver high-level after sales support with remote access. “We remotely monitor the machine and make sure it is functioning efficiently and as designed for purpose.”

Inside the candy machine control cabinet

“This kind of flexibility eliminates downtime. You don’t have to stop the machine to load up a cam profile,” Tester

says. “And this, once again, creates higher productivity and higher efficiency in all sorts of ways.”

Indeed, customer service and support on both a local and international level is something that JH Tester prides itself in providing to the manufacturing sector. “We reduce complexity in what can be very complex systems; we’ve simplified the cabinets; we provide high speed communications on the motion platform. The resultant benefits are simplicity and

power,” says Tester “And, using the MOVI-C, it is very configurable for the end client: it is a stable, reliable, powerful platform that is energy efficient, that doesn’t stop when we change cams, that gives you real-time statistics on what it is doing, as well as realtime power consumption and real position monitoring of every axis. SEW uses ‘smart’ IoT enabled-encoders, so positional data is retained during a power cycle,” Tester adds. According to Darren Klonowski, National Product Manager at SEW Eurodrive the innovative MOVI-C automation system is a game changer. He says: “MOVI-C is the complete solution for your automation tasks. With the four modules, Movisuite engineering software, MOVI-C controller technology, compact or modular inverter technology and centralised or decentralised drive technology, SEW Eurodrive provides a comprehensive modular automation solution from a single source.” SEW-Eurodrive 1300 739 287

Take control of your productivity and safety Control solutions provide manufacturers with the ability to stay competitive by keeping costs down and maintaining productivity, while still adhering to the latest global safety standards. The Allen-Bradley® Compact 5000TM Safety I/O can be integrated with the next-generation high performance Allen-Bradley® Compact GuardLogix® 5380 controller to deliver a scalable, in-rack, high performance safety solution. It can also be used on a distributed I/O platform with the use of an Allen-Bradley® 5069 Compact I/OTM EtherNet/IP adapter.

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CONDITION AND TORQUE MONITORING SYSTEM TO OPTIMISE MACHINERY UPTIME Schaeffler has combined two of its proven measuring technologies to create a new condition and torque monitoring system particularly suitable for rotary and adjustment drives in the wind power and shipbuilding industries, in large cranes and construction and in mining machinery with turrets and winches. The combined applcation of Schaeffler’s SmartCheck and TorqueSense technologies – both available throughout Australia and New Zealand – was highlighted this year at Hannover Messe, which is the world’s leading trade show for industrial technology, attracting typically 6500 exhibitors and 250,000 visitors, with a strong focus on Industry 4.0 technologies. SmartCheck from Schaeffler Australia is a compact, innovative, modular online measuring system for continuous monitoring of machinery and process parameters on a decentralised basis. It can be used on assemblies where such monitoring was previously too costly.

Schaeffler’s TorqueSense torque measurement module offers a mechatronic solution that allows applications and processes to be monitored and controlled with significantly greater precision, as the

The new combination exhibited at Hannover Messe is one in which a machine’s torque signal can be used for both monitoring and for smooth and precise torque control and regulation of pull cables. The combination system is the product of the long-term development partnership between Schaeffler and Bonfiglioli, which is a global market leader in yaw and pitch drives for wind turbines. This partnership led to the creation of a compact Industry 4.0 solution package, says Schaeffler.



torque is recorded right where it is applied.

In addition to the vibration diagnosis system of the Schaeffler SmartCheck detecting incipient damage at a very early stage, the new combination can detect and limit peak loads and frequencies using the precise torque signal.


Using algorithms that are based on its extensive application expertise, Bonfiglioli converts such data into information throughout the entire lifetime of a wind turbine, for example. Thus, online reporting on relevant performance indicators is provided, for example including the general “health” status of the geared drives, possible critical conditions, and abnormal behaviour of the yaw systems due to predictive monitoring. In total, customers benefit from reduced unplanned downtimes as a result of overloading or unexpected operational conditions of the system and load-based (ie generally longer) maintenance intervals. The Schaeffler SmartCheck device performs frequency-selective condition monitoring of bearings, gearboxes, electric motors, pumps, fans, and machines based on solid-borne vibrations. Conspicuous frequencies can be automatically attributed to damaged components using only



one Schaeffler SmartCheck device. A temperature sensor is also integrated into the device. The torque signal and speed signal of the Schaeffler TorqueSense are sent, preprocessed and supplied to the machine control system and/or maintenance department with the vibration signals that are also analysed via the SmartCheck. The addition of operating data on torque and speed to the SmartCheck condition monitoring system opens up several new scenarios. In the simplest case, the system allows the monitoring of torque peaks and their frequency and thus an evaluation of the utilisation level and the derivation of loadbased maintenance measures. The signals can also be integrated into the operating strategy for drives and initiate torque limitation or shutdown functions. Schaeffler’s Australia’s digitalisation initiatives are available through nine company locations across Australia and New Zealand, which deliver proximity to market while connecting Schaeffler Australia with the experience and resources of the global Schaeffler Group. This includes the new digital transformation team assembled by Schaeffler Australia Managing Director, Andre Kluge. Based at Head Office in Sydney, the digital transformation team is already involved in partnerships with major companies, with which commercially confidential large-scale projects are underway. Schaeffler Australia 02 8977 1000



ANIMAL FEED SPECIALIST FINDS THE RECIPE FOR SUCCESS Rabar is a leading manufacturer and distributor of commodities and premixes for the animal feed industry. From its facilities in Southern Queensland and NSW, the company produces custom formulated vitamin and mineral premixes and “macro” mixes both in powder and pellet form.

Safety is provided using the Omron NXSL3300 modular safety controller optimised for high-speed, high-precision motion control, coupled with the NX I/O standard and safety protocol that enables flexible configuration by mixing the safety units with standard NX I/O. The motive force is provided by Omron MX2 variable-speed drives on EtherCAT, an advanced micro drive frequency inverter developed to harmonise advanced motor and machine control.

Established in 1989, Rabar supplies its extensive range of nutritional supplements to farmers throughout Australia and some products to New Zealand and the Pacific Islands including PNG. For nearly three decades, the company used paper spreadsheets to maintain its batching records and associated data. This out-dated system was time-consuming and costly; and, worse, prone to inaccuracies and human error.

The end result is a fully automated state-of-the-art system designed for maximum flexibility.

data handling capabilities.” The open architecture of the system now gives Rabar the option of using the system integrator (Pac Technologies) for ongoing support as it is not a closed or proprietary system. Kim Simonsen, CEO of Pac Technologies says the new batch and data management

“The trials have exceeded our expectations,” says Fong, adding: “It’s a very good result. We are very happy with the outcome.” Rabar employs 12 production staff at its Beaudesert plant, and Fong admits: “Initially the team was hesitant to move from a manual system to full automation. But they have now embraced the change. It’s definitely made their lives easier.”

Omron supplied all the quality control hardware, which was set up and programmed by Pac Technologies. The hardware is based on the Omron NX102-9020 PLC, which provides fast and accurate control by synchronising all machine devices with the PLC and motion engines while delivering real-time traceability.

“We achieved everything on the customer’s ‘wish list’ with a customised solution,” says Omron Queensland and Northern Territory Manager, Paul Gibb.

This is combined with Omron NA Series HMIs to enable faster, more efficient control and monitoring and V680s RFID hardware combining RFID antenna, amplifier and controller in one unit.

“We mainly focused on the performance and data processing power of the NX102 in conjunction with NA HMIs. This hardware creates a massive amount of value through the

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Rabar owner/director Gerald Fong says he’s more than happy with the new system.

Also, production has been boosted by nearly 25 per cent – from 2-3 tonnes an hour to as much as 4 tonnes an hour.

Using state-of-the-art equipment from Omron, the Pac Technologies team created a new batching system for Rabar at its headquarters at Beaudesert, southwest of Brisbane.


Also, there is no longer a need to conduct a monthly manual stocktake. The stocktakes are now scheduled on a quarterly basis – delivering a higher degree of accuracy.

“It has improved accuracy and reduced human error,” he says.

So the company turned to industrial automation specialist Pac Technologies for advice. The brief was simple: to move from a paper-based records system to a real-time data capture and traceability solution.

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Simonsen says traceability and accuracy in the blending process has improved significantly.

system (BDM) has streamlined the entire operation. “The new system has been fully customised to fit Rabar’s requirements,” he says.

And rather than shed jobs with the automation, Rabar will probably need more staff to cope with the expected increase in productivity. “Already, we have reached a stage where we have exceeded our capacity,” says Fong.

New software now controls the entire blending system from start to finish. It has eliminated manual ordering, record keeping and other paper trails.

“But now with the new system we are ready to take on new business when the market eventually recovers from the current drought.”

“This BDM can be configured to work seamlessly with all pre-existing inventory software packages,” says Simonsen.

Gerald Fong expects that Rabar receive a full return on its investment (ROI) within the next two years.

Integrated scales now precisely weigh every ingredient, and RFID technology is used to track and log each individual step, and barcode recognition ensures only the correct products are used.

The next stage will be to introduce Omron’s LD series mobile robots and TM series collaborative robots for picking and packing products on to pallets ready for dispatch. And Fong says the company is also looking to replicate the new batching system at its Moama facility near Echuca on the NSW/ Victoria border in the New Year.

The system also has facilities for multiple operators to work simultaneously on each order. After nearly 14 months of exhaustive planning and trialling, the new system is now fully operational.

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HOW TO SELECT THE RIGHT POSITIONING SENSOR SOLUTION Today’s machinery and equipment are continuously evolving, designed to enhance efficiency and built to withstand harsher conditions. Therefore, to accommodate performance and reliability demands, manufacturers need to implement positioning sensor solutions that can provide continuous operation and the highest level of accuracy. Sensors using a unique resistance inductance capacitance (RLC) operating principle are designed for accuracy, flexibility and durability to accommodate the widest range of applications and complement production efficiency goals. With this technology, users can overcome common performance limitations experienced with alternative solutions and are now able to implement highquality position sensing that is no longer constrained by application environment, the presence of magnetic fields or space limitations. In order to select the ideal sensor for positioning applications, it is important for manufacturers to know and understand the latest technology available and how it compares to alternative options. This white paper provides an in-depth explanation of how sensors using resistance inductance capacitance technology enhance position sensing in industrial applications. By offering a detailed performance comparison of widely used linear and rotary positioning sensors, this paper serves as an industry guide for choosing the ideal solution for virtually any application.

Inductive sensors with resistance inductance capacitance In the past, manufacturers have typically relied on technologies such as

Figure 1



magnetostrictive and potentiometer sensors for positioning applications. However, newer options, like sensors using resistance inductance capacitance (RLC) provide a solution that precisely measures the position of a target without mechanical or electrical contact. Plus, for additional flexibility and compatibility, sensors with RLC technology are offered for both linear and rotary positioning in a variety of ranges. These noncontact sensors incorporate an advanced microprocessor circuit and precisely manufactured printed emitter and receiver coil systems. During operation, the emitter coils are activated with a high frequency AC field and produce an inductive RLC circuit with the positioning element. The element is inductively coupled with the receiver coils, which are arranged so different voltages are induced in the coils, depending on the position of the actuator. The voltages serve as a measure for the sensor signal. These sensors deliver maximum measuring spans, with minimal blind zone and high resistance to EMI/RFI noise. With the noncontact linear positioning sensor featuring an innovative three-coil design, the excitation coil is surrounded by two sensor coils. Fig 1 illustrates a simplified sensor coil design for a noncontact linear positioning element. As shown in the figure, the coupling factor to the resonator is relatively constant, which causes the positioning element to be continuously powered when it is within the measurement range. The cosine and sine coils are patterned so that their coupling factors to the resonator kCOS and kSIN vary sinusoidally along the measurement range. Since the sensor coils are

balanced, with sections wound in opposite directions, any inductive interference is effectively cancelled out. On activation, a high-frequency AC field (EX waveform) is emitted from the excitation coil. When the excitation coil is shut off, the sine and cosine tracks will pick up the resulting inductive field (echo) created in the positioning element. An internal microprocessor analyses the signals and a produces an output. The outputs available for this coil design are typically voltage (0 to 10V) and current (4 to 20mA). This is demonstrated in Fig 2. Along with the three-coil design,

performance, rotary inductive sensors feature electronics that can compensate for misalignment between the positioning element and the sensor. The microprocessor can analyse the sine and cosine signals and compare the outputs against the expected position and compensate for lateral misalignments of up to 1.5mm.

Performance comparison of sensor technologies When selecting the ideal position sensor, it is critical that users are able to identify the individual strengths and limitations associated with each potential solution. The tables below

Figure 2

inductive sensors are also offered in a dual sine/cosine coil system that uses the same principal of operation as the three-coil design. This system features course coils and fine coils for the sine/ cosine tracks, delivering fast and precise measurement over longer distances with the course tracks enabling the microprocessor to locate the positioning element faster and then the fine coils determine its precise position.

provide a snapshot comparison between inductive sensors based on the RLC operating principal and other available technologies in the marketplace, including potentiometer, magnetostrictive, optical encoders and variable differential transformers.

