Manufacturers' Monthly July 2012

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ANALYSIS >> TECHNOLOGY >> SOLUTIONS

Est. 1961

July 2012

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INSIDE Industry News & Comment >> Coming Events >> New Products >> Metal Working >> Automation & Robotics >> Production Software >> Compressors & Pneumatics >> Materials Handling

MANAGEMENT >> Workplace Safety Limiting workers’ exposure to airborne hazards p.16

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Associate Publisher Martin Sinclair martin.sinclair@reedbusiness.com.au Acting Editor Alan Johnson Ph: (02) 9422 2325 Fax (02) 9422 2722 alan.johnson@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) 0811 3184 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) (02) 0811 3184 anthony.head@reedbusiness.com.au 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

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Inside

For daily news visit manmonthly.com.au

JULY 2012

4 Editorial Q

Why there is no cheap LNG

20

6 Comment

Connecting shop floor with management systems – Middleware delivers increased functionality for manufacturers.

Q

Regulating electrical product standards

16

8 Analysis News Q

Innovations focus brings rewards Q Carbon tax does have a silver lining Q Expanded role for industry

16 Management Q

Airborne hazards unmasked

44

19 IT@MM Q

Middleware, bridging the gap Siemens PLM Connections event Q Touch panel PC Q ERP software Q

22 What’s New Q

Latest products for Australian manufacturers Q Flange pressure transmitters Q Modular valve and block assembly system

manmonthly.com.au

ANALYSIS >> TECHNOLOGY >> SOLUTIONS

Est. 1961

July 2012

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Print Post Approved PP255003/00324

ABN 80 132 719 861 Average Net Distribution Period ending March 12 15,300 ISSN 0025-2530

INSIDE

38 Compressors & Pneumatics

32 Metal Working

44 Materials Handling

Q

Q

Surviving the rise of low-cost economies Q Arc projector shows welding effect Q Durable grade option for insert drills

MANAGEMENT >> Workplace Safety Limiting workers’ exposure to airborne hazards p.16

Q Q

Lowering compressed air costs Safety air guns with chip shields

Countdown revamped DC in operation Q Desktop printers for light-duty labeling Q Industrial printers with thermal transfer capabilities

Behind the cover BOC are proud to introduce the GMA and TIG welding arc projectors, which display the significant difference BOC shielding gases can make to your weld.

The GMA arc projector produces an optically-magnified arc image of a real, live welding arc which changes as welding parameters are changed.

The TIG arc projector utilises a camera, and images are relayed onto

A Member of The Linde Group

Industry News & Comment >> Coming Events >> New Products >> Metal Working >> Automation & Robotics >> Production Software >> Compressors & Pneumatics >> Materials Handling

Frequency inverters with variance control Q Swarf resistant energy chain

Q

a plasma screen. An interactive demonstration, it allows control over the selection of shielding gas which in turn shows the impact on the arc and travel speed.

The arc projectors are housed in a portable container and are available for demonstrations near you.

For more information, contact BOC on 131 262 or visit www.boc worldofwelding.com.au

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Website: www.profilecuttingsystems.com Manufacturers’ Monthly JULY 2012 3

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Editorial

ALAN JOHNSON – Editor

editor@manmonthly.com.au

Why no cheap LNG for us?

Both sides of politics know the question, but not the answer.

T

HE carbon tax has made its ugly entrance onto Australia’s economic landscape and is rightly hogging all the headlines, however we can be quietly confident that when Tony Abbott takes over the reins in Canberra the insidious tax will become history.

However, this is not the case with our LNG industry. With electricity prices soaring, both sides of politics seem prepared to sell our gas off at any price with no regard for domestic consumption.

Australian manufacturers depend upon reliable supplies of energy and resources, priced competitively, in order to manufacture a range of vital commodities.

Despite being in abundance, access to domestic sources of gas by local manufacturers is often made difficult by policy confusion, perverse incentives for international competitors and pricing uncertainty or inconsistency. It’s a shortsighted energy policy that favours sending our abundant natural resources overseas at the lowest point in their value chain, while other nations reap the benefits of adding value to our resources.

James Fazzino, MD and CEO of Incitec Pivot, says he sees no reason why we can’t have a vibrant LNG industry on the back of a re-invigorated manufacturing industry, and also have

Overseas competitors are taking advantage of our cheap energy resources.

some of the gas available for electricity generation.

We have ended up in this curious situation where all the gas on the east coast of Australia is going to be exported.

He says government on both sides must recognise that the gas belongs to the Australian people, and ensure we end up with a balanced outcome with a certain amount set aside for local use; for consumers and manufacturers rather than just for export. “Australia needs to look at its sustainable competitive advantages and exploit those advantages. “If you look at China, their advantage has been cheap labour, but expensive energy.

We can have competitive energy and expensive labour.�

Fazzino says the mistake we make is believingthat the global gas market is not a free or fair market. He points out that Australia has allowed four global gas majors to take all the gas and export it.

However, in the US for example, President Obama has said he will keep the vast majority of its gas on-shore and is going to build manufacturing off the back of it. He has a vision of creating 600,000 new manufacturing jobs from the gas industry.

The US has this endowment and is leveraging it to create jobs.

One major difference between the US and here is that the US has around 3000 gas suppliers, while we have four multinationals who monopolise the industry

and sell it offshore; they clearly don’t have Australia’s best interests at heart, only their shareholders.

At the moment, Incitec Pivot is considering building an ammonia plant somewhere in the world. Fazzino says the location hasn’t been decided yet, it could be the US, but he guarantees it won’t happen in Australia. The difference, he says, is the supply and the price of gas; “the value proposition�.

He points out that if you take gas offshore, for example, you increase its value by three to four times. However if the company produces a complex emulsion for explosives, for example, its value is increased by 20 times.

And if you do that everyone wins; the government gets more tax and you build that balanced economy and all the benefits of local manufacturing. “Our rule of thumb is for every $1 we spend in the plant, there is another $4 we spend in the local community.�

Pollies understand the problem, but they struggle with a solution. The problem is there is no silver bullet, yet.

This is about creating well paid, highly skilled jobs in the economy and being able to pay for that via our birthright in this country, cheap energy – so Australia can have its cake and eat it too.

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The new Fluke 805 Vibration Meter is more than a pen. It’s a Fluke meter that gives you results you can trust, time after time. tChecks the overall vibration, bearings and temperature tAbility to export and trend data tFour-level scale which quickly assesses problem severity tUnique sensor design ensures accurate and repeatable measurements

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Comment

INNES WILLOX – CEO Australian Industry Group

editor@manmonthly.com.au

Getting electrical products up to standard Allowing non-conforming products to saturate the market will breed non-compliant business models.

B

USINESSES manufacturing and supplying products are concerned at increasing competition from products that do not conform to standards and regulatory requirements.

One recent example is an electrical safety product that badly failed the relevant standard. Competitors highlighted the product to electrical safety regulators with multiple reports over three years before it was eventually recalled.

However, despite the clear dangers involved, the regulatory burden is falling increasingly on importers and producers who do the right thing. And despite government efforts on regulatory reform in recent years, the burden associated with business regulation is rising, not falling.

This regulatory burden is being exacerbated because non-compliant products are unfairly affect-

6 JULY 2012 Manufacturers’ Monthly

ing the market for legitimate product suppliers.

Concerns are heightened in circumstances where governments move to impose cost-recovery enforcement models on industry, under which businesses feel they are effectively forced to pay twice: once to cover the cost of their own compliance; and secondly to fund Government enforcement on non-compliant competitors. There is clearly a problem with the system when a growing number of companies believe the benefits of non-compliance outweigh the risk of being penalised. This is putting those who are adhering to the growing regulatory burden at a huge competitive disadvantage.

The electrical equipment industry is working with regulators to redesign the current state-based electrical safety regulations. The aim is to achieve harmonisation

across jurisdictions; visibility of equipment suppliers to regulators and consumers; and increased surveillance and compliance activity.

Ai Group’s own electrical industry awareness campaign, highlighting to electrical contractors the dangers and regulatory risks of purchasing non-conforming products, has also been endorsed by all electrical regulators.

The entire electrical equipment supply chain, including manufacturers, suppliers and contractor installers, have serious obligations under Australian law to ensure that equipment supplied or installed meets our compliance and regulatory standards.

Possible solutions in the electrical equipment sector include the use of a common compliance mark and a suggestion that electrical contractors ask equipment suppliers for proof of compliance.

The regulations in this industry sector require suppliers to be able to prove compliance to product standards.

The wider issue of non-compliant products across all industry sectors needs to be addressed by industry and governments at all levels.

With different regulations, standards and compliance mechanisms applying in different sectors, there will not be a single solution across all sectors or product issues. Identifying the failure points in each sector will provide direction as to the solution for that sector. Focus will need to be maintained on areas that are regulated – product safety and claims of compliance with standards.

If governments do not prioritise this issue, legitimate businesses will continue to underperform and may resort to non-compliant business models in order to compete.

manmonthly.com.au

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Enough said.

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22/02/12 12:12 PM

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AnalysisNEWS Innovation focus brings rewards

By Hartley Henderson

A

T a time when Australia’s manufacturing industry is facing significant challenges, the recent opening of ANCA Group’s new facility in Bayswater North, Melbourne highlights a real success story.

Officially opening the new head office of ANCA Group subsidiary, ANCA Motion, Industry Minister Greg Combet pointed to ANCA as a role model for the Australian manufacturing sector – an innovative company delivering first class products to a global marketplace.

A leader in the design and manufacture of precision machine tools, the ANCA Group exports over 99% of its production to the main industrialised nations of the world, and spends around 9% of sales on R&D. ANCA Group Chairman, Pat Boland, believes

8 JULY 2012 Manufacturers’ Monthly

ANCA exports over 99% of its production, and spends around 9% of sales on R&D.

advanced manufacturing requires excellence in ability, attitude and training at all levels. “Recent government initiatives in support of staff in-service training is an excellent example of short term and long term thinking,” he said.

Combet pointed to several government initiatives directed at facilitating productivity, innovation and competitiveness, including the creation of a new $29.8m Manufacturing Technology Innovation Centre, and a new loss

carry-back scheme to encourage companies to invest and innovate by allowing them to offset a current year tax loss of up to $1m against tax paid in previous years; a refund of up to $300,000.

Boland also emphasised the importance of establishing a favourable business environment as a critical factor in successful manufacturing. “For example ANCA has significantly benefited from the free trade agreement with the US in cutting the cost of shipping machines to their market,” Boland told Manufacturers’ Monthly.

The agreement with Thailand has allowed ANCA to develop a business model where key components are manufactured in Australia and lower value-adding tasks are performed in Thailand.

