Manufacturers' Monthly August 2012

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ANALYSIS >> TECHNOLOGY >> SOLUTIONS

Est. 1961

August 2012

SEW-EURODRIVE

Print Post Approved PP255003/00324

celebrates 30 years in Australia

INSIDE Industry News & Comment >> New Products >> IT@MM - Manufacturing Software >> Materials Handling >> Industrial Doors >> Motors & Drives >> Packaging Equipment

MANAGEMENT >> Contracts & Tenders How to win tenders p.12

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Inside

Publisher Martin Sinclair martin.sinclair@reedbusiness.com.au Managing Editor Cole Latimer Ph: (02) 9422 2352 Fax (02) 9422 2722 cole.latimer@reedbusiness.com.au Deputy Editor Annie Dang Ph: (02) 9422 2964 Fax (02) 9422 2722 annie.dang@reedbusiness.com.au Journalist Angela Welsh Ph: (02) 9422 2898 Fax (02) 9422 2722 angela.welsh@reedbusiness.com.au Graphic Designer Ronnie Lawrence ronald.lawrence@reedbusiness.com.au Creative Director Julie Coughlan Production Co-ordinator Mary Copland Ph: (02) 9422 2738 mary.copland@reedbusiness.com.au VIC/Overseas Sales Michael Northcott PO Box 3069 Eltham VIC 3095 Ph: 0448 077 247 michael.northcott@reedbusiness.com.au NSW Sales Anthony Head Tower 2, 475 Victoria Avenue, Chatswood, NSW 2067.

Ph: (02) 9422 2368 Fax: (02) 9422 2722 Mobile: 0414 644 664 anthony.head@reedbusiness.com.au QLD Sales Sharon Amos PO Box 3136, Bracken Ridge QLD 4017 Ph: (07) 3261 8857 Fax: (07) 3261 8347 Mobile: 0417 072 625 sharon.amos@reedbusiness.com.au NSW, SA/NT & WA Sales Reed Business Information Ph: (02) 9422 2368 anthony.head@reedbusiness.com.au

For daily news visit manmonthly.com.au

AUGUST 2012

6 Editorial Q Anti-dumping, a move towards protectionism?

22

12

8 Comment Q Churning out carbon

9 Analysis News Q Strong push for rail coordination Q Business as usual, that’s the

24

manufacturing attitude

12 Management Q How to win tenders

19 IT@MM Q Designing agile factories Q Improving production line

Winning tenders: it’s all about the preparation.

visibility

22 Materials Handling

16 What’s New

Q Multishuttle: revolutionising

Q Latest products for Australian

Head Office Tower 2, 475 Victoria Avenue, Chatswood NSW 2067 Locked Bag 2999 Chatswood DC Chatswood 2067 Ph: (02) 9422 2999 Fax: (02) 9422 2966 Published 11 times a year Subscriptions $140.00 per annum. (inc GST) Overseas prices applyPh: 1300 360 126 Printed by Geon Impact Printing 69 – 79 Fallon Street, Brunswick VIC 3056 Ph: (03) 9387 7477

manufacturers Q Hydraulic pullers Q Pressure sensors Q Vacuum pump systems Q Safety barriers Q Self-tracking conveyor belts

manmonthly.com.au

ANALYSIS >> TECHNOLOGY >> SOLUTIONS

Est. 1961

August 2012

SEW-EURODRIVE celebrates 30 years in Australia

Print Post Approved PP255003/00324

ABN 80 132 719 861 Average Net Distribution Period ending March 12 15,300 ISSN 0025-2530 INSIDE Industry News & Comment >> New Products >> IT@MM - Manufacturing Software >> Materials Handling >> Industrial Doors >> Motors & Drives >> Packaging Equipment

MANAGEMENT >> Contracts & Tenders How to win tenders p.12

order fulfillment

28 Motors & Drives Q Driving down energy costs Q Power-optimised gearhead Q Analogue servo drives

24 Doors & Access Systems Q High-speed doors: keeping the elements out Q Insulated roller shutters Q Door controllers

30 Packaging Equipment Q An edible packaging future Q Halal-approved products: an

untapped market

Behind the cover SEW-EURODRIVE celebrates 30 years in Australia: For over eighty years SEWEURODRIVE has been delivering quality German engineered drive technology worldwide. 2012 marks thirty years of driving Australian industry. That’s thirty years of quality. Thirty years of reliability. Thirty years of innovation.

Thirty years of leadership. SEW now supplies a range of products including gear motors, frequency inverters, servo

technology, decentralised systems and heavy industrial gear units. All engineered in Germany to provide our trademark quality stamp. All assembled locally to provide our trademark timeliness. Thirty years of drive technology in Australia – A piece of cake! www.sew-eruodrive.com.au

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Editorial

COLE LATIMER – Managing Editor

editor@manmonthly.com.au

One step forward, two steps back Is a proposed anti-dumping agency designated to investigate claims, a win for protectionism?

F

ollowing calls from the industry to protect Australian manufacturing and increase our anti-dumping regulations the government has taken a massive step forward – appointing someone to investigate the feasibility of an antidumping agency.

A bold move no doubt.

Anti-dumping concerns have been a feature of the industry for some time now, and the government’s relatively slow reaction is doing nothing to help the manufacturing industry as it goes through a sluggish dip.

All the while Australian manufacturers are missing out, particularly on the mining boom, as cheaper and lower quality products flood our shores.

Local content mandates are helping to ensure that Australian manufacturers are getting a larger share of the boom, but is it a little too late?

6 AUGUST 2012 Manufacturers’ Monthly

Can Australia withstand the sheer weight and scale of Asia’s manufacturing giants while at the same time fight to innovate and become a country recognised for the quality of its products?

Either way Ai Group chief executive Innes Willox agrees that it is a good start, saying the Government has been taking positive and welcome steps towards addressing anti-dumping, however more needs to be done to ensure complaints are investigated in an efficient and timely manner.

“The creation of a broader authority with extensive powers would be a very welcome and important next step,” Willox said.

Since the Howard government, the issue has not been taken seriously by seceding governments and is now only being viewed as a problem.

Last September the government

Local content mandates; a little too late?

announced it was introducing a 30-day time limit on minister’s decision making for investigations into dumping cases.

Now it has appointed John Brumby to investigate the feasibility of a

Commonwealth anti-dumping agency.

Willox said: “the establishment of a properly resourced and standalone anti-dumping authority may help address some of the industry’s continuing concerns, some of which relate to the skill levels of customs officials and their ability to get to the heart of dumping claims”.

However, there are fears that it is the first step towards protectionism.

And really, we can’t limit foreign imports into the country and then expect them to happily take our goods; Australia has been one of the first to complain when other countries do something like this, such as Brazil, with its automotive industry.

Are local content mandates and a renewed focus on anti-dumping signposting the beginnings of protectionist policy? Are import tariffs next?

Or are we just protecting Australia’s manufacturing future?

manmonthly.com.au

What’s the carbon price really about?

What about compliance?

What do I need to do?

2012.

The year your business will need clear thinking on carbon.

2012 will be a year of great change in the energy sector as the carbon price takes effect and Australia begins its transition to a low-carbon economy.

No one is better placed than Synergy to provide your business with clear and straightforward information on complex issues like carbon and to help you find ways to minimise the impact on your energy bill.

For clear thinking on carbon and to discover some clever energy saving ideas for your business, visit synergy.net.au/clearthinking

Impacts • Actions • Assistance

CUBED SYN0023/MM

How much more will I pay?

Can I get assistance?

Comment

INNES WILLOX – CEO Australian Industry Group

editor@manmonthly.com.au

Churning out carbon There is nothing certain about carbon pricing except its uneven impact on businesses.

A

s of July 1, manufacturing businesses already under pressure from the high dollar and high costs now face the uncertainty of how they will be impacted directly and indirectly by the carbon price.

Most don’t know how much of the increased costs faced by energy producers and others with direct and indirect liabilities, will be passed on to them. They also don’t know whether they can pass those costs on to customers, given the intensifying competitive pressures they face locally and internationally.

In June Ai Group surveyed 200 manufacturers asking whether they intended to increase their selling prices as a result of the carbon tax from July 1. Less than half (40%) intended to try to put up their prices immediately. Of those who did, about half (51%) will try to raise

prices on all of their items; 22% will do so on more than half of their products; and 27% will do so on less than half of their products.

