October 2018

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MANUFACTURING TECHNOLOGY What if machinery components were the sensors?

SMART MANUFACTURING The connected factory.

makes skin care product from hoki skins

BUSINESS NEWS Aurecon appoints CSIRO leader to Manufacturing practice.

Custom-built “Iguana”

A Waikato company has designed a new machine to mass produce a natural skin care range made from fish skins to meet growing international demand for the product. Custom-built by Stafford Engineering Ltd, the electrospinning machine nicknamed “The Iguana” manufactures ActivLayr, a skin care product made by West Auckland nanofibre producer Revolution Fibres. With more than 9000 components, and at 7m long, it is one of the largest machines of its kind in the world. Revolution Fibres Operations Manager Brent Tucker says while the company has been producing nanofibre for almost a decade, the Iguana enables a greatly increased production capacity to meet demand for ActivLayr both locally and internationally.

clients know what they want to produce but don’t have the expertise or capability to build it themselves. “That’s where we come in. For us a machine is a machine and in the case of Revolution Fibres, they had a very good idea of what they wanted. “The design of the Iguana is a collaboration of Revolution Fibres’ knowledge and requirements, and our engineering expertise to ensure the equipment performs and functions the way it should and produces the best possible outcome.”

“The Iguana is a fantastic collaboration between the best Kiwi minds from the science and engineering worlds. It allows Revolution Fibres to increase production to meet demand, but it also means we can grow the production of ActivLayr in New Zealand.”

The nanofibre manufacturing process starts with fishing company Sanford supplying hoki skins, from which pure collagen is extracted. Using the process of electrospinning in the Iguana, Revolution Fibres transforms the collagen into nanofibre. During the electrospinning process natural ingredients such as

Roger Evans, Stafford co-founder, says most of its

continued on Page 12

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www.nzmanufacturer.co.nz BUSINESS NEWS What’s all the blockchain fuss about?

14 DEVELOPMENTS

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2018

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Analytics leaders wrestle with AI challenges for 2018.

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16 DEVELOPMENTS

Engineering firm takes mentoring to another level.

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Is there a standard for smart manufacturing?

Waiting for smart manufacturing standards to develop before implementing the Industrial Internet of Things into your operations may not be the most productive choice. By Dave Vasko, director of Advanced Technology, Rockwell Automation Smart manufacturing is called different things in different countries: Manufacturing USA (United States), Industrie 4.0 (Germany), China 2025 (China) or Industrie du Futur (France). The U.K., Sweden, Japan, Korea and India all have country-specific efforts as well. What do these initiatives have in common? They are all: • Creating a vision for smart manufacturing. • Using the power of digitalization to help manufacturers reduce capital expenditures, improve time to market, reduce inventory and improve productivity. • Extending existing standards to realize the vision. The last point is an important distinction: These initiatives are not creating new standards — they are classifying how best to use existing standards. That means the groundwork for smart manufacturing, Industrie 4.0 and other initiatives is being done in standard developing organizations such as the IEC, ISO, ISA, IEEE and the OPC Foundation. These organizations are where the influence starts and leadership takes hold.

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policy issues pertaining to, among other things, global economic growth. On the agenda is digital technology. Countries and companies around the world are eager to adopt digitalization strategies because it levels the playing field for smaller companies, allowing them to reap the same benefits as larger firms, and remain globally competitive and relevant.

Industry is slow to adapt to new technologies, mostly because replacing existing assets with new, smart manufacturing versions can be complex and take time. The transition should take place in phases.

This means if you look only at one count initiative, you’ll have a limited view of global movement. You must look at glo standards to understand global impact.

So rather than the name of the initiative t differentiates the work, it’s the standa behind that initiative that make the differen

The Time to Start Is Now

For organizations hesitant to start their journ

continued on Page 2

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CONTENTS DEPARTMENTS

1 DEVELOPMENTS Custom-built “Iguana” makes skin care

ADVISORS

products from hoki skins.

NEWS 5 BUSINESS An engineering excellence partnership. 6 BOOKS How power works; The value of everything…and more.

Leeann Watson

Is the Chief Executive of the Canterbury Employers’ Chamber of Commerce (the Chamber).and is a strong voice for Canterbury business.

TECHNOLOGY 7 MANUFACTURING What if machinery components were the sensors? What next for the industrial internet?

Dieter Adam

Chief Executive, New Zealand Manufacturers and Exporters Association has a Ph.D. in plant biotechnology, consulting and senior management roles in R&D, innovation and international business development.

12 DEVELOPMENTS Nothing artificial about the intelligence of Kiwi students.

13 ANALYSIS Transformation delivers priorities. R& D tax credit policy finalised.

PROFILE 14 COMPANY Democratising carbon fibre.

Kirk Hope

Is Chief Executive of BusinessNZ, New Zealand’s largest business advocacy body. He has held a range of senior positions at Westpac and is a barrister and solicitor.

15 DEVELOPMENTS Hamilton businessman wins Australasian

engineering award. Boost for infrastructure decision making.

16 SMART MANUFACTURING

Aurecon and Seequent lead on NZ’s largest transport infrastructure project. Increase your productivity efficiency. Lightweight scanning solution. Want to build a moon base? The connected factory, where standards are starting to stick.

UPDATE 23 PRODUCT What are the different types of air

compressors? Kemppi releases tough X3 MIG welder. Cordless pump offers portability and safety.

CHAIN 25 SUPPLY Wipak leads with intelligent digital

Lewis Woodward

Is Managing Director of Connection Technologies Ltd, Wellington and is passionate about industry supporting NZ based companies, which in turn builds local expertise and knowledge, and provides education and employment for future generations.

Dr Troy Coyle

Is HERA Director, she has extensive experience in innovation, research management and product development, most recently as Head of Innovation and Product Development & Pacific Islands Export Manager at New Zealand Steel..

packaging.

MANUFACTURING 26 FOOD Breakthrough technology could save dairy industry millions. Why you should hope your next tomato’s grown inside by robots.

Craig Carlyle

Is Director of Maintenance Transformations Ltd, an executive member of the Maintenance Engineering Societyand the Event Director of the NationalMaintenance Engineering Conference.

29 DEVELOPMENTS World renowned space company partners with NZ research institute. Engineering NZ adds expertise to claims resolution service.

30 BUSINESS NEWS

Aurecon appoints CSIRO leader to manufacturing practice.

VIEW 31 REAR Telling a good innovation story.

EDITORIAL

When your work speaks for itself, don’t interrupt.

PUBLISHER Media Hawke’s Bay Ltd,1/121 Russell Street North, Hastings, New Zealand 4122.

MANAGING EDITOR Doug Green T: +64 6 870 9029 E: publisher@xtra.co.nz

Nanofibre manufacturing result of some great collaboration Ian Hosie CEO and his team at Revolution Fibres have been doing some interesting things over the past few years. Now they have teamed up with Waikato company Stafford Engineering Limited which has designed a new machine to mass produce a natural skin care range made from fish skins to meet growing international demand for the product.

CONTRIBUTORS Dieter Adam, Holly Green, Helen Trappitt, Julian Birkinshaw, Kevin Maney, Bernd Muller, Morgan Saletta, Kirk Hope, Mark Ciechanowicz www.mscnewswire.co.nz

ADVERTISING Doug Green T: + 64 6 870 9029 E: publisher@xtra.co.nz

DESIGN & PRODUCTION Kim Alves, KA Design T: + 64 6 870 8133 E: kim.alves@xtra.co.nz

Their story can be read on Page 1 of this issue. The electrospinning machine nicknamed “The Iguana” manufactures ActivLayr, a skin care product made by West Auckland nanofibre producer Revolution Fibres.

WEB MASTER Bruce Metelerkamp E: bruce@hha.co.nz

PUBLISHING SERVICES On-Line Publisher Media Hawke’s Bay Ltd

Stafford Engineering can make one-off machines like The Iguana which makes them unique both locally and internationally. The company has been in the Waikato for 30 years. And Roger Evans, company co-founder is a fine company leader.

DIGITAL SUBSCRIPTIONS E: publisher@xtra.co.nz Free of Charge.

MEDIA HAWKES BAY LTD T: +64 6 870 4506 F: +64 6 878 8150 E: mediahb@xtra.co.nz 1/121 Russell Street North, Hastings PO Box 1109, Hastings, NZ NZ Manufacturer ISSN 1179-4992

Vol.9 No. 9 OCTOBER 2018 Copyright: NZ Manufacturer is copyright and may not be reproduced in whole or in part without the written permission of the publisher. Neither editorial opinions expressed, nor facts stated in the advertisements, are necessarily agreed to by the editor or publisher of NZ Manufacturer and, whilst all efforts are made to ensure accuracy, no responsibility will be taken by the publishers for inaccurate information, or for any consequences of reliance on this information. NZ Manufacturer welcomes your contributions which may not necessarily be used because of the philosophy of the publication.

NZ Manufacturer October 2018

During the electrospinning process natural ingredients such as kiwifruit and grapes, and hyaluronic acid (an ingredient to help the skin retain moisture), are infused to create rolls of anti-aging ActivLayr.

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Stafford commenced working with Revolution Fibres three years ago. This development is but one of many great reads in October issue which can inspire your own manufacturing processes or set you on the path to a whole new range of ideas for manufacturing out of left field. This is a magazine about manufacturing, not a magazine about a media company. And because the focus will always be on what our readers are doing, your manufacturing stories are always welcome. Enjoy the read.

Doug Green

Success Through Innovation

- Henry J. Kaiser

It doesn’t make sense to hire smart people and then tell them what to do; we hire smart people so they can tell us what to do. – Steve Jobs

BUSINESS NEWS

Buteline/Ditron

– an engineering excellence partnership Buteline is a household name in NZ and around the world, which develops and manufactures it’s innovative and acclaimed plumbing system used both in domestic and commercial building from its address in Highbrook. Buteline’s absolute commitment to excellence is evident by the outstanding durability that allows its products to be embedded inside building cavities around the world with confidence. What few people know is that standing alongside Buteline since 1980 is an equally diligent and successful company, Ditron Design & Engineering. Ditron is solely responsible for independently servicing all R&D, tool manufacture, tech support and product development, engineering and testing for the Buteline Group. By nature, Buteline polymer and metal fittings have to adhere to very precise tolerances and dimensions across multiple tools. Small variations in quality or consistency can have catastrophic consequences when the product is installed. As

result,

the

manufacturing

Commercial & industrial growth

processes behind the tools are critical and this is where skill and technology merge at Ditron.

For Mark, ZW3D has proved “to be really user-friendly with great CADCAM options.”

We asked Ditron’s Plastic Tooling engineer Mark Clayton, what are some of the real challenges faced? - Apparently most of the inserts are master/final impressions and these inserts have various sizes so being able to accurately model these in CADCAM has been essential.

ZW3D is an ‘All in One’ CADCAM suite and in Mark’s own words “The ability to switch from CAD to CAM is so easy and at the touch of a button, easy to modify models and modify CAM programming to suit”

Tool quality and precision is always at the highest level. Ditron have used ZW3D CADCAM 4-5 axis software for five years to construct and model a CNC machine fixtures to accommodate all the variants in size and form. ZW3D is used to drive the primary machining centre, a Victor Taichung Vcenter – A72 with 4th axis. Mark is responsible for taking the IGES and STEP files sent to him for tool development and building the tools around them. Typical machining will cover materials such as STAVAX, D2, P20, Aluminium HMWPE, Polycarbonate and others.

Mark has also found support to be excellent and prompt although these days he seldom needs it.

Ditron staff from left to right: Giovanni Diamante, Steve Graham, Dave Housley, Mark Clayton.

ZW3D provides Ditron with a very powerful CAD system that can repair and modify any CAD model in the toolroom and move that into CAM and production without crossing software boundaries.

Buteline and Ditron may have been together for 38 years but new things are brewing. Buteline MD, Llewellyn Picton and his team at Ditron Design & Engineering are now expanding their vision and preparing to open their doors so that other New Zealand manufacturers can access the depth of experience and skill acquired. You are invited to call Mark if that is of interest.

Along with reliable CAM code, Mark notes, ZW3D provides a user level Post editor which is easy to understand and manipulate. Ditron will continue to upgrade ZW3D annually to receive the benefit of enhancement and performance improvements rolled out each year.

ZW3D in NZ can be found at www. zw3d.co.nz where you can link through to trial software and talk to your local supplier.

For example, VoluMill support was recently added.

Employment growth

Economic output

Crime rate East Tamaki is the largest industrial precinct in Auckland with 2000 businesses and a growth rate higher than the regional average.

getba

getba.org.nz

Greater East Tamaki Business Association Inc.

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NZ Manufacturer October 2018

BOOKS

Self-discipline is the ability to get yourself to take action regardless of your emotional state. - Steve Pavlina

The Billionaire Raj: A Journey Through India’s New Gilded Age By James Crabtree A portrait of India’s new tycoon class, rapid growth, and deep inequality, written by a professor at Singapore’s Lee Kuan Yew School of Public Policy

Capitalism in America: A History By Alan Greenspan and Adrian Wooldridge A sweeping history of the US economy, co-authored by the former Federal Reserve chairman and a correspondent for The Economist

New Power: How Power Works in Our Hyperconnected World—and How to Make It Work for You By Jeremy Heimans and Henry Timms An analysis of how digital communication has changed the spread of ideas, the growth of movements, and the distribution of power, co-authored by the CEO of Purpose and the president and CEO of the 92nd Street Y

The Value of Everything: Making and Taking in the Global Economy By Mariana Mazzucato A University College London economics professor critiques modern capitalism’s unsustainable tendency to reward activities that don’t create real value and may in fact destroy it

Give People Money: How a Universal Basic Income Would End Poverty, Revolutionize Work, and Remake the World By Annie Lowrey An economics writer from The Atlantic analyzes the increasingly popular idea that governments should provide stipends for every citizen

Bad Blood: Secrets and Lies in a Silicon Valley Startup By John Carreyrou The rise and fall of Elizabeth Holmes and her Theranos blood-testing firm, as told by the investigative reporter who uncovered the fraud in the Wall Street Journal

TechRentals® is an IANZ endorsed Calibration Laboratory. We offer both IANZ Endorsed and Traceable Calibrations of test and measurement equipment, including:

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NZ Manufacturer October 2018

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The best way to predict the future is to create it. -Peter Drucker

Real Metal Parts with Desktop Metal The Studio System+ from Desktop Metal produces strong, durable metal parts. In this video, Dave Belanger demonstrates part properties at each stage of fabrication.

