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18 The value of hard anodising for industrial processes

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32 A renewable solution for worn-out machine tools

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Manufacturers’ Monthly Contents 4 Editor’s Comment

21 Compressors

32 Machine Tools

6 Comment

25 Welding

34 Test Machines

10 News@MM

26 Regional Manufacturing

37 What’s New

18 Industry Focus

28 Safety & Protection

40 The Last Word

5 News

12 Automation

15 Products

10 Robotics

14 Actuator Systems

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MANAGEMENT >> TECHNOLOGY >> SOLUTIONS

OCTOBER 2020

BRINGING MANUFACTURERS BACK TO THEIR ROOTS

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the expertise of precision tooling engineers to Australia, to help manufacturers save on the cost of machine tools – a mechanic for your machine tools.

We also hope that you’ve been enjoying PACE magazine with Manufacturers’ Monthly, as a supplement. This issue in PACE, we caught up with Baird Technology and Backplane Systems Technology on their exciting business venture creating germicidal medical robots.

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Local manufacturing is at the heart of regional communities in Australia.

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Connected with more than 60 growers across Australia, they exemplify what it means to be a local manufacturer.

The tool reclamation industry has traditionally not existed in Australia, but that is starting to change with the introduction of UK-based Northern Tooling Reclamation. The company is now branching out by bringing

18 The value of hard anodising for industrial processes

22 A first-ever solid desiccant from Atlas Copco

32 A renewable solution for worn-out machine tools

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Comment

SYED SHAH – Managing Editor, Manufacturers’ Monthly

Not the end of the road

T

HERE have been many studies over the decade that have estimated a large segment of the labour market will be displaced due to increased automation in the workplace. The McKinsey Global Institute recently predicted up to 800 million workers worldwide – or one-fifth of the global workforce – could lose their jobs by 2030 and be replaced by robotic automation and advanced manufacturing. And now, with the current economic climate and COVID-19, manufacturing companies are looking to invest more into these technologies to streamline workflow.

In the manufacturing sector, the McKinsey report notes machine operating and production line jobs as two areas more susceptible to automation. It says that workers will need to adapt, as their occupations evolve alongside increasingly capable machine. Now, it is more crucial for this adaptation to automation and work with AI to happen – this means upskilling is needed.

For millions around the world, the fear of intelligent robots taking away their jobs remains top of mind.

But the future manufacturing landscape is not one without humans.

The Fourth Industrial Revolution has also prompted a movement to

4 OCTOBER 2020 Manufacturers’ Monthly

ensure new value-added, highly skilled human jobs are created despite the unavoidable, impending effect of industrial automation on the labour force, On the other side of the world, it is understood that roughly 42 per cent of the Canadian labour force would be affected by automation within the next 10 to 20 years.

This is according to senior policy advisors at their government linked institutes aimed at innovation and entrepreneurship. In all likelihood, in some cases technology will replace entire jobs. But for others, technology will complement labour, improve productivity and help to create more specialised jobs.

The McKinsey report also describes how training can be improved. It mentioned that to achieve good outcomes, policy makers and business leaders will “need to embrace automation’s benefits and, at the same time, address the worker transitions brought about by these technologies.”

It also mentions that mid-career job training will be essential, as will enhancing labour market dynamism and enabling worker redeployment.

These changes will challenge current educational and workforce training models, as well as business

approaches to skill-building. Another priority pointed out is the rethinking and strengthening transition and income support for workers caught in the crosscurrents of automation.

Meanwhile, much earlier on in the year, Rockwell Automation and US workforce solutions company, ManpowerGroup, recently committed to upskilling 1,000 American veterans every year to help strengthen the talent pool for in-demand advanced manufacturing roles.

We must ensure today’s workers have the training and skills needed to transition to the jobs of tomorrow.

But, that being said, we have to keep it local, as far as possible.

While practicality is at the top of the minds of major businesses and state budgets, state and federal governments need to focus on how to keep as many jobs local as possible. Of course, offshoring work will no doubt save costs, but at what national cost? The jobs of the future here would (and should be) highly skilled jobs, targeted at more R&D and innovation.

While it is true that manufacturing is currently much smaller than it once was when at its peak in the 1960s reports about the demise of the sector is greatly exaggerated – and we

would like to keep it exaggerated.

Manufacturing remains a significant part of Australia’s economic activity, supporting 1.27 million jobs, according to a report from AMGC, Advanced Manufacturing: A New Definition for a New Era. NSW’s state leaders recently commented about the quality of local train manufacturing and why the latest batches were manufactured on foreign soil. Unsurprisingly, it garnered strong responses from the local industry leaders such as Geoff Crittenden, CEO of Weld Australia, who said that there is the potential for thousands of jobs to be created in Australia and to support the country’s economic recovery from COVID-19 if trains are manufactured in Australia – an accurate statement. If state procurement practices support local welders and fabricators, thousands of jobs would be created and that would then spur research and development in the process.

Moving forward, to keep the local businesses up and running, the mindset towards automation and advanced technologies has to be more open. And this includes the skills and training portion. At some stage the governments will get the jobs in the sector coming in again and those that apply for it, need to be ready. manmonthly.com.au

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Comment

GEOFF CRITTENDEN – CEO, Weld Australia

Geoff Crittenden says that there is an opportunity to invest in creating a strong rail industry.

State government investment in local rail manufacturing would create thousands of jobs

R

ECENT comments from the New South Wales state government that Australia is ill-equipped to manufacture trains locally are inaccurate.

Australia has a proud and successful history of railcar manufacture; one only has to look at the Tangara trains, which were one of the most advanced and internationally successful trains of their time.

Weld Australia is calling on all state governments to support local welders and fabricators in their rail procurement processes. This would create thousands of jobs, a solid local supply chain, and an industry equipped to export world-class trains all over the world.

There is a real opportunity for the state governments to invest in creating a robust, resilient rail manufacturing industry that can compete on the world stage.

State government rail

6 OCTOBER 2020 Manufacturers’ Monthly

procurement practices that support local welders and fabricators would create thousands of jobs, supporting local families and local economies in a post COVID-19 world. It would facilitate technology transfer and drive some of the world’s most innovative research and development.

With a long-term procurement commitment from the state governments, rail industry

manufacturers would have the confidence to reinvest in their own capabilities, strengthening the industry from within. This type of business innovation strengthens businesses and creates new and better jobs, which together support a move to higher living standards.

Innovation investment by business is crucial to our ongoing prosperity.

It would make Australia home to a world-leading rail industry, with

the capability to build and export superior quality trains.

In recovering from the COVID-19 pandemic, this type of economic expansion is essential; both the Federal Government and the Reserve Bank of Australia have emphasised how important it is for state governments to spend money. And yet, our state governments consistently spend our money overseas.

The state governments need to be investing more locally to promote businesses in the country.

manmonthly.com.au

All of New South Wales’ trains are manufactured overseas; the $900 million Waratah 2 trains are being fabricated in China, the $2.3 billion Intercity fleet of trains is being fabricated and built in South Korea, and the light rail trains are being built in Spain. Worth well over $4bn, had these three projects been awarded to local fabricators, they would have created thousands of jobs in New South Wales alone, and seen the development of cuttingedge new technology.

The situation is the same across the rest of the country. Victoria’s trains are fabricated in China and only fitted out in Melbourne.

Western Australia’s new metro trains will be fabricated in India and fitted out in Perth, and the latest Queensland trains were fabricated in India.

Offshoring rail industry welding and fabrication work to India, China and South Korea does not strengthen the Australian economy in any way. In fact, it weakens

Worth over $2.4bn, the local rail industry needs a lot more support from the governments at all levels.

the Australian economy.

Australia already has a substantial rail repair and maintenance industry. With over 900 companies involved in manufacturing and supplying in the industry, our local rail industry is already worth over $2.4bn to Australia’s economy – but it is not being supported by the state governments. Only weak-minded nations and leaders

export strategically critical infrastructure projects.

If our state governments adopted a nationally consistent procurement process that considered whole of life costs and prioritised local content, not only would it create thousands of jobs, it would deliver better quality public transport. Locally fabricated trains would adhere to all relevant Australian and international Standards, reducing

expensive rework and repair. Cheap imports from overseas often cost more in the long run.

While unveiling a new fleet of Chinese-built Waratah 2 trains in early September, New South Wales Transport Minister Andrew Constance said “there’s a reason” why the trains weren’t built locally.

Minister Constance said that locally manufactured trains were likely to cost 25 per cent more due to higher labour, energy and material costs.

But how many jobs did they cost?

These comments were made just a week after New South Wales Premier Gladys Berejiklian said that Australia and New South Wales are “not good at building trains”.

It is precisely this attitude – that sees state governments send what could be local jobs offshore – that will prevent Australia from recovering from the COVID-19 pandemic. State governments must invest in industries and projects that will create jobs and strengthen our economy.

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Manufacturers’ Monthly OCTOBER 2020 7

Comment

SIMON DAWSON – Director Industrial Transformation, IMCRC

Deciding where to start

E

ARLIER in my career I worked with many ‘best in class’ lean manufacturers and I was struck by how many of their employees could remember, even years later, where it all started.

They openly shared their story, and often I would meet the team that had been the catalyst for their ongoing lean deployment.

Years later, when working as a lean management consultant helping organisations commence their lean journey, I would ask the team what story they would like to tell me five years down the track, who they would introduce me to, where we would go on the site, and what tools from the extensive lean toolkit would have been their starting point.

When looking to start an Industry 4.0 journey, to explore the opportunity, I believe the same is true. Making the right call on how and where to start is crucial to getting people on board, both internally and externally. Three things should be considered:

engaging the right people, picking the right place to start, and applying the right controls.

Engaging the right people People are at the core of every lean success story. They are the catalyst for continuously improving your operation and driving innovation.

Similarly, finding the right people who understand the potential of Industry 4.0 and will thrive in an environment that offers them freedom and encourages them to explore new ideas and play with new technology is crucial.

At a recent futuremap event, I heard a great story about an organisation that had been looking to get into additive manufacturing.

After buying their first 3D printer, the management team presented the technology to their workforce as the next new thing, only to be pleased to hear that three employees had similar printers at home and some great experience to bring. The organisation now has

a new offering in the market, from their additive manufacturing team.

Getting the right people involved worked very well for them.

As well as those directly involved in developing the Industry 4.0 initiative, a support network is required. In his 1995 Harvard Business Review article, Leading Change: Why Transformations Fail, John Kotter discusses his eight-stage process for change management, with the second stage suggesting that businesses need a guiding coalition. The concept of a guiding coalition perfectly captures what is needed to support early stage Industry 4.0 adoption – a guiding group offering direction to the team.

By describing it as a coalition, Kotter emphasises that guidance is most effective when it comes from a diverse group of people who value differences of opinion, challenge each other and bring different skills, backgrounds, and perspectives to the table.

When designing the team that will kick start the journey of Industry 4.0 transformation for your business, it is worthwhile reflecting on whether you have this diversity of thinking at the table. Is there perhaps a role for someone from the university sector able to stretch the art of the possible? Or perhaps, a customer representative could get involved, continually testing whether an idea will have business impact?

Picking the right place to start With the right team in place, it is equally important to pick the right place to start – identifying an opportunity or area within the organisation that stretches the team’s innovative thinking while maximising the likelihood of some quick wins.

Industry 4.0 is a broad term used to describe the digital transformation of manufacturing and related industries. It can

Making the right call on how and where to start when embarking on the Industry 4.0 journey is crucial to getting people on board.

8 OCTOBER 2020 Manufacturers’ Monthly

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IS THE CAP ON YOUR CAPEX HOLDING YOU BACK?

contribute to all aspects of an organisation’s value chain, from the supply of the original materials to the end customers and everything in between. For an organisation operating a complex and/or extensive processing facility, the initial focus could be internal, for example, improving internal control and reducing costs through better data capture and smarter analysis. Installing sensors in a filling machine could provide a wealth of data that inspires the engineering team to find new productivity options. Or adopting augmented reality solutions for training purposes could reduce a long-standing safety risk and support staff in their daily routine.