The majority (60%) indicated they do not plan to increase their selling prices, and will instead absorb the cost rises. This will result in further erosion of margins and will put even more stress on this sector, especially as it is a cost not being borne by most overseas competitors.

The single biggest impact will be increased electricity and gas prices as suppliers pass through some or all of their own carbon costs.

Smaller energy users, who already pay high prices but tend to spend a lower proportion of their revenue on electricity and gas, will see a price increase of about 10%.

Larger users face increases of around 20% for energy inputs that are central to their business, since

they currently pay lower prices.

One thing that is certain is that carbon pricing will have very uneven impacts on business. These impacts will depend on a business’s emissions intensity and its international competition, and the extent to which businesses can reduce their exposure by becoming more energy efficient.

However, governments hold the big levers on policies like the carbon tax, and they have a responsibility to avoid unnecessary expense and burden. Ai Group has proposed three changes that would sharply reduce the competitiveness impacts and improve the cost effectiveness of the current scheme.

First, the starting, fixed price should be more in line with current international pricing. Had the Rudd/ Turnbull emissions trading scheme been passed in 2009, businesses would now be looking at paying a

far lower internationally comparable price, of around $5 a tonne, instead of the $23 they now face.

Second, there should be an earlier transition to full emissions trading, linked to credible international abatement credits. Currently industry must wait until mid-2015 for a flexible, market-driven carbon price.

And third, the carbon floor price to operate from 2015 should be reduced from its current level of $15 to no more than $10, or dropped altogether. International price expectations have fallen sharply since the current $15 floor was set.

Do all that, and the bipartisan 5% emissions reduction targets will still be met with a higher ratio of affordable international offsets in the mix.

Australian carbon prices would likely be at least 50% lower, and would certainly track our international competitors more closely.

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8 AUGUST 2012 Manufacturers’ Monthly

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AnalysisNEWS Strong push for rail coordination Can the industry stay on track?

By Hartley Henderson

A

MAJOR study into the Australian railway industry has found that 6,000 new passenger cars will be required in the next 20 years to cater for the country’s aging national passenger car fleet. This equates to about $33 billion in government expenditure for new passenger rolling stock and whole of life maintenance.

The study reports that investment benefits to suppliers, sub-contractors, service providers and the community would be about $116 billion over the 20-year period. It also identified inconsistent and fluctuating demand for rolling stock by state governments, and the need for smoother and coordinated demand and supply profile.

Garry Whiting, Australian Railway Association general manager, says the future viability of Australianbased rail car manufacturing plants is threatened if uncoordinated procure-

ment practices continue.

“There used to be three local producers of freight wagons, but now there are none. This is an indication of the direction in which the passenger sector could also go,” he said.

“There is a lack of government

support for Australian manufacturing which needs to be rectified urgently.

“Currently, a large part of Australian passenger car manufacturing and maintenance is supplied locally without any subsidy and against global competition.

ABCOR wins PACCAR Supplier of the Year 2011

“The high Australian dollar and slowing productivity are also major challenges that Australian manufacturers have to contend with.

“Coordinated national demand for passenger rolling stock, as well as assistance in funding new plant and equipment, would go a long way to improving the competitiveness and future viability of the sector.

“Although the Australian rail manufacturing sector has revenues of around $5 billion and employs some 15,000 people, the majority of rail equipment is imported.

“Government intervention is needed to stimulate import replacement, and to head-off a trend for Australian suppliers to relocate manufacturing to low cost Asian-based production,” Whiting said.

In June this year, Downer EDI signed a five-year deal with locomotive company Electro-Motive Diesel which will see its locomotive manufacturing slowly move offshore.

Advertorial

Manufacturing can be unpredictable at the best of times; however it is the transport industry suppliers who are at the forefront of success.

One key industry supplier, Abcor Pty Ltd (Preston General Engineering), who has been a supplier to Kenworth Trucks since 1971, recently received the prestigious Paccar Supplier of the Year Award.

Based in Campbellfield, Victoria, Abcor won its individual category ‘‘C’ Parts Propriety to Kenworth’ and the overall award by achieving less than 50PPM defects for quality and delivery on time.

John Kaias and the team set their target in 2008 to be the best supplier of Heavy Automotive Components in Australia by 2011, and they achieved this with flying colours.

Aside from a dedicated approach to quality, Abcor has heavily invested in the latest ‘lights out’ automation to ensure competitiveness is maintained now and into the future. This investment, along with dedicated and long serving staff has ensured a successful implementation of this technology, previously only seen in large European companies such as Thyssen Krupp.

“Winning this award means a great deal to the business, it’s an external acknowledgement that our commitment to quality and technology is important for the future success of our customers.” - John Kaias, Director, Abcor.

Left to Right – James Kaias (Abcor); Joe Rizzo, Managing Director, PACCAR Australia; Greg Kaias (Abcor), John Kaias (Abcor)

Abcor is the industry leader in the truck and bus, defence, automotive, mining and construction sectors.

manmonthly.com.au

Manufacturers’ Monthly AUGUST 2012 9

AnalysisNEWS EVENTS

Business as usual Alan Osrin

AUGUST 1: 2012 Food Magazine Awards The Food Magazine Awards recognises and rewards best practice and innovation in food and beverage processing in ANZ. The gala dinner will be held at Doltone House, Sydney. For more information visit www.foodmag.com.au/awards 7-9: WA Safety Show To be held at the Perth Convention Exhibition Centre, the show will afford an opportunity to network and learn from industry experts via interactive live demonstrations, dedicated feature areas, free seminars and workshops.

For more information call 03 8672 1200 or visit www.wasafetyshow.com 23-24: Queensland Supply Chain & Logistics Conference Suited to supply chain, logistics, transport and procurement professionals and practitioners, the event will take place at the Sofitel Hotel Brisbane. Further information and registration details can be found at www.qldscc.com 28-30: Mining & Engineering (M&E) NSW Exhibition A range of mining community-focused events and information sessions will be a major feature of this year’s M&E NSW exhibition, to be held at the Newcastle Entertainment Centre. For more information call Warren Queenan on 02 9422 2563 or visit www.miningandengineeringnsw.com.au

M

ANUFACTURERS are adopting a “business as usual� approach despite challenging economic times, according the latest Sage Business Index report.

The report sheds light on the attitudes, priorities and perceived challenges facing Australian businesses. Over 500 owners and decision makers across all business sizes and industries were surveyed.

A key finding was the reaction of the manufacturing industry to the current climate of business pessimism. There’s a distinct positive difference in the way that manufacturers are going about their business compared to other industries, despite the fact that manufacturing has been one of the hardest hit sectors since the global economic downturn.

A high dollar, increasing prices, plus consumer and business caution leading to decreasing demand are all taking their toll on Australia’s manufacturers.

Industry figures, including Australian Industry Group’s Australian Performance of Manufacturing Index has recorded a trending decrease in nine of the 12 manufacturing sub-sectors, specifically in the month of May. Such figures correspond with Sage Business Index finding, which reports that confidence within the industry has declined slightly over the past 12 months, with nine out of ten manufacturers concerned about business growth as a result of economic issues.

Surprisingly, just over 50% of manufacturers are determined to continue on with business planning and decision making despite the uncertainty.

This is a more positive response when compared with all other industries which recorded a slightly higher proportion of deferred decision making.

Among those manufacturers that do report postponing decisions, the top two areas of deferral were upgrades to plant and machinery and development of new business areas. Neither of which are particularly surprising.

Upgrades are expensive so if manufacturers can safely be put off for a year or so without negatively impacting the business, it’s a sensible move at a time when money is tight.

Similarly, attempting to develop new areas of business in a contracting market can be high risk. It typically requires upfront investment, a healthy amount of ongoing support and a high degree of fortitude.

The third notable area of deferred decision-making among manufacturers is staffing.

One in three manufacturing businesses report postponing decisions about new staff hires, and a similar number say they have delayed pay rises within the past year.

To cope and to remain within headcount restrictions, more than one third of manufacturers say they have increased their use of contractors or part-time staff during the past year to help fill roles.

A similar number are also actively considering using older staff to help with staffing issues.

It’s business as usual for Australian manufacturers despite economic uncertainty for the year ahead.

If the predictions and expectations of manufacturing business owners are correct, the industry can look forward to another difficult year.