Additionally, the feedback signal is available in either analogue (12bit), analogue with I/O Link (16bit) or SSI (25bit). All position calculations are performed using specially designed microprocessor circuitry.

Featuring a simplistic operating principle, potentiometers remain a common solution for displacement measurement. As a contact solution, potentiometers require that contact must be made along a precise path with uniform force for accurate results. This causes friction that can result in wear and tear and ultimately impacts productivity.

For rotary applications, noncontact rotary sensors use the same coil principal, but the coils are arranged in a circle formation and are patterned to produce a sine/cosine variation of the couple factor when the position changes (Fig 3). To further enhance accuracy and


Additionally, since these sensors are not engineered to withstand harsh environments, they are prone to failure from wear and moisture ingress.



Figure 4

Although they offer a rugged solution for demanding applications, they are expensive to manufacture and do not offer some of the more sophisticated features found in the inductive sensors, such as their ability to compensate for misalignment or accommodating multi-axis sensing.

Figure 3

ability to use a sensor in a confined area (Fig 4). Plus, offered with numerous features and performance capabilities, these sensors provide superior flexibility, allowing them to accommodate a wide range of applications.

Conclusion Magnetostrictive Another commonly used sensor solution for linear positioning is magnetostrictive sensors. Containing ferromagnetic materials, they are used to measure the position of a moving magnet. To detect an object’s position, a strain pulse is applied to a magnetostrictive wire that runs the entire length of the probe. When the strain pulse encounters a magnetic field produces by the slide or floating magnet assembly, a current pulse is produced. With this technology, the linear positioning is measured by the time difference between the pulses in relationship to the preprogrammed “zero” and “span” to be detected. Due to their ferromagnetic makeup, magnetostrictive sensors can be problematic in applications containing magnetic fields, as this will cause interference with the sensors, leading to performance errors and measurement inaccuracies. Further, any interruption costs users additional expenses from lost production and downtime for troubleshooting and equipment replacements.

Hall-effect encoders Hall-effect encoders integrate Hall-effect sensors and interpolation electronics on a single chip. Used with a rotating magnet, they deliver a precise measurement of angular position, but they are also extremely sensitive to misalignment, which typically requires them to be manufactured as a packaged device with bearings to compensate. Linear sensing is also possible with a linear magnetic track but misalignment is also a large factor in output accuracy and reliability.

Linear variable differential transformers Linear variable differential transformers (LVDTs), and their rotary counterparts rotary variable differential transformers (RVDTs), are electromechanical transducers that provide a variable alternating current output used to measure either linear or rotary displacement.

Optical encoders Optical encoders offer fast response times and a simple output interface. However, they can be expensive to build into products, particularly when high resolution is required, as they require their own bearings to avoid any misalignment. Many encoders also lack inherent durability against the ingress of dirt, dust or moisture, making them unsuitable for multiple environments.


Tables 1 & 2

Inductive sensors with RLC operation As inductive sensors using the RLC operating principle have their sensing coils imprinted on a PCB, they are much simpler and easier to manufacture and offer improved precision. This extra design freedom available from PCB coils means that the sensors are engineered to be highly tolerant of misalignment and rarely require additional bearings. Inductive sensors equipped with fully sealed housings provide dependable performance by preventing moisture and dust ingress and avoiding sensor malfunction. Their noncontact design allows these sensors to accommodate applications with constant motion without resulting in costly wear, while their nonmagnetic properties eliminate the risk of interference from magnetic fields that impact results. These sensors were developed with small blind zones relative to the measuring track giving the designer the

As industries continue to adopt newer machine designs that complement production and efficiency strategies, selecting sensing components that promote these initiatives is key. Therefore, using sensors that deliver more accurate results, minimise downtime and increase flexibility can ensure continued productivity, profitability and product quality. Turck offers a wide range of positioning sensors for many industrial applications. Turck’s linear position sensors are available in a variety of sensing technologies that provide a designer with many options when deciding which solution best fits the application. The company’s inductive linear position sensors are noncontact sensors using the RLC principle of operation, with measuring ranges up to 1000mm. Magnetic linear position sensors use external magnets with embedded Halleffect sensors with measuring ranges up to 200mm. Turck’s magnetostrictive linear position sensors use external magnets and offer measuring ranges up to 7.6m. Turck’s rotary position sensors are available as rotary inductive sensors, as well as optical and magnetic encoders that offer a variety of options when deciding what solution best fits the application. Inductive rotary position sensors use the RLC principle of operation with a choice of analogue, incremental, SSI, or CANopen interfaces. Turck Australia 1300 132 566




THRIVING MACHINE SHOP KEEPS QUALITY IN HOUSE FOR QUEENSLAND ENGINEERS did increase the capabilities of the DGH Engineering machine shop, the reliability of the second-hand units proved to be less than perfect. Dave Hackett is General Manager of DGH Engineering, and he admits: “We always knew the limitations of buying second hand – you’re generally buying somebody else’s problems!” So, with new personnel in charge, in the shape of Machine Shop Supervisor James Tabberer, the decision was made to upgrade and (in Dave Hackett’s words) “buy what we really wanted.” Tabberer made a business case for purchasing a quality CNC lathe, and, as fortune would have it, the business expansion that this would entail made the company eligible for a grant from the Queensland Government. For a relatively young company, DGH Engineering has swiftly become one of Queensland’s most respected engineering enterprises, and a go-to supplier for the state’s mining, sugar, defence and ports industries. And it has achieved this status as much by the quality of its work as it has by the recommendations it has received from local industry leaders. One of the key factors in its success has been the company’s insistence on providing a complete “one-stopshop” service on engineering projects, and that has led DGH Engineering to make substantial investments in its own capabilities that today allow it to fully “own” the projects it works on, rather than

relying on external subcontractors for key aspects. Founded in 2005, the company’s mission is to provide quality engineering solutions through design, fabrication, construction and maintenance of assets and equipment. Today, the company has fabrication workshops in both Mackay and Emerald and runs mobile engineering teams from both locations. The Mackay site is the DGH Engineering headquarters, with a 3000m2 fabrication workshop, featuring four overhead cranes and 3 hectares of hardstanding area.

It was a recently as December 2013, that DGH began the move to bring machining capabilities in-house with the acquisition of local company JM Machining. And while the acquisition, complete with manual machinery and personnel meant that DGH was not setting up its machine shop in Mackay from scratch, the capabilities with which the shop opened in 2014 were limited by today’s standards. Immediate expansion was required, so the company purchased two second-hand CNC machines in order to increase the throughput of the machine shop. While the newly installed machines

Having drawn up a shortlist of CNC lathes from three different manufacturers and assessed the overall packages available, the decision was made to go for a Doosan Puma 5100LYB from Hare & Forbes Machineryhouse in Brisbane. Hackett explains: “The Doosan wasn’t the cheapest – nor was it the dearest – but the package had everything we needed.” And Tabberer adds: “We knew that a machine like that could cost us a lot of money if it wasn’t running, so reliability and support availability were key factors in the choice.” The Puma arrived during the second half of 2018, and was immediately put to work on longwall shear pins – a job that the





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The extension will be completed by the end of 2019

& Forbes base in Brisbane, the company has been very successful in supplying Doosan CNC machines to several companies in the “sugar city”.

James Tabberer programs the DNM 6700 machining centre watched by Dave Hackett

previous machinery had struggled with. With the new Puma more than earning its keep, James Tabberer could see another gap in the armoury of the DGH Engineering machine shop. He needed a quality CNC machining centre that would not only complete his existing workload more quickly and with greater precision, it would enable him to bid for new work and effectively open up new fields. Doosan offers a range of different capabilities in its machining centres, and the best fit for DGH Engineering was an DNM 6700 machining centre. With its high spindle speeds up to 12,000 rpm, Tabberer saw a machine with true multi-materials capabilities that would cater for the company’s increasing demands for machining aluminium and plastics in addition to steel.

younger workers are by the inadequate documentation we receive with some of the work we still have to subcontract out,” says Tabberer. In the meantime though, Tabberer is ensuring that his prize machines are kept in top working order with a rigorous regime of weekly, monthly and quarterly preventive maintenance, backing up the annual service provided by Hare & Forbes Doosan technicians. And while Mackay is not exactly close to the Hare

“So we do have a handy little Doosan club locally, which certainly helps keep the travelling costs down for the technicians when the come out to see all of us!” DGH Engineering Hare & Forbes MachineryHouse

And with that machine delivered in early 2019, DGH Engineering did start to feel like the “one-stop-shop” that it had set out to become. Says Tabberer: “We really feel that the new machines have given us a competitive advantage. Rather than subbing out certain jobs, we’re doing it all in house, and that means we’re fully in control of the tolerances and the quality of the finished product. And that’s not even mentioning the dangers of damage to subcontract work in transit.” The addition of the two Doosan CNC machines, however, did create a problem for DGH Engineering: the machine shop was effectively full. The company’s response to this problem was typical of its “one-stop-shop” ethos: double the size of the machine shop… and do it yourself. The extension will be completed by the end of 2019, at which point James Tabberer will be making another business case, probably he says for a CNC boring machine to occupy some of the newly found space. Why? “Well, there are a couple of boring machines around Mackay…. And they’re always busy!” No doubt, the expansion will cause further recruitment problems for the company. There simply aren’t enough qualified CNC operators in the region, and both Hackett and Tabberer despair of the lack of training available locally, and have been campaigning for the local TAFE to take a serious approach to CNC training.

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EXTRA LONG LATHE EXPANDS JOBBING SHOP CAPABILITIES 700XL CNC lathe. But the story doesn’t end there. 2019 has seen two new arrivals in the Ziggy’s workshop. The first was a Doosan Mynx 7500/50 machining centre to support the increase in manufacturing work. The second new arrival this year is something of a “favourite child” for Ziggy Butschle. He had seen the newly designed Doosan Puma 5100 Series of horizontal turning centres and was impressed with their high-power heavy-duty cutting capabilities, but was concerned about their size. In standard form, the Puma 5100LYB with live tooling has a maximum turning length of 2 metres. “But most of the shafts we are asked to work on are between 2 and 3 metres long,” he says. When Sigbert (Ziggy) Butschle says that his company will take on any job, it is a fair comment on the capabilities of Ziggy’s CQ Engineering, which has become one of the best-equipped jobbing shops in Queensland. Operating from a purpose-built 1200m2 workshop in the sugar city of Mackay, Ziggy’s Engineering serves the mining, manufacturing, transport, construction, engineering and agricultural industries, and specialises in the machining and repair of one-off parts, small to long production runs and in the development of prototypes. The company was founded in 1999 when Butschle was running a workshop for a belt-splicing company. He reasoned that his services and skills were in considerable demand in the area, so he struck out on his own and Ziggy’s CQ Engineering was born, operating initially from premises he describes as “a shoebox” with just two machines.

industry very much in the ascendency during the 2000s, the company found increasing levels of business coming from that sector at a time when the sugar trade was winding down in the area. That mining boom saw Ziggy’s not only increase the amount of repair work running through its doors, but also significant quantities of manufacturing, such as components for roof supports used in the coal mines of the Bowen Basin.

The company has assembled an impressive array of CNC machinery over the intervening period from a variety of manufacturers. But in recent years it is the Korean-made Doosan brand that has accounted for the majority of acquisitions, all sourced from Hare & Forbes Machineryhouse.

And while the manufacturing work does continue, Butschle is fully aware of the competition.

Ziggy’s association with Doosan began in 2007, with the purchase of two second-hand turning centres – a Puma 240M and a Lynx 210L – both of which are still in productive use, each benefitting from an annual service carried out by Hare & Forbes’ Doosan technicians.

“Were up against a fair bit of competition. But we can compete,” he insists, citing his company’s ability to work to both tight deadlines and tight tolerances. “It’s good to keep it local,” he concludes.

Indeed, Butschle has been so impressed with the performance and the reliability of those two second-hand purchases that ten years on in 2017 he returned to Hare & Forbes for a brand new Doosan machine, this time a larger Puma

Butschle made this point to Doosan and Hare & Forbes, and this led to the development of the Puma 5100XLYB – a special extra-long version with live tooling capable of working on shafts up to 3 metres long. And the first one of these machines ever made by Doosan now has pride of place at Ziggy’s Engineering, sitting alongside the Puma 700XL, which is capable of handling shafts up to 5 metres. Support is of course essential, and Butschle acknowledges the advantage of having Hare & Forbes’ service team based in Queensland. And while Brisbane is a 90 minute flight away, it does mean that problems can be solved a lot more quickly than might be the case with less local support. With the five Doosan machines performing well in the workshop, and an engineering staff of ten, with four support staff, Ziggy Butschle feels that his company has reached the optimum size. He acknowledges that these are potentially trying times for the mining industry, and this can easily have an impact on his workflow. “The work never stops though,” he says. “It might slow down, but then it will build up again.”

“In the beginning,” says Butschle, “big companies were coming to me with little jobs. And then the jobs started getting bigger and bigger, so I had to expand.” That expansion was a gradual process, moving from the aforementioned shoebox to a 250m2 workshop and then next door to a 650m2 workshop that Butschle remembers fondly as having its own crane.