Others might focus on their business model. Adding sensors to their products or joining the Internet of Things (IoT) could allow them to provide significant downstream services, strengthening and/or enhancing a product offering. Perhaps the questions to consider here are: which product would be easiest to move forward; which customer would be most responsive to the innovative idea and is there a market ready to accept change?

In either case, like the makeup of the team, this should be a conscious choice. manmonthly.com.au

Applying the right controls While exploration implies that the end goal might be unknown, it will be important to support this initial Industry 4.0 exercise in the same way you would any other project. Thought should be given to issues like the assessment of returns. A full Return on Investment (ROI) expectation in these early stages may not be helpful, but the organisation needs to use these first steps to learn how an innovation could influence their market or cost base. Discussions should therefore include defining the opportunity value that the project is starting to open up. Similarly, timelines should be established to ensure that the project continues to get leadership focus and that exploration does not revert to meandering. Incorporating a go/no-go gate or two will also prove useful.

Considering these three elements is a key starting point as an organisation begins to move towards Industry 4.0. Exploration must of course include the freedom to try new things and importantly the freedom to fail, but it is the role of leadership to ensure this is done in the right context that creates not only learnings but establishes something extremely valuable – momentum.

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Industry 4.0 is a broad term used to describe the digital transformation of manufacturing and related industries.

Manufacturers’ Monthly OCTOBER 2020 9

News @MM Cyber the early focus of new small business grant program Defence small businesses will be recruited to join the fight against cyber threats under a new industry support program being launched, according to a statement

by Defence.

Minister for Defence Industry Melissa Price said Australian small businesses will receive funding to develop ambitious, game-changing capabilities for the Australian Defence Force.

The Defence Industry Competitive Evaluation Research Agreement (ICERA) will offer Australian small businesses significant opportunities to investigate innovative and visionary projects that will contribute to improving Defence industry’s ability to support Australian Defence

Force capability priorities.

Support of up to $300,000 per proposal will be provided for projects for up to 18 months.

Price said ICERA is being funded through Defence’s Next Generation Technologies Fund, in a new scheme that will provide $36 million over six years.

“Australia’s strategic context is changing significantly, and our defence strategy is responding to these changes,” Price said.

“This change is something which has been clearly highlighted in the 2020 Defence Strategic Update that was released recently.

“Our small business sector has a more important role than ever in contributing to Defence’s science and technology research priorities

that support ADF capability needs.

“Which is why I welcome that the first focus of the ICERA initiative is targeting on cyber defence and cyber security.”

Later rounds of ICERA are expected to focus on a range of other priority areas, including integrated intelligence surveillance and reconnaissance, medical countermeasures, space, and trusted autonomous systems.

The federal government is continuing to invest in Australia’s growing defence industry, which is playing an essential role in our economic recovery post-COVID-19.

Successful projects may be considered for further funding or opportunities through other avenues and mechanisms.

Support of up to $300,000 per proposal will be provided for projects for up to 18 months.

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News @MM UNSW Canberra to offer new Naval Architecture degree UNSW Canberra is creating a new naval architecture degree to ensure Australia’s future naval shipbuilding needs are being met.

UNSW Canberra Rector Michael Frater said that the new Bachelor of Engineering: Naval Architecture program will continue UNSW’s long history of educating naval architects, but in a refreshed context in Canberra that is responsive to the future needs of the country and particularly the Navy.

UNSW has had a long and successful history in delivering Naval Architecture as an engineering discipline on the Kensington Campus (at UNSW Sydney) since 1962 and now it is coming to Canberra.

“This new program is planned to be offered from 2022 and will support the current Defence White Paper, the continuous naval shipbuilding policy and the requisite foundational skills development in the discipline,” he said “UNSW Canberra has been educating members of the Australian Defence Force for over fifty years, and this program is the next step we are taking in developing capabilities

The new degree program is planned to be offered from 2022 and will support the current Defence White Paper.

in this important Defence sector.”

The Naval Architectural program at UNSW Canberra is planned to run in parallel with Mechanical Engineering for the first two years.

“What this means is that students who satisfy the requirements of the first two years of the Mechanical Engineering four-year degree program, having studied at any Australasian tertiary institution, may be admitted into 3rd and 4th year of

the proposed program leading to the award of a Bachelor of Engineering degree in Naval Architecture,” Professor Frater said.

“This is exciting as it means the very first students who will be admitted to the degree, and form the first graduating class, are already studying and have begun their career towards contributing to this ship design, production, maintenance and operation capability.

Associate Professor Warren Smith will take the initial academic leadership and responsibility as the discipline coordinator for the program. Key academics from Sydney and Canberra will together develop the new curriculum and course offerings. Together, they will consciously be designing and tailoring the degree to meet the needs of tomorrow’s Navy and Defence’s shipbuilding program.

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News @MM $13.9 billion infrastructure investment to unlock economic recovery in Queensland The capital program reaffirs the Queensland government’s infrastructure guarantee and is expected to directly support around 44,000 jobs.

Queensland Treasurer and Minister for Infrastructure and Planning Cameron Dick released details of the state government’s $13.9 billion infrastructure investment for 202021 as part of Queensland’s plan to support jobs and accelerate the state’s economic recovery.

Dick said this year’s capital program re-affirmed the Queensland government’s infrastructure guarantee and was expected to directly support around 44,000 jobs.

“The Capital Program 2020 Update includes $13.9 billion in infrastructure spending across the state and is aimed at keeping people in jobs, driving our recovery and securing Queensland’s longer-term prosperity,” Dick said.

“Our Unite and Recover for Queensland Jobs strategy for economic recovery has a strong focus on infrastructure, because we know that infrastructure will drive our state’s recovery, future prosperity and resilience.

“Today’s capital program update reinforces our commitment to a $51.8 12 OCTOBER 2020 Manufacturers’ Monthly

billion program of work over four years and gives the private sector confidence to invest in Queensland.

“In addition to creating and protecting jobs within the construction industry and supply chains, this investment will support our industries, regions and communities and be an incentive for further private investment.

“The Capital Program 2020 Update confirms our pipeline of capital projects that will support jobs for tradies, subcontractors and businesses now and into the future.

“It details investment in almost 900 initiatives across transport, energy, water, health, education and training, digital, justice and public safety, social housing, the arts, culture, sport and recreation.

“The update provides visibility of this year’s spend and the anticipated 18-month projected spend to December 2021 for each of these infrastructure classes.

“It shows we’re continuing to invest in traditional sectors by delivering

economy boosting projects such as new and upgraded roads, vital high-quality health, education and social services, and also reflects our commitment to new technologies and priority sectors.

“This year, around 60 per cent of the total $13.9 billion investment will be spent outside of Greater Brisbane.

“These projects will help diversify and support our economic growth, enhance liveability within our communities and provide jobs in our regions and the metropolitan area.”

Some of the highlights within the capital program include: • $6.1 billion in transport infrastructure projects across Queensland including the Ports of Gladstone and Townsville, Cross River Rail, Bruce Highway, Pacific and Ipswich motorways and a wide range of regional roads; • health facility investments such as the $70 million redevelopment of Cairns Hospital mental health facilities; • over $16 million for new ambulance stations at Ormeau, Yarrabilba, Munruben and Urraween; • a new QCN Fibre partnership with Toowoomba’s Pulse Data Centre to provide better internet for thousands of Darling Downs businesses; • $20 million towards the new Queensland Apprenticeships Centre at Beenleigh delivering training for high demand industries including renewable hydrogen; • $3.4 million towards collaborative projects with Balonne, Bulloo, Maranoa, Murweh and Paroo councils to enhance digital connectivity; and • investment in public safety such as $16.9 million for Queensland Fire and Emergency Services’ regional headquarters at Charlton, near Toowoomba, and the $52.2 million Wacol Counter-Terrorism and Community Training Centre, as well as new and upgraded fire and police stations around the state.

Dick said the capital program built upon the State Government’s support for the building and property development industries

through stimulus measures and initiatives including the: • $51.8 billion Infrastructure Guarantee; • $200 million Building Acceleration Fund; • $50 million SEQ community stimulus program; • $400 million Accelerated Works Program; • $200 million Works for Queensland COVID-19 Recovery Package; • $100 million Housing Construction – Works for Tradies; and • reducing red tape and streamlining planning approvals for construction.

“This government is focused on getting our state’s economy back on its feet and building a stronger and more resilient economy,” he said.

“Working in partnership with the private sector to invest and build vital infrastructure strengthening industries, supporting jobs and enabling future growth is vital to achieving our goals.”

Infrastructure Association of Queensland (IAQ) Chief Executive Officer Priscilla Radice welcomed the release of the Government’s Capital Program 2020 Update.

“In our recent 2020 IAQ survey, having a clear pipeline of work was identified by our members as the most pressing issue,” Radice said.

“The infrastructure update gives industry visibility of the government’s continuing significant investment which is exactly what is needed to build confidence, help with workforce planning and grow the economy.

“We know that for every $1 the government spends on infrastructure the private sector spends $13, creating jobs now and long-term economic benefits into the future.”

Master Builders Deputy CEO Paul Bidwell says this is a strong increase of $1 billion on last year’s commitment.

“Given the current circumstances, it was vital spending be increased and we are pleased the Queensland Government has delivered on that front.” manmonthly.com.au

News @MM Australian manufacturing boost at UTS with Centre for Advanced Manufacturing Australia’s manufacturing sector will be supported by the University of Technology Sydney (UTS) with new Centre for Advanced Manufacturing (CAM) that will work closely with industry to understand and explore how communication technologies, devices connected to the internet (Internet of Things, IoT) and data science can make their businesses more efficient and sustainable.

This has become even more imperative in the current COVID19-led focus on economic strengths and renewal, and consideration of a smart way for manufacturing in Australia to meet local, regional and international needs.

Advanced manufacturing will be a clean, green and flexible approach to developing smart products for manufacture in Australia and will secure on-shore jobs.

The key driver of the Centre is to give Australian manufacturers the skills to maintain and expand manufacturing activities in Australia, including supporting a growth in the number of jobs.

Centre Director Professor Jochen Deuse said CAM will be a bridge to

The key driver of the Centre is to give Australian manufacturers the skills to maintain and expand manufacturing activities in Australia.

the manufacturing industry, actively engaging with the profession and that consultation with leading industry experts will inform its strategic direction. “‘We want to be the first choice for industry collaboration and to supply graduates to work in a dynamic and agile industry,” he said.

“The Centre will be a catalyst for strong, lasting industry partnerships, allowing us to support increased self-sufficiency/on-shoring of Australian manufacturing.”

CAM is already working with

Balluf, Marley Flow Control, Siemens and RapidMiner and on jointly funded projects with Alrick Healthcare, Innovation Connections, Defence Innovation Network and Australian Wool Innovation.

Industry training will be at the core of CAM activities, developing innovative approaches to manufacturing education with short courses responsive to the quickly changing needs of industry.

The Centre aims to be: • Australia’s leading research centre in advanced manufacturing, with

the most advanced manufacturing facilities of any university (including Tech Lab, ProtoSpace, and Industry 4.0 testbeds) • number one choice as university collaborator for Australian manufacturers, with a reputation for doing fundamental and applied industry-relevant research with measurable impact leading a revolution in advanced manufacturing education with graduates ready for the global workplace and future leadership in Australian manufacturing.

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Manufacturers’ Monthly OCTOBER 2020 13

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News @MM New tech extracts potential to identify quality graphene Researchers used the data set of an optical microscope to develop a machine-learning algorithm that can characterise graphene properties and quality within minutes.

Monash University engineers have developed world-first technology that can help industry identify and export high quality graphene cheaper, faster and more accurately.

Published in international journal Advanced Science, researchers used the data set of an optical microscope to develop a machine-learning algorithm that can characterise graphene properties and quality, without bias, within 14 minutes.

This technology is expected to be a game changer for hundreds of graphene or graphene oxide manufacturers globally. It will help them boost the quality and reliability of their graphene supply in quick time.