Advantage can then be taken of Thailand’s duty free agreement with China, says Boland.

manmonthly.com.au

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AnalysisNEWS EVENTS

Carbon tax does have a silver lining

By Alan Johnson

JULY 24-26: Queensland Mining & Engineering (QME) Exhibition A range of mining communityfocused events and information sessions will be a major feature of this year’s QME to be held at the Mackay Showground, with related events to be based at the Mackay Entertainment & Convention Centre. For more information call Warren Queenan on 02 9422 2563 or visit www.queensland miningexpo.com.au 26: AIP Extrusion Blow Moulding Course The Australian Institute of Packaging (AIP) has announced a new half-day training course on the Introduction to Extrusion Blow Moulding. The first course will be held at the Viewpoint Centre, St Kilda, Victoria, and will include a presentation by industry expert Stephen Barter. For more information visit www.aipack.com.au

AUGUST 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 communityfocused 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

10 JULY 2012 Manufacturers’ Monthly

W

HILE the unpopular carbon tax comes into force this month it is linked to some good news in the form of the generous $800m CleanTechnology Investment Program (CTIP) specifically for Australian manufacturers.

The goal of the merit-based program is to support manufacturers to maintain competitiveness in a carbon constrained economy through grants for investment in energy efficient capital equipment and low emission technologies, processes and products.

Michael Ryan, Senior Finance Broker with Finlease, says the AusIndustry managed program is very attractive and spells dollars for manufacturing companies.

“It is also interesting to note the tax benefit that flows from the investment in terms of the depreciation allowance, for example, using a rate of 10% prime cost, a deduction of $10,000 is claimable for every $100,000 in value,” Ryan told Manufacturers’ Monthly.

“With the 50% grant contribution plus the depreciation deduction (on full value) it makes this opportunity very attractive.”

Mark Gadd, MD of Autonomous Energy agrees saying this is really great news for manufacturers, but warns companies should move quickly.

“From past experience, with similar programs, the further into a program the harder it is to get the money,” he said.

In terms of rebate, Gadd explains there is an applicant to grant ratio of either one for one, or two for one, depending on turnover, or three for one for projects over $10m.

“Typically it’s one for one for companies with an annual turnover of less than $100m, or two for one if the turnover is higher,” he told Manufacturers’ Monthly.

Gadd says under the program, areas of energy saving are very wide ranging.

“It all depends on what type of equipment is being upgraded but lighting is probably the area with most scope.

“Lighting in most manufacturing plants is inefficient, and there are some large savings there, larger than people might think.

“It’s also a more certain energy efficiency saving, rather than calculating energy savings in upgrades to process controls and high efficiency motors for example.”

With energy efficiency, Gadd says it’s really site specific.

“There is not much point in having a top 10 list of things to do. You need a professional energy audit to show exactly how and where energy can be saved, and what the costs and savings are, with the potential for very short ROIs,” he said.

Getting the money Gadd says his company offers a range of products and services that can be funded by the program. “Firstly we determine their eligibility, that’s just a simple phone call.

“Then if the company already has plans for more energy efficient motors and/or lighting, or other areas, we can work with them to apply for CTIP funding or we can work with them to plan an energy efficiency or renewable energy project, including project design, specifications, cost feasibility, operating performance requirements. We will conduct the energy and emission savings which is a key part of the application as well as develop project milestones and budgets.

“The energy and emission savings can be in the form of an energy audit, but doesn’t have to be. In terms of getting the best energy efficiency options, an energy audit is the best place to start, but some clients might already have done that.

“The cost of the energy audit can be applied for as part of the CTIP, in addition to that some states have their own subsidy programs for energy audits,” he said.

Another option for reducing energy consumption and emissions, which is often overlooked and eligible under CTIP, is solar photovoltaics (PV), says Gadd.

“The financials on solar PV have changed dramatically in the

Up to $800m set to flow into manufacturers’ coffers.

past couple of years and is now far more feasible than a lot of other energy efficiency options.

“The costs associated with solar PV and the costs associated with the electricity generated by solar PV are very predictable unlike gas or co-gen for example.

“In our analysis of solar PV we have found it much more cost effective from day one than cogen. Once we include the CTIP funding, we are looking at a ROI of just over three years, with an average KW/hr cost of just 2.9c, compared with today’s electricity costs of 18c per KW/hr. That’s over a 20 year period.

“These figures apply to any size manufacturer as the systems are entirely modular. Size is determined by roof space and budget and how much energy the company is using.

“We don’t oversize the system, we try to match it to energy demand. It’s grid interactive, so if the company is using more electricity than it is generating, it’s imported from the grid, if the solar panels are generating more than required the electricity is sold back to the grid,” he said.

Gadd admits that different levels of electricity will be generated per year, but says it is feasible right across Australia.

This is because manufacturers have large roofs, plus most of their electricity load is during the daytime when the solar panels produce electricity, he says. manmonthly.com.au

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AnalysisNEWS

Expanded role for industry

By Alan Johnson

W

HILE Queensland is riding the resources boom, the manufacturing industry remains a key component of the state’s GSP. Jim Walker, CEO of QMI Solutions, says the take out message from the organisation’s recent conference was that manufacturing is alive and well in Queensland.

“However the industry is changing its spots in many cases.

It’s moving from straight manufacturing to manufacturing, services and solutions,” Walker told Manufacturers’ Monthly.

“Those companies that are doing well are those that are embracing and unlocking the potential of their organisations.

“The new Queensland Government, the Liberal National Party, want to build the economy on four pillars; construction, mining and resources, and tourism.

“And while manufacturing is not mentioned, the government acknowledges that every supply chain that feeds into everyone of those pillars has a very strong element of Australian manufacturing,” he said.

Walker says the resource sector offers exciting opportunities, but warns manufacturers have to change some of the ways they go about their business.

“Many manufacturers have realised there is actually more money to be made in other parts of the value chain, by providing equipment, and services, to mining companies.

“Successful companies continue to provide the manufactured part, but also provide total life cycle support,” he said.

“One well known Queensland company has moved from being a straight manufacturer to a manufacturing and solutions company with 75% of its revenue now coming from providing solutions through life support

to mining companies. The manufacturing part of the company is now a cost centre. It produces the parts so the company can service the equipment.”

He says you just have to look at Rolls Royce to see how that company has changed from an aircraft engine manufacturer to an integrated turbine solution provider to the aerospace industry.

“In fact, Rolls Royce don’t sell engines to Boeing anymore, they lease them power by the hour.

And if one breaks, not a problem they come and fix it.

“That has driven far more efficiency back into the company’s manufacturing process, because now they are responsible for the total life cycle of that engine, with more money to be made in those parts of the life cycle than just in the straight production,” he said.

Walker says companies that are embracing the solution concept, not just service, are thriving.

Manufacturers have to change some of the ways they go about business - Walker.

“For example, one company we work with in New Zealand makes taps.

“The company has come up with an innovative way to save water and energy by colliding two streams of water together so the person having a shower gets the feeling of more water over their body for half the water.

Get your politicians out of their comfort zones National launch Federation Mall Parliament House Canberra

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What will the program do?

How do I nominate my MP or Industry?

• Every Manufacturing and Farming Sector industry group can participate in the National Launch or in the program itself by nominating on the AMFP website.

• Every Australian can nominate their local Member of Parliament to participate in the program – you could find a cabinet minister working beside you on the shop floor.

• All you have to do is fill in their details on the nomination page of the AMFP website.

• Get MPs and Senators out of Canberra and into the manufacturing and farming industries.

• Close the gap between farmers and manufacturers and their parliamentarians.

• Get politicians out of their comfort zones and into the real world – your world.

• Legislation is not just about economics; it’s about people, families and communities.

• Show politicians the affect legislation has on industries and the people that rely on them.

• Let them see the issues facing ordinary Australians in Manufacturing and Farming.

Where can I find out more? www.amfp.org.au 12 JULY 2012 Manufacturers’ Monthly

manmonthly.com.au

MA N M. J U L 1 2 . P G 0 1 3 . p d f

“Now for a new building, they don’t sell the owners taps anymore, they provide the ‘hydraulic solution’ for water and energy saving, and get a cut of the savings.

“For very little extra effort, the company is able to appropriate value out of a service through knowledge of its product,” he said.

Government’s role Rather than punitive actions by government, Walker says we should create an environment where the owners of the major mining projects are motivated to use local industry.

“The most important requirement is to ensure local manufacturers have the capabilities, skills and capacity required.

“There is a range of strategies the government has put in place to assist, these include us at QMI, and MSQ plus ICN and Enterprise Connect.

“Together we have a number of programs, either free or heavily subsidised, where we can assist companies to make sure they have the right processes in

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place, and that they are productive and efficient, and have quality and environmental processes in place to position them best.

“This new Queensland government has an absolute commitment to creating an environment where local industry can compete. Now it’s up to local industry to make sure they are prepared.

“There is enormous opportunity for manufacturers in Queensland, it is a very strong part of the economy and supports the Government’s four pillars,” Walker explained.

“We have to make sure the industry is positioned for the future and one very important part of that is having the skills and capacity, and that is what our recent conference ‘Making Queensland’s Future’ was all about.

“Manufacturers need to address four key issues to survive: having the right skills to meet demand; ensuring their processes are efficient; having the capability to deliver; and looking for innovative ways to improve business,” he said.

AM

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TODAY’S DEXION : YOUR PARTNER IN SYSTEMS INTEGRATION. Choosing the right systems integration partner is a critical decision and will directly impact the success of your project.

Dexion has a proven track record working with some of Australia’s blue-chip corporations.

We’ve helped them to create smarter integrated systems solutions.

The Dexion approach is unique, in that we will source the best available technology from a range of specialist partners from around the world. Our philosophy is simple: find whatever it takes to achieve the best possible outcome for our customers.

For more information regarding Dexion’s systems integration expertise, visit us at www.dexion.com.au or call 1800 100 050.

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AnalylsisMANAGEMENT

Factory workers are often unknowingly exposed to a range of harmful dusts and fumes.

Airborne hazards unmasked They may be small, often invisible, but airborne contaminants in the workplace can be deadly. Angela Welsh reports.

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UMES, dusts and other inhalable toxins are among the most dangerous of all workplace hazards.

Managers and workers need to be aware, these toxins can cause asthma, chronic obstructive pulmonary disease, asbestosis and cancers of the respiratory system, such as mesothelioma and lung cancer.

Some of these conditions have swift consequences, while others have long latency periods.

This makes it essential for managers of factories, workshops, warehouses – and any workplace where airborne hazards are at play – to minimise workers’ exposure to dust and other particulates, fumes, gases and smoke.

According to a recent Safe Work Australia report, approximately 39% of Australian workers are exposed to airborne hazards in the workplace.

Occupations with the highest likelihoods of exposure to airborne hazards include technicians, trades workers and machine operators. The research data reveals 23% of Australian

workers who reported exposure to airborne hazards were not supplied with controls for the conditions. An additional 22% only received one control for airborne hazards, while the rest reported that they had more than one control.

Managers should take note, companies that fail to comply with set exposure limits can be hit with hefty fines.