Rising costs are predicted to be the major business challenge, while the issues of funding and competition have also markedly increased.

As a result, the delays in staffing decisions seen last year can be expected to continue in the short term.

Investment in information technology is likely to also take a back seat for the time being.

Alan Osrin is the managing director of Sage Software Australia.

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Sustainable Wood & Paper Wood and paper products certified by a recognised eco-label to be from a sustainable source Waste Reduction Products that help manage waste in the workplace

Green Cleaning Cleaning products certified by a recognised eco-label

Recycled Content Products made from recycled materials

Energy Conservation Products that help reduce electricity consumption in the workplace

Cleaner Alternatives Products identified by Blackwoods suppliers to have environmental benefits that do not fit into other categories Water Conservation Products that help reduce water consumption in the workplace

Greener Workplace Range Blackwoods and our people share a commitment to sustainability within our own business striving to continually improve the environmental and social impact of our operations in order to meet community expectations and our own safety and environmental goals.

The Greener Workplace Range is in the 2012 Blackwoods Catalogue, Chapter 22 or alternatively see the range on our website at blackwoods.com.au/greener-workplace

A Greener Solution

AnalysisMANAGEMENT The tendering approach Bidding for government contracts and tenders can be brutal, but like any successful business model, preparation pays off. Sarah Falson reports.

M

ANUFACTURERS are under increasing pressure to adapt tried and true business models to meet the changing global economic climate. However with a high Australian dollar, growing import competition and changing consumer preferences the task can sometimes be overwhelming, even for the most resilient.

While entering new and emerging markets is a smart idea, identifying transferable skills that will open doors to new business can be difficult – especially when some manufacturers are considering laying-off staff.

According to Maurice Downing, director of tenders consulting firm Corfocus, preparing a business for contract and tender bidding doesn’t have to be a formidable task as there are various opportunities available.

“Last year, the federal government spent more than $32 billion on about 80,000 contracts for the supply of goods and services to the Commonwealth, with the lion’s share of those contracts won by small to medium Australian-owned companies,” Downing told Manufacturers’ Monthly, quoting figures from former Minister for Finance and Deregulation, Lindsay Tanner.

“Add state and local government expenditure and the total market approaches over an estimated $85 billion; an immense opportunity for Australian businesses.”

Downing says many manufacturers put contracts in to the ‘too hard basket’ believing they cannot contend with the complex documents and bureaucracy involved in government tendering.

“But any business has the opportunity to win government business, it’s all in the preparation and understanding of what happens inside the evaluation room,” he said.

Preparation pays off Downing advises manufacturers to adopt a three-phase process to prepare their business for tendering.

12 AUGUST 2012 Manufacturers’ Monthly

Good preparation and understanding the evaluation process will help manufacturers succeed in the tender process.

How to win tenders • Prepare – Leaving it to the last minute will reduce your chances of producing a good tender application. Give yourself plenty to learn and understand the tender documents and what is required.

• Answer all parts of the assessment criteria in detail and provide reference projects that show you have done similar work for similar clients.

• Don’t refer constantly to the attachments as evaluators will get tired of this very quickly and your assessment scores will suffer. Mention the relevant project or document succinctly within the text.

• Explain what your company does. Don’t rely on your reputation or assume that because you are known to the tendering organisation that evaluators know what you do.

• Be clear and concise. Using motherhood statements that rattle on for many lines may sound beautiful but they actually add nothing to your application.

with government tenders and are looking to do better. The business can write one-off tenders or help manufacturers build-up their tendering expertise for longer-term success.

Downing said tendering specialists bring objectivity and writing skills to the table, allowing manufacturers to get on with running their business.

The consulting price depends on the scope of the project – how complex the tender is and how prepared the manufacturer is. As a rule of thumb, the more work the consultant has to do, the higher the price, he said.

Where to look “The first phase is to analyse your existing tendering resources to identify where the shortfalls are.

The next phase is to collect a series of Requests For Tender (RFT) that represent the types of projects

you want to bid for. Then develop the information resources you will need when the next suitable RFT is released,” he said.

Corfocus works with manufacturers that have had little or no success

Jeremy Hayllar, BDO (Qld) manager, advisory division, agrees that specialists can help manufacturers maximise their business opportunities by assisting them to identify growth sectors and how they can leverage their key competencies. manmonthly.com.au

“The top industry where our clients see new and fast rates of growth is in the mining and natural resources sector. There is big demand for a wide range of products including specialised trucks, mining related equipment, safety gear, modular housing, water, food for mining camps and so on,” Hayllar told Manufacturers’ Monthly.

“Manufacturers need to strategically review their engineering design capabilities and determine how they can get into the provision of products to the mining sector.”

Hayllar advises manufacturers to speak with the industry association or union for the targeted sector to find out where to look for the key requests for tender. He says building relationships with important people in the industry, and “not just the purchasing person who may issue the tender, but also the end user of your products” will give manufacturers a better chance of winning contracts.

manmonthly.com.au

Last year the government spent more than $32 billion on about 80,000 contracts. SMEs won the bulk of those contracts.

Peter Webster, Industry Capability Network (ICN) NSW’s deputy director, says that when it comes to

finding new business opportunities, one of the biggest challenges manufacturers face is being able to break into new or expanding supply chains.

He says ICN can help in this respect.

“ICN is a business network that introduces Australian and New Zealand companies to the supply chains of projects both large and small,” Webster told Manufacturers’ Monthly.

“In essence we offer a lucrative new business source for suppliers and a sophisticated search service for project managers.

“Our role is to find the suppliers and service providers who are best equipped to meet the requirements of hundreds of projects across Australia and New Zealand.”

Webster says the top three industries providing opportunities are: oil and gas, especially in Western Australia and the Northern Territory, along with coal seam gas projects in Queensland and New

South Wales; coal, with major new projects being developed in New South Wales and Queensland; and clean energy, including biodiesel plants, gas-fired power stations, and solar and wind power developments.

Manufacturers can also look at AusTender – the Australian government’s procurement information system, which publishes all publiclyavailable Government Approaches to Market (ATMs), Annual Procurement Plans (APPs), Multi-Use Lists (MULs), standing offer arrangements and contracts awarded.

Tenders.net is another subscription service providing daily notifications of new and updated tenders.

AusTender 1300 651 698, www.tenders.gov.au BDO (Qld) 07 3237 5999, www.bdo.com.au Corfocus 02 6242 0676, www.corfocus.com.au ICN 02 6285 2033, www.icngateway.com.au Tenders.net www.tenders.com.au

Manufacturers’ Monthly AUGUST 2012 13

TechnologyIT@MM Designing agile factories Having the right software design tools is key to achieving optimal efficiency and better lifecycle management in factories and warehouses, writes Karsten Hojberg from Autodesk.

A

LL new improvements and innovations stem from changing consumer demand and the need to stay competitive.

However, converting the concept into the finished product on the shelves requires more than a brilliant idea.

Every step of the way from product design, factory and production flow design to warehousing and distribution needs to be carefully thought out to ensure that the process is seamless and efficient.

Manufacturers need to consider a combination of factors including materials, seasonal or variable demand, supply chain regulations, sustainability as well as regulatory demands. In Australia, there is also the consideration of ensuring they meet Occupational Health and Safety (OH&S) requirements in the workplace.

In order to grapple with such a multi-faceted set of pressures on the business, manufacturers will need to take a more expansive view of their value chain than they have to date.

By examining the entire lifecycle of the manufactured product, from conceptual design through to its end-

14 AUGUST 2012 Manufacturers’ Monthly

of-life, rather than simply the manufacturing process itself, they will find ways to compete successfully in this challenging climate.

For example, if a company was looking for a new packaging for bottled water, they will need to consider if the machines to manufacture the new bottle need to change with the change in material and shape of the bottle. They will also need to think about how they can optimise their factory for optimal efficiency – can the same number of bottles still fit in the carton? Can forklifts still fit at the end of the production line? Can the cartons still stack optimally in the warehouse?

Yet faced with the complexity of simulating these varied and interacting factors, the human brain proves inadequate. It must be augmented by 3D software design tools that can incorporate, along with aesthetics, structural elements, the traditional architectural concerns, objectives and constraints on the manufacturing process, layout and efficiency.