And with the extended capabilities of its now fully kitted workshop, Ziggy’s Engineering is ideally placed to take advantage of any expansion in the sector.

Ziggy’s moved to its current purposebuilt premises in 2012, and that move gave Butschle the space to expand the company’s capabilities with a succession of new CNC machinery.

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Ziggy Butschle programs the Puma 700XL

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INDUSTRIAL ETHERNET AND FIELDBUS SYSTEMS FOR FUTURE-PROOF FACILITIES Simon Pullinger of Lapp Australia looks at some of the developments driving data networking in the connected factory. With the growth of the Internet of Things (IoT) in the last few years, more devices are now connected and online than ever before. In fact, more than 50 billion devices will be networked via the Internet by the end of this year. In the consumer world, this enables activities such as remotely adjusting the lights through a mobile device. But in the world of smart factories and highly automated plants the stakes are higher. With the Industrial Internet of Things (IIoT), the spotlight is on manufacturing operations and data gathering to optimise production processes and realise the potential of truly predictive maintenance. Due to speed and data integrity requirements, the modern factory is still heavily reliant on wired systems, the cables and connectors that carry critical power and data signals over long transmission runs at lightning fast speeds. With the IIoT, the sheer number of connected devices and their variety are both increasing. This means the physical connectivity layer on the shop floor is more important than ever before. One of the enabling technologies behind the IIoT involves adding machine intelligence at the device level through smart sensors that allow two-way communication with the larger plant-wide system. Such a networked system enables real-time data harvesting and data analysis to make tweaks to improve productivity. Because time is such a critical factor with regard to industrial cables and connected components, one recent development is time sensitive networks. These include new open protocols such as OPC Unified Architecture and Message Queue Telemetry Transport as well as the new physical layer coming soon, single-pair Ethernet. Depending on your plant setup, choosing a cable specifically designed for either industrial Ethernet or the modern fieldbus systems is a critical step in optimising your industrial process control system. When choosing a cable supplier, it is important to look for a manufacturer that is communication system agnostic and supports all the communication systems available for modern industrial environments: major industrial Ethernet systems such as EtherNet/ IP, Profinet, CC-Link IE, EtherCAT and



Powerlink; and fieldbus systems such as DeviceNet, AS-Interface, CC-Link and CANopen.

Single-pair Ethernet cables are more compact, lighter, easier to install, and cheaper than traditional Ethernet cables with four wire pairs

Working with a knowledgeable manufacturer will help you connect smart field devices and communicate in real time with the larger enterprise system.

different manufacturers have already been presented and industrial Ethernet workgroups are now in meetings to work out the details.

Rather than intelligence ending at the control system level, it is beginning to extend into the device level with smart sensors and actuators that send information directly to the enterprise system. The industrial data cable that is specified must support this activity with appropriate transmission speeds and guaranteed data integrity.

Time-sensitive networks It is worth remembering that it was as recently as 2010 that both Profibus and EtherNet/IP introduced real-time protocols: IRT for Profinet and CIP Sync for EtherNet/ IP. Industrial Ethernet came about due to the increased network size, higher data rates for more devices, the need for more flexible topologies and expandability (star, tree, ring layouts), a desire for one network for mixed services and the move toward enterprise-level and cloud connectivity. However, all these proprietary technologies led to the development of ‘real-time islands’ inside factories. In this context, ‘real time’ refers to cycle times below 1ms. For example, synchronised cycle times of roughly 62.5 or even 31μs are typical requirements for drive systems. This is where the concept of time sensitive networks (TSNs) comes in. TSN is an open standard that aims to enhance traditional Ethernet by improving quality of service (QoS) in terms of bandwidth reservation, synchronisation, low latency times and seamless redundancy. In this scenario, mixed services are possible, for example Profinet and OPC UA. TSN is implemented on the data link layer (where switches typically work, just above the physical device level) and standardised in IEEE 802.1. The beauty of TSNs is threefold: no changes in existing application software, easy integration for device manufacturers, and the end of real-time islands. Products should be available for industrial use within the next few years. Prototypes from

OPC Unified Architecture The next open technology to be familiar with is the OPC UA, a machine-to-machine protocol for industrial communication developed by the OPC Foundation. OPC UA is manufacturer neutral and supported by all major PLC suppliers. It is standardised in IEC 61850 and designed for communication between PLCs, and from PLCs to ERP systems. In April 2018, OPC UA released PublishSubscribe (PubSub) for the lowest levels of the factory floor, controllers and sensors (1 to 10ms range, that is, for streaming real-time data). The main advantages include end-toend encryption for high security and the fact that OPC UA is supported by industrial device manufacturers with a large installed base. Further, OPC UA can be used in combination with the TSN for real-time communication between machines.

Message Queue Telemetry Transport Another modern protocol to become familiar with is MQTT, a very lightweight IoT protocol for small devices such as sensors and networks with high latency and low bandwidth. MQTT is standardised by the Organisation for the Advancement of Structured Information Standards (OASIS) and is best described as an optimised solution for directly connecting devices from the lowest field level to the cloud. For example, a sensor could publish information such as temperature to an MQTT ‘broker’, and this intermediate device could share it with a ‘subscriber’, such as a cloud server or an enterprise-level server within the factory. All this information can be exchanged without making any changes to the PLC.

Single-pair Ethernet Originally used in the automotive industry, a new standard called single-pair Ethernet is

making gains in IIoT connectivity. The driving force for the new standard was that the increasing size of fieldbus cables due to their multiple cores making installation difficult in constrained spaces. So the automotive industry spearheaded the movement to singlepair Ethernet, with new standards from the IEEE (such as IEEE 802.3) in 2015. New chips were developed for automotive Ethernet communication at 10Mbit/s, 100Mbit/s and 1Gbit/s using just one pair. The particularly appealing aspect of single-pair Ethernet in industrial applications is the ability to transmit data at 10Mbit/s for 1000m. This makes it a seriously viable fieldbus replacement because although protocols such as Profibus, DeviceNet and CANbus also cover around 1000m, it is only at a reduced data rate. Different user groups are now exploring single-pair Ethernet, including various industrial Ethernet, Profinet and EtherNet/ IP workgroups. Although it may take two or three years to see the first devices, proactive cable manufacturers are now developing cable and connectors to meet the requirements of single-pair Ethernet and ‘Ethernet to the edge’ plant designs.

Conclusion Navigating the evolving world of communication protocols in the context of IIoT can be challenging. Today’s automation environments are still heavily reliant on wired systems including cable and connectors to transmit data and power over long transmission 
runs at incredibly fast speeds. As smart products are developed to bring intelligence to the device level, specifying the appropriate physical layer of industrial data communication is more important than ever. Be sure to work with 
a cable provider that is knowledgeable about the various protocol choices and has products to meet the needs of both current and future plant layouts. Lapp Australia 1800 931 559


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TOMORROW’S AUTOMATION SOLUTIONS TODAY. TURN-KEY SOLUTIONS FOR ALL INDUSTRIES At Robotic Automation we strive to work with our customers continuously delivering the latest robotic technology systems to increase productivity, which is key for today and for tomorrow. With unrivalled experience in automation projects that are unique, large and small as our customers are. We have been operating in Australia and New Zealand since 1988, installed and continue to support over 3,500 applications across manufacturing, warehousing, hospitals, testing laboratories and even banking processes. As the direct representative of leading system brands, Robotic Automation has all the pieces to your automation solution. We’ll also put them together and solve it for you! Our expert team of trusted consultants, engineers and project managers put together all the elements to build turn-key solutions, tailored to your manufacturing needs.

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A whole new safety culture is growing among the workforce at the Real Pet Food Company’s factory at Ingleburn in Sydney’s southwest, and it all began with a workplace traffic management plan. The Ingleburn site occupies 5 hectares, producing high-quality all-natural canned dog and cat food for domestic and export markets, with China as a significant and growing export destination. However, having evolved and expanded through several changes of ownership over the course of 30 years, the site had no clearly defined traffic routes for either pedestrians or the growing fleet of forklifts travelling between the factory, the canning and packaging plant and the warehouse. There were also potential areas of conflict in the yard between the incoming raw materials and the outgoing pallets of pet food.

vehicles and pedestrians. And it was crucial that everyone could easily recognise where they should be and where the hazards were.” So the plant safety team mapped out all the high traffic areas of the site and created designated routes for pedestrians and forklifts through the factory, the canning plant and the warehouse. These routes have been clearly marked with liberal quantities of floor paint and ample additional signage at eye height – all successfully designed to be visually

impactful without relying on language. Attention then turned to safety barriers to physically separate the pedestrian and vehicular traffic. There were already a number of steel barriers in place, but these were showing considerable signs of wear, with dents, flaking paint and damage to the concrete floor where mounting bolts had been put under stress due to impacts on the barriers. Sue Wood had in mind a more technologically advanced alternative, and



That supplier was A-Safe, and its test installation ticked all the boxes for Sue Wood, who says: “The team liked it immediately, and it had the look of something that would last.” And that durability was an important criterion for Real Pet Food: while its products are destined for canine and feline stomachs, its manufacturing operations need to meet stringent hygiene regulations just like any food and beverage manufacturer. Therefore the manufacturing operation at Ingleburn is HACCP certified and SQF audited. A-Safe polymer barriers are selfcoloured (with the safety yellow pigment as part of the polymer). So there is no paint to flake off and potentially contaminate foodstuffs, and the barriers can be subjected to full washdown procedures.

When Sue Wood became Site Manager at Ingleburn she quickly identified the need to formalise traffic management at the site, a task made all the more urgent by the increasing throughput from the factory and the growth of the workforce, which includes a significant proportion of non-Englishspeaking staff. Says Wood: “When we set out to determine what to do to make the team safer throughout the site, the first priority was to create clearly defined routes for

so she drew up a shortlist of suppliers of polymer safety barriers, before inviting one supplier to set up a test installation on the site.

More to the point, they are tested to the PAS 13 code of practice, proving that they will absorb even heavy impacts from vehicles such as forklifts and return to shape, rather than splintering or being ripped from their floor mountings. Walkways are clearly defined and protected by barriers

Having successfully completed the trial, Wood commissioned A-Safe



Simultaneous with the safety barrier installation, Real Pet Food also upgraded its forklift fleet, beginning a switch from petrol power to electric traction. And A-Safe barriers had a role to play in this as well, with each of the charging stations constructed using the polymer barriers. In this application, the barriers not only separate pedestrians from the charging areas, they protect the chargers themselves from an over-running forklift. The A-Safe team were also able to make a number of additional suggestions to improve safety, such as the construction in the yard of two further “safe areas”: one for truck drivers awaiting loading and unloading, and a second one as a dedicated forklift maintenance area. Additional barriers in the factory protect critical process assets

Australasia Director Mark Collins and his team to install pedestrian barriers throughout the warehouse and canning plant – complementing the floor markings and signage, and creating clear and obvious protected pedestrian walkways. But the installation did not end there. Just as A-Safe’s barriers are designed

to protect pedestrians from impacts from forklifts, they are also used to protect valuable infrastructure. So Collins and his team also installed forklift protection around a number of critical process assets within the factory itself. This is an important consideration in an area where forklifts might lose traction on a floor still wet from washdown.

As chance would have it, inspectors from Safe Work NSW visited the site during the installation, and were impressed with the progress made over the preceding 12 months. Of course, any safety programme will always be on-going. But, thanks to the traffic management scheme, with its clearly defined walkways and forklift areas backed up by protection using A-Safe barriers, Real Pet Food has made major strides using best practice in workplace safety.

As Sue Wood puts it: “It’s starting to look and feel safer, and the team have taken it onboard. There really wasn’t any history of a strong safety culture, but that’s been uplifted with the changes. Now we’re seeing everyone taking responsibility for their own safety and for the safety of the rest of the team.” And as to the performance of the A-Safe barriers? Sue Wood admits there have been a small number of “soft contacts” with forklifts, but the barriers have coped with them each time with no lasting damage to either the forklift or the barrier. The Real Pet Food Company has clearly been impressed with A-Safe’s pedestrian barriers and their contribution to workplace traffic management and safety in general. So much so that the company has gone one to order similar installations at its facilities in Dubbo and Somersby (NSW) and at its original home in Yatala in Queensland. A-Safe Australasia 02 9625 8927

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ORGANISATIONAL CULTURE IS KEY TO ENDING WORKPLACE BULLYING In partnership with peak health and safety bodies, The University of South Australia has developed a novel approach to tackling the distressing and costly problem of bullying at work. And with the total cost of bullying at work in Australia estimated to be as much as $36 billion per annum, tackling the problem would benefit employers as much as it would employees. Australia is home to some of the worst workplace bullying in the developed world, ranking sixth highest in a recent study comparing us with 31 European countries.