Learn more >> https://www.objective3d.com.au/desktop-metal-quicklook/

Key Applications for Metal 3D Printing Plastic 3D printed parts have a variety of use cases, but applications demanding specific part properties—such as stiffness, strength, corrosion resistance, machinability, or others—require metal. Now, with the increasing accessibility of metal 3D printing, designers and manufacturers are able to produce complex parts quickly using a broad range of materials. The Desktop Metal System leverages the most widely-used plastic 3D printing process (FDM) to produce high-quality metal parts.

Learn more >> https://www.objective3d.com.au/bound-metal-depostion/

Case Studies

Built-Rite Tool & Die

Lumenium

Injection moulding firm investigates quick-turn mould application, identifies 90% cost savings.

Desktop Metal Studio System™ for rapid prototyping: Virginia-based startup to reduce product development timeline by 25%.

Find out more >> https://www.objective3d.com.au/built-rite/

Find out more >> https://www.objective3d.com.au/lumenium/

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NZ Manufacturer October 2018

MANUFACTURING TECHNOLOGY What if machinery components were

Proceed as if success is inevitable. -anon

the sensors?

By Mark Ciechanowicz, Manager - Industrial Services, Schaeffler Australia Pty Ltd. Mark is responsible for Industry 4.0 technology and service concepts and implementation within Australia and New Zealand. intelligent sensors, offering data transmission in real time. With Sensotect, the forces and torques that act on a component can also be rapidly recorded in places where existing sensors cannot be used.

Mr Ciechanowicz has an Electrical Engineering background, with more than 20 years in the field of reliability, covering disciplines ranging from vibration analysis, infra-red thermography, electric motor testing, through to tribology. Mark has worked in various industrial sectors including aluminium, chemical, paper, steel, sugar and mining.

Sensotect is engineered to have a number of advantages, including no adhesives, a high strain sensitivity, no aging drift and no temperature creeping.

Sensotect allows multi-functional surfaces that are characterised in particular by their sensor properties to be created without affecting the design envelope – in other words, components that are coated with it become sensors in their own right. Development of the technology for applications in Australia and New Zealand is supported by Schaeffler’s local manufacturing and research facilities, backed by the extensive international research facilities of the Schaeffer Group, which employs more than 90,000 people at 170 locations in over 50 countries.

conveyors, presses, and steel mill rollers, for example. Schaeffler BEARINX software is one of the leading programs for performing rolling bearing calculations. It enables rolling bearing supports to be analysed in detail – from single bearings to complex gear systems and linear guide systems. All calculations are performed in a consistent calculation model. Even for complex gears, the contact pressure on each rolling element is considered in the calculation.

Schaeffler’s digitalisation offensive The innovative coating system opens up strain and force measurement possibilities that have always been impossible with adhesive strain gauges, due to their limited operating life.

Schaeffler’s revolutionary Sensotect coating allows components to become sensors in their own right

In all industrial machinery, components add value to the system, and the life cycle of the system creates an entire value.

This innovative measuring technology means that it is also possible to precisely determine the torque acting on drive shafts and vehicle transmissions, and to adjust the engine’s output to exactly match the occurring load. Sensotect therefore makes an important contribution to achieving energy and fuel savings, and helps to reduce CO2 emissions as well.

Digital technologies typically play an important role in analysing data from components and sending this back to the cloud, to what we call a ‘digital twin’. This data can be used to optimise maintenance schedules or improve the performance of the system by changing the way it is used.

With Sensotect, the actual measuring function is performed by a thin PVD (physical vapour deposition) coating that is sensitive to expansion. After the component has been coated, this layer is then created using a micromachining process.

To solve this accessibility problem, and revolutionise the way we think about sensors, world bearings and digital technology leader Schaeffler has developed new technology that allows the industrial or automotive component to be the sensor.

The structures that are thus created undergo the same degree of distortion as the carrier component, which makes it possible for the distortion to be measured. Schaeffler has already successfully demonstrated the function of this type of sensor system in its demonstration vehicles.

Schaeffler’s Sensotect coating system is a directly coated sensor layer that can sit over the top of components such as bearings to measure forces in previously unavailable places within machinery, which can help achieve fuel and energy savings.

One of the greatest challenges posed by this type of sensor coating system is the manufacturing process itself. By using very high-performance coating sources and adhering to particularly high requirements with regard to cleanliness in the manufacturing process, Schaeffler can achieve a level of quality previously only found on planar substrates in semiconductor technology, even in components with narrow radii.

With the aid of modern thin film technology, the component becomes a sensor and the sensor becomes a component. Sensotect is a globally significant technology that has enormous potential in Australasia for use as

NZ Manufacturer October 2018

Smart technologies highly relevant in Australia and New Zealand include the latest evolutions of Schaeffler’s SmartQB and SmartCheck condition monitoring systems, along with a host of digitalisation and cloud-based technologies that harness the advantages of Industry 4.0, such as Schaeffler’s BEARINX software.

Coating performs measuring tasks

Sensors are one of the main methods of data collection, and are commonly placed on parts such as bearings, shafts, axles, bending beams and other moving parts. But they can’t always measure component parts, because of limited space or a lack of availability.

Advantages such as Sensotect are integral to Schaeffler’s global initiatives at the forefront of Industry 4.0 automation and data exchange technologies.

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Schaeffler’s latest predictive maintenance solutions enable machinery operators to look ever more clearly into the future – they provide machine operators with vital information about the future condition of their machines. Predictive maintenance allows not only the capacity utilisation of factories, mines, utilities and processing plants to be optimised, but also makes it possible to plan maintenance intervals at precisely the right time for optimised “Total Cost of Ownership” calculations. An important prerequisite for predictive maintenance is automated rolling bearing diagnostics, a function that is used in motor gearbox units, for example. These units are used not only in machine tools but also in belt

Because machine drives are operated virtually without interruption, they require intensive maintenance in order to prevent production downtimes. This is why it is so important for operators to know the condition of the drive components at all times, and why the bearings are becoming particularly important as a central machine element. The latest generation of the FAG SmartCheck diagnostic system now represents a further step forward for Schaeffler in these areas. In addition to identifying the threat of bearing damage, wear, and irregularities such as imbalance and misalignments based on vibration pattern changes, this system also features a cloud connection. The system creates an automated diagnosis in the cloud from the raw data supplied by the FAG SmartCheck and from additional data, e.g. from the machine control system. Applications for which this technology applies include bulk handling and conveyor applications, mining and energy; building, construction and access equipment installations, such as forklifts and logistics; food and beverage and agribusiness processes, including paper and packaging; manufacturing, metals and process engineering, transport and industrial motor and transmission applications, including pumping and HVAC installations and utilities including electricity, water and waste water.

The best way out is always through. - Robert Frost

MANUFACTURING TECHNOLOGY

With rapid growth in data communication through Industry 4.0, companies are increasingly opting for Ethernet connection solutions - which, however, have to meet different requirements to those in the office. Speed is not the most important factor: Demand for simple and cost-effective solutions is also increasing, as is demand for hybrid connections. Wireless standards, however, remain a niche in factories, says Guido Ege, Head of Product Management and Development at global automation technology and cable technology leader Lapp, of which Lapp Australia is an integral part, working in close consultation with Lapp product distributor ECS in New Zealand.

What next for the Industrial Ethernet? By Bernd Müller for LAPP

Xerox’s Palo Alto Research Center is deemed the birthplace of many ground-breaking computer technologies. In Xerox PARC, pioneers developed the first mouse-driven graphical user interface and the laser printer. Robert Metcalfe was one of the pioneers in the early days. As a doctoral research student at PARC, he was asked to network the company computers. From 1973, the electrical engineer worked on developing a network technology that sent data over the “ether”, which was not entirely correct, since it was a wire-bound technology, even though derived from radio technology. The name Ethernet nevertheless prevailed - and became one of the biggest success stories in computer history. Since the 1990s, Ethernet has been the undisputed leader in local data networks (LAN: Local Area Network). While Robert Metcalfe’s data still crept along the lines at 3 Mbit/s, nowadays that has increased to 10 Gbit/s, and new standards can even reach 400 Gbit/s under certain conditions. The Institute of Electrical and Electronics Engineers (IEEE, also pronounced as I triple E) monitors the compliance of standards for Ethernet. This is highly effective for applications in an office environment, for example, for connecting PCs to each other. When you plug a LAN cable into a computer, you can generally be sure that it will communicate perfectly with another computer or an Internet router.

Proliferation of Ethernet standards It’s a different story for factories. There are now more than 20 industrial Ethernet systems and all of them differ in terms of technical details to varying degrees, which makes them incompatible. In addition, there are more than 50 fieldbus systems, such as PROFIBUS or CAN BUS, which are favoured by automation technology providers. These also tend to be incompatible with each other. Fieldbus systems are widely used in factories, since they are more robust.

They transmit smaller data packets than Ethernet, but are real-time capable. This is important for time-critical machine processes, for example, when a drive needs to react to a signal from a sensor in microseconds. Not only that, machine operators want to be sure that a machine will stop immediately if they press the red emergency stop button. Until now, this has only been possible to a limited extent with Ethernet, although the IEEE have made attempts at standardisation to also implement the standardised real-time capability in Ethernet. Market data gives reason to believe that the future also belongs to Ethernet in factories. Industrial Ethernet is currently growing at 22 per cent a year compared to only six per cent growth in fieldbus systems. In 2018, the number of Ethernet installations in factories will exceed those of fieldbuses for the first time. The reason behind this is the increase in networking and digitalisation in Industry 4.0 times, resulting in a resolution of the automation pyramid. This refers to the levels in factory communication with the field level as the lowest one. Above the field level, there is the control level, the process control level, the operations control level, and at the top the company level with its ERP systems, in particular, SAP. Until now, these levels had different functions and therefore different programmes also worked there, sensor data had to make its way upwards from one level to the next and vice versa, planning data also filtered downwards. That makes factory control complicated and not particularly agile; the classic automation world is not made for flexible production with batch size one.

Future thinking: The Industrial Ethernet represents an attractive alternative to the classic field bus system.. The open Ethernet standard opens up new opportunities for industry.

Flat hierarchies in industrial communication

Among the products that go with it is the EPIC MH Gigabit data module, a rectangular connector with a modular design, which allows the transmission of data and energy.

With the resolution of the automation pyramid, these levels disappear, and communication occurs in flat hierarchies. Everyone communicates with each other - ERP systems can, for example, access sensors directly on a machine and establish whether a malfunction might occur that would affect the delivery capability.

Or the robust ETHERLINE Access switches for data distribution in harsh industrial use.

Many cables, one sheath LAPP has been observing the market for industrial Ethernet for many years and has identified two trends that will become increasingly important on the market in future.

However, this is only possible if connection technology can also think out-of-the-box. It therefore comes as no surprise that the Ethernet established in the office environment is now also finding its way into production and logistics, with correspondingly more robust components, of course.

One trend is hybrid cables, so-called single-cable solutions. These are cables that combine different functions in one sheath and are normally connection cables for servo drives with integrated feedback cables for monitoring sensors. LAPP provides such hybrid cables for the Hiperface DSL Motor-Feedback-System from Sick or for the ACURO link from Hengstler.

LAPP has such components in its portfolio. Traditionally, products for fieldbus systems have dominated the market, but customers can now find everything they need for networking with industrial Ethernet - ranging from cables to connectors and through to ready-to-install cables from the ÖLFLEX Connect range.

The second trend is downsizing. Whereas the previous Ethernet required two or four wire pairs, single-pair Ethernet can transmit up to 1 Gbit/s via a wire pair. The user benefits from the reduced work involved in installation and has both space and cost advantages.

Highlights include, for example, the ETHERLINE PN Cat.6A FC with 10 Gbit/s at 500 MHz bandwidth. It is fast-connect capable thanks to the absence of pair screening, an inner sheath or a central cross, enabling fast and safe assembly. In addition, the cable is also certified for the N. American market.

The necessary hardware development on the chip side has progressed in the automotive industry and can be adapted. Costs, robustness and the

continued on Page 10

Single pair Ethernet cables are more compact, lighter, easier to install, and cheaper than traditional Ethernet cables with four wire pairs – and sufficient for many applications on the field level.

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NZ Manufacturer October 2018

MANUFACTURING TECHNOLOGY title

longer lengths that are possible due to the lower data rates indicate that single-pair Ethernet will also gain in importance in industry. Otherwise, users are also realising that not every sensor needs to be connected to a 10 Gbit/s capable cable. Although a single-pair Ethernet cable only achieves 1 Gbit/s, that is sufficient for many applications at the field level. The vast majority of sensors deliver small amounts of information and some of them only report an on/off signal now and then.

Downsizing of cables According to the Roland Berger management consultancy, the demand for sensors will increase by 17 per cent a year by 2020, while prices will fall by

eight per cent annually. That will boost demand for cost-effective connection solutions. Single-pair Ethernet cables are, however, not yet available, at least for use in industry.

Excellence is not a skill. It is an attitude. -Ralph Marston

wireless technologies occupy the first place, even though their market share is low at six per cent. WLAN, Bluetooth or mobile communication have

sensors in large plants, for example, in the chemical industry or in mobile In terms of range, robust data connection,

energy

efficiency

and, in particular, latency, wireless technologies cannot compete with wire-bound

technologies.

Cables

are also less susceptible to malicious disturbances or hacker attacks.

The first serial products for single-pair Ethernet will be available in two to three years from LAPP.

With a growth rate of 32 per cent,

and mobility, such as for connection

applications.