Today, optimisation tools for product and building design do exist, but in complete isolation from one another, used by entirely different

3D modelling provides manufacturers with the agility to adapt existing factory and warehouse layout. industries and disciplines and often with mutually exclusive goals. In the majority of cases, the current process for factory or warehouse design is based on the view that it is simply a shell to house equipment, and is therefore not treated with the same design respect as the design of office buildings and apartment buildings.

But just as a high performance building requires a deep understanding of the energy loads associated with its use and schedule, manufacturing facility design should

also consider the energy and water consumption effects of the systems within the facility – industrial machines, production lines, and tooling systems – which are much more complex than the typical building.

Meanwhile, most manufacturing design tools pay no attention to a factory’s building or equipment systems. And different tools are used by product designers than by those designing the factory in which it will be manufactured.

Continued on page 15

manmonthly.com.au

Improving production line visibility ieman Industries, a manufacturer and distributor of materials handling equipment and liquid road tankers, has installed Epicor ERP system to better integrate its company processes and improve visibility for its production line at Keon Park, Victoria.

The manufacturer considered solutions by vendors including SAP and Oracle, however decided on Epicor due to the “complete visibility” the company’s software provided.

T

Tieman required a solution that covered their entire operation, especially Engineer-to-Order (ETO) manufacturing, Make-to-Stock (MTS) and after sales service including in-house and mobile service units.

The Epicor system allows staff to know exactly where a job is up to in the production line at any stage of the production process, said Marcel Wynn, Tieman’s general manager.

Implementation commenced at the company’s largest division – the

tanker business. More time at this stage allowed the company to identify opportunities between engineering and manufacturing, Wynn said.

The system integrates all areas of the Tieman business, from finance to production engineering, through to distribution and warehousing, production planning and scheduling, and milestone tracking and billing.

Wynn said the company now has greater control over its cash flows, demand and resources.

“The ERP system gives us the ability to drill down from any screen through to the originating transactions. We [are] be able to track and trace jobs by serial number through to the originating transactions once fully implement,” he said.

Tieman have entered a strategic partnership with Epicor on its future rollout plans, including PLM and mobility.

Tieman Industries 03 9469 6700, www.tieman.com.au

Continued from page 14 Digital Prototyping (DP), when coupled with Building Information Modeling (BIM) and the improvements in the speed and cost of cloud-based computation, signify an entirely new set of tools that could provide an end-to-end workflow with 3D, intelligent models at every level of development, design and manufacture. By having all the information required upfront,

such as design needs, machinery and equipment needed, the flow required from production floor to warehouse, manufacturers can import the information into software to generate a digital design first to ensure no clashes or interference before continuing with the actual building and assembly of the factory floor. This enables them to better communicate their needs to architects and Mechanical, Engineering

and Plumbing (MEP) specialists to ensure the “shell” is built to specifications and needs of the factory and warehouse, rather than having to retrofit their needs to an existing building. At this stage, they can also involve the relevant OH&S teams to ensure that the facility meets the necessary regulatory safety requirements, and get sign off before these concepts are pushed on to the construction stage. With

all the information in 3D models, it provides manufacturers with the agility needed for change, as they use the models to adapt their existing factory and warehouse layout.

They can also use the information for ongoing facility management and manage the lifecycle of their factory.

Karsten Hojberg is Autodesk APAC’s senior manager, business development, manufacturing. www.autodesk.com.au/factorydesignsuite

EtherNet/IP ENABLING BOTH AUTOMATION AND SAFETY CONTROL ON STANDARD, UNMODIFIED ETHERNET. Integrate the safety in your plant using the same unmodified Ethernet network you use for information sharing and automation control. By integrating automation and safety control on the same network, you could lower life-cycle costs, streamline work processes and protect equipment and employees. Rockwell Automation and its partner, Cisco, have been driving these developments so that you can take standard, unmodified Ethernet and do extraordinary things.

See something extraordinary at: www.apac.rockwellautomation.com/ethernetip/MMS

manmonthly.com.au

Manufacturers’ Monthly AUGUST 2012 15

What’sNew See more new products at manmonthly.com.au

The gloves are available in sizes 8 to 11.

The systems are powered by natural gas or LPG.

Gas-powered VRF air conditioning YANMAR’S gas-powered variable refrigerant flow (VRF) air conditioning systems have been designed to reduce power upgrade costs and electricity usage, as well as improve green credentials of the facility where it is installed.

Suitable for factories and warehouses, these gas-powered air conditioning systems (GPAC) come in size range of 14kW to 85kW condensers, with some models available in three-pipe

heat recovery configuration. Multi-split, reverse-cycle, inverter-style and aircooled systems are available with gas heat pump condensers.

The air conditioners run on natural gas or LPG. Origin Energy is the sole distributor for Yanmar gas powered VRF airconditioning systems in Australia.

Origin Energy 1300 280 105, www.originenergy.com.au

Air impact wrenches CHICAGO Pneumatic has introduced a new range of air impact wrenches designed to provide maximum power output in a lightweight unit.

The CP7748 family of 1/2” impact wrenches offer 1250Nm of torque.

The tools offer reduced sound (93dA) and vibration (7.4m/s2) to minimise operator fatigue.

They feature a full-teasing trigger, rubber injected grip and lightweight composite housing.

The CP7748 and CP7748-2 wrenches are equipped with a 2” anvil extension which the company says can be used on flip sockets.

Chicago Pneumatic 1800 278 665, www.cp.com/en

Electric shock glove protection HONEYWELL Safety Products has launched new insulating gloves designed to protect workers from electric shock.

The Electrosoft AS2225 Approved Natural Latex Rubber Insulating Gloves are 100% latex and have glove ratings from 650V up to 4000V. The gloves have a straight cuff for easy wear and a non-flocked lining.

They should be used in conjunction

with leather over-gloves to provide mechanical protection of the electrical glove against cutting and tearing.

The gloves come packaged in a UV resistant opaque bag for easy storage.

They must be stored at ambient temperature, away from direct sunlight and heat. They are available in sizes 8 to 11.

Honeywell Safety Products 1300 139 166, www.honeywellsafety.com

High-pressure transducers SETRA Systems has introduced a new series of compact, high-pressure transducers for larger volume OEM applications, available with mA, V or ratiometric output.

According to the company, the units have 0.25% full-scale measurement accuracy with long-term stability better than ±0.1% FS/Yr over the full operating temperature range of -40°C to +105°C. Available in standard and heavy duty versions, design of the 3100/3200

series incorporates the use of thin-film strain gauge sensing technology in a Wheatstone bridge configuration.

Strain gauge molecular layers are sputtered onto a corrosion-resistant 17-4 PH stainless steel diaphragm.

With a diameter measuring less than 25mm, the transducers can be easily installed in space constrained environments.

Pryde Measurement 1800 688 211, www.pryde.com.au

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1300 134 223 1300 307 895 sales@storemasta.com.au www.storemasta.com.au 16 AUGUST 2012 Manufacturers’ Monthly

manmonthly.com.au

Heavy-duty hydraulic pullers Front and back jacks are hydraulic powered.

Heavy lift systems

The pullers are available in 20, 30 and 50 tonne capacities.

SYKES-Pickavant has launched its hydraulic Loadstar Plus range of heavy duty pullers available in 20, 30 and 50 tonne capacities.

The kits include heat treated forged, alloy steel legs, portable aluminium hand pumps rated to 690bar, hydraulic ram assembly, and heavy duty beam assembly.

The range incudes comprehensive kits or entry-level puller kits with the capacity

to add on additional packs as required.

Additional options include separator packs and accessory packs.

In the smaller 20-tonne range, a press frame pack is available.

The hydraulic pullers are used for heavy-duty pulling and extracting applications across the manufacturing and industrial sectors.

Tridon Australia 1300 362 263, www.tridon.com.au

Pressure sensors for flexible data transfer IFM efector’s new pressure sensor communicates data flexibly via switching outputs or IO-Link 1.1. Process data and diagnostics information may be transmitted using a standard cable. The parameter setting of this PN7 type pres-

sure sensor also uses IO-Link communication. If the IO-Link function is not used, then the pressure sensor operates with two switching outputs (SIO mode), or a switching output and a diagnostic output. ifm efector 1300 365 088, www.ifm.com/au

ENERPAC has released its DLS Series lift system designed for heavy lifting applications of around 100,000kg.