There’s no doubt that the humble ladder is one of the most useful tools ever invented. However, used incorrectly it can also be one of the most dangerous, with countless falls recorded each year leading to dislocations, broken bones, severe lacerations and head injuries, and in some cases workers have died. While safety authorities recommend that in an ideal world nobody should use an extension ladder alone, there are bound to be occasions where single-handed ladder use is inevitable. And that’s where the Lacket comes in. The Lacket is the brainchild of two mates from the Illawarra – one an engineer and one a paramedic who was fed up with seeing the results of falls from unsecured ladders. The novel device will fit to any standard extension ladder, and secures the ladder against any overhang, preventing it from slipping sideways or falling backwards. Importantly, the Lacket secures the ladder before the user climbs it – unlike other ladder safety devices that require the user to climb the ladder to secure it.

The concept is deceptively simple: the ladder is simply “wedged” into place using the Lacket, rather like wedging a chair under a door handle. And just as pushing against a chair-wedged door makes the wedging effect stronger, pulling against a Lacket secured ladder has the same effect. The Lacket is made in Australian using stainless steel, T-6061 alloy and highdensity impact-resistant plastic. Each pair of devices comes with safety straps for tying off the base of the ladder, ensuring that the ladder is fully jammed into position and cannot be moved. For applications where there is no overhang available to anchor the Lacket, an optional stabiliser bar is available that allows the devices to operate against a flat wall or on a roof. The Lacket has been extensively tested by qualified bodies, and in 2017 received the SafeWork NSW Award for best solution to an identified workplace health and safety issue for small business. The Lacket Company

Around 10 per cent of Australian employees admit to being bullied at work, but that figure may hide the true extent of the problem, with much antisocial workplace behaviour going unreported and research suggesting up to two-thirds of workers may experience unfair treatment on the job. Although laws to discourage workplace bullying have been strengthened in recent years, employment experts acknowledge that further protective measures are needed. Researchers at the University of South Australia have developed a novel diagnostic and response solution to address that need, providing a simple, evidence-based approach to recognising and addressing bullying issues in Australian workplaces. Lead researcher, Associate Professor Michelle Tuckey, says the key to curbing workplace bullying lies in understanding that the behaviour can rarely be blamed on isolated individuals. “Workplace bullying is often mistaken as a problem between staff members, an interpersonal problem, when evidence shows it’s really a reflection of how the organisation functions,” says Prof Tuckey. “It’s a cultural issue, a systems issue – if you have a healthy culture and healthy systems, then you don't get a lot of bullying, but if you don't have that culture and those systems, bullying is more common.” Building on six years of research, Prof

Tuckey and her team have devised a method to help businesses develop the sort of cultures that prevent bullying at work. “We're taking a safety risk management framework and treating bullying as a work health and safety hazard, following the normal risk management approach, which is to identify hazards, assess the level of risk, implement risk controls, and then monitor and evaluate,” says Prof Tuckey. “An important feature of our approach is the involvement of staff and managers in each stage.” The risk management solution was developed through extensive engagement with 342 documented bullying complaints lodged with SafeWork SA and is currently being trialled with peak health and safety bodies to enhance the regulatory response to bullying and to support proactive risk management in a range of other organisations. “We analysed about 5500 pages of information to learn what's going on in the culture and the work systems when people feel mistreated,” says Prof Tuckey. “Then we turned that into a survey-based measurement tool with 10 different domains used to deliver a score predictive of a broad range of work health and safety outcomes, including exposure to bullying.” “The diagnostic tool shows an organisation where they should focus their efforts and prioritise their resources,” says Prof Tuckey. “Many organisations already have policies, training and complaint systems in place; our tool complements those structures to prevent bullying behaviour.”

SAFETY IN ACTION SEES PROTECTION IN ACTION Rack Armour (Australia) would like to thank everyone that visited its stand at the recent Safety in Action show in Melbourne. The company reckons there was a fantastic response from a wide group of people involved in warehousing, safety, racking installation 38


and auditing companies. Although most knew of the Rack Armour products, many were still surprised at the way Rack Armour could take such an impact from a forklift, with no damage to the unit or the racking. The most common comment after

seeing the impact video demonstration was “we have a forklift driver like that in our warehouse”. You can check out the video on the Rack Armour website to see what they mean.

Rack Armour 02 9722 0502


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MaxX lifters are available from Serpent & Dove in lifting capacities from 125 to 2000kg, with special models for thinner gauge steels or for vertical lifting.

LIFT TRUCKS BACKED TO SATISFY A STRONG AUSTRALIAN MARKET NEED Adaptalift Group is backing the new Hyster UT and Yale UX Series lift trucks to satisfy a strong need in the Australian market for qualityengineered, cost-effective forklifts suited to lower frequency applications typically limited to 1000 hours a year. “We’ve been an Australian Hyster dealer for many years, and we see the new UT Series forklift model opening up the opportunity to have three levels of product in markets with significant volumes, like retail, warehousing, food and beverage, and logistics,” says Steven Taylor, CEO, Adaptalift Group. “Through our long-term relationship with Hyster-Yale Group, we were appointed as one of Hyster-Yale’s Yale dealers in Australia in 2018, and we see the new Yale UX Series as an ideal opportunity to lift the profile of Yale in key markets with lower-intensity usage forklift demands,” says Taylor. The new Hyster UT Series and Yale UX Series diesel or dual-fuel counterbalance forklifts, pallet trucks and stackers, in six different capacities from 1.5 to 3.5t, deliver an attractive, affordable and uncomplicated range for 40


enhanced user choice across many industries. Adaptalift Group is a major dealer for both Hyster and Yale in Australia, and is demonstrating its full support for the launches of the reliable new forklift ranges through strong local stock levels. “Not only do the new ranges fill a gap in the market for a high quality, low usage forklift backed by reliable service, they also have outstanding features for the user. We’re impressed with the 3-piece overhead guard, comfortable seat and access step,” says Taylor. Adaptalift Group 03 9547 8000



BLAST CURTAIN ALLIANCE TAKES AUSSIE INNOVATION STATESIDE When Bomac Engineering received a request for a quote in mid-2017 from a company in Texas, USA, the company couldn’t have guessed what a significant relationship this would become and how quickly it would grow into something much larger than a single order.

“I was searching the Internet to find a support system that would accommodate a new blast curtain product we had introduced to the market,” explains Merritt. “I saw the Altrac rail and thought it looked great, then realised it was in Australia. I just kept searching online, and kept ending up back at the Bomac website. There’s really nothing else like it. So finally, I thought I’d just go ahead and send an email to see if it was possible to get the product here.” It was. Since then several more containers full of Australian-made Altrac rail and components have made their way across the Pacific Ocean. And the two innovative business directors have worked closely to develop custom components and trolleys to suit the specific application of Blast Control’s unique projectile barriers. After using the Altrac system with several different configurations, Merritt realised that if he had found a gap in the US market in his own industry, there were probably many


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“We’ve sent Altrac overseas before,” says engineer Tate McFarlane, “and it’s always exciting to see your product enter a new market. But they’re usually one-off jobs, for a specific application.” Initially, McFarlane didn’t expect the order from Blast Control in Kilgore, Texas to be anything other than that – a single order to fulfil a specific project. Less than a year later, however, McFarlane travelled to the USA to meet with CEO Thomas Merritt. And shortly after that, Merritt travelled to Melbourne to see the Bomac facilities in person and discuss potential for ongoing supply.

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Bagging & Palletising more. Altrac would be an ideal solution for the US manufacturing sector. And so Altrac USA was born. Bomac Engineering and Blast Control have teamed up and will formally launch the joint endeavour in the USA at the annual FabTech trade show, this year from 11th to 14th November in Chicago, Illinois. “I’m really looking forward to experiencing a trade show in a market more than 10 times the size of the Australian market,” says Tate McFarlane. “It’s a great opportunity for both businesses to expand our reach, and also a great chance to spread the concept of Australian innovation around the world.” Needless to say, any Aussies visiting FabTech in Chicago will be made most welcome at Booth A6368. Bomac Engineering 03 9796 5300

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HEAVY-DUTY WHEELS LAST FOR YEARS One World Trade Centre, New York, The Marq, Singapore and One One One Eagle Street, Brisbane, as well as many smaller projects.

As both models posed a danger for both employees and the goods being transported, Interpane approached Tente for a practical alternative.

Interpane is one of the few manufacturers worldwide to produce coated glass in sizes up to 18m long, 3.2m wide and 20mm thick. However, most orders measure about 7.5 x 3m and weigh no more than 2.5t.

Tente developed system that combines rigid steel and flexible natural rubber elements. Rigid guardrails attached to the side of the each wheel ensure that it is guided safely around a foot.

Interpane attaches great importance to workplace health and safety when manufacturing and transporting its products, and pursues a proactive, zero tolerance strategy, planning and optimising all of its processes.

A weight of 100t is too large for ordinary heavy-duty wheels to handle, and after a short time, their treads will tear off. But now Tente has developed a customised wheel for one particular client that needed long-term durability, even with loads of that weight. Georg Kramp is a German manufacturer of jacks, trolleys and remotely operated transport systems under the brand name GKS perfekt. These products are designed for loads up to 100t, including safes, machinery and train components. The jacks are used to raise the loads, and the trolleys are then be used to transport them to their place of use. During these operations, ordinary trolley wheels can suffer serious damage. After only a few months, the treads detach from the wheel core and the wheels have to be replaced. The situation isn’t helped by the variety of different surfaces at the company’s different facilities, which can be a major contributor to the excessive wear on the wheels. So Georg Kramp approached Tente looking for a solution that could not only withstand its heavy loads but also perform reliably even on difficult floor surfaces. These combined requirements meant that Tente would need to develop a completely new design. The result is a wheel with four ball bearings, a toothed aluminium core and a fibre-reinforced polyamide tread. The interlocking of the core and the tread is crucial, providing a larger connection surface and resulting in maximum hold for a particularly strong connection.



The polyamide used for the tread also plays a key role in ensuring durability. It is characterised by high strength, stress resistance and outstanding impact strength. It also has good anti-friction properties, which make the tread abrasionresistant and provide additional protection on uneven floors. To ensure precise rotation and the largest possible contact surface, the running surface of the wheels is given a plain finish. The wheels can be supplied with black or white treads, and for electrostatically protected working areas, conductive models can also be provided.

When the glass is cut to size and loaded onto transport trolleys, it presents a particular challenge in terms of operational safety. If heavily loaded trolleys move too quickly or get caught on uneven surfaces or obstacles, they could bump into an employee’s ankles or run over their feet. In order to prevent injuries, Interpane had previously used two different foot protection systems, neither of which was ideal. There was a rigid system that was fine on level floors, but as soon as the trolleys hit a bump the foot protection came into contact with the ground, potentially causing the trolleys to stop suddenly or even tip over. The alternative, a flexible device, posed a similar risk as it could be drawn under the wheels and jam the castors.

At the same time, flexible aprons made of rubber with a Shore hardness of 80 are fitted in front of and behind the wheel. These are mounted so that they are pressed in towards the wheel as soon as it comes into contact with a foot, and this braking effect prevents the castor from moving on and crushing the foot. The design is available in several sizes, and is suitable for quick and easy retrofitting. What’s more, it is suitable for use at temperatures between -40 and +80°C. The foot protection system has proved a hit with Interpane Group’s corporate safety coordinator Tobias Rüther, who has recommended it for use in all of the group’s factories. “With Tente’s solution we have improved both occupational safety and the protection of our products,” he says. Tente Castors & Wheels 1300 836 831

The new GKS perfekt trolleys featuring Tente’s newly designed heavy-duty wheels have allowed Georg Kramp to significantly improve its market position. The company is now looking to collaborate with Tente internationally, making the most of Tente’s advantages as a global manufacturer.