The automotive industry is already using similar cables in vehicles, but there are still no standards for industrial applications. Newly established working groups are currently working on this.

In terms of growth, Ethernet only ranks in second place for connection solutions for industry.

advantages when it comes to flexibility

That will also not change with new standards such as 5G. Guido Ege says: “Wireless has its justification, but it Guido Ege, Head of Product Management and Development at global automation technology and cable technology leader Lapp

doesn’t pose a threat to wire-bound systems, instead it is a supplement for special requirements.”

Kiwi ingenuity shines at energy efficiency awards The theme this year was ‘innovation and leadership’ and only the largest of New Zealand’s energy users were eligible to enter.

the smartest in New Zealand. Their success can be drawn on by others for solutions in energy efficiency and emissions reduction.

An outstanding selection of energy efficiency and low emission stories were submitted by businesses, health and education providers and the public sector – and the University of Waikato set to work as judges to separate the good from the great, from the totally awesome.

The University of Waikato’s Engineering Energy Research Centre gave their world-leading expertise to the judging process and were impressed with the broad range of organisations and projects in the mix.

EECA Business award winners 2018

“There are no losers here,” said Andrew Caseley, Chief Executive of the Energy Efficiency and Conservation Authority (EECA). “Least of all our environment and economy.

Innovation Award Hanmer Springs Thermal Pools and Spa The Canterbury tourist attraction is converting methane - a greenhouse gas and by-product of collecting underground thermal water - into electricity with a 65kw Capstone Turbine generator, which provides power to the facility.

“Every entry to the EECA Business Awards demonstrates the effort New Zealand companies are making in their daily work to bring a low-emissions future closer to becoming a reality for the country.

Public Sector Award Victoria University of Wellington

“Those businesses that were commended, highly commended or that won their category, are some of

The University is more than a decade

in to its comprehensive energy management programme and despite a 15 percent increase in floor space and an additional 500 equivalent full-time students in that time, energy use continues to drop, reducing greenhouse gas emissions by 2,800 tonnes per year. A combination of improved building management systems, renewable energy generation and student buy-in has achieved the result. Energy & Emissions Reduction Project Award Goodman Property Trust Using the NABERSNZ tool to assess the performance of buildings and provide a benchmark to measure system optimisation and upgrades has led to an overall targeted rating of 4.5 stars for Goodman Property’s seven waterfront commercial buildings, which support a 7,000 workforce. Lighting and HVAC are the main energy-efficiency heroes that have saved tenants more than $1.1 million in operating costs since 2014 and avoided 775 tonnes of carbon

Only 14% of all our engineers are women. We want to change that. Join us and scores of other Kiwi organisations that have galvanised around one common goal: 20% more women engineers by 2021. www.diversityagenda.org

NZ Manufacturer October 2018

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emissions so far. Energy & Emissions Leadership Award Roseline Klein, Watercare Services Ltd Energy efficiency is everybody’s responsibility at Watercare, due to a staff engagement and empowerment strategy led by Roseline Klein. Making energy-saving a team effort and introducing technologies into a long term energy efficiency strategy has them set to achieve their energy neutrality targets for the waste-water plants. Large Energy User of the Year Award Red Stag Timber The installation of a new 4.2MW steam turbine and a 10MW biomass boiler at Red Stag’s wood-processing plant has closed the gap on their long term energy-efficiency and low-carbon business plan. Wood waste is used as renewable fuel to generate all the electricity the site needs, their energy self-sufficiency has put production up, and the power bill down.

ENERGY

Challenges are what make life interesting and overcoming them is what makes life meaningful. -Joshua J. Marine

How independent power producers

can improve sustainability the IPP, negating risks to both the mine site and its power supply. Other contractors can assist a mining company, but once their contract ends they may leave behind the result of poor work. IPPs have a vested interest in the success of their partners and will work to ensure an energy-efficient and sustainable partnership. Enable flexibility and reduce waste A professional IPP will be able to handle different requirements with ease. Every mine site, location and operation will be different, and there is no one size fits all solution. The flexibility of an IPP allows it to optimise operations for power production and tailor its approach from the ground up, beginning as early as the planning and construction phase and lasting for the life of the partnership. IPPâ€™s can also assist with scaling your businessâ€™ potential. Scalability of power capacity is a key consideration for any mining project and can be affected by a range of circumstances. As dedicated professionals, independent power producers will be able to independently manage changing power needs in an optimised way which maintains operational efficiency and reduces waste.

When considering power infrastructure for a mine site, there are generally three options available to mine operators: rent temporary power solutions, build their own power supply station or contract an independent power producer (IPP). While short-term power solutions have their benefits, independent power producers offer the best of both worlds by providing mine sites with stable, energy-efficient power which is geared for long-term results. This can improve sustainability for businesses and communities while enabling the use of renewable energy innovations. Independent power producers can improve the sustainability of a mine site in a number of ways:

Contracting an IPP avoids the temporal and financial pressures process of power station construction and ownership, saving valuable capital which can be invested into further energy efficiency measures such as renewable energy. The lower initial capital investment of an IPP means that a mining company can be more flexible with their funding, taking advantage of short-term opportunities and lowering their financial risk profile.

Manage safety Independent power producers take on the costs and risks involved in the construction, operation and maintenance of their power stations, relieving the mining company of this responsibility. Additionally, the long-term nature of the partnership between a mine site and their IPP allows for a strong investment in service, performance and efficiency. Safety concerns are also handled by

With lower funding requirements and a strong commitment to mutual success, independent power producers can provide a more energy-efficient and sustainable solution for mine operations. -Daniel Defendi, KPS Power, Perth.

Renewable Energy Innovations Renewable energy is an innovative benefit of engaging an independent power producer. Not only can IPPs utilise renewable energy to boost their normal power production, but these methods can also improve cost-efficiency and reduce emissions and waste. Renewable innovations such as waste heat recapture and solar/diesel hybrid technology are what set IPPs apart and can make a large difference in reducing the cost of maintenance and downtime. IPPs which have made the investment into renewable energy will be able to both reduce costs and help to conserve the local environment. Lower implementation costs Constructing, running and maintaining your own power station can require a vast outlay of initial capital and, depending on the specifications of a site, can even be cost-prohibitive in the long term.

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NZ Manufacturer October 2018

DEVELOPMENTS

Perfection is not attainable, but if we chase perfection we can catch excellence. - Vince Lombardi

continued from Page 1

Custom-built “Iguana” makes skin care product from hoki skins kiwifruit and grapes, and hyaluronic acid (an ingredient to help the skin retain moisture), are infused to create rolls of anti-aging ActivLayr.

two years ago for Revolution Fibres which was then used by a research facility in the US, and that gave us sufficient knowledge, together with design input and insights from Revo to take on The Iguana.”

Nanofibres – measuring between 100-500 nanometres in width (a human hair is 50,000 nm wide) – can create vast changes in mechanical strength, reactivity, and, in the case of skin care, absorbancy.

“It’s great to have companies like Stafford in New Zealand,” says Revolution Fibres CEO, Iain Hosie. “Our trust in Stafford means we can continue to grow our manufacturing operations in NZ with confidence. We have huge input into the design and know the output will be professional and built-to-last.”

After more than 30 years in the Waikato, Stafford has worked extensively in the dairy industry as well as attracting local and international clients from the food processing and packaging industry that need customised machines to meet their individual needs.

The Iguana will enable Revolution Fibres to quadruple its existing production output, with capacity to increase scale in the future. The company currently has large orders for ActiVLayr in Asia, and an increased demand for nanofibre products from a diverse range of sectors, including Formula One racing teams and the aerospace industry.

“We’ve found a niche in supplying bespoke machines like The Iguana – so making one-off, complex machines makes us unique both locally and internationally.” Evans says when Stafford started working with Revolution Fibres three years ago they knew nothing about electrospinning technology.

“There is a growing number of industries embracing what nanofibre can do for performance and gaining

“We built a far smaller ‘pilot’ machine

Nothing artificial about the

a competitive edge,” says Hosie, “and that will only increase as research uncovers even greater opportunities

in life sciences. The scope for what you can do with nanofibre feels limitless.”

intelligence of kiwi students

Three University of Auckland students have had their advice for the New Zealand Government on artificial intelligence (AI) published in The New York Times international edition. different disciplines across the University. They were Marcus Wong (Commerce, Engineering), Jaffar Al-Shammery Bui (Economics, Public Health, Chinese Language), and Tomu Ozawa (Computer Science).

The team of students beat entries from 23 other universities to win The New York Times and Association of Pacific Rim Universities (APRU) 2018 Case Competition. The prize - an excerpt from their essay on AI published in the global print edition on October 9, reaching hundreds of thousands of people worldwide.

The competition asked teams to respond to the rapid evolution of artificial intelligence by writing a policy brief ensuring social goals are built into AI research and development, that the benefits of AI are shared equitably,

The winning students were from

and mitigating risk.

entries, and The New York Times gifts.

The students’ winning essay makes direct policy recommendations to the New Zealand Government on measures such as an AI-Score metric to guide enterprise taxation; a universal basic income system; and to facilitate communication streams between regulators, researchers, and business.

Accepting the trophy on behalf of the students, Professor Jenny Dixon, Deputy Vice-Chancellor (Strategic Engagement) at the University of Auckland commented: “We are incredibly proud of the students who faced intense competition from their peers across the Asia Pacific region – their policy brief is forward thinking and we are delighted with their success.”

The winners also received a trophy, a profiled article in a booklet of winning

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ANALYSIS

I can’t change the direction of the wind, but I can adjust my sails to always reach my destination. - Jimmy Dean

Transformation delivers priorities On 1 October, Engineering New Zealand celebrated their first birthday. However, the pedigree stretches back far more than a year: previously known as IPENZ, there is a proud 100-year history representing engineers. Several years ago, members were asked what they wanted from their professional body, and they said greater recognition, influence, credibility and connection. So, transformation took place to deliver these priorities. Recognition means appreciating the value that engineers bring. It’s not about fame or boosterism – it’s about our society genuinely recognising engineers for the work that they do and the genuine difference they make to everyone’s lives and to New Zealand. Credibility for Engineering New Zealand means doing the right thing, doing what you said you’d do, and doing the best job possible. For Engineering New Zealand credibility means standing up for quality, raising the bar for engineering professionals and making sure everyone is accountable. It also means having robust processes and systems, so that everyone knows where they stand. Connection means creating networks together to be more powerful – networks across industries, with like professions and between members. Networks fill in blind spots and help

create movements for change. Influence means leverage: leverage to affect decision and policy in the areas engineers’ care about or think are important to New Zealand. This means not just central and local government but other spheres of decision making as well. As part of the new strategy, based on these four pillars, on 1 October 2017 there was the name change and a new, more inclusive Membership Pathway. This new pathway creates a professional home for engineers previously unrecognised by membership classes, including chief executives and other leaders who’ve stepped away from day-to-day technical work. It makes space for academics, and it genuinely recognises technicians and technologists, as well as engineering geologists.

key challenges facing New Zealand: seismic resilience and water. In Engineering a Better New Zealand, there is a call for a new regulatory approach to existing buildings, to better protect people from severe earthquakes.

75 engineering or architecture firms has signed up, well beyond our initial targets. The Diversity Agenda has been supported by such publications as this one, NZ Manufacturer with women engineers being prominently profiled.

Engineering New Zealand supports the Government’s move to fix our broken drinking water system, and the community needs to place a greater value on safe water. And there is a look at lessons from recent floods and a call for hard decisions to be made in the face of climate change. At the heart of Engineering a Better New Zealand is resilience, and how risk is thought about.

There has also been a revamp of the programme to attract young people into engineering. The new initiative in the school space is called the Wonder Project. It aims to spark a curiosity in children about the possibilities and excitement STEM provides and to show them it’s creative and fun.

Additionally, Engineering New Zealand is more deliberate in speaking out on engineering issues that matter to members and New Zealanders.

In April 2018, the Diversity Agenda was launched, a provocative campaign in collaboration with the New Zealand Institute of Architects and ACENZ that calls for increased representation of women in engineering and architecture.

The first phase is based around a rocket challenge, which has been piloted this year and will go into 200 schools next year. This phase is particularly targeting girls, Māori and Pasifika, and low-decile schools.

As well as engaging more with the media, in August 2018 Engineering New Zealand launched a thought-leadership publication, Engineering a Better New Zealand, which pulls together an expert engineering view on two

The campaign has an ambitious goal of getting 20 percent more women in engineering and architecture by 2021. It asked firms to sign up to this commitment and to a six-point code or tikanga. So far, more than

All these programmes run alongside the support provided to members, through branch networks around the country, technical groups, engineering practice advice and competence assessments.

Realising a new strategy has also meant launching several new programmes and initiatives.

R&D tax credit policy finalised

-Dieter Adam, Chief Executive, The Manufacturers’ Network

– How does it look for manufacturers? After consultation with the public and businesses, the Government released the final details of its R&D tax credit policy. The policy is not perfect, with areas in which we are going to push the Government further, but they did listen to some of our concerns and made adjustments to the policy and we are happy that a number of these issues we at least partially addressed in the final policy. In The Manufacturers’ Network submission, we pushed for the initially-proposed rate of 12.5% to be increased to 20% to start with. This would bring our innovation support closer to what is offered in many of the countries our manufacturers are competing with, both in export markets and through import competition. While the Government did not raise it that high, they did increase the rate to 15%. This is a definite improvement, but we will continue to push the Government to raise this higher over time – this is something they need to

do if they are serious about reaching their target of improving New Zealand’s R&D expenditure to 2% of GDP by 2020. The slightly higher rate will make this a bit more worth the effort for smaller companies and align the system with growth grants for the larger companies who were receiving them. The second major issue we outlined in our submission was the proposed threshold for eligibility – requiring a minimum of $100,000 of eligible R&D expenditure to receive the tax credit is too high. We pushed for this to be significantly lower to make sure small companies have the opportunity to benefit and put them on a path for growth and even more R&D expenditure in the future. Again, while the new threshold is not as low was we would have liked, we are pleased to see the Government bring this down to $50,000. Most

small

and

medium-sized

However, the test will really be how this is followed through in practice – the Government needs to set the clear expectation to IRD that process development innovation is included.

manufacturers were left out under the previous project grant system – we hope this change is a move in the right direction to provide support for our small and medium-sized manufacturers. The other area of major concern for us in the proposed policy was the definition used for eligible R&D expenditure. This was based on a definition (Frascati) that would have excluded much of our manufacturers work in the area of process innovation.