Built for machinery such as large forklifts, the lift system is suitable for track and side frame maintenance while utilising single-operator lifting.

Lifting speed is approximately 46mm/ min (1.8�/min) allowing users to finish a lift quickly to reduce equipment downtime. This controlled lifting aims to provide easy access, while minimising operator effort.

The front and rear lifting jacks are driven by a hydraulic power unit (HPU) and controls which includes a 25-foot pendant for operator mobility and safety during lifts.

The entire HPU and controls are contained in a rolling cabinet which includes storage for cable reels and hoses. The controls include PLC and software which can monitor and control a maximum of four lifting points simultaneously.

Enerpac 02 9743 8988, www.enerpac.com.au

Positive displacement flowmeters TRIMEC Flow Products has developed the Multipulse series of positive displacement flowmeters which combines oscillating piston design principle with modern engineering materials for a range of industrial flow measurement applications.

The flowmeters have only one moving part and offer both high resolution open collector and reed switch outputs as standard.

As each piston rotation passes a known liquid volume, the inherent repeatability of the positive displacement flowmeter makes it particularly suited to batching and dispensing duties.

Commonly metered liquids range from non-conductive low viscosity solvents through to extremely viscous lubricants,

chemicals and food bases.

According to the company, application flexibility is further enhanced as meter performance is independent on flow profile.

This eliminates the restrictive need for straight pipe runs required with most alternate metering technologies, the company says.

The flowmeter has no stagnate chambers to harbour contaminants.

There are no restrictions on mounting orientation and the flowmeter may be operated under vacuum flow, pumped flow or gravity flow conditions.

The flowmeter has as simple and robust design.

Trimec Flow Products 03 9937 1811, wwww.trimec-fp.com.au

sales

manmonthly.com.au

Manufacturers’ Monthly AUGUST 2012 17

What’sNEW Vacuum pump system The switches feature a diaphragm and two sealing Belloframs.

Differential pressure switches DUFF and Macintosh P/L has introduced the Pyropress Industrial Differential Pressure Switches which are ATEX-certified and suitable for use in harsh industrial environments.

The switches can be used to monitor filter blockage and air movement through ducting and for offshore applications.

Incorporating a diaphragm and two sealing Belloframs, they are designed to provide reliable switching action when a differential pressure is required to be sensed.

By venting either the HP or LP connection, the switches can be used as a low-pressure vacuum switch.

Duff and Macintosh 02 9482 1411, www.duffmac.com.au

ATLAS Copco has introduced the new GV oil-sealed rotary screw vacuum pump; the company’s first pump system for “rough vacuum� between 0.5 and 500 mbar.

According to the product’s designers, this operating pressure range along with oil-sealed rotary screw technology means the pump delivers high performance at a low energy cost.

With a modulating valve fitted at the pump inlet, the pump’s capacity can be matched to the demand.

This concept minimises the system’s vacuum level fluctuations and allows the pump to operate at the lowest energy point possible.

It also means the pump stops/starts less frequently, leading to less wear.

The system features oil-sealed screw technology.

The pump delivers capacities between 500 and 5000m3/h, making it suitable for applications from printing and packaging, to plastics, electronics, woodworking, bottling and canning.

The device can be installed close

to the point as it has a quiet operating level. The technology also allows for remote installation as part of a centralised vacuum system.

Atlas Copco 1800 023 469, www.atlascopco.com/vacuum

Roller sensors for conveyors SCHNEIDER Electric has released a new range of XYU roller sensors for conveyor applications. The unit features a multibeam photo-electric sensor across the width of the conveyor. It is also designed

for simple installation between the roller conveyors, without the need for tools.

Encased in an Ă˜ 12mm aluminium tube, the roller sensor can be ordered to suit roller conveyor widths from 200mm to

900mm and, depending on the conveyor width, will accommodate from one to six sensors across the tube.

Schneider Electric 1300 369 233, www. schneider-electric.com.au

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Modular forklift and pedestrian safety barriers MATERIALS Handling has released its A-Safe forklift and pedestrian barriers made from polymer-based material.

Unlike steel, the polymer barriers will spring back into shape immediately after impact. The barriers consist of a single 40cm rail with an impact height of 30cm.

Standard post centres are 1.6m with an overall height of 40cm.

The hand-rail post extends through the traffic barrier post to a height of 1.1m. This hand-rail post comprises a 9cm-square post with two rails.

Designed to protect personnel as well as valuable machinery and equipment, the Traffic Plus barriers provide a clear delineation between vehicle zones and personnel areas. According to the company, barriers made from

The barriers are made from polymer-based material.

polymer-based material will supersede conventional steel barriers.

Materials Handling 1300 467 791, www.materialshandling.com.au

Self-tracking conveyor belts RYDELL Industrial (Belting) and Ammeraal Beltech have introduced self-tracking conveyor belts to the Australian market. The belts are intended for use in situations that require cor-

rection of mistracking due to pushing, pulling, side loading or other processes performed on the belt.

They are also suitable for applications where the conveyor design can cause

mistracking, such as square belts, knife edges, reverse running direction belts and asymmetric loading.

Rydell Industrial (Belting) 1300 190 392, www.rydell.com.au

Compact power distribution units RITTAL will launch four new compact PDU (power distribution unit) systems this year.

The new generation of compact PDUs are made from anodised extruded aluminium sections for easy assembly.

They come with international C13 and C19 connectors, which are the norm in data centres.

The units are available as single or three-phase versions and, depending on the type, they support phase currents of 16A, 32A and up to 3 x 63A with individual versions. As a result, electrical outputs of over 40kW can be distributed by one rack PDU. Depending on the model involved, the new PDU versions enable energy management by phase (feed) or even down to server-level (single energy measurement per output slot).

The power distribution bars can be easily configured and managed via a Web interface.

Rittal 1800 350 665, www.rittal.com.au

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manmonthly.com.au

Manufacturers’ Monthly AUGUST 2012 19

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What’sNEW - Dust & Fume Control Protection against airborne hazards

LV EHWWHU IRU No fuel costs

The cost to recharge an electric forklift is minimal compared to the equivalent fuel required to operate an engine-powered truck. Electric users also save time and eliminate the safety risks associated with constantly changing gas bottles.

No dirty exhaust fumes With fume-free operation, electric forklifts contribute to a clean and healthy workplace – they are better for your people and better for the environment!

Quieter operation Engine-powered forklifts can be very noisy, especially in enclosed spaces. Electrics, on the other hand, are quiet operators that let the user focus on driving, optimising productivity and safety, and minimising operator fatigue.

Greater reliability With a lot less moving parts, electric forklifts are intrinsically more reliable than engine-powered units. They are also much more durable with many 30+ year-old Nichiyu forklifts still in operation throughout Australia.

Low maintenance costs Electric forklifts are also much cheaper to maintain than engine-powered trucks, with operating/maintenance costs per hour often less than half that of comparable gas trucks.

Nichiyu Forklifts Australia Pty Ltd 25 Liberty Rd Huntingwood NSW 2148. Tel: +61 (0) 2 9672 7430. Fax: +61 (0) 2 9672 7423.

33 Kilkenny Court Dandenong VIC 3175. Tel: +61 (0) 3 9554 6555. Fax: +61 (0) 3 9794 7307.

The respirators meet ANZ Standards AS/ NZS1716:2012.

3M has released the 8300 Series Disposable Respirators designed to protect workers from airborne particulate hazards.

The respirators are available with the company’s Cool Flow exhalation valve. The valve reduces heat and moisture build-up in humid conditions or during prolonged wear, making breathing easier.

The M-noseclip can be moulded around the nose for custom-fit, while the soft edges provide a secure fit for

better protection. The colour-coded straps (Blue for P2 and Yellow for P1) allow safety officers to determine the protection level from afar.

8310 and 8312 respirators with P1 rating filter mechanically generated particles, while the 8320 and 8322 respirators with P2 rating filter mechanically and thermally generated particles, such as dust, mists and fumes formed during blasting and light welding fumes.

3M 136 136, www.3M.com/au/PPESafety

Digital infrared thermometers FLUKE has introduced the new 62 Max and 62 Max+ Infrared Thermometers.

Dust, water and drop resistant, the thermometers are suitable for use in harsh conditions, such as maintenance applications.