Currently, manufacturers can only detect the quality and properties of graphene used in a product after it has been manufactured.

Through this algorithm, which has the potential to be rolled out globally with commercial support, graphene producers can be assured of quality product and remove the time-intensive and costly process of a series of characterisation techniques to identify graphene properties, such as the thickness and size manmonthly.com.au

of the atomic layers.

Professor Mainak Majumder from Monash University’s Department of Mechanical and Aerospace Engineering and the Australian Research Council’s Hub on Graphene Enabled Industry Transformation led this breakthrough study.

Study co-authors are Md. Joynul Abedin and Dr Mahdokht Shaibani (Monash, Department of Mechanical and Aerospace Engineering), and Titon Barua (Vimmaniac, Bangladesh).

“Graphene possesses extraordinary capacity for electric and thermal conductivity. It is widely used in the production of membranes for water purification, energy storage and in smart technology, such as weight loading sensors on traffic bridges,” Majumder said.

“At the same time, graphene is rather expensive when it comes to usage in bulk quantities. One gram of high-quality graphene could cost as much as $1,000, a large percentage of it due to the costly quality control process.

“Therefore, manufacturers need to be assured that they’re sourcing the highest quality graphene on the

market. Our technology can detect the properties of graphene in under 14 minutes for a single dataset of 1936 x 1216 resolution. This will save manufacturers vital time and money, and establish a competitive advantage in a growing marketplace.”

Discovered in 2004, graphene is touted as a wonder material for its outstanding lightweight, thin and ultra-flexible properties. Graphene is produced through the exfoliation of graphite. Graphite, a crystalline form of carbon with atoms arranged hexagonally, comprises many layers of graphene.

However, the translation of potential to real-life and usable products has been slow. One of the reasons is the lack of reliability and consistency of what is commercially often available as graphene.

The most widely used method of producing graphene and graphene oxide sheets is through liquid phase exfoliation (LPE). In this process, the single layer sheets are stripped from its 3D counterpart such as graphite, graphite oxide film or expanded graphite by shear-forces.

But, this can only be imaged using a dry sample (once the graphene has been coated on a glass slide).

“Although there has been a strong emphasis on standardisation guidelines of graphene materials, there is virtually no way to monitor the fundamental unit process of exfoliation, product quality varies from laboratory to laboratory and from one manufacturer to other,” Shaibani said.

“As a result, discrepancies are often observed in the reported property-performance characteristics, even though the material is claimed to be graphene.

“Our work could be of importance to industries that are interested in delivering high quality graphene to their customers with reliable functionality and properties.

There are a number of ASX listed

companies attempting to enter this billion-dollar market, and this technology could accelerate this interest.”

Researchers applied the algorithm to an assortment of 18 graphene samples – eight of which were acquired from commercial sources and the rest produced in a laboratory under controlled processing conditions.

Using a quantitative polarised optical microscope, researchers identified a technique for detecting, classifying and quantifying exfoliated graphene in its natural form of a dispersion.

To maximise the information generated from hundreds of images and large numbers of samples in a fast and efficient manner, researchers developed an unsupervised machinelearning algorithm to identify data clusters of similar nature, and then use image analysis to quantify the proportions of each cluster.

Abedin said this method has the potential to be used for the classification and quantification of other two-dimensional materials.

“The capability of our approach to classify stacking at sub-nanometer to micrometer scale and measure the size, thickness, and concentration of exfoliation in generic dispersions of graphene or graphene oxide is exciting and holds exceptional promise for the development of energy and thermally advanced products,” he said.

Professor Dusan Losic, Director of Australian Research Council’s Hub on Graphene Enabled Industry Transformation, said the technology will help fill a gap in the market.

“These outstanding outcomes from our ARC Research Hub will make significant impacts on the emerging multibillion-dollar graphene industry, giving graphene manufacturers and end-users new a simple quality control tool to define the quality of their produced graphene materials, which is currently missing,” he said.

Manufacturers’ Monthly OCTOBER 2020 15

News @MM World-first UQ rocket headed to space Project Asteria demonstrates Australia’s space capabilities to the rest of the world.

The University of Queensland could soon be the first university to fly a student-built rocket and scientific payload into space next year.

UQ Space is designing and building “Project Asteria”, a rocket that will zoom past the Kármán Line, 100 kilometres above sea level, reaching speeds greater than Mach-5.

With support from UQ aerospace

engineering experts and industry partners including Queenslandbased Black Sky Aerospace, the 90-strong student team hopes to set a new world record.

UQ Space managing director, engineering and arts student Myrthe Snoeks, said the team had been working towards this ambitious goal despite delays caused by the global COVID-19 pandemic.

“We started developing the rocket in 2019, and we are now planning and undertaking static testing and sub-orbital launch preparations before our official launch next year,” Snoeks said.

“The UQ Space team has achieved so much already, having taken out the top position in Australia for competitive university rocket launches in 2019, only one year after

establishing the team.

“While 2020 has presented some additional challenges to our progress, we haven’t given up – we absolutely intend on achieving this goal with the help of our supporters.”

UQ Space will be using the Beyond the Blue Aerospace launch and test facility near Goondiwindi in western Queensland, known as “Funny Farm Space”.

This will be one of the first industry collaborations to take advantage of the $3 million commitment from Black Sky Aerospace and Beyond the Blue Aerospace to encourage space ventures from Queensland.

The launch facility is Australia’s only sub-orbital facility permitted to fly through and above controlled

airspace and was home to Australia’s first commercial payload rocket launch by Black Sky Aerospace in 2018.

Black Sky Aerospace Director Blake Nikolic said there were real benefits to working on Project Asteria.

“Together we are advancing Australia’s space capabilities and showing the world that we’re here and we’re ready,” Nikolic said.

“Working with these bright and committed students also helps us as we develop our internship program in this new industry and provides our future employees with practical knowledge-based learning.”

The team plans to travel to Goondiwindi in the coming months for their first static test fire of Project Asteria.

Victorian manufacturers create new ventilator industry Victoria’s world-leading manufacturers have created a ventilator production industry from scratch with Ballarat’s Gekko Systems to start making the country’s first Australian-designed machines within weeks.

Gekko has made its name as a manufacturer of mining equipment since its establishment by Sandy Gray and Elizabeth Lewis-Gray in the mid-1990s. It will now harness its local suppliers and 100-strong workforce to build the GeVentor ventilator, which Gray designed in his shed with help from Ballarat anaesthetist Doug Paxton.

The Victorian Government provided development grants to Gekko Systems and three other groups in the early stages of the pandemic. The outcome has proven the agility of Victorian manufacturers, bolstered confidence in planning for future public health emergencies and provided a potential new avenue for export earnings.

“Creating a local ventilator 16 OCTOBER 2020 Manufacturers’ Monthly

industry in a matter of just months is testament to the excellence and agility of Victorian manufacturers,” Victorian Minister for Industry Support and Recovery Martin Pakula said.

“We have seen an amazing response to the challenges posed by the pandemic and that has helped to shore up jobs and place the state in the best position possible to recover once the health crisis is behind us.”

“It’s terrific to see a Ballarat company leading the country in designing and producing ventilators – it means continued jobs not just for Gekko but for companies all along the supply chain,” Minister for Innovation, Medical Research and the Digital Economy Jaala Pulford said.

Health Purchasing Victoria has placed an order for 170 ventilators with Gekko Systems after the company’s machine was provided with a production exemption from the Therapeutic Goods Administration (TGA).

Gekko has reported interest in its GeVentor machine from humanitarian organisations for potential use in developing countries. With the success of its ventilator initiative, Gekko has now created a medical arm with a view to producing a range of equipment to supply local, national and international markets.

Health Purchasing Victoria has also placed orders for 200 ventilators that are being produced

by Grey Innovation. The company established a consortium of local companies to build its transportable Notus Vivere Emergency Ventilator, with components coming from manufacturers ANCA, Marand, Hosico, Bosch Australia and Hydrix.

Grey Innovation is also producing machines under licence to fill an order from the Commonwealth Government.

Two other Victorian companies – Planet Innovation and Compumedics – are in the final stages of the TGA process for their ventilators.

The Victorian Government provided development grants to Gekko Systems and three other groups in the early stages of the pandemic.

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Industry Focus Hard anodising: Strong coating, long life Manufacturers’ Monthly speaks with Accurate Repetition Engineering design engineer, Brett Turner, about the long-term benefits of DECO Industrial’s hard anodising service.

Aluminium components are racked on an electrically conductive rack prior to commencing the anodising process.

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AW aluminium is susceptible to corrosion if exposed to pollutants.

However, aluminium tends to naturally oxidise, forming a hard skin, almost as hard as diamonds, which protects the aluminium beneath from corrosion. To enhance corrosion protection for aluminium parts and machine components, as well as increasing their wear resistance, this layer can be made thicker through a process known as anodising.

Anodising is an electrolytic treatment process which grows an even aluminium oxide skin on the surface of the component by immersing it in an acid solution.

The resulting coating increases the corrosion, scratch, and chemical resistance of the part.

For an even more durable aluminium oxide coating, aluminium parts can also be hard anodised.

The hard anodising process involves growing a denser, more hardwearing aluminium oxide layer into and

18 OCTOBER 2020 Manufacturers’ Monthly

out of the surface of aluminium components. Achieved by lowering the temperature of the acid bath, this highly durable coating has narrower pores and significantly increases durability and corrosion resistance. Hard anodising

is especially useful for tough engineering applications with high temperatures or high levels of wear.

DECO Industrial – the protective coating arm of DECO Australia, the aluminium finishing experts – offers both standard anodising

During the anodising process, components are immersed in an electrolytic sulphuric acid solution, which causes an aluminium oxide coating to grow on the surface.

and hard anodising capabilities to suit project requirements. As the only commercial hard anodiser in NSW – and one of only a handful of commercial hard anodisers in Australia – DECO has capabilities to hard anodise a range of custom parts up to 2.8m long.

The hard anodising process imbues aluminium parts with high resistance to corrosion and mild acids and increases durability and heat resistance up to 800°C, which is especially beneficial for engine parts. Hard anodising improves the longevity and lifespan of aluminium components, reducing the frequency of replacement and allowing more efficient use of machinery with less downtime. This can be extremely beneficial for manufacturers and their customers.

One such company that has seen the benefits of DECO Industrial’s hard anodising for more than ten years is Accurate Repetition Engineering. The company manufactures CNC-machined metal manmonthly.com.au

Industry Focus components for their customers’ machines, servicing the engineering, defence and automotive sectors.

“The bulk of the product that we make would be primarily made out of aluminium,” said design engineer Brett Turner. “On one hand, we do bright anodising for appearance and protecting the aluminium, but the hard anodising that DECO do for us is quite specific because it is subject to wear.”

An example of a part requiring a wear-resistant coating would be a piston or a valve in a turbocharged car.

“They see quite a lot of cycles, and we found that the regular bright anodising will wear out after five years of use,” Turner said.

Accurate Repetition Engineering switched to DECO’s hard anodising 12 years ago, and according to Turner, since the company began using the process, the parts have never worn out.

“Hard anodising is much thicker and far more resistant to abrasion,”

he said. “It’s a grey finish, so it’s not really used for a decorative appearance. The part that we hard anodise is housed within an assembly, so you don’t see it, but the wear characteristics are much better than regular bright anodising.”

Although hard anodising is a tougher finish than regular anodising, according to Turner, the vast majority of aluminium parts are protected by regular anodising.

Some anodisers also offer an alternative “hard” anodised finish by adding chemicals to the acid baths – but this form of “hard” anodising is not as effective. True hard anodising is achieved by lowering the temperature of the acid baths to between -2 and 0 degrees Celsius, which creates a thicker aluminium oxide build up. Using ‘true’ hard anodising will result in greater durability – and greater longevity for components.

“The interesting thing in the automotive industry is everybody always incorrectly advertises hard

anodising,” he said.

“That term unfortunately is misused. Hard anodising is not regular anodising, and it’s not actually to do with the hardness.

“Companies will often advertise their parts as being hard anodised, but in fact they’re not. That’s something that we make sure we explain in our advertising.”