PANES, NOT PAINS Another German company approached Tente with a different requirement for its trolley wheels. Transporting panes of glass requires great care, especially when the panes can be as large as a minibus. The task calls for transport trolleys that are highly manoeuvrable and also safeguard the physical wellbeing of the user. The Interpane Group is now owned by Japanese glass group, Asahi Glass. It employs 50,000 people worldwide and has provided glazing for the façades of large-scale construction projects including

Tente's novel approach to foot protection



TOUGH PLASTIC SHEAVES CUT STRESS IN WIRE ROPE APPLICATIONS Wire rope is integral to lifting, shifting and power transmission across a host of industries, starting with mining in the 1830s and since then extending across wide swathes of industry. Uses today include cranes and lifting, cargo handling, elevators, construction, primary and food product harvesting, power generation technology (such as tendons in windmills), winching and conveying in manufacturing, minerals processing and materials handling and fixed and mobile plant used in paper and timber processing. The major initial advantage of wire rope over the chains it replaced was that it would not snap catastrophically where there were flaws in chain links or solid bars, but rather individual strands could fail while others around them would take up the load safely and flexibly without shock. However, even the best quality wire rope will ultimately wear and potentially

fail if it is subjected to constant abrasion, such as that induced by uneven metal-to-metal contact across sheaves and where lubricants attract grime to gradually compromise strength while attracting impurities into industrial processes. To help protect against such issues, Cut To Size Plastics custom-engineers sheaves and rollers for wire ropes using some of the world’s hardest-wearing engineering plastics, formulated to reduce wear and maintenance and enhance safety in a wide range of machinery and materials handling equipment. Examples of such sheaves are fabricated from Cut To Size’s internationally proven Wearlon range of hard-wearing cast polyamide engineering plastics, such as the Linnotam products of the globally respected Licharz organisation. These products are formulated both for

OEM use and metal replacement in applications involving transmission of mechanical force and minimising friction. According to Cut To Size Managing Director Laurie Green, “Steel wire ropes are important and highly stressed machine elements in force transmission and conveying technology. In many cases, large plant depends on their functioning not only for efficiency but also safety. Wearlon can extend lifespan and enhance safety by reducing maintenance and preserving structural integrity for longer.” “Wire ropes are stressed by fluctuating forces, by wear, by corrosion and by extreme forces. Ropes that run over sheaves made from metallic materials are subject to high stress due to the surface pressure that occurs between the rope and the groove. When the rope rolls over the sheave, only the outer strands lie on the groove. The result of this is wear in the form

of individual strands breaking or, more serious, rope breakage,” says Green. “Sheaves made from Wearlon prevent this due to their elastic behaviour. The pressure between the rope and the roller in the combination steel rope/polyamide roller is around 1:10 compared to steel rope/steel roller. This can be attributed to the viscoelastic behaviour of polyamide. It is not just the outer strands that lie in the groove, but almost the whole projected strand width. This reduces surface pressure between the rope and the roller and considerably extends the life of the rope.” Cut To Size Plastics 1800 288 274

An Altrac monorail crane will I MPRO V E S A FE T Y CRE ATE BE T TE R W OR KF LO W I NCREA S E P R O D UC T I VI T Y But don't take our word for it - ask our satisfied customers . . . .

Bathurst Bell Tower uses a curved monorail to safely move 160-yearold church bells for maintenance.

Lowbake has incorporated turnouts to run a monorail like a railroad line to reach all corners of its client's facilities.

Amcor uses a curved monorail to protect workers' backs without disrupting existing workflow.

Contact us or visit our website for a free quote (03) 9796 5300 est. 1984


Visit us at Booth A6368





programming solution, the setup time on UR robots is now faster than ever.

“This brings us another step closer to a unified OnRobot one-system solution that makes it easy, fast and cost-effective for manufacturers to build collaborative applications, no matter which robots they choose.”

All OnRobot products now have a unified communication platform using standard fieldbus protocols, making it easy to program the tools, regardless of robot used. With the new fieldbus protocols, manufacturers can easily set software values and use more functions via a standard Ethernet cable, supporting an increased level of sophistication with a simple plug-and-produce approach that doesn’t require additional cables. Deployment time can be cut from 3 hours to 30 minutes, so manufacturers can get their collaborative application up and running quickly.

James Taylor, General Manager, APAC at OnRobot, adds: “The introduction of the One-System Solution is a huge step forward for the industry and is much needed in Australia to help local manufacturers embrace automation easily. With a speedy robot deployment process, manufacturers can reduce operational cost and reap the benefits of automation, faster”. End-of-arm tooling specialist OnRobot has expanded its offerings with a pair of interface products that combine with its tooling to create a novel onesystem solution that it claims dramatically simplifies automation. OnRobot’s Digital I/O Converter Kit allows the company’s tooling to be used with a full range of leading collaborative and light industrial robot brands. All OnRobot products now have a unified mechanical and communications interface based on the OnRobot Quick Changer, which is now an integrated part of all OnRobot products. An additional Dual Quick Changer

incorporates these same new capabilities while allowing the use of two tools in one cycle, mixing and matching to suit application needs and maximising robot utilisation. According to OnRobot CEO Enrico Krog Iversen “Manufacturers are demanding more from their robotic applications, and end-of-arm tooling has become the key to optimising their investments. “This integration of our Quick Changer across our current product lineup makes it easier than ever to switch between tools and robot types, allowing flexibility and reducing downtime for more

With the OnRobot Quick Changer – which is now integrated in all OnRobot tools - a single cable provides a universal interface for tools and communications, so there is no need to disconnect cables when changing tools, and extended communications options support a full range of robotic platforms. For Universal Robots robot arms, OnRobot now provides a unified URCap that allows all tools to work together, even in a single program. For example, using the new Dual Quick Changer, manufacturers can use an RG2 two-finger gripper together with a VG10 vacuum gripper in one cycle, achieving greater utilisation of a single UR robot. Thanks to the unified

For robots that connect through digital I/O, the new OnRobot one-system solution includes an OnRobot WebLogic interface. Using the IP address of the OnRobot Compute Box, manufacturers can sign in via the OnRobot WebClient from a phone or any other networkconnected device to monitor the robot or create simple robot programs. OnRobot is supported in Australia through six distributor partners: Mobile Electrics, Scott Automation and Robotics, Collaborative Robots Australia, Auto Controls Systems, Australis Engineering, and Diverseco. OnRobot

LARGER PAYLOAD COBOT MOVES INTO MACHINE TENDING Universal Robots (UR) has expanded the capabilities of its e-Series cobot family with the release of the UR16e which combines an impressive 16kg payload capability with an extended reach of 900mm.

duty tasks reliably and efficiently. This launch significantly expands the versatility of our product portfolio and gives manufacturers even more ways to improve performance, overcome labour challenges, and grow their business.”

The new larger unit claims a pose repeatability of +/-0.05mm, making it ideal for automating tasks such as heavy-duty materials handling, heavy-part handling and machine tending.

As with the other models in the e-Series platform, the UR16e is particularly easy to deploy. The unit can be unpacked, mounted and programmed to perform a task in less than an hour.

According to UR President Jürgen von Hollen: “In today’s uncertain economic climate manufacturers need to look at flexible solutions to stay competitive.

And with its small footprint and 900mm reach, the UR16e can be easily integrated into any production environment without disruption.

“With UR16e, we meet the need for a collaborative robot that can tackle heavy-

With its rugged construction and high reliability, UR reckons that the UR16e is



ideal for automating high-payload CNC machine tending applications, including multi-part handling, without compromising on precision. According to Peter Hern, ANZ Country Manager at Universal Robots: “Today, we’re making it easier than ever for every manufacturer to capitalise on the power of automation by bringing a cobot to market that is built to do more as it delivers more payload than our other cobots. “Australia is one of our most important markets in the region, and we believe there will be strong demand for the UR16e.” The UR16e meets the most demanding compliance regulations and

safety standards for unobstructed humanrobot collaboration, including EN ISO 13849-1, PLd, Category 3 and full EN ISO 10218-1. Universal Robots +65 6635 7270



VENTURI AERATOR IMPROVES WASTEWATER TREATMENT FOR BEGA CHEESE In 2018, Bega Cheese Environmental Manager – Northern Victoria, Sean Trebley was given the task of upgrading the wastewater aeration system at the company’s Strathmerton plant. The wastewater system consisted of a dissolved air flotation (DAF) unit, which flowed into an aerated lagoon, and after this the effluent was stored in two non-aerated lagoons during winter, before irrigation in summer. Aerators are needed to keep the chemical oxygen demand (COD) down and reduce odours in both the aerated lagoon and the downstream non-aerated lagoons. The company had an ageing system of surface aerators in the aerated lagoon, consisting of two 22kW units and six 8kW units. However, generally only one or two of these units were operated at any given time. Over a number of years these surface aerators had progressively failed because of their age and repairing them meant deploying cranes and/or boats to access them. This process was expensive and had resulted in damage to the dam liner. Eventually it became uneconomical to keep

on repairing the aerators. So Bega Cheese decided to look for a solution that was safer for operators and easier to maintain. Sean Trebley contacted Hydro Innovations to discuss the application of “bank-mounted” Venturi Aeration systems. These systems are mounted on the banks of lagoons and use a self-priming pump to draw water from the lagoon. The pump discharges it under pressure through the venturi aerator. The unit draws in atmospheric air using the “venturi effect”, mixes it with the water being pumped, and discharges it back into the lagoon, charged with dissolved oxygen. Trebley and his team liked the idea of bank-mounting because it gave operators easy access to equipment for monitoring and/or repair, making it much safer and more cost effective to maintain. Their only concern was whether the units were as efficient as the surface-mounted technologies. Hydro Innovations was able to provide information indicating that with the use of the right pump, oxygen transfer efficiency for Venturi Aeration units can be as high or higher than 1.86kgO2/kWh, making them as at least as efficient as the surface (floating) technologies.


The condition of the lagoon after the previous system had been decommissioned several months before.


The aerated lagoon contained 45ML of effluent, with in-flows from 80 to 120ML per year. This required a 150mm Venturi Aeration unit and was paired with a GormanRupp V6A60-B self-priming pump, with a hydraulic efficiency of 70%. Bega Cheese installed the unit early in 2019. Since installation, operators have seen a continued increase in the dissolved oxygen (DO) level, and have seen COD fall by 50% even though the higher level of mixing was resuspending settled solids, which became more “bioavailable” to the colony-forming units. Sean Trebley and the Bega Cheese

crew are happy with the ever-increasing levels of DO, the reduction in COD, and their odour-free lagoon. The wastewater and maintenance teams are also pleased that monitoring and maintenance can be done safely, and without the use of cranes, boats or winches. More information about Venturi Aeration venturi aerators and GormanRupp pumps can be obtained from Hydro Innovations. Hydro Innovations 02 9898 1800


Two weeks on, and it can be seen that ripples from the aerator “radiate” to all parts of the lagoon, ensuring a good level of mixing.



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The $900,500 project has undertaken ten pre-feasibility studies at sites across Tasmania, South Australia, Victoria and New South Wales, and five of these sites are to be chosen to progress to a full feasibility study. Three companies already confirmed for full feasibility are: McCain in Ballarat, Simplot in Devonport, and Lion in Adelaide. The sites will test commercially available technologies not widely used in Australia that have significant potential to optimise the application of process heat in manufacturing, while increasing the uptake of renewable energy. These technologies include heat pumps powered by renewable electricity and direct renewable heating options including biomass and biogas and associated storage.

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With process heating accounting for the largest share of onsite energy use in Australian manufacturing, lowtemperature processes offer the greatest opportunity for displacing fossil fuelled heat with renewably powered alternatives.


A full feasibility study and business case for all five sites will be complete by the end of 2019. If proven to be feasible, the projects will be eligible for further ARENA grant funding.

According to ARENA CEO Darren Miller: “A2EP’s project aligns with what ARENA is aiming to achieve through its new investment priority in helping industry to reduce emissions by supplying case studies which can be replicated more widely. “There is significant potential to increase the application of renewable energy for process heating in manufacturing. By switching to renewable energy technologies, industries such as food and beverage processing can significantly reduce their reliance on traditional forms of energy and save money on their operating costs, thereby encouraging more companies to adopt this approach,” he concluded. A2EP CEO Jonathan Jutsen added: “Australia lags behind other economies in deployment of process heat technologies that are innovative but proven. There is great potential to be smarter about process heat. “We waste a great deal of energy and we don’t take advantage of cost-effective renewables. There are literally thousands of businesses that could benefit from these ideas. “With the support of ARENA, this feasibility work will identify opportunities for manufacturing businesses across Australia to transition to cost-effective renewable energy solutions tailored to their businesses that will reduce their emissions and energy costs,” Jutsen concluded.




COMPOSTABLE SHRINK WRAP IS A PACKAGING FIRST A fully compostable shrink wrap for cucumbers has been developed in South Australia and is set to be launched on international markets. The compostable wrap is manufactured by BioBag World Australia and took 12 months to develop in partnership with South Australian produce and packaging businesses IG Fresh Produce. It was launched in September as an environmentally friendly alternative to the traditional polyethylene plastic wrap and has already generated export interest from Qatar and South Africa. IG Fresh Executive Director George Antonas said he was approached by South Australian independent grocer Drakes Supermarkets to develop a compostable fruit and vegetable wrap to replace traditional shrink-wrap.