The thermometers are built to survive 9.8ft/3m drops to wood floors yet are small enough to carry on a tool belt.

It features a multi-angle, backlit display for easy read. Measurements are performed with a trigger click.

The 62 Max+ model has dual rotating lasers to accurately identify spot size.

The 62 Max is suited for quick temperature scans of systems to identify anything from unusual hot spots that signal electrical and electro-mechanical malfunctions, to undesirable air intake/ output patterns in the building envelope.

Both models operate on a single AA battery.

Fluke 02 8850 3333, www.fluke.com.au

Tel: 1300 369 899 Email: sales@nichiyu.com.au Web: www.nichiyu.com.au

Measurements can be taken at a safe distance from moving machinery.

20 AUGUST 2012 Manufacturers’ Monthly

manmonthly.com.au

:K\ Cartridge filters reduce airborne dust

LV EHWWHU IRU 70+ years experience Nichiyu is the largest dedicated and most experienced electric forklift manufacturer in Japan, having produced the country’s first electric forklift in 1939.

Superior build-quality With its on-going commitment to excellence in design and manufacturing, Nichiyu has achieved an unrivalled reputation for reliability and durability.

Proven, reliable technology The filters can be installed close to the dust source.

AIRTIGHT Solutions has developed the FMC200 cartridge filters which has been designed to handle air volumes of 1,200 and 21,000m3/h containing different types of dust.

Manufactured from galvanised steel, the filters aim to provide maximum filtration efficiency with a minimal footprint. They are modular and compact in design, allowing them to be installed close to a dust source.

The filters are supplied with a

pressure control system that enables cleaning on demand. They also feature a patented cleaning system called UniClean, designed to clean the cartridge thoroughly over the length of the cartridge.

Cartridges are available in a range of materials to suit various applications, irrespective of the dust type and quantity, according to the company.

Airtight Solutions 1300 534 562, www.airtight.com.au

Nichiyu’s on-going technology innovations including Japan’s first AGVs and automated forklifts, enclosed cabins for cold storage and explosion-proof forklifts for hazardous areas have greatly enhanced forklift performance, reliability and safety.

High levels of safety From ergonomically-designed operator cabins to impact absorbing masts, travel speed-sensitive lift control, auto-lifting stop and laser pointers for accurate pallet handling and a host of other features, Nichiyu delivers the ultimate in safety in even the toughest of applications.

Factory flameproofing Nichiyu is the only electric forklift supplier in Australia that can offer factory-fitted flameproofing for all hazardous goods handling classes and zones.

Carbon dioxide level sensor PACIFIC Sensor Technologies has released the new T5540 CO2 – a carbon dioxide level sensor with Ethernet interface – suitable for industrial buildings.

The device contains microprocessorbased control circuitry in a durable plastic case with connection terminals, with the CO2 concentration sensor built inside the case.

It features a large dual line LCD display, which can be switched off.

According to the company, a computerised design ensures maximum long-term stability and failure indication.

The synchronising of time, recording and measured values history to an online table is enabled by SNTP via Internet.

The device has a patented autocalibration procedure that compensates for aging of the infrared source. manmonthly.com.au

The sensor can be used to measure indoor air quality.

This technology reportedly ensures high reliability, long term stability and eliminates the need of periodical recalibration in the field.

Carbon dioxide level is as an important parameter in determining the quality of an interior climate, the company says.

Pacific Sensor Technologies 1300 662 720, www.pacificsensortech.com.au Manufacturers’ Monthly AUGUST 2012 21

MaterialsHANDLING Improving order fulfillment Multishuttle technology has revolutionised the market for automated storage and retrieval systems (ASRS) worldwide. Pas Tomasiello writes.

D

EMATIC’s new approach to automating the handling of small unit loads, like totes and cases, has made a whole new range of integrated logistics and supply chain solutions possible, with many Multishuttle systems now driving high-rate order fulfilment and assembly operations in Europe, North America and Australia.

Unlike conventional ASRS, which typically use cranes to access stock, Multishuttle uses a fleet of self-propelled carts to retrieve and put goods away in an ultra spaceefficient storage system, at very high speeds. Lifts at the end of each aisle transfer goods in and out of the system via integrated conveyors.

Another significant advantage Multishuttle has over conventional ASRS is its ability to sequence workflow and do parallel processing, by handling multiple loads across multiple levels at the same time.

Driving order fulfilment Just as more powerful software drives the need for faster computers and vice versa, Multishuttle technology drives the need for faster sequencing and integration of stock and orders. The technology’s high throughput rates have made it possible for Dematic to develop a series of intelligent applications to automate activities in the DC that weren’t possible before.

By deploying Multishuttle as a buffer and sequencing platform between bulk storage and order picking stations, a new goods-to-person (GTP) picking methodology evolved that would change the face of picking forever, and provide an efficient platform for dealing with a constantly changing distribution challenge.

However, Dematic hadn’t counted on the success of the Multishuttle buffer concept creating a new problem of its own.

The Multishuttle system had the capacity to move stock and order totes so fast, pickers could not keep up with the flow of goods.

22 AUGUST 2012 Manufacturers’ Monthly

Keeping up with changing volume demand: Multishuttle has enabled integrated distribution solutions to become more modular, scalable and flexible.

In response, Dematic developed a new concept of high speed picking station, enabling operators to achieve previously unheard productivity rates of up to several thousand picks per hour.

Dematic RapidPick System configurations include one-to-one workstations where a single order tote and stock tote are presented to the operator. One-to-multiple stations can also be used depending on requirements.

In these cases a single stock tote is used to fulfil multiple orders at the same time. Configurations may include any arrangement from 1:1 up to 1:24 or more, depending on order volumes, order profile and the type of products being handled.

As picking stations began to facilitate faster picking, operator ergonomics became an important issue.

With a design objective of working smarter, not harder, the RapidPick workstations include height-adjustable platforms and screens to optimise comfort, minimise fatigue and ensure sustained productivity.

The operator picks only in the “golden zone”, and does not need to move hands above shoulder height or extend arms beyond a comfortable reach. Stock and shippers are automatically delivered to and removed

from the workstation eliminating the need for operators to lift or push cartons and totes.

Smart design The next challenge for Dematic was finding a way to keep the stock and orders flowing to pickers fast enough to optimise the high throughput rates achievable with the new pick station designs.

This led to the development of sophisticated sequencing software and technology including new sequencing towers, which provide access to an intermediate buffer of active stock and/or orders.

Adding sequencing towers close to picking stations makes it possible to either ‘pull ahead’ the stock required for orders, or buffer orders such that they can be married to arriving stock totes. Complex sequencing algorithms ensure stock and orders flow to the picking stations in the correct sequence, when required.

And, with less than one second tote exchange time, picking station operators don’t have to wait for the next item to be picked.

There is no doubt that Multishuttle technology has driven a paradigmshift in materials handling and order fulfilment thinking. It is important to understand, however,

while Multishuttles are an important component, ultimately they are only a transport mechanism in what is a very complex and intelligent integrated system.

The real smarts lie in its design, configuration and the powerful software and controls developed to prioritise, sequence and co-ordinate the thousands of actions required every second the system is running, and to interface it seamlessly with upstream picking and downstream replenishment processes.

It’s not enough to simply have the fastest shuttles and smart picking stations. It is the integration of all the critical software, controls and subsystems handling all of the different activities such as replenishment, buffering, sequencing and picking, that is the key to the successful implementation of extremely complex integrated systems.

And with the manufacturing landscape changing at a faster pace than ever before, it is essential that integrated distribution solutions be modular, scalable and flexible so they can be replicated quickly, and scaled to suit the necessary volumes as business needs change.

Pas Tomasiello is head of integrated logistics systems at Dematic ANZ. Dematic 02 9486 5555, www.dematic.com.au manmonthly.com.au

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IndustrialDOORS & ACCESS SYSTEMS Finding the right speed With a wide range of high-speed door options now available in the local market, choosing the right door is about understanding the purpose for which it would be used. Angela Welsh writes.

C

ontrolling the conditions of factory and warehouse space is as much about containing internal conditions, such as temperature, as it is about keeping out external elements.

Automated high-speed doors with fast closing rates and enhanced sealing properties provide a reliable barrier against unwanted heat or cold, and can better cope with the high cycle nature of industrial facilities compared with traditional manually-operated doors.