Don Brereton, Micronair Dust Control’s MD, recommends periodic monitoring of air quality in a workplace to determine the level of contaminants workers are exposed to. “When dealing with dust, it is important to remove the dust closest to the source rather than letting the dust escape and dealing with it at that stage. “When capturing dust particles, it is better to focus on the work zone – the 2 to 3 metres around the machine operator. “Another essential step is to change the air in the room, rather than just re-circulate it,�

Brereton told Manufacturers’ Monthly. “Devices such as particle size assessors can provide readings on the number of grams of airborne contaminants that exist per cubic metre of air in a work zone. “Some of these devices also identify what types of particles are present. These measurements are useful in checking whether the concentration of particles in a work zone is over the limit,� he said. continued on page 18

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Mongrel SP Range Because what you do makes a difference to the boots you wear Our Mongrels SP Series was designed to incorporate the most significant technological, comfort and safety features into one premium range. Now Mongrels have expanded the SP designation to meet the requirements of different work conditions.

For example the mining industry and light manufacturing industries have very different needs. Now, along with SP>P Originals we offer SP>R, SP>S, SP>Z, SP>T and SP>N ranges. Take a look on our website or call for a Mongrel salesman for more information.

Features many of the original and popular styles of our SP Premium Range launched in 2006.

The high tech rubber-soled work boot that’s built to take the heat no matter how rugged the conditions – heat resistant soles up to 300˚C

The lightweight, work boot with aluminium toe-cap and advance Sport technology soling.

The revolutionary ZipSider style allows for great ankle support with easy on and off features required by many trades.

Our Trade range featuring high spec features matched with a comfort innersole and value for money rugged leather uppers.

Many workers don’t require a steel toe cap. So Mongrels has provided a number of non-safety styles from riding boots to classic elastic sided boots and a security range.

SP RANGE The Aussie born and bred work boot designed to work best for you

Victor Footwear 15 George Young St. Auburn NSW 2144 p: 02 8667 2555 f: 02 8667 2500 e: sales@mongrelboots.com.au w: www.mongrelboots.com.au SPS 003

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Analysis MANAGEMENT Penalties for violating airborne contaminants standards can range from $6,000 to $30,000.

continued on page 18

Employers responsible David Morton, Fume and Dust Control’s MD, said it is the employers’ responsibility to supply a safe working environment for all employees and people visiting the site. “The manufacturer also has a responsibility to the local government (council) and the Environmental Protection Authority (EPA),� he added. “Obviously the first step is to identify the hazard. This can be hard in some cases as quite often no two manufacturing processes are the same and there has to be an honest exchange of information between the client and ourselves which is always kept confidential,� Morton told Manufacturers’ Monthly. “Once we have identified the hazard, we look at putting controls in place, this can sometimes be as easy as putting a lid on an open container to contain the contaminant, changing the work method or materials, so that the operator and the environment is not affected,� he explained. “When we have looked at all the options in consultation with our client we will make recommendations to control, filter or capture the airborne contaminant at source prior to the operator’s breathing zone.�

Morton explained that there are many quick and simple solutions on the market at the

moment, from fume arms to dust collectors and scrubbers, all of which limit workers’ exposure to airborne contaminants.

One solution is to adopt a separation method that removes a complete spectrum of pollutants such as mists, vapours, gases, dusts and smoke, including superfine particles.

Paul Fowler, Dimac Tooling’s MD, points out that the term ‘fine dust’ refers to the mass of all particles with a diameter

below 10Îźm included in the total dust quantity. “Grinding machines with very high cooling lubricant pressures and corresponding rotation rates for instance can produce extremely small particles that are more like vapour than solid matter,â€? Fowler told Manufacturers’ Monthly. “We are dealing with a molecule range with sizes of about 0.001Îźm. The admissible air pollution Workplace

Exposure Limit (WEL) is 10mg/mÂł for cooling lubricant vapours and aerosols with a flash point above 100°C that are emitted during metal processing,â€? he said. “The same limiting value applies to processing machines with a minimum lubrication system. This exposure limit is two hundred times as high as the limit for outdoor air pollution,â€? he added.

Manufacturers should also be aware that Regulation 49 of the Workplace Exposure Standards for Airborne Contaminants requires any person conducting a business or undertaking to ensure that no person in their workplace is exposed to concentrations of airborne contaminants that exceed the standards for those substances.

Exposure standards can be defined as exposure over an 8-hour period, a peak limitation or a short-term limit.

Penalties for violating this legislation are $6,000 for businesses owned by an individual and $30,000 for those governed by a corporate body.

Violation of the legislation could also create vulnerability for potential litigation from employees in the future.

Dimac Tooling 03 9561 6155, www.dimac.com.au Fume & Dust Control 07 3388 1131, www.fumeanddust.com.au Micronair Dust Control 03 9720 7244, www.micronair.com.au

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18 JULY 2012 Manufacturers’ Monthly

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TechnologyIT@MM sations to develop enhanced products and solutions.

“IBM typically hosts workshops with clients and prospects to scope out a prospective solution that addresses a client’s particular need,” Albert told Manufacturers’ Monthly.

Increased visibility

Middleware connecting shop floor data with ERP systems.

Bridging the gap How manufacturers can use middleware as the glue that binds management systems with the shop floor. By Sarah Falson.

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merging in the 1980s when distributed client server systems became popular, middleware has been reinvented in various shapes and forms, but only recently has the concept proven its worth in the manufacturing realm.

If you use mobile applications or cloud computing in your company, you are already using a form of middleware, allowing

manmonthly.com.au

your mobile to talk to your control system and then report the goings-on in the plant. Similarly, if you have implemented a software system to synchronise your MES (Manufacturing Execution System) and ERP (Enterprise Resource Planning) systems, you are also already using middleware.

Adrian Albert, IBM’s local executive for Websphere, says

it’s often referred to as ‘the dash in client-server’ as it provides the software layer that lies between an operating system and applications, and its goal is to reduce the complexity of developing, running and managing applications.

“Middleware software supports business applications and is increasingly becoming more intelligent and enabling organi-

Manufacturing operations today can be very complex and inflexible, which adds cost, lengthens delivery time and increases project risk by threatening business agility. However, as managers realise the benefits of developing visibility across their operation, more companies are turning to middleware.

Middleware for manufacturers can provide functionality such as automated decisions, serviceoriented integration, business process management, information security, event processing, reporting and systems management.

It can also incorporate portal technology used to build private and public information about employees and customers, as well as business intelligence such as real-time reporting tools.

According to Oracle’s ANZ Fusion Middleware principle product manager, Alex Peattie, middleware can provide a competitive advantage for manufacturers by creating an automated continued on page 20

Manufacturers’ Monthly JULY 2012 19

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TechnologyIT@MM continued from page 19 and managed end-to-end system. “A manufacturing organisation’s eco-system typically consists of individual applications to manage production, supply chain execution, sales and operations, logistics and transport. “Middleware orchestrates each of these components, passing the relevant information between them to optimise the overall outcome,� Peattie told Manufacturers’ Monthly.

According to Peattie, middleware can be a comprehensive family of products, which allows you to adopt the solutions as you require them. “But it is imperative its components are seamlessly pre-integrated to help you create, run, and manage agile and intelligent business applications,� he warns. “Manufacturers may want to develop mobile interfaces to existing control systems on the shop floor. “Middleware integration and user interface technology could be used to enable this type of solution, enhancing control systems to provide updates,

alerts and reports to a user’s mobile device. “Middleware event management systems can allow manufacturers to handle the vast amount of sensory data that can be collected from SCADA systems,�

Peattie said.

Implementing middleware Since every company faces unique challenges, each middleware solution will be different.

Solutions can range in price from tens to hundreds of thousands of dollars, depending on licenses and engineering services. Importantly, many companies that sell MES or ERP can also provide a middleware solution to link the two areas.

Rockwell Automation’s South Pacific Information Solutions sales executive, Serena Moreno, says most traditional manufacturers run production systems in isolation, sometimes linked tightly to control. “Middleware is the glue that binds the different levels of the ISA 95 Communication Standard (global standard for info communication in an

enterprise) together. It provides the ability to automate the link and write the points of interaction that you want between the layers (eg layer 0-5). “Middleware helps you link everything up. “The power that can be leveraged by tightly coupling your ERP, MES and control layers translates to significant operational savings and performance improvements. “The ERP layer provides business system information and the MES layer provides visibility into the shop floor through production management, materials management, quality and compliance. “Tightly coupling these functions with the control layer provides real time information from the manufacturing plant level. Coupling these layers through middleware is the key to operational efficiencies,�

Moreno said.

IBM Australia and New Zealand 132 426, www.ibm.com/au Oracle ANZ 1300 366 386, www.oracle.com/au Rockwell Automation Australia 1800 762 593, au.rockwellautomation.com

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SIEMENS PLM will host its first Connection Event in Australia. The event is part of a set of annual unified user conferences that connects leading industry analysts, peers, partners and Siemens executives from around the globe.

The 2-day event will discuss how Siemens PLM Software’s HD-PLM vision is helping manufacturing and engineering users make smarter decisions and better products. Other topics discussed will include effectively managing big data and systems integration, customer success stories and the latest Siemens PLM product launches, such as NX 8 Teamcenter 9, Solid Edge ST 5, and the new Insight XT, with a products breakout session, parallel industry discussions and networking opportunities.

Held in Melbourne on July 24 (Enterprise Day) and 25 (Velocity Day), Siemens PLM Connections will bring together more than 300 enterprise and mid-market partners and customers to discuss industry, key trends and the future as seen by Australian manufacturers. www.plm.automation.siemens.com

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ERP software updated ORACLE has released JD Edwards EnterpriseOne Version 9.1 designed to help customers further streamline business processes.

Extensive updates in the ERP software’s new release include enhancements such as One View

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Reporting that allows business users to create interactive reports without IT support.

User interface updates include predictive auto suggest search and query refinement capabilities.

Oracle www.oracle.com

OP TION S

WASHERS Fast Delivery

The PC has a high level of water/dust-proofing.

BACKPLANE Systems Technology has announced the release of Avalue’s LPC-1203 touch panel PC. The PC is powered by an Intel Atom N270 processor, which reduces the power usage and saves operation costs.

The decrease of thermal energy makes the computer a high safety and green product under a fanless condition.

The unit comes with a 12” touch panel LED backlight screen, which supports resolu-

tion up to 1024x768. Using the modular system-on-module design concept, the PC supports diversified performance levels such as COMe/ETX CPU modules and lower scalable baseboard. It also allows the user to group the boards according to individual needs.

The entire PC is water-proof, including front panel, rear data transmission connectors, and power sources.

Backplane Systems Technology 02 9457 6400 www.backplane.com.au

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

Flange pressure transmitter AUTOMATED Control Engineering and STS have released the ATM/F/ Ex flange pressure transmitter.

Manufactured from stainless steel, the pressure transmitter has a compact design and is designed for use in hazardous environments.

The transmitter features a piezoresistive measuring element and can be calibrated for use in most common pressure units.

The safety features include reverse polarity and short circuit protection, with an additional option for surge (lightning) protection according to EN 61000-4-5.

The flange pressure transmitter is suitable for use in hazardous areas.

The transmitter is capable of measuring pressure between ranges of 100mbar to 25bar to an accuracy of ≤ ± 0.50/ 0.25 /0.10 % FS. The operating temperature of the transmitter ranges from -25°C up to 85°C, while the process temperature can span -25°C up to 100°C The output signal produced by the pressure transmitter is 4 to 20mA, the company states.