Turner said the standout quality of DECO Australia’s hard anodising service is the consistency, which ensures parts that are subject to “extremely fine” machining tolerances can function together.

“We effectively have six tolerances to deal with, and these parts have to fit together precisely,” he said. “The housing that it sits in is bright anodised, so we have machining tolerance, we have an anodised tolerance, and then we have the sleeve, which has machining tolerance inside and outside, anodising tolerance, and then a piston itself which is brass.

“All of those parts have to fit and

slide together, and that can cause a bit of a headache, so the DECO consistency with the anodising thickness certainly is a benefit when we settle these things so we don’t have to worry about the parts not fitting together properly.”

DECO Industrial offer true, low-temperature hard anodising from 30 to 100 microns and tests its anodising processes to the US military standard MIL SPEC to ensure the highest quality.

DECO’S ANODISING PROCESS • The part is racked on a specially coated rack designed to conduct electric currents; • The aluminium part is chemically cleaned to remove surface contaminants; • The part is dipped in an acid solution with an electric current running through it, which creates a buildup of aluminium oxide; (for hard anodising the temperature of the bath is lowered to 0 degrees Celsius) • An aluminium oxide layer grows into and out of the product, converting the surface of the metal into a coating; • The microscopic pores of the aluminium oxide coating can be sealed or coloured or left as they are depending on the application.

• The parts are inspected for quality before leaving DECO according to customer specifications.

ANODISING APPLICATIONS • CNC machined parts ; • machinery components e.g. Cogs, plates, panels, bodies and cases; • interior or exterior applications; • window and door frames; • door handles; • shelf brackets; • appliance parts (eg. grills, pans, trays); • motor vehicle components (eg. trims, wheel covers); • light fixtures.

For more information on DECO Australia’s hard anodising services visit deco.net.au/protective-coatings

Anodised and black dyed components after the anodising process has been completed.

manmonthly.com.au

For more information on Accurate Repetition Engineering visit www.accuraterepetition.com.au/

Manufacturers’ Monthly OCTOBER 2020 19

Compressors Efficiency and reliability are top concerns at speed car racing Chicago Pneumatic business line manager, Sume Perera, introduces the new oil-cooled interior permanent magnet motor compressor.

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SIDE from the Olympics and the FIFA World Cup, there are few sports with the global appeal of motorspot.

According to a 2017 Niesel Sports survey, motorsport reaches over 194 countries.

The efficiency and reliability of the car are top concerns in fast paced

Chicago Pneumatic Oil Cooled Interior Permanent Magnet Motor Variable Speed Drive Air Compressors 7.5 – 75kW. and highly competitive event like motor sport racing. The same applies to manufacturing industry, where the products manufactured are highly competitive and productivity plays a key role in business profitability.

It is more than ever important for manufacturers to have the most efficient and reliable compressed air system to ensure increased productivity with minimum downtime and highest energy efficiency to guarantee fastest payback on the equipment.

The new Chicago Pneumatic oilcooled interior permanent magnet motor compressors are solidly built, keeping reliability and optimum efficiency in mind. In-house design is completed by Chicago Pneumatic engineers and manufacturing follows stringent ISO quality standards. manmonthly.com.au

“Where this particular compressor captures the energy saving is because of its ability to slow down and speed up, and slowing down to the minimum speed the compressor can run,” Chicago Pneumatic business line manager Sume Perera said.

“The technology we use is direct drive. Unlike a gear drive or a belt drive, there’s no maintenance in there. In this case, there’s no coupling, so there’s no maintenance and no downtime.”

Designed and assembled inhouse since 2015 using the latest production technology, the oil- cooled interior permanent magnet electric motor and screw compressor element drive train has IE4 super premium efficiency and IP66 protection class with industry leading Specific Energy Requirement (SER) levels.

The oil-cooled interior permanent magnet (IPM) motor is maintenancefree and saves energy, which ensures lower overall ownership costs.

The integrated direct drive,

Michael McDowell driving the CP Compressors sponsored Ford Mustang at NASCAR Cup Series race in Daytona USA.

element and motor share the same rotor shaft. The modern drive train is approximately three per cent more efficient than belt drive transmission and approximately one per cent more efficient than a gear drive transmission, which results in reducing energy costs.

design features IP5X protection. The inverter is tailor-made in Europe for screw compressor applications and compact integrated inside the compressor electric canopy.

Energy saver imperium inverter

Increased reliability through remote monitoring

The in-house designed and patented imperium variable speed drive matches air supply to air demand, ensuring no unload losses for fixed speed compressors. Precise pressure setting 0.1 bar helps to narrow pressure band and lower working pressure. This guarantees no peak current at start-up, which helps to avoid maximum demand penalties from power companies.

The robust in-house, industrial

User friendly ES4000 touch controllers are used with the air compressors. A four-inch touch screen display gives the user full control and protects the machine with sensors and algorithms. The remote monitoring gives a clear overview on machine parameters via ICONS built in GPS communication, and allows to the operator to visualise service intervals and warnings.

The integrated direct drive, element and motor share the same rotor shaft.

Manufacturers’ Monthly OCTOBER 2020 21

Compressors Atlas Copco introduces solid desiccant compressed air-drying technology Atlas Copco introduces CERADES, a solid desiccant created after years of R&D. Manufacturers’ Monthly(MM): What is CERADES (pronounced as “seradas”)?

Atlas Copco(AC): CERADES is the first-ever solid, ceramic desiccant.

Until now, desiccant in air dryers has always consisted of loose beads made of activated alumina, molecular sieves or silica gel, being used in compressed air drying in lots of industries to have a certain quality dry air needed for applications. CERADES desiccant dryer’s offers customers – significantly better compressed air quality, lowering pressure drops by up to 70 per cent, with improved energy efficiency, lower service costs, and improved environmental benefits.

MM: How long has this desiccant been in development? Who are the inventors/developers?

AC: In 2016, after years of testing, Atlas Copco’s R&D team had its first breakthrough. Our new mission became bringing this idea to the market with benefits not found in a conventional desiccant dryer. We filed for the patent in 2018.

To create something outstanding like CERADES is a real breakthrough, and we are extremely proud to be able to deliver a product that is unique in the market and will bring many benefits to our customers.

MM: How does CERADES work?

AC: Simply put, as a structured desiccant – consisting of a solid, ceramic block – CERADES dries the compressed air as it flows through straight, structured tubes.

MM: How does CERADES differ from conventional desiccants?

AC: CERADES is the first-ever solid desiccant. Instead of simply improving traditional adsorption dryers, which use thousands of tiny, loose desiccant beads to dry compressed air, we devised a product that is superior and best explained through five key points: 22 OCTOBER 2020 Manufacturers’ Monthly

CERADES desiccant dryers offers customers significantly better compressed air quality.

• F irst, lower energy costs. The compressed air flows straight through the structured CERADES, reducing the drop-in pressure of the dryer. In loose desiccant, the air must overcome more resistance as it pushes and weaves through the beads.

• Second, the desiccant beads get pushed around through the drying tower during the cycle. This friction causes the beads to decay over time, which can compromise your dew point. CERADES lasts much longer to protect your air quality and extends service intervals.

• Third, as loose desiccant decays, it releases a fine dust into your air system – which creates a requirement for extra filtration and maintenance, adding to service costs. This dust is also a health and environmental issue, as it circulates in the ambient air during desiccant replacement. CERADES eliminates this dust problem to give you environmental and health protection, lower operational costs,

and reduced downtime.

• F ourth, CERADES is vibrationresistant and can be mounted horizontally. This is very important for a number of applications, especially in the transportation industry – which can now enjoy trouble-free installation and continuous operation.

• Finally, dryers with ceramic desiccant can handle a higher airflow. That means we can make them more compact.

MM: What are the benefits of using CERADES over dryers with conventional desiccants? How does purging compare between the ceramic and conventional materials?

AC: When it comes to purging, whether a solid or bead desiccant, you want your purge rate to be between 15-20 per cent. CERADES hits this mark, achieving a rating as low as 16 per cent. Dew point ratings impact the efficiency of the purge, and dew point controls affect the airflow and amount of air being dried. With CERADES,

if the customer is not using a PDP (pressure dew point) sensor, it will continuously dry the air to the required PDP, improving its efficiency.

It maintains a constant dew point, alleviating decay over time, protecting air quality and extending the service intervals. Additionally, by maintaining a stable PDP, operators can save energy, reduce their carbon footprint and keep money in their wallets.

As standard desiccants decay over time, it influences the PDP levels and impacts the efficiency. With CERADES, there is no desiccant decay. With no desiccant decay, CERADES is also environmentally friendly, providing clean compressed air and eliminating hazardous fine dust.

An inherent disadvantage of a standard desiccant is that it will lose its drying capacity when liquid water enters the dryer. This causes problems for the drying process and negatively affects air quality. CERADES overcomes this issue and will retain its drying capacity even when wet. That is manmonthly.com.au

an additional benefit that nobody else is offering.

MM: Can this desiccant be used with existing dryers, or does new equipment need to be purchased? If so, what about the old existing dryers?

AC: To ensure the customer receives the full benefits of CERADES, we are only offering this technology in new equipment. Currently, our engineers are developing a plan to create a rebuild kit for bead dryers. When Atlas Copco launched its CD+ dryer range series in 2017, CERADES was already in the works, and we were prepared for the units to be replaced. The CD 20⁺-335⁺ is the first dryer to use the revolutionary CERADES. MM: What is the expected life span of the CERADES material? How does the cost to replace it compare with that of conventional desiccants?

AC: CERADES desiccant lasts on average a minimum of two years longer than traditional desiccant, and under normal operating conditions

manmonthly.com.au

you would only change CERADES desiccant every seven years. Changing a traditional loose desiccant in a dryer, due to the amount of dust particles, is a time-consuming health and environmental hazard, which is eliminated by CERADES. MM: Is the technology available now in Australia?

AC: Yes. Atlas Copco’s new CERADES CD20-335+ (CD+) range of more than 30 models are the first dryers where the CERADES desiccant will be used.

In addition to the benefits created by the incorporation of CERADES, the CD+ desiccant dryers are an extremely powerful, efficient, reliable, and quiet dryer which can operate continuously with 100 per cent airflow. The CD+ range offers a standard-pressure dew point of -40°C and customers can adjust the dew point to optimise the dryer performance for the needs of their specific applications.

MM: Why are existing manufacturers choosing CERADES?

The CD+ desiccant dryers are an extremely powerful and quiet dryer.

AC: • Lower pressure drop, so it saves you money; • It has higher flow, so you can downsize and save money; • Smaller footprint, so you use less of your plant room; • No dust creation, so you save on extra filters; • No decay of desiccant, so your staff

are safer; • N o decay of desiccant, so the dryer performance is consistent; • Structured desiccant, so you have the flexibility to mount the dryer in any direction; and • Connected to Smartlink, so you can remote monitor warning and service needs and improve your productive time.

Manufacturers’ Monthly OCTOBER 2020 23

Smart Welding Embrace technology and leverage possibilities to improve productivity and efficiency in the welding industry Lorch South Pacific managing director, David Wilton, speaks about Industry 4.0 Smart Welding Solutions and how it drives customer productivity.

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HAT do people think about when they hear the words “welding industry”?

Many would think “old school”, “dirty job”, “uninspiring”, “slow to change”. But what if these were just perceptions standing in the way of our welding industry being seen as innovative, progressive and cutting edge?

The invention of the steam engine heralded the first major industrial revolution, followed by mass production and electricity for the second revolution, and computer processing and automation, the third revolution. Today, we are powering into the fourth industrial revolution, Industry 4.0, and the opportunity to re-invent welding as we know it.

Industry 4.0 and welding “Smart factories” is the description Industry 4.0 is often given when cyberphysical systems are integrated into the production process. Industry 4.0 is based on the Internet of Things (IoT), connecting and digitising automated tasks and updating manufacturing processes directly between equipment and operator.

Why is this all so important?