According to Andrew Bykersma from Albany Door Systems, highspeed doors can also serve as a valuable energy saving tool for manufacturers.

“By controlling an environment a company can reduce energy consumption through efficiency of refrigeration or heating,” Bykersma told Manufacturers’ Monthly. “[T]his will now become more critical than ever due to the introduction of the carbon tax and the increased cost of refrigerant gases.”

According to Mil Lozanovski, M.T.I. Qualos national sales manager, temperature control is the main advantage of high-speed doors.

The quick-acting operation of

modern shutter doors allows for rapid access in and out, which is beneficial for all sorts of traffic, Lozanovski says.

“It also prevents wind from blowing in from outside. You can also have a high-speed door in a cooler room or a freezer room to stop temperature escaping” he told Manufacturers’ Monthly.

Other than helping manufacturers to reduce energy costs through temperature control, Bykersma says high speed door also function as a means of contamination control – that is reducing and eliminating the ingress of dust, pollution, pests and rodents.

Doors for this purpose are made from durable materials and should seal tightly, without any gaps for unwanted pests or pollutants to pass through.

Fit for purpose Choosing the right door is about knowing the purpose for which it is to be used, whether that be temperature control, security or maintaining food quality standards.

For temperature control, doors with high thermal rating generally provide better insulation. In some

cases, temperature control can be better maintained due to the speed of closure.

For example, Lozanovski says for freezer rooms, a Libex Iso-speed door made of 80mm thick foam and operating at a speed of 3m/s, is suitable as it “totally seals the area so you get a 100% seal”.

However, doors in this category can be a considerable investment for companies costing anywhere from $28,000 up to $40,000, depending on the size of your door.

For cold storage of pharmaceuticals, Lozanovski says the S1500 pharmacy door allows manufacturers to have the level of air pressure required within the pharmacy lab area to manufacture the necessary drugs without losing temperature.

Insulating doors are also useful in settings where dust and fumes are at play. For example, a wood workshop might use an insulating door on the outside of the woodworking room.

So when the extraction fan works, it extracts within that area only.

Whether it is blowing down or pulling up air, Lozanovski says, the whole area can be sealed off.

Vision doors are also a popular option for manufacturers. These

see-through options allow for safety monitoring. For example, factory managers or leading hands can keep an eye on the factory floor through the panels on these doors.

It is also important no to over look safety features when choosing doors.

Albany Doors’ Rapid Roll 3000 model has a pre-running photo cell which travels down in front of the door’s curtain to ensure that the door will retract/reverse before coming in contact with any object in the doors path.

Another key purpose of industrial doors is security; providing a reliable barrier through effective integration with facility-wide security system as well as assisting to ensure no unwanted access to the premises.

A relatively new development in the doors and access systems market is the modern “knock-out” systems, which has become available in Australia in the last six months.

If a forklift driver happens to hit a door, the door can self-rectify or the driver can just push a button and it goes back up without damaging the bottom panel.

Albany Door Systems 02 9756 4330, www.albanydoors.com/au M.T.I. Qualos 02 9756 5577, www.mtiqualos.com.au

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1300 537 742 | sales@kerrick.com.au | www.kerrick.com.au 24 AUGUST 2012 Manufacturers’ Monthly

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Industrial DOORS & ACCESS SYSTEMS Insulated roller shutters ENVISAGE Building Systems (EBS) has developed the insulated, high-speed ThermaShutters, manufactured with polyurethane-foam filled, aluminium slats of 20mm in thickness.

Lightweight aluminium (approximately 9.9kg/m2) has been used to increase longevity by minimising stress on the motor and components, providing higher resistance to corrosion. The roller shutters are constructed using a small number of manageable components, which facilitate fast and economical installations.

The insulated shutter can be operated with an average opening speed of up to 1.7m/s. Their thermal transfer U-value is 2.51 W/m2K. With the aid of PVC guides on the tracks, the shutter can operate in a quiet and fluid manner.

A powerful microprocessor with an inverter provides smooth acceleration and soft braking to protect materials.

The company manufactures and supplies German high-speed roll-up and sectional doors for environments with temperatures ranging from -35° C to +95° C. Envisage Building Systems (EBS) 03 9775 0268, www.ebs-building.com

The shutters are made of aluminium and filled with PU-foam.

Door controller with touch-screen HMI LEDA and Fast Automation have developed Dockbrain â&#x20AC;&#x201C; a loading dock control system that allows distribution centres to book and manage truck arrivals in a similar way to airport traffic control.

The system allows users to pre-

book a truck to a unique door at a specified time. Easy-to-follow pictorial instructions on the touchscreen helps to ensure a safe workplace around moving hydraulic equipment.

Queuing can be reduced and trucks matched to the right door for

manoevering and optimal warehouse loading. The system is equipment independent so will integrate with existing loading docks, RFID and access control.

Leda Security Products 1300 780 450, www.ledasecurity.com.au

Self-repairable high-speed doors DYNACO industrial high-speed roll-up doors are self-repairing, sealed, flexible high performance doors suitable for food, pharmaceutical, industrial, freezer, clean room and sector-specialised applications.

With a flexible curtain design, these doors have two different operating systems. The Push-Pull system is a top-driven door with no weight or rigid bar at the bottom. In the Gravity system, doors have a soft-weighted ballast edge at the base.

If the door is accidentally dislodged from the side frames, it will instantly re-insert itself in order to be back up and running with less downtime.

When closed, the roll-up door curtain provides an airtight seal on all four sides, providing a barrier against dust, dirt and contaminants. No gap exists between the side guides and the door curtain.

The flexible bottom bag moulds to the floorâ&#x20AC;&#x2122;s surface in order to seal off floor inconsistencies, while a top seal avoids extra energy loss at the top.

Materials Handling 1300 467 791, www.materialshandling.com.au

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Motors& DRIVES

Efficiency gains are there for the taking, but manufacturers need to know where to look if they want to take advantage of these cost savings.

Invest to save

Driving down costs Escalating demands to save energy have led suppliers to develop new, more efficient motor and drive systems. Sarah Falson investigates.

W

ITH the carbon tax in motion and energy prices rising, there has never been a better time to assess factory

equipment running costs. But considering the array of systems used in a plant, it can be difficult to identify areas where savings can be made.

According to Tony Sculpher, NORD Drivesystems AU’s regional sales manager for Victoria, Tasmania and South Australia, manufacturers should begin by auditing the energyhungry equipment at the heart of the production line: the motor and drive systems.

“Here in Australia, the consumption of electric power by electric motors accounts for approximately one-third of all electric power generated. Electric motors are the single largest consumer of electric power as one identified group,” Sculpher told Manufacturers’ Monthly.

Know your system Ensuring factory equipment is properly matched to the job at hand can help reduce surplus energy use on site.

28 AUGUST 2012 Manufacturers’ Monthly

“An electric motor running continuously at full load current requires investigation to confirm its correct size selection. A frequency inverter with flux optimisation software can minimise the usage of full load current when it is not actually required,” Sculpher explained.

“Further consideration is required to ensure that the gearbox with the most efficient gear set is utilised, as this further enhances the efficiency of the total drive package.”

Sculpher says manufacturers often make the mistake of purchasing a drive system based on price, forgetting that operating and maintenance costs will vary depending on the unit.

“Many drive systems are often selected by a secondary source, for example an original equipment manufacturer or a design engineer, and these decisions are based on their purchase cost, and for the selection to remain competitive against competition,” warned Sculpher.

“For a manufacturer or end-user who requires the most efficient drive system package, he must identify the efficiency goal for his installation, and communicate his preferences to the selection source.”

Steve Dumbrell, Bonfiglioli Transmission’s application sales engineer, electronic automation, recommends conducting a motor audit to identify areas for potential savings.

“Audit your plant to work out: what motors you have; what KW size; what application they are being used for; and whether or not the resultant effect of the motor is being reduced by other means – for example, pumps flow being reduced by manual flow valves after the motor,” he told Manufacturers’ Monthly.

Dumbrell suggests using variable speed drives (VSD) to manage motor output, advising that suppliers are constantly updating drive designs to improve energy efficiency.

“VSDs are generally around 94-98% efficient. In many pumping applications it can be very costeffective to replace the direct-on-line start with a VSD. This can see installation payback in less the 12 months some cases,” he said.