Automated Control Engineering 02 4954 5004, www.aceg.com.au

Hearing protection communication system HONEYWELL Safety Products has introduced the Quietpro QP100Ex hearing protection and communication system.

The system is able perform a calibration to detect a suitable fit and adequate hearing protection for the user.

22 JULY 2012 Manufacturers’ Monthly

It alerts users prior to over exposure to excessive noise and includes volume control buttons which allow the user to adjust the level of the surrounding sound accordingly.

Honeywell Safety Products 1300 273 608, www.honeywellsafety.com

High speed non-contact laser displacement sensor MICRO-EPSILON’S new high-speed non-contact optoNCDT 2300 laser displacement sensor is now available from Bestech Australia.

The latest high precision model of laser sensor utilises the triangulated beam principle, and has a frequency response of up to 50kHz. The laser triangulation sensor can be set up to measure vibration of the target or its position, displacement, or in some instances thickness. It will be available in five full scale ranges from 2mm to 100mm.

The resolution of the sensor is from 0.1μm, and its non-linearity is from ±0.4μm.

To simplify installation and set-up, all the electronics are integrated in the compact (80mm x 75mm) housing.

A new development included in the sensor is the A-RTSC (Advanced Real Time Surface Compensation) technology. This feature, an enhancement of the manufacturer’s existing RTSC

The sensor has a frequency response of up to 50kHz.

technology enables the laser sensor to achieve the above specified precision and reliability.

The output signal also remains precise when the sensor is focussed on rough and irregular surfaced materials.

Bestech Australia 03 9540 5100, www. bestech.com.au

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Modular valve and block assembly system

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Mobile receipt printers The printers are equipped with a belt clip and optional belt loop or shoulder strap.

The block systems support media to 180°C, 16bar and 600mm2/s viscosity.

BÜRKERT has released a modular valve and block package designed to create block systems quickly and easily.

The modular solution features a stainless steel pneumatically actuated valve and standard block modules with eight standard port channels. Strainers, check valves, and sensors can also be included in block construction.

The block and valve system supports media to 180°C, 16 bar and 600 mm2/s viscosity, and has a chemical resistance for process media including water, alcohols, oils, fuels, hydraulic fluids, salt solutions, alkali solutions, organic solvents, steam, and air.

System configuration eliminates the use of elbows and t-adapters, and reduces connections to a minimum, to avoid leaks and deliver high overall system performance relative to traditional block solutions.

The system is suitable for manufactured blocks and any solution where high system capability and environmental integrity is necessary.

The externally piloted valves feature a compact design.

They are available with threaded, external threaded and welding connection ports.

Bürkert Fluid Control Systems 1300 888 868, www. Bürkert.com.au

INTERMEC has released the PR2 and PR3 model of mobile receipt printers for use in direct store delivery (DSD), field service, route accounting, mobile point of sale and electronic citation.

The printers can be used in conjunction with the company’s mobile computers, with shared charging, docking, accessories and remote management capabilities. They are compatible with the FlexDock system which, and according to the company, they offer a

new level of efficiency for docking and charging. The printers are equipped with a belt clip and optional belt loop or shoulder strap so they may be fastened to the body. Users are able to keep track of battery usage so they may be replaced before the battery runs out. Field-replaceable batteries can be charged independently of the printer, which is said to reduce battery replacement costs.

Intermec 02 9330 4400, www.intermec.com

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What’sNEW Positive-drive conveyor belting AMMERAAL has developed the Aeon-50 sprocket-driven positivedrive conveyor belting.

According to the manufacturers, the belting technology eliminates tracking and slippage problems.

It is fabric-free and simple to sanitise, making it suitable for the food manufacturing industry.

Made of 3mm Blue FDA approved, 95 Shore A polyurethane, the conveyor belting is high-cut, non-absorbent and abrasion resistant.

The belting is available in a smooth top surface or a diamond embossed form for easy release and low friction surface.

According to the company, the Aeon-50 is a hygienic, easyto-clean conveyor belting characterised by its high cut and abrasion resistance, and nonabsorbent aspects.

Ammeraal Conveyor Belting 03 9794 8870, www.ammeraal.com.au

Modular industrial patch panel MADISON Technologies has launched the new Belden modular industrial patch panel (MIPP), which combines copper and fibre management in the one solution.

Designed for industrial use, the MIPP aims to provide functionality and reliability in order to contribute to the uptime and availability of systems.

The unit offers a connection between cables and Ethernet switches.

According to the company, installation of the patch panel is quick and easy, saving time and reducing initial

The industrial patch panel combines copper and fibre management.

set-up costs. At the same time, the MIPP offers efficient system management that requires low maintenance.

Using patchcords to connect to active equipment, cables can be terminated outside the cabinet in an organised and structured manner to ensure the reliability levels are maintained. The small housing, high port density and modularity keep cabinet space to a minimum. The MIPP is suitable for use in machine building, transportation, alternative power generation, power transportation and distribution, and oil and gas markets.

Madison Technologies 1300 606 359, www.madisontech.com.au

Managed industrial Ethernet switches WEIDMULLER has released its IES series of industrial Ethernet switches to supersede its existing range. The new series is designed to handle the increasingly complex tasks of monitoring and controlling operational data.

With three ranges to choose from, the series offers a choice of Fast Ethernet or Gigabit Ethernet managed switches with various port combinations. Users can select from entry level IES21 Fast Ethernet, IES31 Fast

Ethernet with Gigabit Uplink, up to IES41 full Gigabit Ethernet switches.

The switches feature Ring redundancy with floating master, latest security features, IGMP snooping and a built in virtual cable tester. In addition, they meet all current Australian standards.

The switches are designed to withstand operating temperatures up to 85ºC as well as excessive vibration.

Weidmuller 1300 914 822, www.weidmuller.com.au

The managed Ethernet switches feature MSTP for additional redundancy

Solenoid Valves

Think Bürkert for „First“ Subhead

Solenoid valves are the most used fluidic control device.

Bürkert has been manufacturing solenoid valves for 60 years, and continues active R&D. Our track record of ‘firsts’ says it all: • Inventor of the now-ubiquitous Cable Plug • Creator of the first ‘industrial’ solenoid valve • Designer of the original encapsulated solenoid coil • Patentee of the ‘Twin-Power’ design to reduce power consumption by 75% Make Bürkert your first call for solenoid valves.

Head Copy

Tel 1300 888 868 www.burkert.com.au 24 JULY 2012 Manufacturers’ Monthly

Reliable & robust Complete range & spares Competitive & bulk rates manmonthly.com.au

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High-speed data transfer module The hydraulic hose has a small bend radius, and a small outside diameter.

The interface module is designed for high speed remote data gathering

ENZED has introduced a compact high-pressure spiral hose, which has a bend radius 50% smaller than its conventional equivalent.

Manufactured to ISO 18752-DC specifications, the parent company, Parker Hannifin, claims that its Compact Spiral Hose in 5000psi and 6000psi specifications is a world-first.

The hose is designed to allow simple installation.

It is also lightweight and compact in size. With half the bend radius of its SAE spiral hose equivalent, the company says the spiral hose can reduce the length required from 20 to 55%.

The hose also has a small outside diameter, which results in less physical effort in bending and routing.

Parker Hannifin (Australia) 02 6055 7100, www.enzed.com.au

Anti-slip angle plates BRONSON Safety has introduced a new range of carborundum-modified angle plates to provide protection against slips in the workplace.

The angle plates are suitable for applications such as the rungs of ladders or other applications where stair

nosing is not practical. They come in a range of sizes and profiles, and in yellow, black and grey finishes. The plates are UV-stabilised and epoxy-coated to withstand harsh conditions.

Bronson Safety 1300 359 545, www.bronsonsafety.com.au

GE Intelligent Platforms has released the new SPR507B, four channel serial FPDP interface PMC/XMC module.

It offers a total bandwidth of up to 1.4GB per second and features Xilinx Virtex-6 FPGA for high speed serial data transfers.

The interface module is available in either a PMC module for legacy systems or as an XMC module.

It is designed to be more easily deployed in confined spaces, where cooling can be a challenge and where the environment is subject to extremes of heat, shock and vibration.

The low Latency protocol used in serial FPDP and the noise immunity of the fibre-based data transport is the ideal combination for applications

which require a dedicated data link to run between sources of data to a remote processing station.

The interface module allows for fibre lengths up to 10km with the choice of single mode fibre.

In addition, it delivers a transfer rate of around 30% and includes 1GB of high speed on-board storage in FIFO configuration.

The architecture of the module allows for each fibre link to be configured independently, providing for multiple baud rates to be simultaneously supported. Each link can operate in either direction.

The SPR507B is said to minimise long term cost of ownership.

Metromatics 1300 589 932, www.metromatics.com.au

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What’sNEW New series frequency inverter with variable control modes The frequency inverter offers up to 160kW of nominal power.

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.

SEW-Eurodrive has launched the Movitrac LTP B frequency inverter.

The new series offers variable control modes of various motors types.

The inverters are available with a high degree of protection enclosure throughout the power range.

The series has been designed for universal use offering a high level of motor control of both induction and permanent-magnet synchronous motors (with or without encoder feedback). A wide range of control options including an ‘energy saving function’ makes the series an optimum drive solution in terms of efficiency and energy consumption, according to the company.

A range of I/O and communication interfaces ensure quick and efficient integration into a variety of control systems. An intuitive parameter structure with standard factory settings

and an integrated key pad shortens the commissioning process.

The frequency inverter is available in six frame sizes from 0.75 kW to 160 kW for a supply voltage of 230 V or 400 V. The inverter is comes in two housing variants, IP20 for cabinet mounting and IP55 field mounting, suitable for operation in challenging ambient conditions.

The unit is fitted with a dedicated ‘Safe Torque Off’ binary input which immediately disables the drive in Emergency conditions.

Delivering up to 200% torque from zero speed, the inverter is recommended for applications with inherent high starting torque characteristics, such as conveyors, crushers, winders and mixers.

SEW-Eurodrive 1300 331 968, www.sew-eurodrive.com.au

SET TING THE WITH STANDARDS AFE INNOVATIVE S TIONS STORAGE SOLU EF CTIV EFFECTIVE EFFECT IVE COMPLIANCE COMPLIA ANCE FOR F THE MANUFACTURING INDUST TRY INDUSTRY

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.

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

26 JULY 2012 Manufacturers’ Monthly

• • • • • • •

Relocatable bulk stores Safety cabinets Gas cylinder stores Lube stations Bunding Safety showers Custom design to suit your situation

DESIGNED AND MANUFACTURED IN AUSTRALIA

protecting the

1300 134 223 1300 307 895 sales@storemasta.com.au www.storemasta.com.au manmonthly.com.au

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:K\ The energy chain is resistant to dirt, heat and humidity.

70+ years experience

Swarf resistant energy chain TREOTHAM has released a new 42mm design size of the Igus RX plastic energy chain.

The company claims the energy tube is almost 100% airtight, after 2.7g chips were tested over 251,900 cycles.

The product was also tested underwater to comply with the absolute airtight requirement, IP40.