Overall – while this policy is not perfect, we are happy that the Government has at least worked to address some of our major concerns from the initial proposal. There are still areas in which we need to push the Government to make R&D support work most effectively for manufacturers, and we will continue to do so.

Even though the original proposal did say that process innovation and development could be included, those who have used project or growth grants in the past know how difficult it can be to have this included in grant applications.

Getting innovation policy right is critical for New Zealand’s future – we have some catching up to do with many of our competitors in terms of overall spending as a country. Innovation through R&D is a vital component of moving New Zealand down a more productive and prosperous path to the future.

Again, we are pleased to see this being partially addressed in the new definition of R&D expenditure, which on the surface appears to be more open to such process development activities.

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COMPANY PROFILE

The shortest way to do many things is to do only one thing at once. -Samuel Smiles

Democratising carbon fibre If you think about Auckland and carbon fibre technology, scenes of the America’s Cup and the industries that surround it spring to mind. Both factors create health and safety issues. In contrast, Rivers’ Premium High Carbon Fibre tubes are light, durable, and can be easily lifted above the shoulder making them far easier to install.

Ventilation tubes in dusty Australian coal mines are probably not your first mental image. Yet this less than glamorous gear represents the start of a promising new trade, thanks to the ingenuity of Graeme Rivers, founder of North Shore-based Rivers Carbon Technologies, and a Callaghan Innovation Project Grant.

The company exported its first shipment of ventilation tubing to Australia in March and has been producing consistently ever since.

All sorts have come out of Rivers Carbon’s Albany workshop – from the foils for elite America’s Cup yachts to replica chassis for E-Type Jaguars.

Staff at BHP Billiton Illawarra Coal’s West Cliff mine in New South Wales say they’ve had no injuries to people or breakages since they started using carbon fibre tubing, and the company is now looking at other applications for the material.

But while money may be no object in these high-end industries, the wonders of carbon fibre are generally outside the budget of ordinary businesses.

“We have a lot of manual handling, a lot of heavy implements, so really

Until now. Rivers Carbon has come up with a lower cost way of making carbon fibre products for everyday sectors such as construction and mining.

we’re looking to find the next level use of carbon fibre,” Health and Safety Manager Peter Rolfe says. Rivers Carbon is already making wheel hub covers for the motors on giant mining trucks and man doors for mine shaft safety. It’s investigating using the new carbon fibre in everything from prosthetic feet to dinghies to construction beams. “There’s no limit to where we can go. If something requires strength and it moves, so that weight is an issue, then we can play in that space,” General Manager Stephen Beaumont says.

Automation the next step Graeme Rivers set up Rivers Carbon in 2004 and did a wide range of innovative small run production such

as parts for race cars. The company attracted the attention of investment firm Lewis Holdings in 2010. “Graeme is quite brilliant in some of the problems that he’s solved through the use of carbon fibre,” Director Dave Tibby says. The Project Grant from Callaghan Innovation allowed the business to expand its focus and develop a manufacturing process for a cost-effective alternative fibre. “We wouldn’t have done it, couldn’t have done it without it,” Commercial Manager Ngaio Merrick says. “Once we got the Callaghan Innovation grant we kicked off our R&D in earnest, and that was really exciting,” she says. The next step for Rivers Carbon is to automate the new process and it’s hoping to employ students under the Callaghan Innovation Student Grant programme to help with the research. The Project Grant was a great way for a company of Rivers Carbon’s size to access R&D support, Callaghan Innovation’s Business Innovation Adviser Transport and Logistics, Nick Brewer, says.

After months of researching cores, cloth types, resins, hardeners and trihydrate mixes, Graeme Rivers developed a ‘cold cure’ method of setting carbon fibre, rather than pressurising and cooking it in an autoclave. Rivers Carbon settled on ventilation tubing for underground mining as its first application for the new carbon fibre.

The company’s technology is unique and difficult to achieve at the right price point, he says. “The key is the core in the middle and it’s hard to make it into a tube. Rivers Carbon has found a process to create the tube using a superlight core,” he says.

Currently the fibreglass tubes used in the mines are heavy and tend to crack and break.

Callaghan Innovation looks forward to working alongside Rivers Carbon as the company grows, Nick says.

NZ Manufacturer October 2018

Rivers Carbon is already making wheel hub covers for giant mining trucks

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DEVELOPMENTS

Limitations live only in our minds. But if we use our imaginations, our possibilities become limitless. -Jamie Paolinetti

Hamilton businessman wins prestigious Australasian engineering award Hamilton businessman David Platts of PDV Consultants was awarded the prestigious Chemeca Medal at the Chemical Engineering Awards in Queenstown. The Chemeca Medal is awarded to a prominent New Zealand or Australian chemical engineer who has made an outstanding contribution, through achievement or service, to the practice of chemical engineering. Mr Platts received the award at a dinner during the 47th annual Chemeca conference, in front of an audience of industrial chemists, chemical and process engineers and academic professionals. Mr Platts recently announced his retirement from PDV Consulting, the international engineering firm founded 28 years ago with wife Anne Platts. “The Chemeca Medal is an award for the business, and for Anne and everyone who has contributed over the years,” says Mr Platts. “It comes at a really special time for us, as it is 28 years ago this week that Anne and I started our business. At the end of November, we’ll be retiring, and this is a wonderful note to finish on.” PDV Consultants is a global expert in food process technologies and systems design with offices in Hamilton, New Zealand and Belfast, Ireland. Their team of chemical and process engineers have delivered projects for many of the world’s leading food companies including Fonterra, Tatua, the Dairy Goat Cooperative, Danone, Glanbia (Ireland and USA), Dairconcepts (USA), First Milk (UK), South West Cheese and others. The company was founded in October

1990 and over the past three decades has grown from two people to 25, with 21 staff based at PDV’s Alexandra Street, Hamilton headquarters and four staff based in Ireland. “We started working out of our home office, just the two of us, and it’s grown exponentially over the years,” says Mr Platts. It’s a Waikato success story, and one that has operated largely under the radar. “We turnover up to $5 million a year and we are a New Zealand-owned business that is highly technically competent and draws in quality people and revenue to the Waikato region and New Zealand,” says Mr Platts. “I’m really proud of that, because our business benefits the local economy.” Mr Platts, who was born and raised in South Yorkshire, England, began working as a technician in the food research industry after leaving school at the age of 15. In 1972, at the age of 22, he immigrated to New Zealand. Within a week he had two job offers and started working at the New Zealand Cooperative Dairy Company (NZCDC), the precursor to Fonterra, setting up a quality control system for their Avalon Drive milk powder canning factory. He also worked on drying evaporation end engineering products for the company’s engineering departments. He met Anne, a fellow expat from Belfast, Ireland, at a social club in Hamilton a few years later. They married and had three children: Nuala, Gemma and Jonathan. His expertise in chemical and process engineering for the food processing industry took Mr Platts and his family

to the Netherlands in the early 1980s to work for Stork Friesland, now known as Tetra Pak, doing design engineering.

the engineering design, energy efficiency and food safety capabilities of New Zealand’s processing industries.

He was transferred back to New Zealand, where he was involved in developing the first nutritional infant formula manufacturing plants in New Zealand at Waitoa for NZCDC (Fonterra). When the New Zealand office closed in 1990, Mr Platts was made redundant.

“New Zealand engineers are world-leaders in innovation and invention – at looking at problems and generating solutions,” says Mr Platts. “It’s important to keep our number-eight-wire approach to problem solving alive.”

It was the push he needed to start his engineering consulting business, and Platts Drievap Engineering – as it was then known – was launched in October 1990.

Over his career Mr Platts has given back to his industry by mentoring and providing job opportunities and internships for the next generation of chemical engineers.

It’s the personal attention to detail, and the focus on building strong relationships that has helped in PDV’s success. “A lot of business, especially in the early years, was driven by word-of-mouth,” says Mr Platts.

He has served as a chair on the industry advisory board for the University of Waikato School of Engineering and has also provided input into Massey University’s programmes.

“People would call up and ask if we could come and look at something or help them solve a problem, and it grew from there.”

Mr Platts is a fellow of the Institute of Chemical Engineers (IChemE), a global professional engineering institution with more than 40,000 members in more than 120 countries worldwide.

Mrs Platts, PDV’s business and financial manager has been a big part of the company’s success over the past three decades. “She’s been the glue that held everything together and her business, IT, financial and administrative skills have been a key reason for our success,” says Mr Platts.

He is a fellow of the New Zealand Institute of Food Science and Technology (NZIFST), the country’s leading professional association representing those working in the food industry, food research and education or those who apply science and technology to the processing, manufacture and distribution of foods.

Mr Platts has been a strong supporter of Chemeca events over the past three decades and was involved in the organisation of the 2012 event in Wellington.

PDV’s engineering manager for Asia-Pacific, chartered engineer Gerard O’Connor, has been named as the firm’s new MD and Lynn Waters, former financial controller at Livingstone Building has been named PDV’s new business manager.

He has served on the committee of ICHemE in New Zealand, including two years as chair. He has actively promoted New Zealand food and dairy industry competencies overseas, championing

Boost for infrastructure decision making BusinessNZ has welcomed the planned establishment of a new independent infrastructure body. Chief Executive Kirk Hope says New Zealand needs to get systematically better at matching infrastructure demand with its delivery. “For too long our planning and delivery cycles have been mismatched with periods of rapid growth and slow-downs. Once more we find ourselves in a period of rapid growth with infrastructure failing to keep pace.

“The Government’s approach is timely. Consultation on the form and focus of the new body will help us achieve optimal outcomes. “BusinessNZ recommends the new body should be focused on strategy, planning and support for project delivery. “We need a strategic approach to defining our infrastructure needs and a centralised agency to provide standardised contracts and funding expertise to help reduce the costs of delivery.

“The new body needs to take a strategic long term view, based on alternative future possibilities, to ensure our infrastructure is resilient and fit-for-purpose. “Our insight from the energy scenarios work done by the BusinessNZ Energy Council is that we simply do not know the future, and to get resilient policy and investment decisions we need to be open to different futures playing out. “We

would

hope

for

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infrastructure body that contributes to integrated procurement and investment decision-making, gives business the confidence to invest in people and equipment, and will result in long-lasting, high quality infrastructure for New Zealand.”

NZ Manufacturer October 2018

ADVISORS Mike Shatford

Sandra Lukey

Matt Minio

Phillip Wilson

is an expert in the field of technology development and commercialisation. His company Design Energy Limited has completed over 100 significant projects in this vein by consulting for and partnering with some of New Zealand’s leading producers. Among Mike and his team’s strengths are industrial robotics and automated production where the company puts much of its focus.

Managing Director, Objective3D Matt has extensive hands on experience as a user and supplier of 3D Printing technology. He comes from a mechanical design and engineering background with 25 years’ experience in multiple high end 3D cad applications across a range of industries, including aerospace and automotive. He has been heavily involved in the 3D printing evolution - from initial early prototyping to todays advanced 3d printing technologies producing production parts straight off the printer. As Managing Director of Objective 3D, he provides Stratasys, Desktop Metal and Concept Laser 3D printing solutions to a host of industries across Australia and New Zealand.

NZ Manufacturer October 2018

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Sandra Lukey is the founder of Shine Group, a consultancy that helps science and technology companies accelerate growth. She is a keen observer of the tech sector and how new developments create opportunity for future business. She has over 20 years’ experience working with companies to boost profile and build influential connections.

Phillip Wilson of Nautech Electronics has over 25 years of experienced in the development, commercialisation and implementation of advanced manufacturing technology, robotics, automation and materials. Serving companies operating within the aerospace, automotive, offshore, defence, medical and scientific industries on a global basis. More recently specialising in change management and business re-alignment for a range of commercial entities from medium sized SME’s to divisions of large corporates.

Don’t find fault, find a remedy. -Henry Ford

Auckland city set on challenging geology including volcanoes

Aurecon and Seequent lead on NZ’s largest transport infrastructure project Global engineering and infrastructure advisory company Aurecon and Seequent, a developer of revolutionary visual data science software, are leading the way for digital engineering on New Zealand’s largest transport infrastructure project ever to be undertaken. Auckland’s City Rail Link (CRL) project is a 3.45km twin-tunnel underground rail link up to 42 metres below the city centre, transforming the downtown Britomart Transport Centre into a two-way through station that better connects the Auckland rail network.

a city located on a volcanic field.

Infrastructure projects this size are challenging enough, without the added complexity of building them in

To help attain and communicate this detailed technical analysis, Aurecon used Seequent’s 3D geological

Embarking on a massive project like the CRL through an area of complex geology, including volcanoes, requires a very clear assessment of the ground conditions. This demanding task fell on the shoulders of Aurecon.

Dan Wallace, Seequent

Philip Kirk, Aurecon

Infrastructure projects this size are challenging enough, without the added complexity of building them in a city located on a volcanic field.

modelling solution, Leapfrog Works, which is specifically designed for the Civil Engineering and Environmental industries. Helping reduce risk on infrastructure projects Critical in any major infrastructure project, Aurecon needed to carry out detailed technical analysis of the

continued on Page 18

Auckland’s City Rail Link modelled in Leapfrog Works

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NZ Manufacturer October 2018

If you’re offered a seat on a rocket ship, don’t ask what seat! Just get on. -Sheryl Sandberg

continued on Page 18

Aurecon and Seequent lead on NZ’s largest transport infrastructure project uncertainty in the ground conditions in a way that the engineers understand, relevant to the design.”

ground conditions to identify the risks and then clearly communicate and mitigate these risks to the consortium of engineers and architects involved.