Pack King has come up with a costeffective alternative to manual pallet wrapping for companies that can’t justify the purchase of a conventional semiautomatic stretch wrap machine. The Rapid Wrapper is a pallet-sized powered turntable with a generous 2 tonne working load capability that rotates at 8rpm, allowing the operator to wrap a pallet of goods with ease. “It simply doesn't make sense to wrap a pallet of goods with stretch wrap, while the operator is pulling on the film to stretch it, and walk backwards at the same time,” says Ron Mileham of Pack King. “It invites strains, aches and trip hazards. “It's far easier and safer to load the pallet onto the Rapid Wrapper, hold the film dispenser, push the foot switch, and let the powered turntable do the hard work, while the operator tensions the film and overlaps it as required,” Mileham concludes. The Rapid Wrapper is around half the price of basic masted semi-auto stretch wrap machines. It is perfect for small businesses and as a stand by for larger businesses for when their expensive stretch


wrappers fail, and they have to wait for them to be repaired. As there is no mast, there is no limit to the size of the load that can be wrapped, so long lengths of pipe, or pallets full of bumper are no problem. The compact unit is only 280mm high. It comes with a heavy-duty low-voltage (24V) foot control with a 3m cable and removable plug. The 4m heavy duty power lead also has a removable plug. There are notched fork sleeves that enable the whole unit to be lifted and stowed on pallet racking, with no fear of falling off. And as both cables can be unplugged there are no trailing cables to worry about. As a special offer Pack King will include four rolls of hand stretch wrap film and a stretch film dispenser free with every Rapid Wrapper ordered before Christmas 2019. That’s a total additional value of $150.00. Pack King 03 9720 0425

Antonas said the product was being used exclusively on cucumbers sold at Drake’s 38 South Australian supermarkets until 16th October, after which it will be available for a wide range of purposes. “JP Drake put the challenge to us and so we gave them product exclusivity for the first four weeks,” Antonas said. IG Fresh produce is a fruit and vegetable wholesaler located the South Australian capital Adelaide. Antonas said a potential investment partner from Qatar had travelled to Adelaide for the product launch with Drakes. He expected to begin exporting cucumbers dressed in the compostable wrap to Qatar by the end of October, with exports to South Africa and Europe to follow. The bioplastic film is made from a compostable resin called Mater-Bi that uses substances obtained from plants including nongenetically-modified corn starch. While there are other compostable products on the market, Antonas said creating a 100 per cent industrially compostable cucumber wrap required a unique process. “That’s where Scott Morton’s expertise came into it – because it’s heat shrunk onto the cucumber.

There’s plenty of compostable products out there but this one is for a specific purpose,” Antonas said. “There’s a big push to make all single use packaging compostable. So, you buy a cucumber, you peel off the wrapper and you put it in your greens bin and you know it’s not going to add to landfill and that sort of thing. Plastic has its place but not for single use, it just creates too much waste.” According to Antonas, the cucumber compostable wrap has the potential to be used on all fruit and vegetables, and BioBag World Australia director Scott Morton agrees. “The potential is endless. It’s improving all of the time. I see it as a direct replacement for plastic,” Morton said. Norway-based BioBag has six factories and 20 market or distribution partners around the world, producing over one billion bags a year. Morton said BioBag was also working on a nonshrink-wrap compostable product that could replace plastic cling films. He added that the cucumber wrap developed in South Australia could also be distributed in major global markets including the USA. “We’re trying to enhance the current cucumber wrap. It’s not quite suitable yet as a cling wrap alternative,” he said. “We’re developing a new product that’s more for the international market. That’s a product that will especially keep fruit and vegetables fresh. “We have some proprietary technology that we incorporate into it, so that way it’ll keep fruit fresh.” BioBag World Australia 1300 301 911






steel are made of inert plastic, so as to completely eliminate any potential to cause contamination to the product it is working around. Units are available with blade diameters of 460, 630 and 810mm, and Fanquip reckons they have the highest air output of any air circulator on the Australian market. The technology is rated as IP56 (for 240V) and IP69 (for 415V) hose proof, allowing the complete wash down of the equipment at regular intervals without causing any damage whatsoever. The hosing aspect enables Fanquip stainless-steel air circulators to have a long lifespan. Fanquip’s stainless-steel air circulators are reliable at meeting strict temperature control requirements to satisfy the demand of industrial companies wanting to maintain better working conditions for staff without compromising hygiene standards. Being made from stainless steel, they have a very long lifespan and not only lower the temperature of a site but also provide air movement to reduce condensation. Fanquip’s completely stainless-steel air circulators include stainless steel guards, stainless-steel motors and stainless-steel brackets for complete rust proofing and cleanliness. Any components that are not stainless

It is a completely relocatable product, therefore allowing the user to reposition the item as often as necessary to where it is most effective. Because of the threat of airborne spores, many sensitive industries such as the food production sector cannot afford to take the risk with air-conditioned equipment. This makes the Fanquip air circulator the obvious solution; and to have the advantage of stainless steel that lasts for years is a major asset to any operation. Fanquip 1800 224 308

Fanquip reckons its stainless-steel industrial air curtains are suitable in just about any new construction project, particularly those buildings which will be used in food handling or primary industry. Simple in design, this technology is specifically made with stainless-steel construction to provide a long life and keep it applicable even to the most sensitive industries. The potential for rust is all but eliminated and keeping the unit clean is very simple. The Fanquip air curtain technology also covers all the mandatory expectations of such equipment, ensuring the end user is totally compliant with industry expectations. In fact, Fanquip air curtains exceed the AQIS standards: a velocity of

8m/s at 900mm above the floor across the entire opening, and a minimum stream thickness of 50mm. These air curtains keep flies out of premises, maintain the integrity of cold stores, allow excellent visibility and access and are rated IP56 or IP66 as an option. With curtain widths of 900, 1200 and 1500mm available, Fanquip air curtains can be used to cover any size of doorway. And, being Australian made, technical support is rapid and reliable. Fanquip 1800 224 308

KEEP COOL ENCLOSURE CABINET PRECISION COOLING Designed to keep your electronics cool and operating at optimum performance. - Cooling capacities range from 200W to 6kW. - IP Ratings – IP54 & IP56. - Mild Steel and Stainless Steel finishes. - Seifert also offer Heat Exchangers, Peltier Coolers and Fan Systems - complete Thermal Solutions. / +61 3 9801 1906





KEEPING COOL IN CONTROL: A GUIDE TO THERMAL MANAGEMENT low and the temperature is approximately +35°C. As the temperature in an enclosure rises it can have a lasting effect on the electronics. Tests have shown that an increase in temperature of as little as 10°C shortens the life expectancy of electrical components by more than 50%. Enclosure climate control prevents critical temperature fluctuations, avoids overheating and protects against the formation of condensation. It is essentially the backbone of your entire production process, prolonging the life of your electronics and protecting your investment.

Preventing enclosure overheating in the summer can be a challenge for many factories, where temperatures can rise quickly on hot days. These high ambient temperatures can easily cause electrical components located inside control cabinets and enclosures to overheat. This not only reduces their lifespan, it also= contributes to downtime and repairs. When this happens, the temptation

is to open the door panel (and maybe use a fan) to remove heat and cool the components. But this allows dust, oils and surrounding debris to get inside the cabinet and risks damage to sensitive electronic components - not to mention the obvious safety issues. Determine the proper enclosure thermal management Electronics are typically most efficient in an environment where the humidity is

To choose the best thermal management solution you first need to understand your environment. Indeed, the environment in the electrical enclosure can be affected by weather conditions, solar radiation or other external temperature sources. As an example, an air to water heat exchanger will be suitable for an enclosure placed in a factory that faces hot weather spikes or an extremely dirty or caustic environment compared to traditional industrial air conditioners.

Electronics sensitive to electromagnetic interference may need a shielded EMC Filterfan. An enclosure located outdoors or in a humid environment may require hygrostats or thermostats and heaters to eliminate the formation of condensation, which might otherwise lead to corrosion and short circuiting.

Sizing software To determine the right thermal management solution, Pfannenberg has developed powerful web-based sizing software to help you configure Filterfans, cooling units, air/water heat exchangers, and heaters for electrical enclosures. The easy-to-use interface works for both indoor and outdoor applications and helps to calculate the heat dissipation in a cabinet, component by component. Control Logic 1800 557 705

NOVEL BYPASS TECHNOLOGY GIVES FANS A JET Billed as the next innovation in fan technology, Airius’s patented bypass technology enables its newest fans to produce unprecedented airflows, with the largest model, the G560, producing a whopping 21.28N of thrust. The bypass technology used in the new hidden-blade fans works in much the same way as the engines used in the Dreamliner jet, capturing and propelling


large volumes of air through the system.

new technology.

So while traditional fans push available air down, existing Airius hidden blade fans capture and push massive amounts of air through. The addition of the bypass technology takes their effectiveness to the next level by capturing and propelling air from the top and side of the fan for additional effectiveness.

The G560 is the mother of all fans, designed for Australian heat and for the large open spaces market. It is the company’s most powerful to date, and is designed to cool in the hottest of Australian warehouses and even stadiums.

There are two models initially using the

Also new, the Onyx is billed as a great all-rounder fan designed for optimal performance in a compact and effective

fan. Ideal for spaces from 4 to 8m high, the Onyx features an optimal balance of output and cost. Airius Oceania 02 6608 2736




Tim Webster

Australia’s National Icon and News Presenter

(Channel Ten, Foxtel, Sports Tonight, 2UE And 2CH)


Industry Update Youtube Channel Statistics

1,250,000 impressions* 588,000 views* *Since service launch in 2017

Since its launch in 2017, Industry Update Video has been a phenomenal success, with content spanning the whole of manufacturing industry.

• Hosted by national TV icon and news journalist Tim Webster • Filmed in a 6pm nightly news broadcast style • Creating a high level of integrity for clients’ products and services • Average video length of 1 to 2 minutes • Individual client playlists, have all your videos in one place • Embed these videos on your website or any social platform (Facebook, LinkedIn etc) • All magazine advertising includes a QR code that links back to your website

Product Video Packs Companies must have good video content now - buyers expect it and will just go elsewhere if they don’t have something interesting and informative to watch. More importantly it increases sales by 81% (see below). It is a no brainer.

More facts: With over 1.5 million impressions and 600,000 views in less than 12 months, our videos are getting great rates of engagement. Plus, each video has an accompanying story published online, in e-news and in the magazine (with a QR code) to integrate all media options.

76% of businesses with product videos say their sales have increased, while the improved educational quality of the content reduced support enquiries by 47%1 One billion hours of video are watched on YouTube every day, with a user’s average viewing session lasting 40 minutes2 Source: 1) 2)

Some of our Industry Update Video clients

Number one manufacturing publication in Australia Circulation of 19,233 and readership of 76,932 Audited by

02 9439 1288 /


ADVANCING LIGHTING TECHNOLOGY FOR INDUSTRIAL ENVIRONMENTS It’s hard to believe that it took nearly 60 years to perfect the incandescent lamp, which can only convert 5% of energy into light. Today, there many more choices based on efficacy, colour performance and controllability, which are the key visual factors for choosing a light source. However, in industrial environments there are additional criteria, such as resilience to harsh industrial environmental conditions such as extreme temperatures and explosive atmospheres that all require specialised light technology. Fluorescent lamps are cost effective and durable but may not be the best choice for emergency lighting with a start-up time of anything up to 12 seconds, poor operating temperature range and the undesirable presence of mercury. Although incandescent lamps have a very broad light spectrum and offer even illumination, they become very fragile in cold climates, and are a poor choice for high vibration environments. Also, their short lifetimes of around 2000 hours makes them a problem for replacement in difficult-to-access locations. Finally, discharge lamps are not suited

for confined spaces, where heat emission and large light enclosures directly impact the working environment, and have a slow start-up time of up to 30s. In comparison, LEDs can last for more than 100,000 hours. However, not all manufacturers are able to get the colour correct.

To predict accurate colour performance, the colour rendering index (CRI) is a quantitative measure of the ability of any artificial light source to faithfully reproduce object colour compared with natural daylight. Unlike incandescent and halogen lamps, which both have a very broad spectrum, compact fluorescent and LED lamps have gaps in the emission spectrum and require good manufacturing techniques and special electronics to compensate for the typically blue appearance of LED lights. Stahl is pioneering the future of industrial lighting because it takes careful consideration to ensure occupational health and safety at work. The company has revamped its entire lighting range to use hardened LED technology – and not just to reduce operating costs. Stahl’s LED technology meets specific


standards and directives for strict IEC ex explosive atmospheres, while providing start-up to full power in milliseconds, a high CRI index for natural colour rendition, and operating temperature ranges that outperforms other technologies. These factors combine to make it very well suited for emergency lighting and extreme industry environments. LEDs are an obvious choice for low operating cost and long service life between maintenance. Stahl’s 6002/6402/6036 range features environmental compatibility for explosive atmospheres, wide operating temperature ranges and performance for superior efficacy and long life. Control Logic 1800 557 705




QUALITY CONTROL DEVICES COME WITH A 10 YEAR GUARANTEE Arlin Components & Hardware has expanded its portfolio of control and signalling devices following the award of an exclusive distribution deal from French switch manufacturer BACO. BACO’s ranges of pilot devices, switches, cam switches and switch disconnectors are all premium quality devices that Arlin’s ANZ National Sales Manager Anil Garyali predicts will find great support from builders of machines and control panels in both Australia and New Zealand, as well as in the access control market. “This is a major coup for us to be able to introduce such a premium brand to the ANZ market,” says Garyali. “And with all products backed by a 10 year manufacturer’s guarantee, the quality and reliability of the BACO range will make them a first choice for machinery and control cabinets, particularly in critical industrial applications.” The BACO range includes a large

variety of AC-rated pushbuttons (22 or 30mm), pilot lights, selector switches and enclosures for a wide range of standard industrial or commercial applications. Their highly modular design enables maximum design flexibility with a minimum holding of components.

to IP67 for washdown environments.)