The 42mm size is available with the addition of a high temperature variant

that is said to be resistant to swarf up to 850°C, and a reverse bending radius (RBR) variant.

The curved, edgeless design enables chips of varying sizes to glide off while the connection elements and fittings are concealed to prevent contact with any swarf.

The energy chain can be easily swung open in the outer radius.

Treotham 1300 615 110, www.igus.com.au

Shouldered-to-HDPE transition coupling VICTAULIC has launched the Style SC998 Shouldered-to-HDPE transition coupling.

The new couple provides a onepiece, mechanical joint between shouldered IPS and HDPE piping and helps reduce installation time.

The manufacturers claim the new product provides an economical and efficient way to join plain end HDPE pipes to shouldered IPS pipes, valves and fittings.

While the shouldered end of the coupling utilises the design of the company’s existing range of shouldered couplings, the HDPE end of the housing features rows of gripping teeth which bite down on the plain end pipe, resulting in a firm connection around the circumference of the pipe.

The coupling is recommended for use in situations where speed is

LV EHWWHU IRU 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 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 The coupling simplifies transitions with one mechanical joint.

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

essential, such as in ground water and air equipment hook ups.

Available in 63mm and 110mm, the coupling is intended for piping with standard dimension ratios ranging from 21 to 7.4. It conforms to AS/NZS 4130 and PE 80 or 100.

Victaulic 1300 742 842, www.victaulic.com

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tbeck@uretek.com.au www.uretek.com.au

Manufacturers’ Monthly JULY 2012 27

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What’sNEW Multipoint calibration viscometer SHEEN Instruments has developed a new viscometer for measuring Newtonian and non-Newtonian fluids. The Digital Krebs Viscometer measures viscosity at a set speed shear rate.

During measurement, a paddle is immersed in a vessel containing a fixed volume of the sample material.

A constant speed motor drives the paddle at 200rpm.

The torque induced is proportional to the viscosity of the sample and may be converted into viscosity or weight units.

The dimensions of the paddle conform to the specification of ASTM D562.

The instrument displays Krebs units, grams or poise. It has a magnetic base for positive sample location, and multipoint calibration across torque range.

The viscometer can store up to nine measurements and has an RS 232 output for printing.

Novasys Group 03 9752 3766, www.novasys.com.au

28 JULY 2012 Manufacturers’ Monthly

Turnkey systems for the chemical industry BEUMER Group has developed the Paletpac high-capacity layer palletiser.

This flexible unit stacks Polyethylene (PE) and Polypropylene (PP) bags, layer-by-layer, on pallets of all common sizes up to a stack height of 2.4m with geometrical accuracy and stability. The user can set the parameters depending on the objects to be stacked.

The palletiser is fitted with a clamptype turning device or double belt turning device which moves the filled bags quickly and gently into the required position. Even bags filled with granulate can be palletised in a gentle and dimensionally stable manner.

For particularly demanding product handling tasks, such as bags filled with PE granulates which have a par-

The palletiser stacks stock layer-by-layer up to a height of 2.4m.

ticular flow behavior or bags which are subjected to high temperatures and high humidity, the manufacturers

have chosen ventilated and specially coated layer stacking table in the palletising process.

The ventilation produces a cushion of air between bag and layer stacking table. This prevents bags sticking to the supporting surface and enables them to be palletised stably.

The stretch hood medium highcapacity packaging machine is distinguished by high throughput and reliable film handling. The low energy consumption, low compressed air requirement and the ability to process recyclable packaging film make the machine an efficient and environmentally friendly pallet-packaging option.

Beumer Group Australia 02 9450 0380 www.beumergroup.com

Servo drives for precision motion control METRONIX’S new range of servo drives offer a high peak current capability allowing machine builders to boost acceleration times.

An increased overcurrent capability of four times the continuous output

rating is being offered as standard on the company’s ARS 2000 FS range of Ethernet-compatible servo drives. The capability can be exploited in many common motion control applications to increase the speed of moves and the

overall throughput of machines. The drives can sustain the overcurrent for half a second, providing considerable flexibility for the system builder.

Metronix (Apex Tool Group) 02 6058 0300, www.apextoolgroup.com

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Multi-head thermal printer

Respirator systems

Multiple print-heads allow for greater printing speeds.

ALLEN Coding Systems has released its latest multi-head thermal printer, the TP 4000.

The printer is available with 52mm or 106mm print-heads and offers operating speeds of up to 600 units per minute.

The printerâ&#x20AC;&#x2122;s multiple print-heads allow for greater speeds and its automatic code sensors reduce the chance of operator errors.

The thermal printer can print high resolution images with no hot stamp characters to get lost or damaged. It can also print barcodes, 2D codes and logos. The ink prints dry straight away.

The single modular unit can be integrated on to all types of intermittent-

PM

motion packaging equipment, including horizontal form fill and seal, overwrapping, bagging, thermoforming and blister pack lines.

The thermal printer is a versatile way of printing variable information onto multi-lane intermittent packaging machine films.

Other features include: programmable ribbon; self-contained programming handset for fast editing and creation of print designs; non-tamper automatic code change option for elimination of operator error; and optional PCMCIA card for data transfer and memory extension.

3M has released its series of Versaflo Respirator Systems, designed to protect workers operating in a range of hazardous environments for long periods of time.

The product range has three modules: an air delivery unit, a headtop and a breathing tube that can be combined into different configurations to deal with changing environments, hazards and comfort preferences.

The S-Series Headcovers and Hoods can be worn by more users due to new sizing and adjustment options.

The M-Series Faceshields and Helmets are lightweight, compact and provide integrated protection from multiple hazards.

The TR-300 Powered Air Respirator is a slimline air delivery unit for environments with particulate hazards.

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

Result Packaging 03 9706 4474, www.resultpackaging.com.au

The respirators protect workers in hazardous operating environments.

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What’sNEW Look Out Collision awareness sensors MATERIALS Handling has introduced the Look Out Collision Awareness Sensors, the new safety partner in racking, halls, doors loading docks aisles and overhead doors.

To lessen the change of injury due to collision in dangerous intersections, on corners, and with objects in the workers’ blind spots, the company offers a versatile line of rack mounted and ceiling suspended safety sensors.

These sensors will alert pedestrians, forklift operators or other mobile machinery operators that someone or something is approaching around the corner to prevent a collision.

The products are designed to prevent accidents and potential costly situations in the warehouse, yard or office.

The sensors are quiet, yet also easy to see, understand and respond to.

When the sensors detect movement in blind spots around a corner or a doorway, they begin to flash a warning to the pedestrian or machine operator who is approaching that intersection.

In addition, sensors will signal the blind spot as to movement from the other side.

Materials Handling 1300 650 035, www.materialshandling.com.au

30 JULY 2012 Manufacturers’ Monthly

Pallet load gates for controlled access for loading BOWEN Group’s Mezzanine Gates are designed to eliminate the risk of fall by providing safe and controlled access while loading palletised items onto elevated mezzanine areas, using a forklift or other lifting device.

The gate protects the fall edge during mezzanine loading operations ensuring the safety of personnel when working on raised storage areas in warehouses.

The pallet safety gates provide a double barrier for optimum safety.

They are high-strength, yet lightweight designed to ensure ease of operation.

The gates are manufactured from high grade structural aluminium forreliability and durability.

A modular, kit form assembly allows for rapid and simple installation.

The gates are supplied with gas struts for ease of use.

They feature a powder coated in a Safety Yellow finish for optimum visibility.

The gates are designed and manufactured to comply with AS1657 and relevant WHS Codes of Practice/ Guidelines.

According to Bowen, the gates are designed to provide high level of safety for personnel in specific danger area.

The company supplies a range of mezzanine pallet safety gates for loading onto elevated areas.

Bowen 03 9721 5600, www.bowengroup.com.au

The gates provide protection for workers loading palletised items onto mezzanine areas.

manmonthly.com.au

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Body harnesses for fall protection

Level switches

CAPITAL Safety Australia has released its new DELTA II Fall Protection Full Body Harness Range, the next generation harness in the popular Delta style.

The new range includes enhanced features typically only available on the company’s premium models.

It incorporates the patented No-Tangle design, stand-up spring loaded dorsal D-ring, velcro-covered label pack that protects the new permanent indented print labels.

The harnesses include quick connect buckles for fast and efficient donning, and REPEL technology webbing that provides superior abrasion resistance, repels liquids and is naturally self-cleaning. A rip-stitch impact indicator allows the user to quickly and

TRIMOD Besta has introduced a range of level switches suitable for extreme process applications.

The harnesses feature a stand-up spring loaded dorsal D-ring.

easily inspect the harness and identify if it has been involved in a fall.

Easy grip end tabs make for hasslefree adjustments. Each harness is

packed in a bonus reusable harness storage duffle bag.

Capital Safety 1800 245 002, www.deltaII.capitalsafety.com.au

Circuit breakers with high cut-out protection PHOENIX Contact has released a new range of electronic and thermomagnetic circuit breakers designed to protect devices from surges and short circuits.

The one-channel, pluggable circuit breakers enable modular designs for selective power distribution.

Coding between the base element

and the plug is said to ensure errorfree placing. The connector’s catch mechanism holds the circuit breakers securely in place even in harsh installation environments. The push-in connection terminals make it possible to connect wires without any tools, while the bridge system means all circuit

breakers can be readily combined according to individual needs.

The electronic circuit breakers work with active current limitation. This delays immediate cut-outs due to temporary power surges.

Phoenix Contact 1300 786 411, www.phoenixcontact.com.au

A key feature of the new level switches is its three-module design concept comprising the switch module, the flange and the float.

Switch modules are available with electric, electronic or pneumatic output signals.

The switches are shock and vibration resistant. High and low temperature and explosion proof versions are available.

Standard housings offer IP65 ingress protection but IP67 and IP68 options are available for use in extreme environmental conditions.

To simplify installation, the switches have a hinged cover, captive screws and the self-lifting terminal clamps. For convenience of wiring, the connection diagram is shown on the inside of the hinged lid.

A range of floats, made of stainless steel, Hastelloy C or high quality plastics, are available to suit various densities and pressure ranges.

Control Components 02 9542 8977, www.controlcomponents.com.au

EtherNet/IP ENABLING HIGH-SPEED SYNCHRONISED MOTION CONTROL ON STANDARD, UNMODIFIED ETHERNET. Coordinate multiple axes for precise motion control and synchronise servo drives with variable frequency drives - all on a standard, unmodified Ethernet network. EtherNet/IP helps to deliver an open, high performance solution for multi-axis, distributed motion and drive control. 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/MMM

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Manufacturers’ Monthly JULY 2012 31

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Metalworking& MACHINE TOOLS

Volume production is a thing of the past; now it’s about quick turn-around, small-run quantities.

Surviving troubled waters With the rise of low-cost economies and their continued improvements in quality and lead time, Australian sheetmetal manufacturers are forced to rethink and modernise in order to survive. Annie Dang writes.

I

T goes without saying that the uncertainty in the local economy, brought about by the woes of European economies, the unknown impact of the carbon tax, a high Australian dollar, and China’s continuing climb to manufacturing superpower is creating rough waters for the local sheetmetal industry.