Identifying opportunities in reference designs to improve project outcomes

Philip Kirk, Geotechnical Team Leader, Aurecon, says, “We didn’t want the construction team to encounter unexpected ground conditions that would compromise or delay the project. We had to get it right.”

Using Leapfrog Works, Aurecon were able to identify key opportunities in the reference design, ultimately saving time and money over the entire project’s course. This included, for example, the revision and optimisation of ground improvement works at the

Seeing the complex volcanic geology To make informed decisions on structural design, services locations and construction methods, engineers and construction teams needed to ‘see’ how these ground conditions interacted. Using Leapfrog Works, Aurecon’s ground engineering and engineering design colleagues were able to readily visualise in 3D and were quickly surprised by how effective a communication tool Leapfrog Works was.

Water Street shaft to mitigate ground risks. The 3D geological model also proved invaluable in clearly communicating ground risks to both stakeholders and contractors during the procurement phases, for much better time and cost certainty. Leapfrog Works’ dynamic abilities enabled immediate updating of the ground model based on the live data coming from the onsite shaft borehole drilling, saving days and further ensuring structural accuracy.

This dynamic modelling helps keep decision making fluid and on track with the very latest findings. “We hope this is just the start of using 3D visualisation to communicate risks within a project and to help clients and contractors to make sense of them. This is the power of combining technical eminence and digital technology,” says Philip. Construction of the City Rail Link is underway with the completion date set for early 2024.

A key feature in the development of the industry-led solution has been its ability to combine geological models with engineering designs. Therefore, Works not only aided communication with stakeholders but more importantly enabled Aurecon to get the design right from the start. “Leapfrog Works has been an instrumental tool to support our ground engineering team, who are the interface between science and engineering,” says Philip. “Geologists need to be able to communicate the City Rail Link detail with cross sections

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NZ MANUFACTURER • November 2018 Issue • Features

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The Circular Economy

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At NZ MANUFACTURER our aim is to keep our readers up to date with the latest industry news and manufacturing advances in a tasty paper morsel, ensuring they do not get left behind in the highly competitive and rapidly evolving manufacturing world.

I didn’t fail the test. I just found 100 ways to do it wrong. -Benjamin Franklin

Increase Your Manufacturing Efficiency BuildIT Desktop is a CAD-to-part inspection software that enables quick and easy dimensional verification of manufactured parts and assemblies for tool building, assembly, alignment, process automation, reverse engineering and quality control. BuildIT’s advanced analysis and reporting capabilities combine measurement data from multiple sources to produce detailed graphical and textual reports that are used to quickly identify manufacturing and production trends. With both numerical and graphical feedback of real-time deviations, BuildIT allows users to position parts with micrometre accuracy for

high-precision assembly and alignment applications. Key features include CAD-to-part inspection, GD&T analysis, creation of custom automated processes and generation of extensive reports. The software interfaces in real-time with a variety of probing and scanning measurement devices from all major hardware vendors, enabling the quick and efficient acquisition of dimensional information from a tool or part. BuildIT directly reads 3D CAD files from native or neutral formats, as well as GD&T, FTA and NX-PMI assembly level data for model-based inspection and assembly.

In addition, BuildIT imports measured point data from external sources for

maximum compatibility.

D-Link ANZ expands industrial gigabit switch range D-Link ANZ has expanded its recently released range of DIS Series Industrial Gigabit Switches, by launching the DIS-100G Series, consisting of the DIS-100G-5SW 5-Port Unmanaged Industrial Switch and the DIS-100G-5PSW, a 5-Port Unmanaged PoE Industrial Switch.

such as lightning strikes or unstable electrical current.

Joining the DIS-200G Series of L2 Smart Managed Industrial Switches, both Series are available in a combination of PoE, non-PoE, Ethernet, or SFP-based port configurations.

To accommodate outdoor deployments, all DIS Series switches are housed in a highly durable, industrial-grade enclosure with IP30 rated ingress protection, combined with their fan-less, energy-efficient design, enables operations in harsh environments and across wide operating temperatures.

Built from the ground up for reliability and durability, the DIS Series of Industrial Gigabit Switches offer a complete solution for demanding indoor and outdoor industrial network applications, including factory automation, Intelligent Transportation Systems (ITS) and wherever harsh environmental conditions exist All PoE and non-PoE Ethernet ports on the DIS Series feature embedded 2kV (DIS-100G Series) or 6kV (DIS-200G Series) surge protection. This helps protect the switches against sudden electrical surges caused by events

Built-in surge protection significantly reduces the chances of equipment being damaged by electrical surges and effectively lowers maintenance costs by minimising the need for expensive equipment repairs or replacement.

For optimal reliability, the DIS Series provides cold start capability in environments with temperatures as low as -40°C with full-load operation at up to 75°C. D-Link designed the DIS Series with hardened components to reliably withstand harsh environments with high electromagnetic interference (EMI) that would damage ordinary enterprise devices.

All switches in the DIS Series support dual power inputs to provide power redundancy, ensuring the network keeps running in the event of a power failure, as well as DIN rail mount support.

PoE devices, such as IP phones, wireless access points, surveillance cameras, and other standard PoE devices efficiently and with lower deployment costs. The DIS-200G Series also supports Auto-Surveillance VLAN 2.0 (ASV 2.0) which automatically segments and prioritises surveillance data, further simplifying the deployment of IP surveillance infrastructure when combined with PoE.

The DIS-200G Series features carrier-grade 50ms Ethernet Ring Protection Switching (ERPS) recovery for high-speed metro Ethernet ring resilience. In addition, support for loopback detection and cable diagnostics for network troubleshooting and maintenance provide reliable network access for non-stop service. The DIS Series features several models that support IEEE 802.3at PoE+ to deliver up to 30W of power per port to connected PoE devices with a total PoE power budget of 120W (DIS-100G Series) or 240W (DIS-200G Series). These models dynamically allocate power to connected

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DIS-100G Seriesgigabit switch range

NZ Manufacturer October 2018

You don’t get harmony when everybody sings the same note. - Doug Floyd

3D printed press brake tooling Cincinnati Incorporated (CI) has made a new productive link between metal fabrication and additive manufacturing. The three 3D printed press brake enhancements to be showcased are printed upper and lower airbend tooling, printed backgage fingers and a printed inspection gauge. 3D printing of standard style upper and lower airbend tooling is particularly useful for specialised jobs, prototyping, or short production runs, eliminating associated engineering and production times that cause delays in getting these types of jobs up and running in a timely manner. While many parts have complex shapes and contours, there can be challenges and delays in gaging properly and securely. With specialised 3D printed fingers, these challenges

are eliminated as difficult parts are gaged in a fast, simplified, easy way. With 3D printed inspection fixtures, all facets of a formed part can be checked at once, dramatically reducing the time spent measuring. This is especially ideal for longer parts that require multiple check points, or for cross sections with shallow bends. These innovations are 3D printed using PLA, a milk-based plastic, which offers a green, environmentally friendly benefit. Prototype fabricators working in 12-gauge or thinner materials are ideal for this new technology, as are fabricators forming smaller specialty parts.

Lightweight scanning solution The Faro 8-Axis Design ScanArm 2.5C is the first colour capable portable lightweight 3D scanning solution providing an unprecedented ergonomic experience with both the 7-Axis or 8-Axis models. Using the new Faro Prizm™ full colour Laser Line Probe with powerful 3D design and modelling software, the 8-Axis Design ScanArm delivers high-resolution colour point-cloud data enabling more insight into object design and creation, geometry, surface composition and differentiation between materials. The colour information is also used in high-quality 3D visualisation of rendering objects in gaming, movies and online marketing.

quick release, makes the device effortless to operate regardless of skill level or 3D scanning experience.

The Design ScanArm 2.5C comes equipped with dual, hot swappable batteries that enable continuous operation with no need for external power when the application requires measurement in the field or shop floor.

The Faro 8-Axis Design ScanArm 2.5C is the ideal colour capable 3D scanning solution for any organisation that may have the need to:

• Reverse engineer legacy parts for design changes or replacement

• Capture and digitize objects and props in full realistic detail for digital visualisation

• Design aesthetically freeform surfaces

Faro kinematic iProbe’s easy connect/ disconnect combined with a simplified

• Manufacture parts without existing

The 8-Axis Design ScanArm 2.5C is the ideal solution for any organisation that may have the need to develop or manufacture parts and after-market products characterised by different coatings, materials, co-moulded parts or surfaced finishes without existing CAD models. In addition, you can reverse engineer legacy parts to design changes or replacement, create digital libraries to decrease inventory and warehouse costs, design aesthetically pleasing free form surfaces or leverage the power of rapid prototyping. This lightweight and easily manoeuvrable ScanArm is available in

NZ Manufacturer October 2018

• Develop aftermarket products that need to fit tightly with existing products

lengths of 2.5m, 3.5m and 4.0m and seamlessly scans challenging products, objects and prototypes.

The added eighth-axis enables real-time rotation of the object being scanned – eliminating wasted time, reducing risk to delicate objects and supporting more complete scan output.

CAD models

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• Digital archiving and historical preservations

• Create digital libraries to decrease inventory and warehouse costs

• Leverage the prototyping

power

pleasing, of

rapid

In teamwork, silence isn’t golden. It’s deadly. - Mark Sanborn

Want to build a moon base? Easy. Just print it

Morgan Saletta, PhD, History and Philosophy of Science, University of Melbourne Planetary Resources, a company hoping to make asteroid mining into a trillion dollar industry, has unveiled the world’s first 3D printed object made from bits of an asteroid.

of a dome shelter for a lunar base that would also incorporate an inflatable interior structure. The project used a D-Shape printer using Enrico Dini’s company, Monolite.

3D printing, and additive manufacturing processes more generally, have made many advances in recent years. Just a few years ago, most 3D printing was only used for building prototypes, which would then go on to be manufactured via conventional processes. But it’s now increasingly being used for manufacturing in its own right.

Since 2011, NASA has been funding similar research led by Professor Behrokh Khoshnevies at the University of Southern California. His team has been using a technology called contour crafting, which also has the goal of using 3D printing to construct entire space habitations from in situ resources.

Nearly two years ago, NASA even sent a 3D printer to the International Space Station with the goal of testing how the technology works in micro-gravity. While the printer resembles a Star Trek replicator, it’s not quite that sophisticated yet; the objects it can print are prototypes for testing.

After testing 3D printing in space, NASA has decided the technology is

a major contract to the Archinaut project.

can lead to material failures in crucial components. 3D weaving, which deploys fibres on three axes, is set to revolutionise these materials and their performances.

The project will see a 3D printer, built by Made in Space, mated with a robotic arm, built by Oceaneering Space Systems, with Northrup Grumman providing the control software and integration with the ISS systems.

Indeed, NASA is now using 3D woven quartz fibre compression pads for its Orion Space Vehicle and exploring the technology for use in other thermal protection surfaces.

The goal of the project is to provide an on-orbit demonstration of large, complex structure – in this case a boom for a satellite – sometime this year.

But the ability to use in situ materials, both for fuel, water and construction whether on the moon, Mars, or asteroids has long been recognised as a crucial ability to enable human exploration of the solar system.

Archinaut is a technology platform that enables autonomous manufacture and assembly of spacecraft systems on orbit.

Contests such the 3D Printed Habitat Challenge, part of NASA’s Centennial Challenges, are an important element of an innovation strategy designed to push the envelope of technology, leveraging entrepreneurial spirit, scientific and technological know-how and design thinking in a bid to take human space exploration to the next level.

But 3D printing objects don’t have to be small. Entire houses have now been 3D printed, including out of renewable resources such as clay and earth.

The Mars Ice House Habitat, which would be printed out of ice from relatively abundant water on Mars’ northern hemisphere, is a far cry from the bunker like spaces frequently envisioned for Mars bases.

Above and beyond NASA, the European Space Agency (ESA) and entrepreneurs aiming to jump-start human colonisation of space see the 3D printing of large-scale objects, including entire habitations, as a major enabling technology for the future of space exploration.

Multi-dome lunar base being constructed, based on the 3D printing concept. Once assembled, the inflated domes are covered with a layer of 3D-printed lunar regolith by robots to help protect the occupants against space radiation and micrometeoroids. ESA

In 2013, a project led by the ESA used simulated lunar regolith – i.e. loose top soil – to produce a 1.5-ton hollow cell building block. It was conceived as part

But 3D manufacturing is already changing the aerospace industry. Composites, for example, have become a commonly used material for a wide variety of applications.

close to a tipping point. As part of a new programme of public/private partnerships aimed at pushing emerging space capabilities over these tipping points, NASA has awarded

The ice would provide ample radiation protection while creating a radiant, light filled space reminiscent of a cathedral.

Down to Earth

Space exploration has always been associated with visionary fiction and grandiose plans, and it looks like 3D manufacturing and construction may finally bring the printed word to life.

But composites tend to suffer weakness between their laminating layers, which

1.5 tonne building block produced as a demonstration. ESA

Mars Ice House cross section.

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NZ Manufacturer October 2018

You may be disappointed if you fail, but you are doomed if you don’t try. -Beverly Sills

Data networks in factories need to be fast, standardised and real-time capable, according to an international authority on the subject, Oliver Riedel. Yet there is still much to be done before this can be achieved, says Mr Riedel, who is Professor at the Institute for Control Engineering of Machine Tools and Manufacturing Units (ISW) at the University of Stuttgart. The global automation technology and cable technology leader Lapp Group, of which Lapp Australia is part, is gearing up for change.

The connected factory, where standards are starting to stick -Bernd Müller for LAPP random-access protocols and large packets (so-called frames), and is therefore not real-time capable per se.

Real-time capable with TSN

communication standards poses a major obstacle to this goal. And yet the Ethernet standard (IEEE 802.3), which has really taken off since the early 2000s, has been networking PCs for decades and is known for being very fast and reliable.

The Internet has reached the factory. Controls, drives, sensors and machines are all networked, exchanging data ceaselessly. Data volumes and interconnectedness, from the sensor to the cloud, will continue to sky rocket. Traditional IT services, such as business or logistics software, are part of this networking phenomenon.