The reason is simple: embedded in the data is untapped potential for process optimisation to drive cost and efficiency improvements. Industry 4.0 allows us to see future problems before they happen through the analysis of real time production data, giving companies greater control of their entire welding operations.

Industry 4.0 sounds very futuristic and yet it still relies on the human factor. The craftsmanship of a skilled welding operator cannot be replaced by a robot. Industry 4.0 brings the two sides together and is our opportunity to update the welding manmonthly.com.au

Industry 4.0 is all about digitalisation of automation and improvements to existing manufacturing processes through digital interconnectivity. industry, educate new talent, refresh methodologies and deliver cutting edge, next generation performance levels. This has the potential to establish Australia and New Zealand as highly capable, globally competitive manufacturing countries in many industry segments.

Lorch – Industry 4.0 solutions for tomorrow’s industrial challenges As a global leader in welding technology and innovation for over 50 years, the focus of Lorch Schweißtechnik GmbH is on the

development of Industry 4.0 Smart Welding Solutions to drive customer productivity backed with exceptional service and support.

Designed, tested and manufactured in Germany, the development and application of advanced engineered welding systems is what Lorch do, it’s all Lorch do and is what separates Lorch from many of their competitors.

Today, as we accelerate into Industry 4.0, Lorch is the obvious choice with a complete cuttingedge portfolio of Industry 4.0 solutions. The centrepiece is Lorch Wi-Fi Connect Technology

that interconnects the already digitalised welding systems to a cloud platform, unleashing a host of digital management tools to optimise welding processes, costing accuracy, drive productivity, quality and overall production efficiencies.

Lorch Connect is a simple, easy, risk-free entry into the world of smart, digitally interlinked Industry 4.0 technology.

For further information please contact David Wilton: LSP@lorch.eu or visit www.lorch.eu to find a Lorch partner near you.

Manufacturers’ Monthly OCTOBER 2020 25

Regional Manufacturing Innovative farming techniques and the adoption of new technologies have seen significant improvements in productivity and land management.

Sowing the seeds for a wholesome community Wholegrain Milling’s Craig and Renee Neale speak with Manufacturers’ Monthly about their family business and how it has grown with the Gunnedah Shire community.

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RAIG and Renee Neale see flour milling as a family affair.

More than 40 years ago, their family-owned and certified organic flour mill, Wholegrain Milling, was born out of a desire to find more healthy, nutritious, and chemical-free food.

“The business was started primarily by my mother 43 years ago, predominantly from her desire to find food with far less symptoms of allergy in what she was eating, because she was suffering from the effects of chemicals in food,” Craig said.

“So, she was quite ahead of her time. We started experimenting with chemical-free food way back in the late 70s, which was unusual back then.”

Wholegrain Milling’s headquarters are in Gunnedah; the centre of one of Australia’s richest agricultural regions – the highly productive Liverpool Plains. Agriculture is currently leading the way in Gunnedah Shire, with the sector representing more than $1.76 billion in economic value per annum.

This season the area will come alive with golden wheat fields across the plains, much to the growers delight.

Gunnedah Shire Council has prioritised the development of an investment attraction campaign to market the region as the first choice to live, work and invest. Mayor of Gunnedah Shire, Jamie Chaffey, said the campaign will promote 26 OCTOBER 2020 Manufacturers’ Monthly

Wholegrain Milling owner Craig Neale is continuing a family legacy.

Gunnedah Shire and local investment opportunities to regional, national and international markets. “Wholegrain Milling is a fantastic success story of a family finding opportunities within the unique resources available in our Shire,” Chaffey said.

Gunnedah has been experiencing a boom in development and there is keen interest in the Gunnedah Shire for businesses involved in heavy industrial, value adding, and manufacturing associated with primary production.

Gunnedah is a highly desirable location for business, lifestyle and industry. The area represents a major opportunity for further development of food and beverage manufacturing to make the most of the fantastic logistics connections and close proximity growers in the surrounding region.

Nowadays, Wholegrain Milling

is connected with more than 60 growers around Australia dedicated to producing organic or sustainable grains.

When the grains come into the mill during harvest time, the crop is segregated relative to quality and bakeability.

“One of the reasons we do have a premium platter is we are very meticulous with varieties and with quality flour that go into our blends,” Craig said. “We have a slightly higher flour ash content in our white flour than the norm, purely because we try to keep more of the traditional benefits of some of those things that are still in the flour.”

The flour is either roller milled or stone ground then packaged.

“We do some 35 products, 35 different styles of flour, varieties, it gets distributed to up to 180 small bakeries throughout

Australia,” Craig said.

Wholegrain Milling’s stone ground flour is milled in the traditional way – by putting grain in and flour out. There is no mechanisation or modernisation to the stone milling process, which produces a traditional nutty flavour and texture.

The Neales are grateful for the support of the Gunnedah community, with whom they share a strong connection.

“The support of the locals is huge.

I think they love the flour, but also the bread,” Renee said. “There’s a really strong connection between us and the community and for the support, we’re always so grateful.”

After working on the family-owned mill for many years, Renee began her own bakery business, Reverence Sourdough, which is currently selling the family business’ wholegrain flour.

The shop makes and distributes 450 loaves of bread every week to the local community.

The Wholegrain Milling business employs more than 30 employees from the Gunnedah region.

“We’re grateful for the people that work for us, and we try to make it a family concern,” Craig said.

Both of Renee’s brothers work in the mill, while her mum and 91-year-old nan are employed in the bakery. “We’re all very close that way,” she said. manmonthly.com.au

For over 56 years, Manufacturers’ Monthly has lead and informed Australia’s manufacturing industries with its highly credible editorial analysis of the market.

Visit our website and subscribe to get your print and digital editions in additon to our free daily newsletters today! manmonthly .com.au

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Safety& Protection Strength and safety at the core of updated iconic workwear range Manufacturers’ Monthly speaks with the team at industrial workwear supplier Blackwoods about their updated Workhorse range and the due diligence program embedded within the company.

P

RODUCING personal protective equipment during the COVID-19 pandemic has played a key part in Australia’s unprecedented manufacturing activity this year.

While masks will continue to be an essential PPE item, protective clothing for those who work in challenging environments such as manufacturing will also remain important.

Blackwoods, a major industrial supplier with 142 years of experience supplying tools and equipment to businesses across Australia, has updated its tailored range.

Nine years ago, the company decided to create its own exclusive workwear range tailored to Australian industrial businesses, called Workhorse.

While the original range was released in 2014, this year the Blackwoods team saw an opportunity to update the range, bring in new and improved features to the clothing and take it to the next level of comfort and safety.

The brand now has new clothing for night and day wear. While adhering to Australian standards, the team explains how the range holds safety and comfort at its core.

Quality, compliance and responsible sourcing manager for Blackwoods, Sarnia Hobson, said the company has maintained independent accreditation to the ISO 9001:2015 Quality Management System framework.

“We saw this as a positive step forward to gain accreditation in order to continually maintain and improve the quality of our processes and customer service delivery,” she said.

Blackwoods has a supplier risk management program in place for strategic global and national brands

28 OCTOBER 2020 Manufacturers’ Monthly

Blackwoods is committed to delivering workwear that protects the well-being of workers and their communities.

An ‘X’ configuration across the back of the uniform helps machine operators easily identify which way a person is facing.

with regular collaboration governed by a category team to ensure that they are continually delivering against their customer needs.

“Understanding supplier commitments and performance across multiple operational areas such as responsible business practices, quality and compliance and sustainability, allows us to better support our customer expectations and coupled with our in-house technical expertise and site visits, delivers on our customer objectives.”

Blackwoods is committed to continuously improving the quality, ethical and social compliance practices within their exclusive brand manufacturing facilities, to deliver sustainable solutions that protect our brands and the well-being of workers and their communities.

This is also echoed in the engagement and messaging with strategic national brands.

Factories producing Blackwoods exclusive brand range such as

Biomotion retro-reflective tape is another element of design for the nightwear range that is crucial to improving safety.

Workhorse Workwear undertake regular quality and technical assessments and audits by the company’s quality team.

Quality performance at factories is continually monitored, and by utilising customer feedback mechanisms, Blackwoods are able to continually improve their exclusive product range.

Blackwoods has in place a governance framework to ensure manmonthly.com.au

Safety & Protection its Quality and Ethical Sourcing Program is executed and monitored in line with agreed strategy and process.

“Blackwoods opposes the use of modern slavery practices and are committed to the ongoing journey of reducing and eradicating the risk of modern slavery practices in our supply chains,” Hobson said.

KPIs such as independent audit frequency, timely assessment/remedy of compliance criticalities and training deliverables are reported annually and published via the Wesfarmers Sustainability Report which is independently audited.

Apparel program manager at Blackwoods, Cahal Callanan, said the company wanted to provide a “real value proposition” to large industrial businesses who needed workwear to protect employees.

As part of the new range the team is developing new products with a stretch element.

“One of the main factors in the new range was to add in more stretch

fabric, so it fits to workers bodies and allows more movement for people on site doing these active jobs. They are working eight to ten hours each day of really solid work, so if their uniform can fit and move with them it makes them more comfortable and efficient,” Callanan said.

Workhorse has also recently launched a new range with high visibility as a focus.

Instead of using day-time highvisibility colours, such as yellow or orange, the range is made from white fabrics. This was implemented as white is the most naturally luminescent colour and contrasts well in dark environments.

National category and sourcing manager of Apparel and Footwear, Leigh Eam, said the safety aspects of the designs across the Workhorse range is what makes it unique.

“White really does stand out in a dark environment and in addition with our biometric tape applied to the garments a person is really visible,” she said.

Biomotion retro-reflective tape is another element of design for the nightwear range that is crucial to improving safety.

“Usually you may only get one band of tape around the leg and arm for visibility. But to increase this, with our new range we added two bands on either side of the joint on the leg and arm and this makes it easier to identify which direction the person is moving in,” Eam said.

She says there is also an ‘X’ configuration across the back of the uniform so machine operators can easily identify which way a person is facing.

“With two bands featured on the arms and legs of the clothing, each band moves when a person is walking and people can clearly see the motion of that person. I think this range that Cahal has created really focuses on the fit-for-purpose needs for night works.”

Tailored for Australia The entire Workhorse range uses

Blackwoods’ expertise by listening to its customer support staff to identify what unique needs Australian industries have.

“Getting direct information from workers about what they need helps us to develop the right product for them and that has been reflected in this range,” Callanan said.

One aspect that is central to Workhorse’s range is the use of 100 per cent cotton fabric.

“Australians love wearing 100 per cent cotton and we know that the Australian high-visibility standard has been modified to allow workwear ranges to use the natural cotton that Australians want,” he says.

“There are also a range of other factors like clothing vents to combat heat and collars that can be pulled up around the neck to protect from the sun. We created clothing with these elements, and they are intrinsic to our workwear range.”

Call Blackwoods at 13 73 23 or visit www.blackwoods.com.au

Rheinmetall Defence Australia Chooses Lorch Welding Technologies.

“As the manufacturer of Australia’s future military defence vehicles and a leading global supplier of defence and security technology to armed forces around the world, it’s clear Rheinmetall needs the best Industry 4.0 welding solutions. We have standardised on Lorch welding technologies made in Germany. Lorch welding products are among the very best in the world. Their combined leading technologies and partnering approach from their German headquarters with local Australian subsidiary and distribution partner Global Welding Supplies in Queensland address our ongoing welding needs and set the standard for supplier partnerships”.

Neil Fitzpatrick – Manager – GSC / AIC – Rheinmetall Defence Australia Rheinmetall Defence Australia uses the Lorch S Series, a digital Industry 4.0 pulse platform with advanced speed processes: SpeedPulse XT, SpeedArc XT, SpeedUP for all GMAW, GMAWP and FCAW processes. Lorch custom waveforms deliver the specific weld metal mechanical properties required by Rheinmetall to ensure the highest levels of quality and vehicle strength are achieved for the ultimate protection of Australia’s armed forces personnel.

For further information please contact David Wilton: LSP@lorch.eu Lorch South Pacific Pty Ltd is a subsidiary of Lorch Schweißtechnik GmbH, Germany.