Andrew Macquart, president of the Sheetmetal Industry Association, says a combination of economic pressures as well as the dominance of Asia’s manufacturing industry has seen the local sheetmetal industry shift its focus to smaller volume production that yields faster lead times.

“Australia’s sheetmetal industry is becoming one of quick turn-around, small-run quantities. Traditional large volume producers are continuing to move offshore for lower cost production to countries, such as China where quality is improving and supply is becoming 32 JULY 2012 Manufacturers’ Monthly

more reliable,” Macquart told Manufacturers’ Monthly.

According to Macquart, Asia’s strong manufacturing sector has a bigger effect on manufacturers who produce their own products in large volumes, such as Rheem or Sunbeam, or companies who make domestic commercial products in volume.

However as most local sheetmetal manufacturers are in the business of manufacturing smaller volume, on demand products for other industries; its production is harder to be offshored. But it has not stopped companies from trying, and most often unsuccessfully.

Macquart, who is also MD of Alumac Industries, a small Sydney-based sheetmetal fabrication company, says that while lower-cost economies provide an attractive landscape for companies to off-shore the manufacture of products that don’t require technical know-how to make, the draw backs are often longer lead times and lower quality products.

Navigating the way One company successfully riding the waves is sheetmetal manufacturing contractor Advance Metal Products, based in Sydney’s south west.

Over the past 10 years the company has made considerable investments to diversify it business including the addition of a product manufacturing arm making industrial and office storage equipment, plus an in-house design team to meet customer demand for cost-effective manufacturer of goods.

The company’s MD, Ian Stone, says the company can now produce or customise in low volumes or on short notice, and with very short lead times.

“It means we can supply more cost-effectively because we can design a product and supply it within two to four weeks, which is the same as shipping time from Asian countries,” Stone told Manufacturers’ Monthly.

He admits the company has experienced difficult trading for

a long period, but these changes have helped to improve business, so much so that he is confident to start investing in some major capital equipment. However, he is quick to mention that the whole process is not all rosy.

“When you loose major contracts to China, what are you going to do? You’re certainly going to restructure, downsize and change your way of thinking.

It’s what we had to do,” he said.

Stone says that it has been “a long slow climb back to prosperity” and that is the way it is likely to continue for the next five to 10 years in light of the way the economic outlook is for manufacturing in Australia, and also globally.

“I think a common theme for many sheetmetal manufacturers is that we have to contend with imports from low cost-economies, particularly China.

“We have to navigate our way through this as manufacturers and the best way to do this is to become more flexible. We have to rely more on design and be able to customise and be very flexible with our lead times.

“We also have to work internally because there are a lot of things we can’t control outside our business, but there are many things we can control inside the business, and that includes learning to become more lean, establish good training programs, and focusing on better ways to do things within the organisation.”

Stone says asking suppliers for cheaper prices can only take you so far, but working to improve business practices can lead to greater efficiency.

He suggests looking into tradeshows, building an online strategy and developing good promotional materials as some things other sheetmetal manufacturers can do as part of their “internal” focus to promote their business.

Another key factor to consider is to implement practices that will make your business more unique as well as flexible, he says.

Sheetmetal Industry Association 02 9525 2177, www.sheetmetalaustralia.com.au Advanced Metal Products 02 8796 6222, www.advancemetal.com.au manmonthly.com.au

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Servicing the Manufacturing Industry for over 30 years Hydraulic and Industrial hose and fittings 92 Service and Supply Centres Australia wide National fleet of 320+ fully stocked mobile service workshops Rapid response time, 24 hours 7 days All Service and Supply Centres ISO9001:2008 accredited NATA certified hose testing facility Registered training organisation Nationally accredited and certified technicians National pricing policy

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Metalworking & MACHINE TOOLS Arc projectors demonstrate the welding effect BOC has introduced the GMA and TIG arc projector – a state of the art training and demonstration tool which displays the significant difference shielding gases can make to various welds – designed to help manufacturers optimise results and cut costs, to the Australian market.

The projector can be used to highlight the effect on the welding arc when different gases are used. It also provides an interactive display, which allows the customer/trainee to control the shielding gas used and see the impact on the arc type (GMA), travel speed and surface appearance, thus helping them determine the welding gas to use.

By projecting the welding arc on to a screen, the projectors enable large-scale training and demonstrations to larger audiences. According to the company, the projector improves product transparency and makes selecting the right product easier, resulting in significant improvements in efficiencies, productivity and quality for end-users.

Choosing the right shielding gas can reportedly result in savings of more than $3 per metre of weld by keeping traditional cost drivers such as labour and welding wire lower, depending upon the specific application, and can deliver improvements in surface appearance, welding speed, metallurgy and mechanical properties, weld geometry, arc stability, metal transfer and shielding effect.

BOC 131 262, www.boc.com.au

Delivering high processing powers JK LASERS has launched a 2kW fiber laser – the JK2000FL – a viable and cost-effective alternative to traditional CO2 and Nd:YAG laser sources.

Offering excellent beam quality and high processing powers, the fiber laser can be used with different diameter processing fibers from 100μm to 300μm, for cutting and welding sheet metal.

The laser can cut 15mm thick low carbon steel (LCS), 6mm aluminium alloys and 10mm stainless steel (304SS). It can also weld 8mm LCS and 304SS. Accelerating throughput without compromising quality, the company says the laser is ideal for automotive applications such as tailored blank welding, component welding, remote welding and hydroformed tube cutting.

In the aerospace industry, it can be used for titanium welding of aircraft skins and structures, as well as laser cladding.

The laser delivers a stable output power from switch on, as well as a consistent focused spot

The laser is fitted with detachable plug in, pre-aligned (PIPA) beam delivery fibers.

size and beam profile over the complete power range.

Raymax Lasers 02 9979 7646, www.raymax.com.au

Compact welders KEMPPI has launched its new range of compact MIG/MAG welders for the modern mechanic and smash repair workshop.

The new series of welders is built using the company’s latest power source platform.

Available with 180, 250 and 320 A power sources, users can choose from seven models and from either a Regular (R) or Adaptive (A) control panel interface.

The company claims the new technology can reduce energy costs by more than 10% when compared to conventional step controlled power sources.

The welders feature Brights cabinet lighting for easy wire loading in low light conditions, a WireLine service alert function that signals routine wirepath maintenance needs, plus the integrated GasMate chassis design, which makes gas cylin-

der loading and machine movement easy and safe.

The compact welding units are designed with one thing in mind – the user. From the convenient waist-height LCD control panel and simple parameter control, to the improved chassis design, parts tray and LED cabinet lighting, the welders are designed to deliver an easy, accurate and effective welding experience.

Kemppi 1300 465 374, www.kemppi.com

Durable grade option for insert drills SECO Tools has developed a new grade option for its Performax range of insert drills.

The DP3000 grade option is an extension of the DP2000 grade, both of which feature the company’s Duratomic coating technology. This technology is able to produce a hard structure due to the particular arrangement of aluminium and oxygen atoms.

34 JULY 2012 Manufacturers’ Monthly

The toughness of the new grade options come from the gradient design of the substrate on which the coating is applied.

Specifically, the cobalt content is enriched at the surface and reaches a depth of 20 to 25 microns.

The substrate also contains a layer of titanium carbon nitride and another of aluminium oxide.

The new insert grade range includes two physical vapour

deposition (PVD)-coated grades: T250D—suitable for stainless steels and super alloys; and T400D, designed for use on centre inserts in a range of materials.

According to the manufacturers, the drill body has internal coolant channels and optimised flute design, which allows for reliable chip evacuation.

The new grade option features an abrasion-resistant coating.

Seco Tools 1300 557 326, www.secotools.com/au manmonthly.com.au

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Metalworking & MACHINE TOOLS Cutting inverters

Powerful air plasma system HYPERTHERM has launched the Powermax105, a new 105amp air plasma system for hand and automated cutting and gouging designed to cut 32mm thick metal, and sever metal up to 50mm thick.

Based on the same technology platform as the Powermax65 and Powermax85, the Powermax105 has been designed to deliver faster cut speed, improved cut quality, and industry leading consumable life for better performance and a lower operating cost.

It comes with seven different torch options for cutting and gouging versatility, whether done by hand, machine, or robot, and is reportedly easy-to-operate with its simple controls and patented SmartSense technology that automatically adjusts gas pressure for better, more efficient cutting.

The technology also detects when consumables have reached

The system delivers better performance at a lower operating cost for industry.

end-of-life. According to the company, this system is the most versatile in its class and is able to meet demanding metal

cutting and gouging tasks for industrial applications.

Westgate Hi-Tech Machinery 03 9391 1133, www.westgatehitech.com.au

ALL Purpose Abrasives has released the Cutmaster 40mm plasma cutting inverters.

The cutting inverters are specifically designed for high endurance and maximum cutting performance with materials up to 40mm thick. According to the manufacturers, the inverter systems offer a duty cycle of 80% in a 40ºC ambient environment.

With a cutting speed of 250mm/min, the plasma cutting inverters are designed for heavyduty fabrication, construction and mining applications. They can also be used for heavy-duty gouging, piercing and bevelling applications when fitted with the correct torch consumables.

Equipped with a SL100 1Torch, the cutting inverters operate from a 415V three phase supply.

They feature auto-pilot re-start and a “True Guard” roll bar. The units are portable to allow for simple manoeuvrability.

All Purpose Abrasives 02 4628 2800, www.allpurposeabrasives.com.au

Stronger, tougher thread mills for hardened materials SECO has added new thread mills to its Threadmaster family.

The new products include solutions for hardened materials up to 60 HR, materials with tensile strength over 900 N/mm², small holes and complete drilling, chamfering and thread milling in a single operation.

The Drilling Threadmaster (DTM) features a unique design that drills, chamfers and mills a threaded hole in one opera-

tion. Available for applications in cast iron and aluminium, this new tool mills threads using helical interpolation; it also drills and automatically chamfers the entry point when the tool reaches the bottom of the hole.

The Threadmaster Mini provides thread milling for small holes in hard materials, common

in applications ranging from dental implants to aerospace components. Provided for thread dimensions from M1 x 0.25 to M2.5 x 0.45, this thread mill is suited for materials with hardness between 45 HR and 60 HR. The Threadmaster-900 is suited for materials with tensile strength over 900 N/mm², and is available in M4 to M16.

The new mills are suitable for hardened materials up to 60 HR.

Seco Tools Australia 1300 557 326, www.secotools.com

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36 JULY 2012 Manufacturers’ Monthly

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Light fabrication welding machine CIGWELD has introduced its WeldSkill 200AC/DC single phase welding inverter â&#x20AC;&#x201C; a digital controlled unit which is capable of performing AC/DC Lift TIG, HF TIG (GTAW) and Stick (MMAW).

It comes as a complete kit said to be ideal for the light fabrication and maintenance of mild steels, stainless steels and aluminum.

The unit features high frequency (HF) start, lift TIG start, up/down slope, pulse, 2T/4T trigger function and gas purge for AC or DC TIG welding, and is compliant to Australian Standards AS 60974.1-2006 and AS 1674.