However, this standard does not apply to factories because many suppliers have “bent” the Ethernet over time, and there are now a dozen versions on the market that are not automatically compatible with the others. And there are many more fieldbus standards, including Profibus, Modbus and CC-Link, which still comprise almost half of installations.

And yet the infrastructure for data exchange used in many companies is stubbornly defying this trend towards interconnection. Outdated individual networks with separate software and infrastructure dominate here. Every level of the automation pyramid, from the management level right down to the field level, functions with its own infrastructure and separate protocols.

This jumble is caused by many suppliers of automation components, who, in an effort to guarantee steady revenue for many years to come, attempt to force their customers into using proprietary standards. But what has failed to work on the public Internet will also not be successful within the walls of a factory.

“The many different networks here will merge together,” says Oliver Riedel, adding: “The automation pyramid will gradually disintegrate as a result.” Instead of hierarchical communication structures in automation, Professor Riedel expects flexible hierarchies in which cyber-physical systems exchange data with each other, with corporate IT systems and with the cloud via a dense network.

A proliferation of standards Nowadays, users require general, open standards that allow barrier-free data flow for all areas and functions of a company. It is inevitable that the many networking standards will eventually converge into one overarching standard.

A Babylonian confusion of tongues in industrial data communication. This jumble is being progressively untangled as networking standards converge The

current

proliferation

Another important communication requirement in automation, especially at field level, is the ability to transmit data in real time. It doesn’t matter if a website loads half a second faster or slower when clicking on a link in a web browser.

But in automation, it all comes down to the millisecond, sometimes even the microsecond. Ethernet-based networks can currently only do this to a certain extent, as Ethernet works with

NZ Manufacturer October 2018

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One solution would be Time-Sensitive Networking (TSN), a future standard proposed by Ethernet working group participants. Its main benefit is that it does not come from the field of automation, but from audio/video bridging, so it has met with fewer challenges and competitive backlash from automators. Concert halls have real-time Ethernet so that the multitude of speakers can play the audio signals from various microphones unfailingly and without sound delay. Delays of just a few milliseconds between audio channels would cause echoes. In terms of automation, TSN would have a number of benefits as a solution based on network convergence. All participants in a TSN network are timesynchronised, so they perform the right action at precisely the right time. TSN has various traffic classes with different time slots to enable data to be prioritised by bandwidth and fidelity. Important information that must not be delayed gets higher priority, as bandwidth and time slots are reserved for this. TSN will be a standardised expansion of, and 100% compatible with, Ethernet. TSN cannot yet be purchased in many products, but the first devices and early adopters are out there.

OPC-UA gives new meaning to data TSN ensures that data gets to where it needs to be just in time. But it

does not contain any information on what this data means. There is a second standard to handle this: OPC*-UA, a communication protocol for exchanging data between cyber-physical systems. OPC-UA is now accepted as a de facto standard in communications for Industry 4.0. The problem is it is not real-time capable, but experts from the ISW in Stuttgart are already working on this with standardisation committees. “Communication is no longer a unique selling point,” says Oliver Riedel. “Those trying to fight against TSN or OPC-UA and continuing with proprietary solutions will probably not be able to stick it out for long.” Security, in other words defending against cyberattacks, is another topic currently under discussion. Excellent solutions for safety, i.e. protecting employees, are already in place. For example, machine operators need to be able to rely on the machine stopping immediately when the red emergency stop button is pressed. This type of command has top priority in TSN. Given the attributes described here, TSN has the potential to solve the issue of the “Babylonian confusion of tongues” in industrial data communication. *OPC Unified Architecture (OPC UA) is a machineto-machine communication protocol developed by the OPC Foundation (OPC formally known as Object Linking and Embedding for Process Control) is an industry consortium with more than 600 Foundation members globally from countries including Europe, North and South America, Africa, Asia (including China, India, Japan, Korea, Taiwan and Singapore), Australia and New Zealand. OPC Foundation members vary greatly, from small system integrators to the world’s largest automation and industrial suppliers

Oliver Riedel, right, data exchange networks to continue to converge

PRODUCT UPDATE

Average leaders raise the bar on themselves; good leaders raise the bar for others; great leaders inspire others to raise their own bar. -Orrin Woodward

Kemppi releases tough, cost-effective X3 MIG Welder Leading international welding equipment manufacturer, Kemppi, has launched the new Kemppi X3 MIG family, an evolution of its popular HiArc MIG range. The X3 is a basic and cost effective MIG alternative to Kemppi’s premium FastMig welding family, but with a high duty cycle and robust design is suitable for the tough and demanding conditions found in the metal fabrication industry. Available as a gas-cooled MIG/MAG welding package with carbon arc gouging, the X3 MIG Welder delivers excellent performance with up to 500 amperes at a 60% duty cycle. The machine is equipped with a wire feeder for 300mm wire spools and accepts wire diameters from 0.8 to 1.6mm, and with cored wires up to 2.0mm. It also offers outstanding welding control to deliver quality welds. The MIG/MAG process of the X3 MIG

Welder has been carefully tuned at the Kemppi welding lab to give the arc excellent stability. This makes the arc easy to manage and minimises spatter, even when using inexpensive CO2 shielding gas.

A practical, no-nonsense machine for the professional welder, the Kemppi X3 MIG Welder is both robust and rugged.

With less spatter, the need for post-weld grinding is reduced, and welders can use more of their time for productive welding.

The system’s wire-feeder features a fully enclosed and impact resistant dual-skin cabinet to protect the wire spool and feed mechanism so that it can withstand rough handling.

In addition, the machine has a range of functions that fine-tune the start and end of welds, improve the quality of the weld and help boost productivity. These include Crater Fill, Burn Back, Hot Stop, Soft Start, Hard Ignition and Creep Start. Plus, the machine is also very energy efficient. Kemppi is the number one pioneer in welding inverter technology, and the X3 MIG Welder uses the latest IGTB inverter technology to reduce its energy usage and minimise costs.

To select the basic features, the welder just pushes the appropriate buttons and makes selections with the adjustment knob.

Compact and lightweight, the machine is easy to move between work sites. Ergonomically positioned handles ensure easy manoeuvring of the machine. Plus, carriage and wheel set options are available to further facilitate easy transportation.

During welding, wire feeder control knobs are used to adjust the wire feed speed and voltage. What’s more, the X3 MIG Welder automatically takes care of adjusting the amperage according to wire feed speed to create top quality welds.

The X3 MIG Welder is simple to operate. The control panel communicates with the welder entirely by symbols.

What are the different types of compressed air dryers? Compressed air dryers are an important addition to air compressors and allow particles such as oil and water vapour to be safely removed. Filtering and drying compressed air can reduce the chances of corrosion and other issues, improving the life of equipment and reducing the need for maintenance. Many air dryer types can effectively remove contaminants and water vapour, producing quality compressed air which is suitable for sensitive applications. Air dryer types include membrane, desiccant, deliquescent and refrigerated air compressor dryers. What is an air compressor dryer? Air compressor dryers use a number of different methods to remove moisture and water vapour from compressed air, depending on the air dryer types. Each type of air dryer has its own advantages and disadvantages which can make them more appropriate for certain situations. The amount of water vapour in air is measured as its ‘dew point’. The lower the temperature of air’s dew point, the less water vapour it contains and the drier it is. While some air dryer types can remove almost all the water vapour in air, lowering dew point becomes increasingly more expensive and difficult as water vapour is removed.

the most cost-effective to own and operate. Refrigerated air dryers work by cooling compressed air down until the water vapour condenses into a liquid form, which is then drained away. Refrigerated dryers are the best choice to dry air for general purposes, as they remove the largest amount of water with the least amount of energy use. This can greatly reduce the problems associated with wet compressed air without spending more resources to completely remove water vapour. Pros: Cost efficient Cons: Does not completely remove moisture Membrane compressed air dryers Membrane dryers work by shifting pressurised air through a fine membrane. This membrane is designed to let water molecules pass but traps larger air molecules. This effectively separates water vapour from the air and dries it. A small amount of compressed air is then recycled into the system to eject the separated water vapour and reset the membrane. Membrane dryers use up very little space and don’t require electricity to operate. Because of this they’re recommended for use in remote locations and in industries where explosions are a risk factor.

Refrigerated compressed air dryers

Pros: Small and effective

Refrigerated dryers are a popular compressed air dryer type as they are

Cons: Expensive and eventually need replacing

Desiccant compressed air dryers

liquid water before it enters the dryer and helping to preserve the deliquescent material.

Desiccant dryers use materials which absorb water from compressed air and can then be heated up to release and remove water content. This reversible process typically occurs in two separate compartments which alternate between heating and drying.

A particle removal filter may also be needed after the deliquescent dryer to prevent chemical particles coming through, depending on the use of the compressed air.

Desiccant dryers are also known as regenerative dryers or two tower dryers because they can efficiently cycle between their two compartments, ensuring that compressed air is constantly being dried. Desiccant dryers also dry air to a very low dew point and so are best suited for delivering compressed air to sensitive applications. Pros: Can effectively

dry

compressed

Pros: Dries air quickly and efficiently to a high quality Cons: Requires daily replacement of materials and additional filters Removing water vapour from your air compressor is essential to ensuring proper functionality and reducing the need for future maintenance and repairs. Dried compressed air can enable you to power your applications safely and efficiently without having to deal with errors and contamination.

air

Cons: Expensive to operate. Heated dryers require large amounts of electricity

Author Bio: This article was written by Daniel Defendi, from Express Compressors in Perth. You can catch Daniel on Google+ to discuss this piece.

Deliquescent compressed air dryers Deliquescent materials are special compounds which attract and absorb water vapour in compressed air to form a liquid solution through their combination. Mineral salts such as calcium chloride are commonly used in deliquescent dryers. Deliquescent dryers normally require installation of a coalescing filter before air reaches the chemical dryer. Coalescing filters work by trapping particles and water until they grow large enough to drain away, removing

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NZ Manufacturer October 2018

PRODUCT UPDATE

My job is not to be easy on people. My job is to take these great people we have and to push them and make them even better.- Steve Jobs

Quiet ZC cordless pump offers portability, speed and safety An international leader in high pressure hydraulic tool technology, Enerpac, is introducing to Australia, New Zealand and Papua New Guinea compact and outstandingly powerful cordless hydraulic pumps ideal for jobs that require a combination of portability, speed and safety. The 700 bar (10,000psi) ZC Series pumps combine the performance of an electric pump with the convenience, portability and stumble-free safety of a battery pump that is ideal for applications where emissions and noise are concerns.

foundation work; post-tensioning and rail, road, civil engineering and infrastructure development on sites as diverse as mining and energy, construction, oil and gas exploration and development; water and pipeline projects.

The new generation cordless pumps – featuring a rechargeable 82V lithium ion battery with long run times, even under extreme site conditions - work well in remote locations where there is no access to power, as well as indoor uses where trip hazards, ergonomics or size are a concern.

These advanced technology pumps – with impressive run times and national service backing from Enerpac – are among the first of a stream of high-technology products Enerpac is introducing to save users time and money. The ZC-Series is a high-flow cordless solution with an 8-litre reservoir capacity, 0.52l/min flow at rated pressure and reduced noise level of 80 dB a maximum.

Available in single-acting, double-acting and Power Seater Post Tensioning models (weighing 29.7-33.3kg), the pumps provide a high-flow cordless solution for applications such as: lifting, shifting, cutting, pressing, gear pulling and other workshop maintenance tasks;

They are designed to handle, for example, 50 lifting cycles with an RC1006 95-ton cylinder, or 90 cycles of the equally widely used RC504 cylinder

on a single charge.

of high-quality hydraulic hoses and

ZCs save users time and money by eliminating the need for a generator and extension cords. The brushless 1.0 kW (1.4 hp) motor and 3-stage pumps maximise pump and tool productivity while minimizing heat build-up and downtime. Safety of the pump is enhanced by a 3m pendant cord for hassle-free operation.

gauges.

ZC-Series valve options include: • 4-way/3-position manual control valve used with double-acting cylinders • 3-way/3-position manual control valve used with single-acting cylinders • 4-way/3-position manual control valve with locking and power seat functions Enerpac also offers a complete line

THE FACTORY OF THE FUTURE WILL MAKE THE IMPOSSIBLE, POSSIBLE SINGLE PASS WELDS IN THICKNESSES UP TO 200MM WITH NO CONSUMABLES

www.ebflow.com

PLEASE VISIT FOR MORE INFORMATION

NZ Manufacturer October 2018

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SUPPLY CHAIN

The person who says it cannot be done should not interrupt the person who is doing it. -Chinese Proverb

Wipak leads the way with intelligent digital packaging At a time when digitisation is becoming increasingly important in retail, and statistics suggest that more than 90 percent of consumers now use their phones in the shopping process, Wipak is leading the way in intelligent digital packaging by offering Digimarc Barcode, an advanced barcode, imperceptible to consumers. Wipak, which specialises in high barrier films, has been working in close collaboration with US-based technology company, Digimarc, since 2013, pioneering innovative solutions and packaging applications which utilise Digimarc Barcode. Wipak has been tapping into this digital technology for some time now and has gained valuable expertise as a

result. From invisible watermark printing, augmented reality and ‘self-talking’ packages, to offering Digimarc Barcode. Digimarc Barcode is nearly imperceptible and can permeate the entire package, making it easy for consumers to scan large portions of the package to access product information and other engaging digital content. It is also easily read by retail barcode scanners, freeing up cashiers from having to search for the UPC barcode. Products with Digimarc Barcode also increase manufacturing efficiencies and reduce waste in the supply chain. To integrate Digimarc barcode into a

award-winning ProDirect® inkjet digital printing technology to create the finished product.

pack, Wipak will be able to generate the required codes by themselves. Following this, Wipak will incorporate the codes into its gravure, flexo- or

How to not run out of beer (or soft drinks, or chicken) Football tournaments are unpredictable – that’s one of the best things about them. But one thing no one seems to have expected over the course of the FIFA World Cup is how much carbon dioxide (CO2) would be needed to keep the beer flowing in British pubs. But it’s not only beer which is facing a shortage. There is also increased pressure on supplies of Coca Cola, chicken and frozen food. And it’s all down to reduced levels of available carbon dioxide after three of the four production plants in the UK were temporarily out of action. Although this might seem like a rare occurrence, such problems are actually not unusual. It was only in February 2018 that takeaway giant KFC had to temporarily close down hundreds of outlets when it ran out of chicken. All of these shortages happen because of the decisions made regarding a company’s supply chain. With KFC, a

few months before the shortage, the company had decided to switch its logistics service provider from Bidvest to DHL. The result was a massive disruption to the supply chain at the time of the changeover. Six years ago, rival firm Burger King made the exact same decision with very similar consequences. The message to organisations who provide consumers with food and drink should be made loud and clear: start caring about your supply chain like it matters. A complex system In simple terms, a supply chain is a network between a company and its various suppliers which involves a product – say beer – being produced and distributed. The trouble is, for big firms, these networks are never simple. They involve large amounts of complex information related to finances,

services and products. It requires the firm to have a clear understanding of all the parts in the chain and the roles those parts play. Where are certain key products and services at any given time? How is everything connected in order to deliver a constant flow of chicken and beer to the customer?