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Photo credit: Rheinmetall press pictures

Manufacturers’ Monthly OCTOBER 2020 29

Compressors Without air compressors, supermarket shelves would be empty Sullair Australia explains why air compressors play an important role in manufacturing everyday supermarket goods.

A haunting image of what supermarkets would look like without the help of air compressors.

T

O the everyday shopper, food magically appears on the shelves. It is expertly prepared and packaged, fresh and safe for purchasing and consumption. It may come as a surprise to many that every food item in the supermarket depends on an air compressor at some stage of its commercial preparation and distribution cycle. To gain an understanding of the true scale of the food and beverage manufacturing industry’s reliance on air compressors, we need only stroll the aisles of the supermarket.

Take the humble loaf of bread, for example. Air compressors power a range of essential components in the production of simple sliced bread

30 OCTOBER 2020 Manufacturers’ Monthly

that we buy in the supermarket. Air compressors are needed for driving equipment that separates the loaves pre-baking, for slicing the bread post baking and for packaging the loaves into plastic bags to be placed on shelves. Similarly, air compressors have a range of functions in dairy production. Milking machines are powered by compressors, as are machines that blow mould containers for milk, cream and yoghurt. Product packaging requires sterilisation too, via a range of compressor functions; even the equipment used to transport the products use compressors.

If you’ve seen videos of food production lines, you’ll be familiar with food being injected into packaging – yes, air compressors

again. From baked beans to chocolate custard, tubes of toothpaste to bottled water, the filling in meat pies to the icing on cakes; all require a clean, high quality, pressure controlled, supply of compressed air. Even something as simple as a puff of air into a bag, so it can be filled with carrots, comes down to compressed air production.

These are just a few examples, but for any supermarket product line you think of, an air compressor will be involved at some – in fact multiple – stages of its life cycle. Fresh food, frozen goods, dried, dehydrated, marinated and pickled, canned, bottled, vacuum sealed and more – these are all functions that depend on an air compressor, humming away

in the background.

Jean-Philippe Leclercq is the oil free air specialist at Sullair and has worked with a number of food and beverage manufacturers throughout his career. He is all too aware that customising the air compressor solutions to the unique needs of the product and its specific production cycle is pivotal.

“In a factory you have the compressing side, then the filling, then the packing side – all of which require compressed air, at different pressures, for different purposes,” explained Leclercq.

This is especially the case when it comes to oil free air supply.

Though Australian food standards regulations don’t specify a legal manmonthly.com.au

Compressors need for oil free equipment in food manufacturing, this is not the case in some other countries, with international regulations requiring compliance to standards determining specifics around purity and contaminant levels (ISO 8573-1:2010).

Broadly speaking, food safety regulations require that if a material is deemed as hazardous, an acceptable level of that material is predetermined as allowable (based on rigorous scientific testing and data). That being the case, it must be assumed then that until regulations in Australia around air quality in food manufacturing are developed, the acceptable oil level content must be zero per cent.

“Oil free air supply is crucial,” ssaid Leclercq, “because 99 per cent of the time in the food production cycle, the air comes into contact with the product.”

With oil injected equipment – even with adequate filtration barriers in place – the chance of

The manufacturing room of ITO EN Australia, a subsidiary of the largest green tea manufacturers in Japan: ITO EN Japan, at their location in regional Victoria. ITO EN Australia uses oil-free air compressors in almost every stage of their production and manufacturing. oil contamination is still present.

Where ingestible products are concerned, this is a risk that no food manufacturer should be willing to take. As well as being a health and safety issue, the impact to a company and its brand

could be disastrous. In many countries, standards around oil free status are strictly enforced and products that are produced on oil injected equipment may not be approved for import.

“Air quality is so important,

but some people don’t understand compressed air. An oil-injected system won’t do the same thing as oil-free,” said Leclercq.

“With compressed air, you really rely on the supplier to technically support you,” explained Leclercq.

In a great partnership between the end user and the compressed air supplier, the application of experience and specialist knowledge makes all the difference.

With air compressors as the lungs of the business, air compressors failing would cause severe disruptions to the food supply chain that modern Australia depends on.

Shortages of food and products usually stir up feelings of anxiety and discomfort for the public, as well at headlines around the world (even outside of a global pandemic).

With pressure on supermarket suppliers at an all-time high, the importance of reliable, clean compressed air is too. Without air compressors, our supermarket shelves would be empty.

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Machines Tools Saving the bottom line with tool reclamation Northern Tooling Reclamation Australasia director, Andrew Rodgers, and national sales manager, Richard Holden, speak to Manufacturers’ Monthly about helping Australian manufacturers save costs by using their machine tools.

NTR Precision Tooling Engineers has repaired tools with the help of advancements in materials and CNC.

N

ORTHERN Tooling Reclamation (NTR) Australasia is now offering the Australian manufacturing industry a new service to repair damaged cutting tools. Tool reclamation is a repair and refurbish solution to help manufacturers prolong tooling life.

Broken machine tools tend to become a bin item in Australia, but the company is changing that by recycling the tools to help manufacturers save on cost.

“Generally, what would happen in Australia now is that the broken tools would get thrown away,” director of NTR Australasia, Andrew Rodgers, said. “It’s up to the customer to buy a new tool.”

Sales manager, Richard Holden, said the process to reclaim tools is a specialised practice.

“NTR would strip down the broken pockets, weld up each pocket, and then go through a procedure to rebuild each pocket,” he said. “They use manual CNC machines to do that, to rebuild the pocket, and go through stringent testing and measuring.

“All the tools are sent back with a certificate of conformance, so it is like they are back to specifications from a new cutter.”

The service offers manufacturers 50 per cent cost savings, and repairs

32 OCTOBER 2020 Manufacturers’ Monthly

generally take four to six weeks.

Rodgers said although there is often initial scepticism about how the service works, once proven, customers are happy with the result.

“Because tool reclamation such a fiddly process, nobody’s ever really focused on it,” he said.

The replacement cost is often built into the cost of a job for the customer, and a new cutter comes at a higher cost compared to recycling an old one. “That cost saving can be passed straight onto the bottom line for the manufacturer,” Rodgers said.

NTR Australasia has gradually built a customer base through

NTR repairs tools to meet the specifications of a new cutter.

machining tools for clients who make rail products, as well as other kinds of manufacturing.

“Machine cutting tools are expensive to make because of the profile of the cutter. The inserts that are used, once damaged, can cost thousands, up to tens of thousands of dollars,” he said. “We can repair them for a fraction of the price.”

Rodgers said the company has been operating more efficiently while working remotely since the COVID-19 lockdown began, by communicating with customers remotely, online.

“A customer will contact us saying they have a damaged cutter, tell us the details, and then we’ll get them to send the cutter to us so we can visually inspect it, and then we give them the quote on repair. Then we repair and return.”

NTR also repair and service all driven tools on the market by providing a full strip down replacement of worn gears and shafts, and re-grease. Runout is also checked and documented before the tool is returned to the customer in near new condition.

While most cutting tool manufactures now require minimum order quantities for “special tool”

manufacture, NTR offer short run or one-off options.

“This is a potential huge cost saving on carrying of unwanted or excessive high value inventory.

Manufacture can be made from an existing drawing if it’s available, or the existing tool can be 3D-scanned and reverse engineered,” Holden said.

“Customers can even request what manufactures insert is to be used in the new cutters. So swapping manufactures inserts has never been easier.”

About NTR Precision Tooling Engineers Founded in the UK in 1976, NTR Precision Tooling Engineers has repaired tools with the help of advancements in materials and CNC machining.

The reclamation process uses glass beads to polish customers’ tools. The polishing not only ensures seating accuracy, it also reduces the issue of blocked threads – a common problem when tools have been spray painted black.

By only polishing repaired tools, it prevents unnecessary coolant contamination, further prolonging the life of cutting fluid – another problem associated with black spray-painted tools.

NTR’s measuring equipment is accredited under ISO 9001: 2008 to deliver accuracy. All repaired tools come with its own inspection certificate detailing the maximum radial and axial runout, ensuring the tools are within the manufacturer’s specific tolerance.

The business has also invested in a Royal twin scope tool pre-setter for final inspection in addition to six inline Trimos for robust inspection procedures. Internal and external calibration of instruments take place regularly.

Find out more about NTR Australasia at www.ntraustralasia.com.au manmonthly.com.au

Machine Tools Tougher tools, longer life Manufacturers’ Monthly speaks with directors of Daintree Tools, Andrew and Kerry Rodgers, about the company’s specialised expertise in manufacturing live centres for Australian heavy industries.

D

AINTREE Tools is an Australian, family-owned business with more than 15 years of experience specialising in the production of live centres for lathes.

Founded in the early 2000s, the company mainly manufacturers live centres for heavy industry, incorporating heavy duty bearings that are fully sealed and lubricated for extended life.

Technical advances in the production process ensure the live centres maintain accurate concentric work, which has increased the operational range and eliminated the need for adjustment during operation.

“We use state-of-the-art CNC machinery and CNC cylindrical grinders to get very high tolerance and a high accuracy,” Daintree Tools director, Andrew Rodgers said.

“The main manufacturing that

The 600 series centres are spring loaded centres designed specifically for the CNC market. manmonthly.com.au

gives the live centre complete accuracy is that the finished grind of the 60-degree point at the front is ground when the centre is assembled.

So, every spindle is pretty much hand ground to its own bearing pack.”

The company mainly supplies to the machining industry, such as fitting and turning, maintenance facilities, as well as aerospace manufacturers.

“We have a range of centres that go from 500kg capacity all the way up to 28 tonnes,” he said.

Co-director, Kerry Rodgers, said one of the benefits of being a locallybased business is that there are no challenges with accessing stock, and as a result, manufacturing costs stay at a minimum.

“We have a lot of inventory here in Australia, so when we make them, we make them in batches of 50 and 100 at a time,” she said.

The live centres incorporate heavy duty bearings that are fully sealed and lubricated for extended life.

Staying competitive Kerry believes the company is competitive in a global market.

“We can compete in a worldwide market because we make in volume,” she said. “We’re not paying import cost duties and freight, so from a manufacturing point of view, it is possible to make a world-class, very competitive product in Australia.”

“They’re as good a quality as anybody makes anywhere in the world. In fact, they probably have a higher tearing capacity, and the same accuracy – similar to what European countries offer,” she said. “And compared to other main brands, ours are heavier and faster with the same tolerances and possess the same accuracy.

“When you look at an Australianmade product, we’re saving on shipping, we use the same machines as they use over in Europe, China, or Asia. Because we’re doing them in larger quantities, our manufacturing costs are minimal.”

A range of live centres support weight from a 500kg capacity up to 28 tonnes.

Technical advances in the production process ensure the live centres maintain accurate concentric work.

Manufacturers’ Monthly OCTOBER 2020 33

Test Machines Providing reliable and timely service for local manufacturers Manufacturers’ Monthly speaks with The Elastomers’ technical and quality assurance manager, Sam Brumale, about how local test machines from Test Machines Australia are critical to their rubber manufacturing business.

H

AVING a local agent service test machines is critical for Melbourne-based rubber manufacturer, The Elastomers.

The company engages the services of Test Machines Australia, a company that has been involved in materials testing and the design of various test machines for more than 20 years – with a focus on quality.

Test Machines Australia has recently launched 24-hour service support to help manufacturers improve quality, reduce downtime and mitigate costs associated with delays.

In the case of The Elastomers, who mainly supply rubber for the manufacturing of mining equipment and conveyor belts, as well as general rubber products, its business is heavily reliant on quality.

“We need to have equipment that Elastomers uses several different machines for testing.

34 OCTOBER 2020 Manufacturers’ Monthly

is accurate and reliable, and then we need to have the companies that service the machines, so we don’t have downtime,” The Elastomers’ technical and quality assurance manager, Sam Brumale said.

“We can’t sell the product to the customer if we haven’t tested it. If the actual test equipment breaks down, the business stops.”