The unit is digitally controlled.

Optional acccessories include TIG torch 26FV with remote current control (4m lead), and TIG torch accessory kit.

CIGWELD 1300 654 674, www.cigweld.com.au

Hydraulic hole puncher STAINELEC has introduced the Edilgrappa PB-500 hydraulic hole puncher, a precision made cordless puncher that can punch through 6mm stainless steel, 12mm mild steel and 12mm thick

copper plate. Available in cordless and electric models, units are equipped with adjustable support and stripping plates.

Stainelec Hydraulic Equipment 02 9824 2499, www.stainlec.com.au

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Manufacturersâ&#x20AC;&#x2122; Monthly JULY 2012 37

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Compressors& PNEUMATICS Lowering compressed air costs Air compressors can be costly to run, but knowing your system requirements is the first step to reducing unnecessary expenditure. Sarah Falson reports.

W

ITH the carbon tax now claiming a percentage of profits, and power bills increasing by the month, manufacturers need to think seriously about techniques to protect their bottom line.

Air compressors are identified as one area where savings can be made, however simply turning off a piece of manufacturing equipment when production runs around the clock is often not an option.

David Irwin from Atlas Copco Compressors says when lowering the cost of running an air compressor it is all about reducing unnecessary load on the equipment.

“The lower the pressure, the less it costs to produce the compressed air, so reducing pressure losses helps reduce costas. For every 1 bar pressure loss you use 7% more energy,” Irwin told Manufacturers’ Monthly.

He says manufacturers would do well to invest in a compressor that has been designed with efficiency in mind, claiming new technology can help save up to 30% of the energy currently used by air compressors.

However he admits it is a twoedged sword. “Customers need to spend money to save money in the long term, and this is not always easy to justify,” Irwin said.

He explains that pressure loss starts at the compressor and the efficiency of the design so that the compressed air can get from the element to the outlet with as minimal pressure loss as possible.

“Integrating dryers and line filters also significantly helps in this regard, but the dryer and filters must be truly integrated into the design of the compressor, and not just bolted on to the compressor outlet,” said Irwin.

Mark Dudman from Kaeser Compressors Australia says 38 JULY 2012 Manufacturers’ Monthly

Air audits can be negotiated as part of a customer’s service contract.

using the wrong sort of compressor for an application; a ‘leak’ in the system’s pipes, connectors and valves; and the design of the compressor itself can all cause pressure loss.

“Using multiple compressors into too small a size header, too many filters, undersized pipe reticulation, and incorrect reticulation materials – for example using a rubber hose instead of compressed air pipework – can all mean pressure losses of more than 1 bar,” he said.

“The costs are not only in power consumption but also in servicing the compressors and ancillaries.

“If the compressor is running excessive hours just to support system leaks then that adds cost for no purpose,” Dudman told Manufacturers’ Monthly.

He explains that many compressors now offer built-in

controllers, which help to reduce power consumption by continually monitoring an air system’s requirements.

“Easy-to-use control systems are capable of upholding compressor operation and air delivery cutting in or out according to the air demand, without compromising efficiency,” said Dudman.

Help at hand One way to reduce break-downs, downtime and energy bills is to pay for a professional to conduct an ‘air audit’ on the compressor system to identify problem areas and advise where cost savings can be made.

Audit prices range from hundreds to thousands of dollars depending on the requirements of the site, and manufacturers can either appoint a third party to perform the service or purchase equipment from a sup-

plier that factors the cost of audits into a customer’s service contract.

Irwin says manufacturers should make sure that the company performing the air audit provides a detailed report on the expected cost savings related to fixing any problems in the system.

“Measuring the air consumption is only a start; the real trick is to be able to accurately simulate energy efficiency gains against alternate energy saving equipment,” he said.

“A well set up air system will have strategically placed isolation valves so that the affected area can be shut down and rectified without causing disruption. Some customers carry out rectification work in a down time period like a weekend,” Irwin said.

Mark Ferguson from Southern Cross Compressors points out that air compressors have historically been large, cumbersome and inefficient pieces of equipment.

“Which was fine when electricity cost 1 cent a KW/h.

But with electricity costs now around 15-25 cents per KW/h and expected to increase about 15% year-on-year, a regular air audit is highly recommended,” Ferguson said.

However, he admits it is sometimes difficult for manufacturers to know who to go to.

“There are currently no official standards in Australia for conducting air audits and manufacturers should be careful to select a reputable company to conduct them,” he said.

Atlas Copco Compressors Australia 02 9621 9999, www.atlascopco.com.au Kaeser Compressors Australia 03 9791 5999, www.kaeser.com.au Southern Cross Compressors Australia 1300 098 901, www.sccompressors.com.au manmonthly.com.au

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Compressors & PNEUMATICS Safety air guns with chip shields COMPRESSED Air Australia has released a range of Exair safety air guns for blowoff, drying or cleaning needs.

The safety air guns are available with durable polycarbonate chip shields designed to protect workers and help businesses comply with OHSA safety standards.

The company claims that the chip shields will protect workers from flying debris which is often associated with blowing chips off machined parts. They are also suitable for keeping coolant

from splashing during drying operations.

The safety air guns use engineered air nozzles which are designed to maximise room air while minimising compressed air consumption.

There are three safety air gun models available for varying applications â&#x20AC;&#x201C; lightweight precision safety air gun, rugged heavy duty and soft grip safety air guns.

Chip shields can be used on safety air guns with or without an extension pipe

avoiding compressor idling time.

The fixed speed variant GA 30+-75+ with IE3/NEMA motor, offers efficiency and Free Air Delivery (FAD). The FAD base GA 37-90 completes the range.

Other advantages of VSD technology include: no idling times or blow-off losses, inte-

KAESERâ&#x20AC;&#x2122;s new fluid-cooled CSD and CSDX rotary screw compressors offers a motor power range of 45 kW to 90 kW.

grated compressor controls and a start-up under system pressure.

According to the company, the canopy layout is designed to reduce temperatures at the element by 10°C.

The five models of both ranges cover free air deliveries from 8.3 to 16.1 mÂł/min (at 8.5 bar) and are designed for pressures up to 15 bar.

The CSD and CSDX units feature a large, low speed Sigma Profile airend equipped with flow-optimised rotors.

The rotary screw airends are powered by IE3 drive motors for maximum performance and reliability.

These motors will become obligatory in the EU from 01.01.2015.

The 1:1 efficient drive design eliminates the transmission losses associated with gear or V-belt driven systems, as the motor directly drives the airend.

CSD and CSDX compressors are also available as variable speed controlled versions.

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

KAESER 1800 670 770, www.kaeser.com.au

Compressed Air Australia 1300 448 246, www.caasafety.com.au

Oil-injected screw compressors ATLAS Copco has launched its new oil-injected screw compressor GA range from 30 to 90 kW. There are three value offers in the GA 30+ to 90 (VSD) range.

The integrated Variable Speed Drive motor of the GA 37-90 VSD, delivers on average 35% energy savings, while

Rotary screw compressors

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Pneumatics and Automation solutions

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Automation& ROBOTICS operators can receive relevant information automatically that describes what the system’s environment looked like when the alarm was triggered.

With associated tags, you get all pertinent information in one transaction which saves time and effort because it eliminates the need to run multiple reports and correlate the data in separate databases.

Alarm commands

Alarms and events are vital; poorly managed they can be disasters waiting to happen.

Missed opportunities with HMI alarms and events Discovering hidden but powerful features of human-machine interface (HMI) software can help users save time and ease troubleshooting. Tony Carrara* writes.

R

ECENT advancements in technology allow new HMI software applications to be configured to execute a command when the user double-clicks on the alarm in the alarm summary.

Interacting with alarms is one of the basic functions your operators expect from their human-machine interface (HMI)

software. However, if you’re only using the standard alarming functions, your operators might be missing out on lesser-known features that could help you save time and ease troubleshooting.

Associated tags In an HMI system, it’s useful to have additional system information associated with an alarm for

streamlined reporting and more effective alarm handling.

An alarm can be associated with up to four tags that are recorded in the alarm history log and also embedded in the alarm messages visible in an alarm summary or banner.

By associating tags to include process data with event information and alarm messages,

Addressing the cause of an alarm in a time-efficient manner is a top priority for operators.

However, an HMI system that correctly identifies alarm conditions does no good if the operator still has to click through multiple screens and open new programs to access the controls needed to correct the problem.

Recent advancements allow new HMI software applications to be configured to execute a command when the user doubleclicks on the alarm in the alarm summary. For instance, an operator can double-click an active alarm and have the appropriate screen displayed for them to take corrective action.

This is especially effective in a large HMI system where the operator must have access to a process screen or device faceplate to understand the area of concern before taking action.

Preconfigured alarms HMI software should be tightly integrated with plant-floor controls and enable users to capture continued on page 43

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42 JULY 2012 Manufacturers’ Monthly

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Replacing old robots with new

By John Allen

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continued from page 42 additional data beyond alarm and event information.

Collecting data related to environmental factors, such as problems with controllers and other equipment, can help operators better understand what is happening in the system.

Newer HMI applications incorporate preconfigured control-sta-

manmonthly.com.au

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IULHQGO\ DQG SRZHUIXO 7KH FRPSDQ\œV 4XDQWHF DQG .5& DUH ERWK GHVLJQHG WR VDYH XS WR ZRUWK RI HQHUJ\ ³7KH\ DUH GHVLJQHG WR SRZHU GRZQ GXULQJ GRZQWLPH DQG XVH D XQLTXH 352),HQHUJ\ SURILOH ´ VKH VDLG 7KH &OHDQ 7HFKQRORJ\ ,QYHVWPHQW SURJUDP LV D FRPSHWLWLYH PHULW EDVHG JUDQWV SURJUDP ZKLFK VXSSRUWV $XVWUDOLDQ PDQXIDFWXUHUV WR PDLQWDLQ FRPSHWLWLYHQHVV LQ D FDUERQ FRQ VWUDLQHG HFRQRP\ Headland 1300 592 061, www.headland.com.au

Energy saving robots designed to power down during downtime.

tus alarms that indicate when an issue with a controller or its connection arises. In addition, operators should be able to run reports showing in-depth detail regarding the conditions of the alarm.

Effectively organising alarms in an alarm summary or report can be simple when using alarm classes in some applications.

The alarm class is a text string of up to 40 characters that operators enter when configuring an alarm. At run time, the value of the alarm class is recorded in the alarm history log, and the content is filtered based on the

value of the alarm class. This enables you to easily sort or filter your alarms by function including, whether for valves that fail to open or close, pressure, temperature, equipment running or tank levels. *Tony Carrara is Rockwell Automationâ&#x20AC;&#x2122;s FactoryTalk View SE Product Manager 03 9757 1111, www.rockwellautomation.com.au

Alarm classes When viewing many different alarms, it can be a time-consuming task to group like alarms together.

Manufacturersâ&#x20AC;&#x2122; Monthly JULY 2012 43

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MaterialsHANDLING

The new UU-Beam is made from two U-beam sections, and is said to increase frontal impact resistance by over 200%.