Jas Kalra

Jens Roehrich

Research Fellow in Supply Chain Management, University of Bath

Professor of Supply Chain Innovation, University of Bath

to the final assembly plants.

Unfortunately, the nature of supply chain management is such that its importance is only clear when we run out of something we want (or when we hear about horse meat scandals or poor treatment of workers).

Companies now need to be able to coordinate the myriad of activities and information across a network of organisations, including in the case of chicken, pullet farms, breeder farms,

But long gone are the simpler days of Henry Ford, whose car company owned everything in a supply chain – from a sheep farm to source wool for car seats

poultry processors and packers, and distributors – as well as CO2 suppliers (involved in the slaughter).

Attain Global Certifications in Supply Chain, CPIM, CLTD and CSCP

with the help from NZPICS! Enrol now! Contact us Now! Phone: (09) 525 1525 (09) 525 1535 E: info@nzpics.org.nz OR enquiries@nzpics.org.nz Web: www.nzpics.org.nz

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NZ Manufacturer October 2018

FOOD MANUFACTURING

They always say time changes things, but you actually have to change them yourself. -Andy Warhol

Breakthrough technology could save dairy industry millions A new device that detects processing losses in dairy plants could save the industry millions of dollars a year and help prevent pollutants from entering waterways. could save dairy industry millions Lincoln University-owned research and development company, Lincoln Agritech Ltd, developed the breakthrough technology and it was then commercialised by Christchurch-based start-up company, CertusBio.

company profitability.” Dr Jones said current loss-monitoring methods were reliant on retrospective testing collected over 24 hours. “Because this testing is done after the dairy products have been processed, it doesn’t allow for adjustments to be made while the plant is operating, so losses can’t be limited in real time.”

The result is a robust, automated biosensor capable of continuous monitoring in commercial operating conditions. Known as Milk-Guard, the device uses a lactose-specific enzyme to measure the percentage of dairy products present in waste streams and processing lines.

Two-to-three per cent of all dairy products are lost during processing and while this is inevitable to a certain extent, a significant proportion of losses could be avoided. “The estimated total loss for an average dairy industry processing line is $6.5 million per year,” said Dr Jones.

These percentages are automatically sent to a dairy plant process control room, where operators can monitor them and make changes to the production process if necessary.

“This also contributes to the level of pollutants caused by the dairy processing industry, as dairy plant wastewater has a number of characteristics that require careful management, including influent pH swings of 2-13, high fat loads and variable incoming organic and nutrient loads. Variations occur both on a seasonal and daily basis.”

CertusBio CEO Dr Matthew Jones said that due to the vast quantity of dairy products processed in New Zealand, large amounts of valuable products could be lost quickly. “Given the significant economic return to New Zealand from the dairy industry, it is vital to extract as much value from dairy processing as possible by using reliable, fully automated systems to accurately and rapidly monitor losses in dairy processing waste streams.

According to Water NZ, irrigation is the most commonly used method in the country for treating dairy processing wastewater. Soils must have good infiltration capacities because if the infiltration rate is too low, then wastewater will pond on the surface of the land. Wastewater can then undergo anaerobic decomposition, resulting in

“Dairy plant operators will be able to improve the resource and energy efficiency of their plant processes by reducing losses of valuable dairy products and ultimately increasing

odours, acidification and damage to the plant cover. If infiltration rates are too high, then the wastewater will spend insufficient time in the top soil to receive adequate treatment, leading to possible groundwater contamination. Trials at dairy processing plants have demonstrated Milk-Guard’s ability A Milk-Guard device in action at a dairy processing plant, operated to frequently detect by Dr Matthew Jones (CEO, CertusBio). product losses during processing, which reproducibility of measurements and could be worth in excess of NZ$30,000 reduce maintenance requirements for for a single event. process operators. “Milk-Guard is the first interference-free Cartridges are replaced on a monthly continuous monitoring device aimed basis (via courier) with used cartridges at the dairy processing industry. The being recycled for further use by biosensor puts control in the hands CertusBio. of process operators to dramatically reduce processing loses,” said Dr Jones. In addition to wastewater monitoring CertusBio has demonstrated that its to reduce processing losses, the lactose biosensor technology is robust Milk-Guard device can be used to enough for continuous monitoring account for all material entering applications where a single sensor can and leaving a processing plant, be used to make thousands of precise liquid transfers within a plant, and measurements within dairy plant segregating raw materials containing high value products. wastewater. The technology relies on a “biosensor cartridge system” similar to a standard printer cartridge to increase the

The combination of these uses is expected to provide a significant return on investment for dairy processors.

High honour for Lincoln Agritech Lincoln Agritech Ltd was recognised for its cutting-edge innovations at the annual Canterbury Westpac Champion Business Awards in September. “Our company is flexible and dynamic, combining the spectacular expertise of our scientists and engineers with practical industry insight to offer new knowledge and solve complex, real-world problems,” he said.

The research and development company owned by Lincoln University won the ChristchurchNZ Champion Innovation award, which honours businesses that have developed products, services or business model innovations to improve commercial performance, effectiveness or customer engagement.

Lincoln Agritech’s research has improved the commercial performance of many New Zealand businesses, as well as growing its own activities.

Lincoln Agritech CEO Peter Barrowclough was delighted with the win and paid tribute to the talented team of scientists and research engineers who work hard to deliver leading-edge knowledge and technologies across the primary sector value chain.

NZ Manufacturer October 2018

One of its latest inventions is the HydroMetrics optical groundwater nitrate sensor. The sensor can be placed down wells to provide accurate real time nitrate monitoring in groundwater. The HydroMetrics sensor, now commercialised and available for

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purchase, is priced at a third of the cost of international equivalents. “This is disruptive technology which will help us monitor the environmental impact of NZ’s primary production systems. “Our innovation stems from our unique combination of strategy, our people and culture, our collaborative approach and our strong industry partnerships.,” said Mr Barrowclough. “With just 55 staff we regularly punch above our weight when compared to NZ universities and Crown Research Institutes in the highly contested annual MBIE funding rounds. In the latest funding round, announced last week, the company was awarded

$13 million for two five-year research programmes. One programme aims to further understand critical nitrate pathways into groundwater and the other will assist medical professionals to diagnose bone and tissue damage using hand held non-contact novel technology. Mr Barrowclough said Lincoln Agritech had experienced significant growth in revenue over the past five years. “Private sector research revenue has increased by almost 400% and revenue for Government-funded research has more than doubled. Repeat business for professional services was 90% in 2017.”

We are what we repeatedly do. Excellence, then, is not an act, but a habit. - Aristotle

FOOD MANUFACTURING

Why you should hope

your next tomato’s grown indoors by robots -Kevin Maney

If you were inventing the farm today, why would you put it outside, on a giant plot of land? OK, there’s the sunlight thing, but then you get droughts and frosts and plant-munching insects that have to be battled with harmful pesticides. And because outdoor farms need so much acreage, they’re usually far from most of their customers. But now, upstarts such as Bowery farming, AeroFarms, and Lettuce Networks are doing something different. They’re growing food indoors. They’re using data and artificial intelligence to operate more efficiently than traditional farms. And they’re staying small and close to population centres. The new generation of farming promises to feed more people while doing less environmental damage. This kind of distributed farming fits with a larger 21st-century movement that venture capitalist Hemant Taneja and I call “unscaling.” Massive scale was the goal throughout the 20th century. Mechanisation and technologies such as the truck and telephone made it possible. Mass production, mass markets, and economies of scale ruled in every sector. So we ended up with giant companies, huge hospitals, big universities — and corporate mega-farms.

Farms are unscaling, too. Bowery and AeroFarms both operate inside old industrial buildings. Inside these buildings, LED lights mimic natural sunlight. The crops grow in nutrient-rich water beds on trays stacked floor to ceiling. And sensors constantly monitor the plants and send data back to AI-driven software, which can learn what’s best for the plants and tweak lighting, water, and fertiliser to improve yields. Much of the “farming” is done by robots. These unscaled farms can give consumers a better product than mega-farms, too. Food grown nearby doesn’t need to endure shipping — so it can ripen the way it’s supposed to. In the middle of winter, indoor-grown, local tomatoes will taste like tomatoes. As you can imagine, that’s what consumers prefer. Since 2013, about US$2 billion has been invested in hundreds of agricultural technology start-ups. AeroFarms has raised more than $100 million and sells to Whole Foods and FreshDirect. Freight Farms is growing food in container cargo vessels, often selling to restaurants, hotels, and college campus eateries.

BrightFarms says it “finances, designs, builds, and operates” indoor farms close to food retailers and has raised $11 million in funding.

farming should be good news for the environment. Scaled-up farming was the right answer for the past century, feeding a burgeoning population while making food relatively cheap.

Edenworks is operating rooftop greenhouses that grow produce fertilised by ground tilapia and prawns, which are also grown at the mini-farm.

The percentage of disposable income used for food is lower today than it was in the 1970s. But by 2050, the planet is projected to have 2.2 billion more people to feed, just as global warming is expected to make weather less predictable and dry up previously fertile regions.

Lettuce Networks is trying another approach. It is using cloud and mobile technology to create a network of urban farms. Founder Yogesh Sharma calls it an Airbnb for farming. The company contracts with owners of small plots throughout a city and installs sensors that can monitor crops and the surrounding environment. Nearby residents can subscribe to the Lettuce service to get food delivered. The system knows what’s being grown all around the city and, from that network, assembles a basket of local produce for delivery. Owners of the plots make some money off their harvest, while subscribers get an assortment of fresh food grown nearby. Distributed,

indoor,

If food can be grown indoors, in a cost-effective way, in or near cities, climate will be less of a concern, and far less carbon will be burned moving food thousands of miles via trucks, trains, and ships. Whether unscaled farming is a net economic benefit remains to be seen. It’s a new industry, with techniques and business models that are works in progress. Analyst firm Market Research Future notes that urban farms cost a lot to start and don’t yet work for a lot of crops, such as corn or bananas.

AI-assisted

Sunlight is free and sustainable; LED lights require energy. But proponents believe that because these indoor farms are far more productive and are closer to consumers, once there are a lot of them and the techniques and technology get honed, more people will be fed for less cost than ever before. As investment pours in and environmental conditions drive a need for new solutions, unscaled farming looks a lot more like the future of food than does a massive field baking under the sun.

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Innovations in taste for world markets

NZ Food Manufacturer brings you the latest news and developments in food from the land to the plate For further information and to advertise visit

www.nzfoodmanufacturer.co.nz Food October Manufacturer T 0064 6 870 9029 28NZ NZ Manufacturer 2018 / www.nzmanufacturer.co.nz

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DEVELOPMENTS

Great things are done by a series of small things brought together. -Van Gogh

World-renowned space company partners with NZ research institute The Centre for Space Science Technology (CSST) and Airbus Defence and Space has announced a partnership agreement, which will give New Zealand businesses, industry, government and the research community access to an even wider selection of high resolution, weather independent, near real-time satellite imagery. “In the past, New Zealand has lagged behind other nations in our application of Earth observation (EO) data, which has limited our ability to optimise the use of resource-limited inputs, manage risk, remain internationally competitive, respond to regulatory requirements, and minimise environmental impact,” said Steve Cotter, CEO of CSST. “In order to address this issue, a key component of CSST’s original business case was to make EO data more available and affordable. We are starting to execute on that plan by negotiating strategic data partnership agreements which increase the availability and affordability of EO

products and services in New Zealand and the wider Pacific region.” CSST is now the primary provider of Airbus satellite data and products in New Zealand and the Pacific Islands. With science and commercial applications ranging from disaster monitoring and border security through to agriculture and forestry, access to Airbus products increases CSST’s data offerings to include a broad range of satellites, from compact cubesats (which can fit in the palm of your hand) to highly sophisticated radar satellites (size of a bus), used for collecting very-high-resolution data about the Earth’s surface - day or night, rain or shine. Airbus is one of the world’s most renown commercial space organisations, operating in over 35 countries worldwide, supplying satellites for many governmental space organisations including the European Space Agency and German Space Agency. Airbus is also the prime contractor for over 70 EO satellites, with a full suite of observational

purposes and types of leading-edge sensor technology on board. Airbus’s EO data often best serves decision-makers who require daily revisits, need business-critical information regardless of weather conditions or cloud cover, and require access to very-high-resolution imagery (down to the tens of centimetres), which can only be provided by the latest technology.

sustainable decisions,” said Mr Cotter of CSST.

Airbus also provides a very quick turn-around on requests for data (two hours max during times of emergency), meeting the specific needs of many government departments, disaster response organisations and commercial entities.