Snap-in designs simplify installation, and most components carry an IP66 rating. (Many are available optionally rated

BACO switch disconnectors are based on a modular design with three central elements that allow users to cover




The BACO range of rotary cam switches covers a range from 10 to 250A, with more than 50,000 different electrical configurations available. Each one uses a metal shaft rated for more than a million operations.

a full range of applications. All devices satisfy IEC 947-3 and EN 60 947-3 standards and have ULand cUL approvals. Arlin Components & Hardware 1300 362 191

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INTELLIGENT TOUCHSCREEN HMIS ARE EASY TO INTEGRATE Following the signing of a new global distribution agreement, Mouser Electronics is now stocking a range of capacitive and resistive intelligent displays made by Clairitec. Clairitec’s capacitive intelligent displays and resistive intelligent displays are ready-to-install EMCcompliant modules designed to add a touchscreen human machine interface (HMI) to an application.

ENTER THE NEW GENERATION OF WHITEBOARD MARKER TECHNOLOGY easier to read than traditional whiteboard markers.

Available with a choice of 3.5, 4.3, 7.0, and 9.0in touchscreen displays, the modules include an integrated HMI board and a metal protective cover, and can be connected to the host application via a serial RS232, CANbus, or USB connection.

HMI application. The kit is available with a 4.3, 7.0, or 9.0in display and includes all required connecting cables, as well as the GraphConverter HMI software, which allows engineers to quickly and easily create a custom GUI and download it to the Clairitec module.

Clairitec’s capacitive starter kit is based on the capacitive intelligent display and includes everything needed to start a touchscreen-based

Mouser Electronics +852 3756 4700

The whiteboard markers combine a liquid ink with a revolutionary twin-pipe feed system to guarantee constant ink flow. One pipe carries the ink to the tip while the other feeds air back to the reservoir.

The humble whiteboard marker has been transformed by the V Board Master from Pilot Pen, a new range that is equally at home in the boardroom and on the shop floor. Embodying no fewer than 18 applied patents, the technologically advanced V Board Master is both easier to use and

As a result, there is no need to pump or shake the marker, and there’s no danger of leakage – just a constant steady flow of ink. And the transparent ink reservoir gives an instant indication of the ink level and when it’s time to refill. Pilot Pen Australia 1300 325 866


WORK IN TOTAL SAFETY WITH NILFISK INDUSTRIAL VACUUMS Design, ease of use and flexibility make the Nilfisk Industrial Vacuum Range the most popular with companies where safety and hygiene is a must.

Nilfisk work closely with Industry Specialists and safety consultants to ensure the range is WHS compliant and certified. IECEx certified model available.






USING TECHNOLOGY TO MANAGE MULTIPLE CLEANING MACHINES When you have a large fleet of cleaning machines to manage, you’ll quickly find yourself faced with a number of challenges, such as: who’s using which machine (and when); keeping track of machine locations and finding lost ones; monitoring machine performance and maintenance needs; and the all-important calculation of costs per machine. All these are critical to ensure your operations can run smoothly and you get the most from your machines. But doing it all manually just isn’t practical for you or your team. Collecting and reporting on all the data eats into valuable cleaning time (and profits). The good news is that you can purchase machines equipped with smart cleaning technology that allows you to monitor and manage your cleaning equipment. It won’t solve all your problems, but it’ll help minimise them and make them a lot easier to keep under control. Smart cleaning technology, such as Tennant’s IRIS Asset Manager can help manage a large fleet of machines.

Using data to make decisions Today, running any business is all about data. And advanced cleaning technology provides data on each machine, such as how they’re being used, and where they’re located. Getting the right data at the right time

can help empower you to make better decisions based on facts (not just gut feel). And these decisions can have a real impact on operations. For example, swapping an underutilised machine out into the field, or scheduling an extra training session for staff who aren’t following protocol or best practices, or maybe investing more in the machine/technology that demonstrates better performance. Real, quantifiable metrics mean you can confidently make decisions, deliver a better clean, optimise team performance, and run a better business. Which in turn means happier customers.

Spot patterns and solve problems What happens if you get a customer complaint? Or you experience a recurring maintenance issue with one of your machines? Smart cleaning technology can help you find out the source of your problem and fix it. If a customer complains about the standard of cleanliness in an area, you could check the data to make sure your cleaning machines were being used appropriately, and for the expected length of time. To solve the issue, you’d make sure the machines are performing optimally and increase the cleaning time, if needed.

Or perhaps you have certain machines that seem to break down regularly. Data enable you to check the machine’s usage and identify if there are any patterns that might cause problems. Another very useful pattern you can track is spending data - on maintenance, servicing, and repairs. That way, you can forecast future spending and set aside a more accurate budget.

Inbuilt training technology Especially with new cleaning technologies that continually change and improve over time, regular training means your team can keep up with the latest changes, new efficiencies, and improved standards. But what if your training and onboarding processes were built into the machines themselves? These days, many advanced cleaning machines include technology that can speed up your team’s learning. For example, some Tennant machines come with Pro-Panel LCD touchscreens. These control panels offer a huge range of features and options, including on-demand training videos, 28+ language options for diverse workforces, and preoperation checklists.

Save on costs Managing a large fleet can get expensive. But you can control and mitigate those costs with smarter cleaning technologies. For example, by tracking battery charging activities and ensuring team members follow best practices, you can extend battery life and minimise battery replacement costs. You can reduce the likelihood of losing machinery or equipment with location data and alerts, minimising machine replacement costs. And you can ensure efficient cleaning technologies are being used to maximise performance and cost savings. Tennant Australia 1800 226 843

A fully integrated system or a basic component – YOU choose from a single supplier.

Local Manufacturer

Adept has been supplying the materials handling industry with innovative and Bespoke designs for many years.

Not an importer, we use components from our own exclusive European partners and build all conveyor products HERE.

Warehouse order fulfilment systems.

European Quality

Freight and courier parcel handling systems.

Partnered with affiliates from all over Europe for specialised products.

E-commerce - Scope and range to satisfy and support most e-commerce companies. Faster Deliveries - Not subject to long lead times. Faster deliveries than all industry peers. Systems can be up and running before others get theirs off the boat. Flexibility - We provide solutions from a basic component to full system analysis, design and implementation. Long Term Support - Will always have availability of spares no matter how old the design may be.





(02) 9771 4655 (03) 9357 8814



FLAT WASHER RANGE ADDS EVEN MORE NONSTANDARD SIZES During the course of 2019, Boker’s has added tooling for 548 new nonstandard flat washer sizes to its industry-leading selection. With the addition of the new sizes, the company now offers more than 32,000 nonstandard washer, spacer and shim sizes that are available to customers with no tooling charges. “These new tool additions further expands the made-to-order offering for a increasingly wider range of applications and industries,” says Pete Flodquist, Boker’s Sales Manager. “We now offer immediate manufacturing availability for well over 32,000 nonstandard sizes of washers, spacers and shims, and if there isn’t a tool for your exact specifications, our in-house tooling department can design and create one quickly to meet your needs.” Additionally, Boker’s nonstandard precision washers are manufactured in more than 2000 commonly specified and difficult-to-find material options. The comprehensive range of sizes includes outside diameters from 0.08 to 12in, with a

wide range of inside diameters. In addition to flat washers, other shapes and styles are available in metallic and nonmetallic materials. Metallic materials include low-carbon steel sheet, various spring steels, stainless steel, aluminium, brass, copper and nickel silver. Nonmetallic materials include ABS, acetal, polyester, nylon, MD nylon, polycarbonate, fibre, polyethylene and various NEMA grade phenolics. Boker’s +1 612 729 9365

APP-BASED CONTROL IMPROVES VACUUM SYSTEM OPERATION Schmalz has developed a novel smartphone app that simplifies the installation, parameterisation and operation of its vacuum components, such as the VSi vacuum and pressure switch. Available now from Google Play for Android smartphones and tablets, the Schmalz ControlRoom app will help reduce procurement costs, cut start-up time and optimise device servicing. This app-based control removes the need for display and input modules on each vacuum device, and this can reduce procurement costs by up to 40 per cent.

In case of operational malfunction, the app provides easily understood messages in plain text describing the cause of the problem and how to correct it. Users also have the option of storing relevant information on the switch to be accessed later, for example the installation date or the location where spare parts are stored.

In addition, components can be started up out of the box. For example, with the app a user can simply scan a vacuum switch and then enter various values using the app. This eliminates the need for complex setup procedures with long instruction manuals.

The app also helps improve reliability with facilities for predictive wear monitoring to reduce the risk of device failure. Users can set a reminder for predictive maintenance as well as a list of possible high-wear parts.

The app can also transmit settings from already installed switches to other devices in seconds. This allows users to reduce start-up times by up to 75 per cent.

Schmalz Australia 03 9215 8800







Lightweight construction plays a major role in aircraft design, whether they are carrying passengers or cargo. And these weight considerations are not just financial, they are also environmental: a reduction in weight of just 1kg can save an airline 31,000L of jet fuel and avoid around 78,000kg of CO2 emissions per year.

Designing the right shaft for an application is not easy without the right CAD software and in-depth technical knowledge. But now igus has developed a novel easy-to-use online tool in the form of the drylin shaft configurator.

So airlines are constantly on the lookout for potential savings, as well as partners who know how to achieve them. And every little helps sometimes in less obvious parts of the plane. Service trolleys are an indispensable feature of passenger airliners, carrying food, drinks and souvenirs along the aisles for the cabin crew to distribute.

Saving weight was not the only consideration, though. High standards of hygiene, stability, safety and design also had to be met. For example, the synthetic material used is particularly stable, yet still guarantees a high degree of flexibility. The contours of the fork were designed to allow effortless manoeuvrability in the small kitchen and narrow aisles.

One producer of these trolleys, Frankfurtbased Spiriant GmbH, recently set out to design a lighter weight service trolley that would help cut down on fuel consumption and CO2 emissions. With this in mind, the company turned to Tente for suitable castors.

The locking system was designed with flight operations in mind, so the trolleys stand firmly and securely when the aircraft are climbing and descending and even in turbulence. Finally, the castors had to be supplied in the client airline’s corporate colours.

Tente had already developed an impressively low-weight castor at the turn of the millennium: the Aviana. So, in close consultation with both Spiriant and a leading German airline, the company’s designers set about making the castor even better for use in airliners.

The Aviana light saves 1.3kg per set of castors, and the airline has 30,000 trolleys in service. As a result, the new castors are saving the company 11 million litres of jet fuel per year while protecting the environment with a 28 million kilogram reduction in CO2 emissions.

They modified the wheel, fork and bearings using an ultralight synthetic material, and introduced aluminium for the fixings. The result was the Aviana light, weighing just 350g each.

Tente Castors & Wheels 1300 836 831

In just three steps, the user can select the right shaft in the required length from a choice of seven different materials and finishes and with diameters from 6 to 50mm. The configurator then allows the user to machine both the main body and the ends with standard elements such as chamfers and grooves. The guide shaft can then be ordered directly from Treotham Automation. In addition, the user receives the STEP files of their configuration as well as a dimension drawing for download – all free of charge.

The stainless-steel shafts are ideal for the food processing industry, while aluminium shafts are a lightweight and cost-effective alternative for mechanical engineering.

In addition to hard-coated aluminium shafts, hardened or chrome-plated steel shafts, several hardened stainless-steel materials and VA shafts are also offered.

Treotham Automation 1300 65 75 64

EBOOK FOLLOWS PROCESS FROM INSPIRATION TO PRODUCT Mouser Electronics has kicked off its latest Engineering Big Ideas series of eBooks with a free volume in which electronics industry experts look at how innovators move from the first spark of inspiration to product design to the first steps of production. Designing an Idea begins with a foreword by Skullcandy Chief Product Officer Jeffrey L Hutchings, who examines how the path from idea to product is changing, with expanded access to tools and resources presenting organisations and individuals with new, more affordable routes to production. Special contributors to the new eBook include Bob Martin, “Wizard of Make” and Senior Staff Engineer at Microchip Technology; Josh Lifton, PhD graduate of the MIT Media Lab and cofounder and president of Crowd Supply; and Dr Andy Stanford-Clark, CTO of IBM in UK and Ireland. The book also includes an innovationto-productisation model that can help technology creators improve their chances of success. The Engineering Big Ideas series is supported by Mouser



suppliers Analog Devices, Intel, Microchip Technology and Molex. “The road from idea to product can be arduous and filled with obstacles, but new technologies are opening up new and quicker paths,” said Kevin Hess, Senior Vice President, Marketing at Mouser Electronics. “The Engineering Big Ideas series begins with a look at how innovators develop their concepts and where they go from there.” The Designing an Idea eBook is available now from Mouser. Mouser Electronics +852 3756 4700



MODULAR INCLINE CONVEYOR SYSTEM IS FIT FOR FOOD USE The Mi-Con modular incline conveyor system is billed as the first hygienically designed full-washdown system to be made with multiple standardised components. This novel design from Enmin makes Mi-Con a highly flexible system, allowing customers to select what will best suit their specific product and production needs.