Without accurate testing, the company could be faced with the decision to not sell, or to find another company to fulfil testing requirements.

“Anything that causes a delay is a cost inconvenience to our customers, and probably could be a cost penalty to us. The sooner we can get the machine, where there is a breakdown, up and running, obviously that’s an advantage,” Brumale said. “If people

are in a 24-hour business, then there could be some advantage knowing that you don’t have to wait until the next day, you could get someone out that same day to get it repaired.”

In order to meet specifications, either set by clients or within their own business, one of the tests The Elastomers does is a tensile tester provided by Test Machines Australia.

“The advantage of using Test Machines Australia’s equipment in particular is because their CEO Paul Cibotto a local agent. He’s someone in Australia that I can talk to, and even better, someone in Melbourne I can talk to, which helps with the current restrictions,” Brumale said.

Brumale said the company’s laboratory has several different types of machines. However, for some of them, there is no local agent.

“Some of the manufacturers and agents are in the UK, so it means when I have a problem, it’s hard to talk to them because of the time difference. And it’s hard to get service if I do have a problem, as they don’t visit Australia anymore,” Brumale said.

Brumale said that manufacturing has had to continue during the COVID-19 pandemic, and has not stopped during lockdowns.

The company has followed all the government requirements like social distancing, practising good hygiene and having people working from home where possible. For those who do have to be onsite, work shifts are staggered and workers are spread out beyond 1.5 metres of each other.

“We’re not a business where we have a lot of people in a small area.

We’ve got the opposite. We’ve got a large area with a few workers. We’re a bit lucky there,” Brumale said.

In addition, due to the pandemic, meetings are minimised unless they’re essential. That has limited communication with the outside harder because they don’t have many visitors.

Brumale said the quickness offered by Test Machines Australia makes them an ideal business partner, particularly for emergency repairs.

“With Test Machines Australia, I recently had a problem where I needed to get our machine calibrated, and with Cibotto being local, it was easy to do,” he said.

“Having a local business is obviously an advantage in terms of getting service, in terms of not having to communicate across different time zones, and then getting your service done a lot easier and a lot quicker, rather than having to try organise someone to come from interstate or overseas.” manmonthly.com.au

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The highest performing solids-handling pump available Gorman-Rupp has just announced the release of the Eradicator version of its highperformance Ultra-V Series wastewater pump.

Some applications are tougher than others. Whether you are dealing with today’s new sewage of sanitary wipes, plastic bags, feathers, hair, sludge, stringy material, or any other type of debris, downtime costs you money.

The Ultra-V Eradicator is able to deliver higher pressures than any other solids handling self-priming pump, while reducing blockages in wastewater streams from rags, wet wipes, undigested hay, and feathers.

The new pumps are an extension of Gorman-Rupp’s Ultra-V series pumps that are heavily used by sewage treatment plants and meat process plants.

The Eradicator Solids Management System now comes as an option with new design features including an aggressive self-cleaning wear plate incorporating a number of notches and grooves, as well as a patented lacerating tooth that helps break up stringy materials and scrape them off the impeller vanes, passing them through the pump discharge without impacting performance or interrupting service.

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igus hybrid cable for new motor generation In order to supply modern motors with energy and data, users need appropriate cables that function dependably even at high accelerations and on long travels. Especially for use in motion, igus has now developed a hybrid cable that is offered as a drive solution for the new Bosch Rexroth motors. Available from Treotham, it combines energy and data cable in one and is therefore also suitable for compact installation spaces.

Treotham offers the cable as a fully harnessed readycable that is accurate to the centimetre. This saves costs for users.

Ever smaller and more compact with an even higher output: such a trend is becoming increasingly apparent in the field of motor development. But not only the motor but also the cables used must meet the new requirements. Hybrid cables are one solution. They combine energy and data supply in one by integrating the encoder cable into the servo cable. This eliminates the need for cabling with a separate measuring system for the encoder. Especially for use in the energy chain, igus has now developed a new hybrid cable suitable for Bosch Rexroth MS2N and IndraDrive Mi motors. A halogen-free PUR outer jacket ensures oil resistance and increases the service life of the cable. The user receives the drive solution already fully harnessed with connector as the so-called readycable from Treotham.

All cables are tested and inspected under real conditions in the company’s own 3,800 sqm test laboratory. Tests have shown that the new hybrid cable with a bend radius of up to 10xd in the e-chain can safely withstand 10 million double strokes over the long term. Due to the realistic tests, igus is the only cable manufacturer in the world capable of providing a 36-month guarantee on its chainflex cables. In total, igus has over 4,200 drive cables suitable for 24 manufacturer standards in its readycable range.

For a quick selection of the suitable solution, with the readycable product finder igus

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offers a practical online tool. Simply enter the igus part number or the manufacturer or select the name of the drive manufacturer from the menu; then click on the required cable type and the product finder will list all matching parts. An overview provides the different cable qualities such as outer jacket, bend radius, travel and price. The integrated service life calculator also determines the running time.

Company: Treotham Automation Pty Ltd Phone: 1300 65 75 64 Web: www.treotham.com.au

Manufacturers’ Monthly OCTOBER 2020 37

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ARCHMI Series APLEX realised that the global automation market needs a human-machine interface (HMI) which is highly expandable and customisable to satisfy a broad range of industries and applications. Designed for customers who need perfect integration, the ARCHMI series can be tailored to meet a wide range of end-user requirements. The ARCHMI series features IP65-rated flat panels, fanless enclosures, multi-touch capability, extensive expansion options, optional wide temperature support, optional sunlight readable anti-scratch screens, and optional optical bonding.

The ARCHMI series can be customised with a variety of I/O expansion modules and connectivity options. Eleven TB-528 series Mini-PCIe expansion modules are available and providing support for LAN, USB, and COM ports, as well as POE and CANbus.

The ARCHMI series is available with 7-32-inch TFT-LCD displays and supports both resistive or projected capacitive touchscreens. The optional optical bonding of the LCD screen minimises reflections, reduces condensation, and eliminates any dust between the layers to provide a longer service life with improved appearance. Constructed in a corrosion resistance aluminium heatsink style die-cast enclosure, the ARCHMI Series inherently provides very effective fanless thermal cooling. The design also allows easy access to the system’s internal hard disk or solid-state drive storage device. With Intel processor support for Celeron N2930 and 6th Gen. Core i3/i5 with up to 16GB of memory the ARCHMI Series can be optimised to meet the computing requirements of any application. In addition, a wide range 9-36VDC input voltage allows the ARCHMI Series to be power from almost any power source.

Industrial automation has evolved significantly in recent years and the ARCHMI Series has been designed to keep up with the challenges of Industry

38 OCTOBER 2020 Manufacturers’ Monthly

4.0 and IoT. While the ARCHMI Series focuses on smart factory automation it is equally at home in commercial environments including building control, transportation, retailing and education.

Company: Interworld Electronics and Computer Industries Phone: (03) 9593 7555 Web: www.ieci.com.au/

manmonthly.com.au

MARCH 2021 – ERP SOFTWARE Data is a plant manager’s most important tool in ensuring an efficient operation. But with so much data available, how are modern leaders to make sense of it all?

In March 2021 we will look at the enterprise resource planning (ERP) software offerings, to highlight what tools are available to support improving uptime in manufacturing operations.

In every edition of Manufacturers’ Monthly, we’re proud to work with our commercial partners on content that helps connect you with your future customers.

Booking deadline: 27 January 2021

To book contact DANILO CORTUCCI now danilo.cortucci@primecreative.com.au | 0434 419 663

The Last Word Reinvgorating Australia’s national climate policy

T

HE domestic and international effects of the COVID-19 pandemic have had impacts on energy prices and emissions that look positive at first glance – a pre-existing decline in wholesale electricity prices has steepened; a global oil price crash and weak East Asian gas demand have pushed spot gas prices far down; and early signs are that global and Australian greenhouse gas emissions have been significantly depressed.

However, all these effects appear temporary or come with significant baggage. Australia’s long-term interest in a global energy advantage and a successful transition to net zero emissions require continued attention and action on these issues. There are opportunities to advance these long-term goals while also speeding recovery from the economic effects of the pandemic.

Australia has a strong national interest in successful global efforts to limit climate change; in contributing to that success by achieving net zero emissions by 2050; in safely managing the change we cannot avoid; and in increasing our competitiveness and shared prosperity in the process. We have opportunities to emerge strongly from the pandemic through reform and investment across energy and the clean economy – or the risk of a reversion to uncompetitively high energy costs if we do not manage well.

It is fundamentally important that we inform economic policy and reform across multiple portfolios by adopting a clear, agreed and national vision for successful transition to net zero emissions. Setting that vision will help the development of robust and pro-competitive strategies for gas, electricity and a broader clean economy.

Natural gas is an important part of Australia’s economy today, as a fuel for dispatchable power; a heat source for industry and households; a feedstock for plastics and chemicals; and an export commodity. In the course of a transition to net zero emissions, Australia should minimise

40 OCTOBER 2020 Manufacturers’ Monthly

the exposure of our economy and society to risks from high gas prices or short supply, with a strategy including four steps: facilitation of new supply options that make long-term sense; expansion of alternative fuels including biogas and hydrogen; a heavy focus on demand reduction through gas efficiency and electrification; and continued policy reform to promote a competitive and secure local market. The federal government’s recent announcements include exploration of new supply, hydrogen and competitiveness measures. There is still more to be done on demand efficiency, however.

Reliable electricity is crucial to all households and the continuity of all businesses, and electricity costs play an important role in household budgets and the competitiveness of many industries. Australia should maximise long-term opportunity in a net zero emissions world and reduce medium-term risks to electricity price and reliability. Achieving competitive, reliable and clean electricity requires that we: renovate our power markets; enhance our electricity networks; de-link power prices from volatile fuel export prices; manage coal closures effectively; improve energy productivity and management across the economy; aim for globally competitive costs for energy infrastructure delivery; and close the emissions gap in electricity market designs and policies. The recent Federal announcement of $250 million to accelerate three major transmission projects is a significant step.

The successful transition to a competitive net-zero economy extends well beyond electricity and gas, to industry, transport, agriculture and more. Building a broader clean economy demands that we develop clear and practical transition pathways across all sectors and ramp up platforms for supporting clean economy innovation and cost reduction.

Such pathways and platforms (like the expanded ARENA and

Innes Willox, chief executive of the AiGroup.

CEFC that are taking shape) are important to bring low- zero- and negative emissions options forward and lower their costs, but they do not substitute for climate policy mechanisms to drive efficient mass uptake and scale-up while preventing loss of trade competitiveness. Some clean technologies appear highly price-competitive with high-emitting options even without placing a value on emissions – variable renewables have become extremely cheap and both batteries and light battery-electric vehicles look set to become so.

However, other options may always involve some degree of cost premium; for instance, conducting industrial or power generation activities with carbon capture and storage is inherently more expensive.

More fundamentally, emissions reduction and sequestration have a value derived from the impacts and risks of climate change that we wish to avoid. Unless we recognise that value and embed it in policy instruments, emissions will not reduce as far or as fast as is in Australia’s national interest.

There are numerous specific opportunities to build a clean

economy. Fostering a hydrogen economy should be a high priority and public investment should ramp up considerably from the levels contemplated when the National Hydrogen Roadmap was adopted pre-pandemic. Carbon capture and utilisation or storage does not currently look likely to be a competitive technology in electricity generation, but it remains a very important option to address heavy industry emissions, alongside hydrogen, bioenergy and electrification. Transport electrification and hydrogen integration needs major focus, particularly given the parallel concern over Australia’s lack of transport fuel security.

It is also important to manage risks to our existing exports through economic hedges, a more diverse economy and fair transition and opportunity for communities, workers and supply chains.

All of this is a tall order, but well within the capabilities of a talented and richly endowed country – and strongly in the interest of a nation whose future prosperity requires both success on climate and a new energy advantage.

manmonthly.com.au

OCTOBER 2020 | VOL.74 NO.5 | Est. 1953

A focused level transmitter giving reliable and accurate measurements.