“The partnership with Airbus allows us to leverage cutting edge research and development efforts in the international sector towards meeting specific regional and national needs.” CSST will be hosting Airbus for a series of roadshow events in New Zealand in November. If you are interested in learning more about these events, please email sales@csst.co.nz.

“CSST exists to positively impact New Zealand—the land and its people—by providing key insights from EO data to make smarter, safer, and more

Inadequate machine guarding lead to hand amputation -A cautionary tale Machine guarding failures in the meat processing industry are continuing to cause life changing injuries to workers. Alliance Group Limited recently appeared in the Timaru District Court after an incident where an inexperienced worker’s hand was amputated in a piece of machinery in March 2017. The worker had been employed at the plant for only five days and was left unsupervised on a task. Due to the worker’s lack of familiarity with the job, he opened a section of the machinery used for dehydrating blood into a powder and placed his right hand inside. The hand came in

contact with a rotating screw and was amputated. WorkSafe’s investigation found that Alliance Group had failed to ensure the health and safety of its workers and that it was reasonably practicable for them to have undertaken an adequate risk assessment of the machine and to have ensured it was adequately guarded. WorkSafe’s Deputy General Manager for Investigations and Specialist Services Simon Humphries said: “The level of injury and trauma this worker endured as a result of Alliance’s failings will impact him for the rest of his life.

- Alliance Group Limited had voluntarily paid reparations prior to sentencing and no further reparations were ordered.

“This is a stark reminder to others operating machinery in every industry to ensure machinery is adequately guarded. New Zealand has rigorous and accessible standards for machine guarding – adhering to them and mitigating the risks your machinery poses is imperative to keeping workers safe from harm”.

- Alliance Group Limited was sentenced under sections 36(1)(a), 48(1) and (2)(c) of the Health and Safety at Work Act 2015. o Being a PCBU, failed to ensure, so far as was reasonably practicable, the health and safety of workers who worked for the PCBU, while the workers were at work in the business or undertaking.

Following the incident, Alliance Group had in-house engineers guard the machine and produce a standard operating procedure for the task of blood drying. The end result

- The maximum penalty is a fine not exceeding $1,500,000.

- A fine of $332,000 was imposed.

Engineering New Zealand adds engineering expertise to claims resolution service Engineering New Zealand is creating an expert engineering panel to help resolve outstanding insurance claims, as part of the Government’s new Greater Christchurch Claims Resolution Service. Chief Executive Susan Freeman-Greene says engineering disputes are at the heart of many unresolved insurance claims in Christchurch. “Engineering New Zealand wants to help untangle and solve these disputes.

As the professional home for all engineers, we bring an independent, expert point of view.” Ms Freeman-Greene says this will mean creating a panel of independent engineering experts who can provide

expert advice and facilitation services to help resolve claims.

help resolve Canterbury issues. “It’s about getting the right engineering input at the right stage in the claims process.”

“Earlier this year, we launched a process to help reconcile disparate seismic assessments. The Government has asked us to apply this model to

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NZ Manufacturer October 2018

BUSINESS NEWS

If everyone is thinking alike, then somebody isn’t thinking. - George S. Patton

Aurecon appoints CSIRO leader to manufacturing practice joining the CSIRO. “The food and manufacturing industries are responding to new markets that demand safety, product differentiation, high quality and provenance,” said Dr Appelqvist. “Manufacturing can do all this with technology - we’re in a digital age and manufacturing needs to catch-up.”

Dr Ingrid Appelqvist – enabling Australasia’s food opportunity Dr Ingrid Appelqvist, takes up her position at a time when agri-food companies will have to invest in new manufacturing capability or risk losing market opportunities in Asia.

manufacturing business at a time when Australia’s and New Zealand’s agri-business industries are gearing up for growth.

Will bring advanced technical capability and strategic thought leadership to Aurecon’s manufacturing business.

“There is growing demand for high-quality and innovative food products from Asian markets. The ANZ agri-food-dairy industry has an opportunity to capture the most lucrative segments of these value-chains,” said Dr Wonhas. “Dr Appelqvist will help our clients implement leading-edge technologies and processes to give them an advantage in these growth markets.”

Global engineering and infrastructure advisory company Aurecon has appointed Dr Ingrid Appelqvist as its new Client Director for Manufacturing. The appointment of Dr Appelqvist, effective September 17, comes as Aurecon grows its manufacturing work in response to Australia’s and New Zealand’s growing importance as a food supplier to Asia.

Dr Wonhas said advanced manufacturing techniques underpinned by new innovative process technologies, sensors, automation and machine learning - could enable higher quality and higher margin products.

The Australian Trade Commission says that by 2050, 60 per cent of the global demand for food will come from Asia. Dr Appelqvist is a distinguished food scientist with a strong track record as a leader. She joins Aurecon from CSIRO, where she led the Food Structure group at the Agriculture and Food Business Unit - a position that saw her working on healthier foods that retain palatability and nutrition-uptake in the body.

Aurecon’s food manufacturing practice takes a supply-chain view of the industry and focuses on quality of the product, food safety and facility technology. Dr Ingrid Appelqvist is a Sydney-based scientist who worked for Unilever in the Netherlands and UK before

Her expertise in food design includes advanced food manufacturing processes and technologies, an expertise she will facilitate for Aurecon’s agri-food clients.

NZ Manufacturer October 2018

China’s increase in food demand includes a shift to higher-value Western-style diets, including beef, dairy, lamb, goat, fruit and vegetables. Since 2006 Dr Appelqvist has been a CSIRO specialist in food design and advanced manufacturing. She is the Group Leader for Food Structure in CSIRO’s Agriculture and Food Business Unit and has expertise in reformulating food to make it healthier while retaining its functionality, palatability, the breakdown of food in the body and nutrient uptake. Much of Dr Appelqvist’s work is concerned with food manufacturing processes and technologies, to help increase food quality and safety. She sees not only a vast Asian market for Australian and New Zealand food exporters, but one with specific demands. “Consumers in China demand clean, safe, high-quality foods,” says Dr Appelqvist. “They also want novelty products and they’re demanding

By 2050, 60 per cent of the global demand for food will come from Asia.

Dr Alex Wonhas, Managing Director – Energy, Resources and Manufacturing at Aurecon, said the hiring of Dr Appelqvist will bring advanced technical capability and strategic thought-leadership to Aurecon’s

The Australian government forecasts a steep rise in food consumption in China between 2009 and 2050: beef consumption by 236 per cent, dairy consumption 74 per cent, sheep and goat meat consumption by 72 per cent and sugar consumption by 330 per cent (in 2009 US dollars) .

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provenance verification for the food they buy.” The Australasian agri-food industry has the reputation for fresh, quality produce, she says, but the industry will have to invest in technologies and processes to ensure that new food product demand from Asia can be met. She says food processing in Australia and New Zealand has to be modernised, potentially with robotics, modular factory components and processes that preserve product quality and nutrition and enhances food safety in exported food. Another possible innovation is pop-up factories, or mobile processing, where the freshness, taste and texture of a product are preserved by processing close to the farm where produce is harvested, which can be stabilised and can quickly be exported to Asia. “As consumers in Asia become pickier and they have greater disposable income, they demand the freshness and taste they associate with Australia and New Zealand. Processing and manufacturing will have to become more nimble and adaptable to cater to this demand.” She says the Australasian food industry is due for a wave of change which will occur over several categories: food science, where food has its nutrition enhanced and digestion time lengthened; processes, where robotics and automation allow for ‘dark factories’ containing no workers; digital technologies, where bio-sensors in the food supply chain mean Chinese or European consumers can scan a label and see which farm the product came from; nimble manufacturing, using pop-up processing and modular production lines, to allow market-testing with differentiated products; hi-tech equipment, so manufacturers can for instance - separate fat globules by size, to either make yoghurt or cheese. She says all of this is happening against a background of rising food regulation both in Australasia and Asia. “Australian and New Zealand food producers and manufacturers don’t have to meet one growing demand,” says Dr Appelqvist. “There are many demands and many markets. To succeed they will have to invest in technology and processes. I’m happy to be able to assist them through my new role at Aurecon.”

REAR VIEW

-The best way to have a good idea is to have a lot of ideas. - Linus Pauling

Telling a good innovation story -Julian Birkinshaw

Among corporate innovators, the travails of James Dyson and the unlikely insight of Art Fry are iconic. Dyson’s bagless vacuum cleaner was perfected only after a staggering 5,127 tries. Fry’s inspiration, interestingly enough, came during a church service. Pieces of paper he had used to mark hymns kept falling out of his choir book, which led the 3M scientist to think about the materials chemistry that eventually produced Post-it Notes. World-changing products, yes, but also great stories. Companies today are fixated on innovation. Many have reorganised so that ideas can move forward faster and with less internal friction. Companies are experimenting with virtual-reality hackathons and “innovation garages” to step up their product-development hit rate. We know that much of corporate innovation travels along well-orchestrated pathways—a neat tech breakthrough, a product owner, and an orderly progression through stage-gate and successful launch.

as entrepreneurs, in organisations large and small, on what makes a compelling and emotional story.

The disconnect between academic labels and good storytelling “Fast follower” and “self-cannibalisation” are terms long-used by academics to describe, clinically, what some companies are doing to innovate and reinvent their business models. We had two categories that spoke to these terms, and 20 percent of the nominations fell into either one or the other. Significantly, though, many nominees either refused to accept their nomination in that category or expressed discomfort with the terms. As a result, we recharacterised them as “best beats first” and “master of reinvention.”

Occasionally, though, it’s a “crazy” idea that bubbles up through a lone entrepreneur battling the system, overcoming false starts, and surviving against the odds.

A “best beats first” innovator takes the measure of a competitor who may be dominating a market with an acceptable product, and then leaps to the front with something even better.

While such instances are by their very nature idiosyncratic, one thing many have in common is that good storytelling helps them break through. Storytelling has always been important in business, but in today’s environment, with executive and investor attention stretched thin by information overload, the softer stuff is ever more important for getting ideas noticed.

It’s about winning through cunning, instead of using the conventional playbook of scaling a similar product with heavy investment to maintain share.

Over the past three years, my colleagues and I have been researching how people frame their innovation stories to create differentiation and attract attention. Our project started with the creation of an innovation award—officially, “The Real Innovation Awards”—at the London Business School in 2016. The award had several provocative and unusual categories, nominations for which were determined by a mix of expert judges and crowdsourced voting. Over the three years, we have had more than 1,000 nominations1 from companies or individuals, of which 54 were shortlisted and 26 awarded prizes. Based on our analysis of the stories of all nominees so far, here are three lessons for senior managers as well

Many innovators told us that the “fast follower” meme is bereft of emotion: no one ever wins people over by talking about their capacity for imitation. “Best beats first” celebrates doing things in a new way and vanquishes the competitors by seizing an opportunity they missed. A great example among our award winners is Vivino, which created a leading wine-rating and -recommendation app, based on the use of mobile devices to take a photo of the bottle label. The “master of reinvention” story line has a twist. Instead of the innovator taking on the establishment, this one is about the establishment challenging itself. the classic tale of transformation or rebirth, where the archetypical protagonist gets into trouble, goes through a near-death experience, and does some soul searching to reinvent himself as a better person. It’s a common occurrence in business— take Ørsted, the erstwhile Danish

fossil-fuel producer that now gets about 40 percent of its revenues from wind energy—but rarely is it captured with enough emotion.

lightbulb after a thousand failed attempts. How could this not be compelling to investors, customers, or an R&D committee? Just remember that to close the story loop, perseverance needs to show progress.

Companies often disrupt themselves by cannibalising their legacy products before their upstart competitors do so.

Better not to dwell on mistakes and go around in circles. Emphasise how “learning” and “experimentation” and “pivoting” made the perseverance pay off.

Master reinventors bear in mind that people want to hear about the emergence of the butterfly rather than the demise of the caterpillar. Acknowledge your declining products and the external changes causing you to re-evaluate but don’t linger on the internal struggles you have gone through to kill them.

In the underdog, or “the unreasonable person,” category, the innovator is fighting the system—the executives and internal procedures that block progress.

Instead, focus on the forward-looking reinvention story with its new array of potential successes. Investors will relate to this: it suggests you’re in touch with both the company’s past and its future.

Unyielding creators such as Steve Jobs and Elon Musk are the role models. They pit themselves against mere incrementalism and me-too products, while rejecting the usual idea-development pathways and timetables.

The enduring power of serendipity, perspiration, and underdogs

Underdog innovators take on the mantle of the fighter who thrives in battle and relishes proving someone wrong. “Unreasonableness” means not pivoting to get to victory but sticking doggedly to your vision.

Approximately 30 percent of the nominations fell into these “classic” innovators’ categories, which still enjoy broad resonance.

So, you’ll need to convince the world how your idea challenges orthodoxy, takes on vested interests, and—after many struggles—has been proven right.

Serendipity involves stumbling over something unusual, and then having the foresight or perspective to capitalise on it. What makes that such an attractive story? It’s the juxtaposition of seemingly independent things.

The persuasive power of riding trends

In a serendipitous flash, one recent winner, an engineering firm, realised that the gear it designed for scallop trawlers could also be used to recover hard-to-get-at material in nuclear-waste pools.

The story line of external forces propelling things forward at a unique point in history typically credits the idea originator for being in the right place at the right time, while deftly navigating the economic or political currents that have combined to make success almost inevitable.

Surprising connections such as these set off a chain of events that culminate in a commercial opportunity. So, to build this story line, think about the quirky combination of ideas that got you started and remember that serendipity is not the same as chance—you were wise enough, when something surprising happened, to see its potential.

YouTube, in the classic example, rode the winds by capitalising on the emergence of simple video-editing technology and the massive rollout of broadband internet access. In this story framing, don’t tell colleagues and investors you were simply lucky, but instead position yourself as the expert surfer who caught the wave at exactly the right moment: “We were smart enough to see how these trends were coming together, and this is what drove our success.”

The perspiration story theme (or “If at first you don’t succeed . . .”) is all about hard work and tenacity. Things don’t go according to plan, but you conscientiously refine and adapt your idea, and eventually, like Thomas Edison, you wind up with a working

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