Continued on page 29 manmonthly.com.au

Safety compact drives

Compact speed controls

REXROTH has added STO (Safe Torque Off) functions along with SBC (Safe Brake Control) to its IndraDrive Cs servo line.

The IndraDrive Cs compact family of drives is suited to performance range between 0.1 kW and 9 kW. Features such as the Multi-Ethernet communications port deliver extensive functionality in a small footprint.

With STO/SBC functionality, the drives now meet Cat 4 PL e requirements as defined in EN ISO 13849-1 and SIL 3 as defined in EN 62061.

When the STO function is activated, the drive immediately cuts off the current which generates the torque and field in the motor.

That eliminates the possibility of unintended motion when the machine is stopped.

SBC is activated in the drive when the STO function is accessed. SBC activates the motor’s holding brake, providing an additional mechanical block to prevent the motor from starting.

These safety functions are available for all performance classes and levels in the IndraDrive Cs family including the most recent “ECONOMY” performance level.

Bosch Rexroth 02 9831 7788, www.boschrexroth.com Performance range is between 0.1 and 9 KW.

Continued from page 28 “Drive manufacturers are looking at ways to make their VDSs more appealing to the customer and are starting to design the drives with low-loss drive filters, sleep modes to reduce energy consumption when the motor is not running, and load monitoring which will optimise the motor current to the application to reduce energy supplied to the motor.

“Technology has improved greatly in the last 10 years with a large effort being spent on improving environmental footprint, meaning businesses can actually save a lot of money by reassessing how they use

energy in the day-to-day running of their business.”

Assistance available Recognising the key role energyefficient equipment plays in reducing carbon emissions, the government is now providing assistance for industry to invest in ‘clean’ technology.

Shailesh Sharma, ABB Australia’s energy efficiency manager – motors and drives, believes government funding delivers a compelling argument for manufacturers to invest in more energy-efficient technology.

“Clean technology and energy efficiency grants from the government

BODINE Electric has introduced the new type ABL-3906C low-voltage brushless DC stock controls suited for applications where connection to an AC line is not possible. The controls operate from a DC power supply or from a battery, 12VDC or 24VDC depending on the control model. Motor speed can be controlled by an external potentiometer,

the onboard speed trim potentiometer, or a 0-5VDC analog input signal. The controls have continuous output rating of up to 20Amps, and are capable of peak output current of up to 30 Amps. Trim pots allow the user to adjust maximum speed, torque (current) limit, and acceleration time.

Bodine Electric www.bodine-electric.com

Analogue servo drives ELMO has launched a new family of analogue servo drives with low-voltage DC input, built to military standards for extreme environmental conditions.

The new models – the Dragonfly, Butterfly, Robin, Condor, Canary, and Raven – are current mode pulse width modulated servo amplifiers for brush and brushless motors. The ExtrIQ analogue

amplifiers come in compact, high-density power packages.

Motion control is achieved through the implementation of proprietary switching and control methods enabled by customised dedicated ICs and advanced heat transfer and dissipation.

Motion Technologies 02 95244782, www.motiontech.com.au

are the cost-effective way to apply replacement or upgrades of existing installations to support energy efficiency,” Sharma told Manufacturers’ Monthly.

“Being more energy-efficient makes economic sense because it lowers operating costs. From an environmental perspective, it is an effective way for businesses to cut carbon emissions.”

A number of grants are currently available through the Clean Energy Future scheme, which is part of a long-term plan to reshape Australia’s economy, cut carbon pollution, drive innovation, and help avoid the

increased costs of delaying action on climate change.

The plan comprises three separate initiatives: the Clean Technology Investment Program; Clean Technology - Food and Foundries Investment Program; and Clean Technology Innovation Program – which are now open for registrations.

ABB 03 8577 7114, www.abbaustralia.com.au Bonfiglioli Transmission 02 8811 8000, www.bonfiglioli.com.au Clean Energy Future 1800 057 590, www.cleanenergyfuture.gov.au NORD Drivesystems AU 1300 006 673, www.nord.com.au

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Email sales@brevini.com.au

www.brevini.com.au

Manufacturers’ Monthly AUGUST 2012 29

Packaging The whole package New developments in food packaging manufacturing is opening new markets. Cole Latimer writes.

A

N Australian developer and manufacturer of sustainable plastics and packaging has received Halal certification for a new range of resins.

The company, Cardia Bioplastics, is the latest of a number of Australian food packaging manufacturers to develop or use packaging that is either Kosher- or Halalapproved, or both.

According to Cardia Bioplastics, it derived its range of biohybrid resins from renewable products which now have formal acknowledgement of compliance with Islamic laws surrounding safety and quality.

Cardia managing director Dr. Frank Glatz said the certification, announced that the development was a “commercial milestone” for the company.

“It significantly increases our ability to drive sales as we are able to appeal to a further 1.6 billion potential customers,” he said.

“The global Muslim population is huge and growing and we now have the opportunity to tap into it.”

Halal-approved products ; an untapped market for Australian packaging manufacturers.

According to the company “the certification opens up new market share opportunities in previously untapped markets”.

With over a billion Muslims around the world, the sale of Halal certified products is ever-increasing, and according to one Malaysian businessman Tan Sri Halim Saad, this market is set to grow at twice the

average rate of population growth.

This is an even greater step for an Australian company, as the nation exports much of its food, particularly to Asian nations such as Indonesia or Malaysia, which have a high Muslim population.

While, the meat exported is Halal, often the packaging is not, thus creating a problem for food suppli-

ers and manufacturers.

Saad explained that there a number of food security problems in Islamic countries, and prepackaged food may overcome this issue.

He told Fairfax NZ that the concept of tayyib “requires that the halal process to be adhered at each level of production, including the feed that the livestock eats, the financing of the business, the logistics process and so on”.

Cardia is not the first Australian company to manufacture Halal certified packaging, with Blue Lake Milling certified not only for its oats and rice products but also for its packaging.

Cardia explained that its latest packaging resins combine renewable plant based thermoplastic starch with oil based polymer material, which is derived from a corn corp.

“They are also compatible with current recycling processes as well as food safe compliant,” the company explained.

Cardia Bioplastics 1300 735 473, www.cardiabioplastics.com

An edible future New technologies taking the plastic out of packaging.

PACKAGING and food container manufacturers have often caught a bad rap because of the nature of their product.

It needs to be manufactured to be safe, strong, and resilient enough to hygienically contain food and protect it from damage and bacterias, yet also be biodegradable or recyclable.

And unfortunately the two do not always mix.

While packaging products manufactured from corn starch have made their way into the arena, they are still fairly labour intensive compared to basic plastics. On top of this, they still take some time to degrade.

The Wyss Institute at Harvard University in the US has developed a new and edible packaging technol30 AUGUST 2012 Manufacturers’ Monthly

ogy, known as WikiCells, which is helping industry to solve recycling issues, such as reusability, as well as the need for a strong material.

Professor David Edwards, founding core faculty member of the Wyss Institute, whose work encompasses the arts and science and is at the core of a network of art and science labs in Europe, USA and Africa, is the inventor of WikiCells.

The idea for WikiCells was based on the way nature has always delivered nutrients in a digestible skin “held together by healthy ions like calcium”.

WikiCells consist of a natural food membrane held together by electrostatic forces and containing a liquid, emulsion, foam, or solid food

substance possibly within an edible or biodegradable shell. Apples, potatoes and tomatoes, for example, all have an edible exterior protecting the food within.

“This soft skin may be comprised primarily of small particles of chocolate, dried fruit, nuts, seeds, or many other natural substances with delicious taste and often useful nutrients,” the WikiCells team explained.

“Inside the skin may be liquid fruit juice, or thick pudding.”

Edwards and his collaborators, including industrial designer François Azambourg, have so far tested gazpacho-stuffed tomato membrane, a wine-filled grape-like shell, and an orange juice-laden orb with a shell that tastes like an

Edible packaging; a recycling breakthrough. orange.

The team is also looking into other possibilities including edible milk bottles and yogurt containers.

The membranes are so far produced only with a WikiCell machine, however the technology may soon expanded for greater manufacturing capability.

Wyss Institute wyss.harvard.edu WikiCell www.wikicells.com

manmonthly.com.au

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Atlas Copco products and services have been supporting our customers with innovative, reliable, cost effective compressed air supply for over 50 years.

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