Mi-Con is the only conveyor system on the market that can be delivered flat packed in a box. This not only speeds and reduces the cost of delivery, it enables simple installation by the customer’s maintenance team. It can also be delivered to the customer partially complete or fully complete for quicker installation and commissioning.

“We recognised the industry demand for flexible, reliable, cost effective equipment and that’s what led us to designing our Mi-Con modular conveyor system,” says Enmin General Manager Anthony Gallaher.

Fully Australian made, the MiCon system is constructed of 304 stainless steel and all components and running gear used are FDA approved and suitable for a full washdown environment.

“The key benefit of this modular system is that it eliminates equipment redundancy and expands with the customer’s business. It can be added to, extended and modified in the years ahead as a company’s production needs evolve,” he adds.

A range of accessories allows the customer to semi-customise the conveyor to suit the type of product to be handled or the site’s operational requirements. All items have been hygienically designed to meet the toughest of OH&S standards while

maintaining flexibility and quality. The modular intermediate section can be used to extend the available in-feed and out-feed sections and also increase the overall discharge height of the conveyor. With two standard belt widths of 500 and 700mm and incline angle options of 60 and 75 degrees, the Mi-Con will suit a wide variety of applications and space constraints. conveying equipment and provide years of economical, trouble free operation for a multitude of product applications. We believe that the market potential for the product is huge as it can be utilised by any food and ingredient manufacturing facility,” Gallaher concludes.

The system can use either a PU flat, scooped cleated wave wall, or a plastic modular design depending on the application. Other Enmin conveyor options include accumulation, takeaway, bag conditioning/ lattening delivery conveyors and packing tables – all designed to fit perfectly with the MiCon system. “We are confident our new MiCon system will revolutionise product

Enmin 03 9800 6777

1300 362 191

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Warehousing We have large warehouses to store your orders and providing them to you only when needed.

Packaging Our professional packaging service ensures everything you need is protected in a secure package.




Industry Update Video has been a huge success, with more than a million impressions and half a million YouTube views in one month alone during 2018. All our videos can be viewed on the Industry Update YouTube Channel and from the Industry Update Website. And now readers of Industry Update Magazine can check out the latest releases direct from this regular Video Update section. Just scan the QR codes on these pages with your mobile device of choice and you will be taken straight to the video. (Users of some older mobile devices may need to download a QR reader app.)

Adept Conveyor Technologies - Handling Change within the Industry

Adept Conveyor Technologies - MRT Range

Applied Machinery - Yawei Laser at DJN Switchboards

Applied Machinery - Yawei-Nisshinbo HPE Series

Bestech Australia - LA-25-A LVDT

Cigweld - Transarc Welding Units

Control Logic - ABB Power Factor Correction

DMF International - High Speed Security Doors

Floorsafe Australia - Tactiles

Global Pumps - MetaLine

A-Safe - eFlex Forkguard Kerb Barrier

Hare & Forbes - Swifty Plasma Cutter



Honeywell - Sync Wireless Earmuff

Adept Conveyor Technologies- Bespoke Solutions

Hydro Innovations - Aggressive Wastewater



Lapp Austraila - Robotic Cables

Mechtric - Hazardous Area Signals

SEW Eurodrive - Decentralised Drive Technology

Lencrow - EPT20 Pallet Jack

Pilot Pen - Permanent Markers that wont dry out

Southern Cross Compressors - Custom Air Compressors

Spitwater - Scrubber Dryers

Tennant - Factory Direct Service

Turck Australia - Banner K50 Series

Turck Australia - Banner Q5X

Lencrow - HRT Series Affordable 4WD Forklift

M.T.I. Qualos - PE200 Traffic Doors

Protoblast - Abrasive Blast Wheel Machines

Protoblast - The Protoblast Advantage

Southern Cross Compressors - LGX Series

Tennant - Vacuums and Readyspace Technology

Turck Australia - EZ Screen LS

Southern Cross Compressors - LMF Series Compressor

Tente - The History of Tente

Turck Australia - Mil-Spec Cordsets







ENTER THE DRAGON FOR THREE GOOD CAUSES The St.George Bank Happy Dragon made a surprise and rather athletic appearance in Parramatta Park last month as part of the Coleman Greig Challenge. Inside the suit was none other than regular Industry Update contributor Matthew Kelly, Head of Manufacturing & Wholesale at St.George Bank. The Coleman Greig Challenge is an annual event that raises funds for three very deserving children’s charities: St Gabriel’s School, the Royal Institute for Deaf and Blind Children, and the Westmead Hospital Foundation. Participants have a choice of running, cycling and walking events from which to gather sponsorship. And while Kelly and the St.George team did choose the “light duty” 2.5km walk, the addition of the dragon suit certainly added to the calorific value of the exercise! And while the final figures have not yet been published, the event is well on the

way to reaching its target of $250,000 and beating 2018’s record haul of $231,000. The St.George team were delighted to be named Highest Corporate Fundraiser for raising more than $23,000 to date. And the Highest Individual Fundraiser was the Happy Dragon himself, Matthew Kelly. You can learn more about the Coleman Greig Challenge at cgchallenge.


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

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: Web:




Trailer manufacturer MaxiTRANS has raised over $19,000 for the R U OK? campaign. The company once again committed to donating 1% of transactions on R U OK? Day 2019, as well as a number of activities earlier in the year contributing to this outstanding show of support for suicide prevention. MaxiTRANS and its staff, in conjunction with the company’s longest standing dealer partner Mildura Truck Centre, joined together to support this great cause, with 1% of the purchase price from all new trailers, truck bodies ordered, and parts purchased from participating outlets. This year, MaxiTRANS commissioned a Freighter T-Liner semi-trailer with R U OK? branded curtains - sponsored by Fleetmark. The trailer will continue to create awareness for R U OK? throughout the year. A company-wide campaign was held on the day for its staff, which included donations, wearing yellow, taking time out to ask each other about their own welfare, as well as internally promoting discussion around mental health prevention. Sites also had speakers sharing personal experiences about their own mental health. This year brings MaxiTRANS’ total donation to almost $45,000, since its first R U OK? Day campaign in September 2017. R U OK? Day is held every September

and encourages people to “trust the signs” and ask friends, colleagues and family members R U OK? to raise awareness for mental health and suicide prevention. MaxiTRANS Managing Director and CEO, Dean Jenkins, says: “This is why we are actively involved with many Industry bodies driving the safety agenda for all of our customers and the greater road users. “We place significant emphasis on safety at all our facilities. MaxiTRANS has been especially proud of delivering a 48% reduction in the total injury frequency rate over the past 12 months. Safety is a fundamental driver not only in the development of all of our products but it also extends through one of our company values to send all our people home safely. “Safety today whether it be at home or at work, is not just physical it includes mental wellbeing. Which is why in addition to the mental awareness campaign, MaxiTRANS also makes professional services available to our staff and families as part of ongoing support. “Most importantly, we should not limit suicide prevention to one day a year,” he concludes. “If you see someone struggling, at any time, ask them R U OK?”. MaxiTRANS 03 8368 1100



It simply doesn't make sense to wrap a pallet of goods with stretch wrap, whilst the operator is pulling on the film to stretch it, and walk backwards at the same time. It invites strains, aches and trip hazards. It's far easier and safer to load the pallet onto the Rapid Wrapper, hold the film dispenser, push the foot switch, and let the powered turntable do the hard work, whilst the operator tensions the film and overlaps it as required. She/ he can also pass the film under the corners of the pallet, for a more secure load.


Big 2000kg working load. 8rpm rotation speed.

Large 1220mm diameter checker plate turntable.

Only 280mm high.

Engineered notched fork sleeves enables secure stowing on pallet racking.

Can be loaded / re-located / stacked, using a walkie stacker or forklift.

Heavy duty, low voltage (24V) foot control with 3 metre cable and removable plug.

Heavy duty 4 metre, 240V power cable with removable plug (allows stowage without trailing cables).

Finished in Safety Yellow.

Rapid Wrapper is around half the price of basic masted semi auto stretch wrap machines. It is perfect for small businesses and as a stand by for larger businesses for when their expensive stretch wrappers fail, and they have to wait for them to be repaired. When not required, the notched fork sleeves enable the Rapid Wrapper to be stowed on pallet racking, with no fear of falling off. The cables can be unplugged, so there are no trailing cables to worry about. This enables the best use of your work space. Bring down the wrapper only when you need it! With no mast, there is no limit to the size of the load to be wrapped, so long lengths of pipe, or pallets full of bumper bars present no problem to the Rapid Wrapper.

MORE GOOD NEWS! Pack King will include FREE with every Rapid Wrapper up until Christmas, four rolls of hand stretch wrap film, AND a stretch film dispenser, total value $150.00.
















23-24 October 2019, Melbourne Convention & Exhibition Centre

30-31 October 2019, Sydney International Convention Centre

5-8 July 2020, Melbourne Convention & Exhibition Centre



23-24 October 2019, Melbourne Convention & Exhibition Centre

24-27 November 2019, Crown Promenade, Melbourne



23-24 October 2019, Melbourne Convention & Exhibition Centre

13-15 May 2020, Sydney Showground


ARBS 2020

23-24 October 2019, Melbourne Convention & Exhibition Centre

19-21 May 2020, Melbourne Convention & Exhibition Centre



29-31 October 2019, Sydney International Convention Centre

27-28 May 2020, Melbourne Convention & Exhibition Centre ENERGY NEXT 14-15 July 2020, Sydney International Convention Centre

1. What are the next three letters in the sequence WATNTL …?


2. What is special about the number 8,549,176,320?

14-16 July 2020, Melbourne Convention & Exhibition Centre


Where would you find Hyperion, acknowledged as the tallest tree in the world?

"All of the big questions (of today) actually have answers… it’s frankly meshing the answers with the rolling shit of politics which is really hard." Kevin Rudd "I think women are foolish to pretend they are equal to men — they are far superior and always have been." William Golding

Tunnel – the first tunnel to be constructed successfully underneath a navigable river?

2 After whom are the Torres Strait islands named?

6 In international cricket, which side has won the Cricket World Cup on the most occasions?

3 …. and in which year did he first navigate them?

7 Which world city is sinking the fastest due to climate change?

4 Which late US comic actor was born Jerome Silberman on 11th June 1933 in Milwaukee, Wisconsin?

8 Where in Australia is the Big Scotsman? 9 Which medical marvel was developed by Dr Fiona Wood at Royal Perth Hospital in 1992? 10 Is the answer to this question 'No'?


" A man is but the product of his thoughts. What he thinks, he becomes." Mahatma Gandhi "I have left orders to be awakened at any time in case of national emergency, even if I'm in a cabinet meeting. " Ronald Reagan "The kidney has a very special place in the heart." Donald Trump "It's so simple to be wise… just think of something stupid to say and then don't say it. " Homer Simpson

Teabreak Trivia

" Why would we want to contain China's growth? That would be a bit of a numpty thing to do." Scott Morrison

"Patriotism is supporting your country all the time, and your government when it deserves it." Mark Twain

1 Redwood National Park, California, 2 Spanish explorer Luís Vaz de Torres, 3 1606, 4 Gene Wilder, 5 Isambard Kingdom Brunel, 6 Australia (5), 7 Jakarta (sinking by 250mm per year), 8 Medindie, Adelaide, 9 Spray-on skin, 10 Paradoxically, yes.

The best industry and political quotes of the past and present:

3. I dropped a raw egg onto solid concrete but it didn’t break, or even crack. How?


5 Which 19th century engineer began his career by working on the Thames



2019 has been a remarkable year so far, with Australian manufacturing industry defying expectations and continuing to grow month on month, apart from a slight drop around the time of the federal election. And the year is set to end on a high with the November issue of Industry Update, traditionally one of the best read of the year. Special features include: • LED Lighting • Alcohol and Drug Awareness • IT Hardware and Software • Fasteners and Adhesives • Workplace Hygiene • and our ever-popular Christmas Gift Guide Plus all our regular sections on Machinery,

Workplace Safety, the Environment and Industry Politics, and more stories in our new Community section. This is a great opportunity to get your message to our readership of more than 72,000 manufacturing professionals. The deadline for editorial submissions is Monday 21st October 2019. Don’t miss out. Editorial copy and images should be sent to Advertising enquiries to Scott or Glyn on 02 9439 1288. All advertisers are guaranteed editorial coverage.

1. ITS. The sequence is the first letter of the words in the question. 2. It contains the ten digits in alphabetical order. 3. Concrete is too hard to be broken or cracked by a raw egg. Lateral Thinking





CHILL. WE’VE GOT YOU PROTECTED. The A-SAFE Cold Storage range has been meticulously engineered to provide the highest levels of protection to pedestrians, assets and infrastructure. The range includes a full suite of high-performance safety products for applications within very low-temperature environments. Food-safe, robust and effective to -30°C, Cold Storage products from A-SAFE have been purpose-designed for use in frozen food storage facilities and other challenging sub-zero environments.

For more information contact A-SAFE AUSTRALASIA PTY Ltd • Tel: +61 2 9625 8927

Profile for Industry Update

Industry Update Issue 110 October 2019  

Industry Update Issue 110 October 2019