Countdown goes to the top with its revamped DC A 11.925m high top beam level, the highest in NZ, resulted in an additional 3000 pallet storage locations. Carole McCormick writes.

A

S part of its ongoing supply chain enhancement program, NZ grocery retailer Countdown recently commenced operations at its newly refurbished distribution centre (DC) at Wiri in Auckland.

The DC now fulfils the role of a national DC for Countdown’s slower moving and seasonal goods. Over a two year period, the DC grew to over 30,000sqm, including a new 4,000sqm covered dock to improve goods receiving.

Jared Day, Countdown’s National Facilities and Maintenance Manager, said updating the outdated facility had been just as challenging as building a new one from the ground up.

“Brownfield projects are just as complex to manage as Greenfield start-ups. Efficient project management is critical to co-ordinating and scheduling the various works. You also have to work out how best to achieve

44 JULY 2012 Manufacturers’ Monthly

your operational objectives within the physical constraints of the structure,” he said.

The company wanted to take advantage of the DC’s very high roof height. “We have been able to install what we believe is the tallest selective pallet racking system in New Zealand, with the system providing 24,000 reserve pallet storage and over 12,000 pick locations,” Day said.

Throughput rates have ramped up since start up in 2011, with the DC now distributing up to 120,000 cartons a week.

Designed and manufactured

by Dematic in Australia, the ColbyRack high-rise storage system includes the tallest single piece uprights the company has ever produced.

“At 12m long, the uprights just fitted into the 40ft shipping container,” said Dematic’s Account Manager, Bob Partridge.

“Our ability to roll longer than normal uprights enabled our

storage system design to closely follow the DC’s roofline profile, which goes as high as 17m in some places, without splicing the uprights,” he explained.

“Being able to have a 11.925m high top beam level, instead of around 9m in most high-rise DCs, let us utilise a lot of the airspace that would have otherwise have been wasted, resulting in an additional 3000 pallet storage locations for Countdown,” Partridge said.

Protecting storage systems One of the most critical aspects affecting the day-to-day operation of storage systems is how well they have been designed to take the inevitable impacts from forklifts when putting away or retrieving pallets.

“Even the best forklift operators can make mistakes from time to time, and that is why Dematic has invested in developing a range of rack protection meas-

ures which prevent or, at worst, minimise damage from occurring to the rack,” Partridge said.

Rack safety features included custom-designed, thicker, wider uprights manufactured from quality-approved high tensile steel and featuring Colby’s rack profile to increase strength and impact resistance.

Each upright is secured to the floor via extra heavy-duty baseplates fitted with two 125mm deep chemical anchors.

The racking also uses profiled heavy-duty steel guards to deflect forklift impact forces away from the upright, transferring them into the much stronger rack frames.

The introduction of upright protection is said to have virtually eliminated upright damage, with this typically being the most dangerous type of rack damage and the most costly to repair.

Partridge says the company’s UU-Beam is new type of beam designed to solve one of the most common rack damage problems in high volume DCs – the frequent impacts to beams around the 2m level, received when reach truck operators accidentally back into them while retrieving a pallet from the opposite face of the rack.

The new UU-Beam is made from two U-beam sections, and is said to increase frontal impact resistance by over 200%, virtually eliminating damage, improving workplace safety and significantly reducing rack maintenance costs.

To improve structural rigidity and make accidental dislodgement practically impossible, a combination of the company’s 4-Tang Beam Connector, which interlocks with the rack uprights’ patented diamond slots, and new steel Safety Clip, which securely fastens beams to rack uprights has been utilised.

And to improve the safety of pallet put-away and replenishment, and prevent the possibility of pallets falling through the storage system, all pallet locations above 5m high have been fitted with wire mesh decks. continued on page 45 manmonthly.com.au

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Desktop printers for light duty labelling INTERMEC has introduced the PC43d and PC43t desktop printers for light duty labelling applications in manufacturing, warehousing, transportation, and office environments.

The new printers are available in 4” (10.2cm) direct thermal and 4” thermal transfer, respectively, and are well-suited to space-constrained settings.

The PC Series also offers fast throughput at eight inches per second (20.3cm/s).

The PC series also includes the ability for one-handed media loading and quick configuration via a USB stick, making the printers simple to install and maintain.

continued from page 44 Other safety initiatives include equipping the DC’s fleet of rider reach trucks with cameras to optimise the safe handling of pallets during put-away and replenishment. Plus all of the DC’s 72 reach trucks, stockpick-

The direct thermal printer offers flexible placement options with the ability to wall mount or use battery power.

The PC Series is equipped with a universal Icon interface or color LCD in 10 languages for immediate and intuitive notifications to maximise uptime.

The series has the aconehanded media loading and quick configuration via a USB stick device, for easy installation and maintainence.

The PC Series also comes with modular connectivity options for easy migration into the existing network environments.

Intermec 02 9330 4400 www.intermec.com.au

ers and pallet trucks are fitted with the latest Info Link smart controller safety system.

The integrated monitoring system allows only authorised use, and directs the operator through a 10 point safety check before they can use the equipment.

During operation the system automatically notifies the DC supervisor if any equipment is involved in a collision, enabling Countdown to track when and where any incidents take place, and assess the rack for serviceability straight away.

Belt conveyors for heavy loads ROBOTUNITS has released the re-engineered C5N Series of Belt Conveyors for high payloads of up to 150kg per metre of conveyor.

These conveyors are based on the company’s 50mm series of aluminium extrusions, which feature a honeycomb design and are specifically designed to handle high loads.

The conveyors can provide speeds of between 3 to 55m/min standard and up to 120m/min on request.

Based on 55mm diameter drive and idle rollers, they are a cost effective alternative to the company’s C8N range of belt conveyors.

Robotunits 03 9334 5182,

The safety and efficiency of forklift battery changing and charging has also been enhanced with the implementation of a new MTC semi-automated battery management system, housed in a purpose-built area.

Dematic 02 9486 5555, www.dematic.com.au

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Manufacturers’ Monthly JULY 2012 45

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Materials HANDLING Industrial printer with thermal transfer capabilities DATAMAX-O’Neil has introduced the new I-Class Mark II high performance industrial printer.

The printer offers 64MB Flash memory and 32MB DRAM as standard features. It also has a die-cast aluminium frame and metal cabinet to increase durability. Its modular design allows for upgrades in the field, with options such as internal rewind, thermal transfer and W-LAN. A gear-driven design provides for rigorous duty cycles and reliability.

Handheld solution DEMATIC has released the Psion Omnii XT15; a new handheld computer for mobile workers.

The printer can automatically adjust to optimum heat, speed, darkness and contrast settings.

Insignia 1300 467 446 www.insignia.com.au

Features include: a display screen that can withstand a 1.25 Joule impact breakage; sensitive scanners with good/bad scan indicators; and a 5000mAH smart battery with up to 20 hours battery life.

The device has six keypad styles including QWERTY numeric. Each features an easy-to-use ergonomic design and ultra-white backlight to make even one-handed operation in the dark possible.

Dematic 02 9486 5503, www.dematic.com.au

Delivering superior conveyor belt protection FLEXCO has introduced the DRX range of impact beds designed to provide material containment and belt protection in conveyor belt load zones to the Australian market.

The impact beds feature Velocity Reduction Technology, which controls acceleration

to deaden impact energy and reduces reaction forces to provide better belt protection, and a distinctive inverted-design Impact Bar Supports, which allows the impact bars to expand and function properly as a first level of defence against damaging impact forces.

Isolation Mounts provide a second level of reaction force reduction – absorbing additional impact energy, while minimising transmission back to the belt.

The impact beds are available in a range of grades to take applications from low- to extreme-impact applications

that require the highest energy absorption.

They are available in 1.2m and 1.5m bed lengths, with standard impact bars that have 13mm of UHMW polyethylene.

Bars with 25mm of UHMW are also available.

Flexco 02 9680 3322, www.flexco.com.au

CANTILEVER STORAGE SYSTEMS PTY LTD The No. 1 Choice in CANTILEVER RACKING Sipag Storage Systems Aust Pty Ltd was established in Australia in 1991, we have recently changed our name to Cantilever Storage Systems Pty Ltd We now supply CANTIPRO Cantilever Racking from the Provost/Redstock group of Companies based in France.

Cantilever Storage Systems Pty Ltd is 100% Australian owned with its manufacturing facilities in Coffs Harbour NSW. The CANTIPRO range meets all Australian design standards and an engineer’s certificate can be provided if required.

CANTIPRO Racking systems manufactured, imported and supplied by Cantilever Storage Systems Pty Ltd are designed to meet a broad variety of individual requirement.

CANTIPRO Why Cantipro Racking?

Redstock has redesigned the original Sipag System and now market it as Cantipro The columns are straight, not tapered, giving greater strength.

The bases are bolted, not welded, allowing for lower freight charges and easier handling.

Columns are finished in Senzimir (electroplate galvanization) finish at no extra charge.

The removable connecting lugs installed through each column giving a good stability to the whole column row compared with lugs welded only from one column side.

All steel is sourced from europe.

46 JULY 2012 Manufacturers’ Monthly

Contact: Tel: (02) 66583744 Email: info@cantistor.com

manmonthly.com.au

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>L ^HU[ [V W\[ [OL YHUNL [V [OL [LZ[ ^P[O `V\Y [LHT ¶ ZV ^L»K SPRL [V VɈ LY `V\ H MYLL ZHTWSL JHY[VU VM 7YVZHML YLZWPYH[VYZ ]HS\LK H[ 0UJ .:; :PTWS` ]PZP[ ISHJR^VVKZ JVT H\ 7YVZHML6Ɉ LY [V [HRL \W V\Y -9,, [YPHS VɈ LY ;LYTZ HUK *VUKP[PVUZ VM 6Ɉ LY! Please check the expiry date on the product prior to use and ensure the product is suitable for the intended application. The offer includes a pack of 20 respirators, to the value of $30.80 Inc. GST (Blackwoods Part No. 0443 1686). This offer is limited to 500 packs, limit of 1 pack per company and can only be redeemed by addresses within Australia. Respirators have an imminent expiry date and are suitable for use up until the indicated date. Users may be contacted for feedback on performance in your work environment. Requests for trial offer must be received before close of business 31/07/12.

For your FREE trial offer simply visit: blackwoods.com.au/ProsafeOffer BLA488/0612/INT

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EFIC DID MORE THAN FINANCE OUR CONTRACT

THEY ENABLED IT. Cory Stevens, Managing Director, Lean Field Developments

When we won the contract to be part of the supply chain to the massive Queensland Curtis LNG project, we were delighted. This was an opportunity to further establish our track record and reputation within the oil and gas industry in Australia.

However, like other suppliers, we were required to provide performance bonds in support of our contractual obligations. We also needed to ensure that we had access to additional working capital for other contracts. Yet, as a company without a long

trading history in Australia, we couldn’t get sufficient bonding or bank finance for our needs.

Luckily we knew in which direction to turn. With the support of EFIC’s export working capital guarantee and bonds, we were able to meet the financial requirements and demonstrate our company’s ability to take on such challenging projects.

Overcoming financial barriers for exporters Visit efic.gov.au/mm