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80GHz TECHNOLOGY A new era in radar level measurement began a few years ago when VEGAPULS sensors based on 80 GHz technology were introduced. Thanks to the more precise focusing of the radar beam, the sensor virtually eliminates any unwanted or interfering reflections – the level measurement therefore becomes easier to read and is more reliable.

• Highly resistant encapsulated PTFE antenna • Non-contact level for maintenance-free operation • Easy integration – effortless performance • Unbeatable application versatility • Optimised signal processing

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OCTOBER 2020 | VOL.74 NO.5 | Est. 1953

INSIDE PACE

Automation

Actuator Systems

Latest Products

How IoT and a collaboration has brought greater benefits

Why an electric solution is better

The latest components from the market

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NEWS

Helping to put you in Control

N1540 Process Indicator + RT 240 VAC

$1.5bn energy project welcomed by SA government

T

he SA state government has welcomed the federal government’s announcement accelerating delivery of the critical $1.5 billion Project Energy Connect interconnector.

The energy project in South Australia will deliver cheaper and more reliable energy for the South Australia and New South Wales.

The project will create jobs and unlock further investment in renewable generation in SA, and the announcement is well timed to support economic recovery from the global coronavirus pandemic.

The interconnector will also pave the way for new projects such as Neoen’s mammoth $3 billion

Goyder Project near Burra.

Minister for Energy and Mining, Dan van Holst Pellekaan said the interconnector will stabilise the grid and address the legacy of blackouts.

“The interconnector will lead to cleaner, more reliable and more affordable energy for people across our state,” van Holst Pellekaan said. ““The Australian Energy Market Operator has deemed the SA-NSW Interconnector ‘critical’ and a ‘no regrets’ project to address SA Labor’s legacy of blackouts.

“It’s time for Labor to swallow its pride, admit that it was wrong, and get on board with the SA-NSW Interconnector.

“Peter Malinauskas should stop

standing in the way of cheaper, cleaner and reliable electricity for South Australians.

“ESCOSA’s annual report into power prices records a $158 savings on electricity bills for households in the last two financial years and shows the Marshall Government is on track to deliver its promise to cut electricity bills by $302 over four years.”

Modelling shows that small and medium businesses with significant electricity consumption will save many thousands of dollars each year when the interconnector is complete.

The interconnector will also deliver an average $66 saving for households. PACE

Five digit universal process indicator accepts thermocouples, Pt100, 4 to 20 mA, 50 mV and 10 V signals. 4-20mA programmable analog transmission . 240 VAC Powered. Mini USB interface.

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S0 pulse counter with MODBUS RTU interface

Designed for counting pulses from water, gas and electricity meters. It has 4 isolated 32-bit counters held in non volatile memory.

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RW-TH Indoor air quality sensor

Unipi RW-TH indoor air quality sensors are designed for measuring Temperature, Humidity, VOC, Bar. Pressure and Ambient Light. Feature WiFi and RS485 Modbus RTU connectivity.

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Closed-Loop Stepper Driver

Leadshine CS1-D507S closed-loop stepper motor driver with encoder feedback input, Suits 2 phase stepper motors up to 7.0 A.

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7 A, Closed-Loop Stepper Driver Closed-loop stepper motor driver with encoder feedback input, operating at 20-50 VDC. Suits 2 phase stepper motors up to 7.0 A.

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Dual Axis Inclinometer ±45º Degrees - Voltage Output MCA420T-45-V1 dual axis inclinometer senses tilt angles from -45º to +45º and gives a 0 to 5 V analog voltage out.

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Ultrasonic sensor measures level and distance through the air using ultrasonic sound waves up to a distance of 30 feet (9.1 m). 4-20mA, 0-10V and Modbus RTU interface and digital alarms.

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The interconnector will stabilise the grid and address the blackouts which have been happening.

For Wholesale prices Contact Ocean Controls Ph: (03) 9708 2390 oceancontrols.com.au Prices are subjected to change without notice.

NEWS

Deakin’s Boron Nitride Nanotubes (BNNT) are pure and industry-ready

A

new study has revealed that Boron Nitride Nanotubes (BNNT) produced by BNNT Technology Limited using patented Deakin technology have reportedly the highest purity among commercial products in the world.

Conducted by another leading Australian University, the independent analysis of seven commercially available Boron Nitride Nanotubes (BNNT) samples from around the world confirms Deakin’s place at the forefront of this cutting-edge nanofibre technology.

Co-inventors of Deakin’s BNNT manufacturing process Professor Ian Chen, Deakin’s nanotechnology group leader; and Dr Luhua Li, Senior

Research Fellow at Deakin’s Institute for Frontier Materials (IFM), welcomed the outstanding result.

“The commercialisation of BNNTs is the culmination of two decades of research and it is exciting to see the rapid progress that is being made”, Chen said.

BNNTs are super flexible fibres that are 100 times stronger than steel but as light as carbon fibre, with potential applications in industries ranging from aviation to mining, medicine, and space travel. They are notoriously expensive to produce, with one kilogram valued at $900,000, and difficult to manufacture at scale.

IFM has led global research

in BNNTs for a number of years, becoming the first in the world to develop and patent technology that allows BNNT to be manufactured in bulk for the first time.

In 2018, IFM licensed its BNNT manufacturing technology to BNNT Technology Limited, a start-up based at the University’s ManuFutures facility in Geelong.

The company’s new $3 million plant at ManuFutures began production in 2019 and is now in the advanced stages of scaling up to meet worldwide demand for BNNT product in a variety of new material applications.

Deakin’s executive director of research innovations, Ben Spincer,

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believes BNNT Technology could become a major new business, boosting Geelong’s reputation as the home of advanced manufacturing in Australia.

“As part of a broader partnership between Deakin University and the PPK Group, joint venture companies have already been established to use advanced BNNT composite materials in Li-S battery (Li-S Energy Ltd) and3D dental ceramics (3D Dental Technology Pty Ltd) with more expected to follow.

“We look forward to continuing our support of BNNT Technology at ManuFutures both as a shareholder and research partner as it seeks to fulfil the exponential growth in global demand for BNNTs,” Spincer said. PACE

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NEWS

CS Energy taps into UQ’S Warwick solar farm

C

S Energy has signed an offtake agreement to purchase a proportion of the renewable energy produced at the University of Queensland’s 64 megawatt Warwick Solar Farm.

Energy generated by the project is used by UQ to offset its own energy needs, with any surplus being sold into the market – a portion of which will now be supplied to CS Energy.

The company will pass the benefit of this renewable energy from the solar farm on to our Queensland Government customers, as part of their energy supply agreement with large Queensland Government sites.

The Queensland government is supporting UQ’s energy ambitions through providing retail administration and hedging services.

It is also supporting UQ’s energy ambitions through providing retail administration and hedging services.

CEO Andrew Bills said CS Energy

was excited to be adding further renewable energy to its portfolio to support customer requirements.

“Our supply agreement with the

Queensland Government includes a renewable allocation as well as energy from CS Energy’s thermal generation assets,” Bills said.

“We’re proud to offer these kinds of tailored energy solutions to our customers and support the Queensland Government’s target of 50 per cent renewable energy generation by 2030.”

Representatives from CS Energy visited the Warwick Solar Farm on 17 July for its official opening.

The Warwick Solar Farm utilises low impact solar photovoltaic technology to generate around 160,000 MWh of clean energy every year. PACE

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linak.com.au/techline OCTOBER 2020 www.pacetoday.com.au 7

NEWS

ARENA announces $8.2 million funding to Tesla for battery and solar systems deployment in SA

Previously, ARENA has supported virtual power plant (VPP) projects in South Australia led by AGL and Simply Energy.

O

n behalf of the Australian Government, the Australian Renewable Energy Agency (ARENA) has today announced $8.2 million in funding to Tesla Motors Australia (Tesla) to deploy residential battery and rooftop solar systems at 3000 properties owned by Housing SA across Adelaide.

As part of the South Australia’s Virtual Power Plant (SA VPP), Tesla will install 5 kW of rooftop solar and a 13.5 kWh Powerwall battery system at each property, at no cost to the tenant.

The system will provide approximately 80 per cent of average household energy use.

Together with 1100 systems already installed in a previous phase, the combined 20 MW / 54 MWh of residential energy storage will be used by Tesla in a centrally controlled VPP trial.

With this, more than 3000 social housing tenants in South Australia will 8 www.pacetoday.com.au OCTOBER 2020

soon join in the VPP, helping to deliver lower energy bills and a more resilient electricity grid.

Housing SA tenants involved in the trial, like other renters, are usually locked out of being able to benefit from renewable energy. The tenants will benefit from cheaper household electricity bills, with the project offering electricity rates 22 per cent lower than the default market offer.

A VPP is a centrally-managed network of battery systems installed behind-the-meter that can be collectively controlled to deliver benefits to households, energy retailers and the local network.

The $60.6 million SA VPP is also supported by $10 million from the South Australian state government’s Grid Scale Storage Fund in ongoing payments, $30 million debt finance from the Clean Energy Finance Corporation and an $18 million equity contribution from Tesla.

With the support of the SA Government, Tesla has previously installed 1100 solar and battery systems.

This next phase of deployment supports Tesla’s ambition to create the world’s largest VPP comprising 50,000 solar and storage systems across both social housing and private dwellings.

The 3000 additional systems will also participate in AEMO’s VPP trial to provide a range of grid stability services by exporting excess energy to the National Electricity Market.

Previously, ARENA has supported VPP projects in South Australia led by AGL and Simply Energy.

ARENA CEO Darren Miller said this was the next step towards the commercialisation of VPPs. “This project represents a significant step towards a technology and commercial model for battery and solar that requires no upfront cost or risk to the customer. Another benefit of this approach is that it is

open to households that otherwise wouldn’t have access to renewable energy options,” he said.

With more than 2.5 million households already owning rooftop solar and more than 60,000 home battery storage systems already installed in Australia, Miller said VPPs would be important to Australia’s future energy security and reliability.

“As rooftop solar and home battery storage increases in Australia in the coming decades, virtual power plants potentially have an important role to play in harnessing distributed energy in a way that maximises the benefit to the customer as well as the electricity system as a whole.

“By supporting this pioneering project, ARENA is excited to help support the evolution of virtual power plants that can provide dispatchable power and essential grid stability powered by clean energy technology, at scale,” Miller said. PACE

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ROBOTICS

Backplane Systems hardware allows the disinfection units to operate in a safe manner without the presence of humans.

Germicidal robot manufacturing PACE speaks with Backplane Systems Technology and Baird Technology about the challenges involved in the business of robotics during COVID-19.

T

he COVID-19 pandemic has created unprecedented challenges for many businesses during the past six months. During this time, some manufacturers are riding out the storm by taking the opportunity to develop innovation.

Baird Technology has maximised the opportunity during COVID-19 to focus on creating autonomous robots for infection control by partnering with Backplane Systems Technology, an Australian-owned and operated supplier of customised industrial PC systems.

Baird Technologies CEO David Baird said one of the key aspects of the disinfection units it manufactures,

10 www.pacetoday.com.au OCTOBER 2020

known as NÍGHTINGALE and AIR ANGEL robots, is its computing power.

“Backplane’s hardware is critical to our projects because we need the latest computer hardware to put in our algorithms. We’re starting to advance the levels of both machine learning and artificial intelligence,” he said.

Finding new customers during the pandemic means reassessing business models, methods of communication to potential clients, and adapting to customer needs as they are being presented.

“It’s a very unusual period of time and the way we’ve done things in the past for Baird Technology,

focusing on face-to-face presentations of critical concepts and technological capability, that doesn’t lend itself well to Zoom meetings. A lot of the early adopters who we work with, they really are hands-on people, especially overseas, and that’s presented a difficult challenge,” Baird said.

Baird said while infection control using ultraviolet light (UV-C) has existed since the 1950s – traditionally within hospital wards in air conditioning units and hospital operating beds – he believes the current levels of surface disinfection is unprecedented.

“We’re seeing an upsurge in the understanding of UV-C, because there are no known pathogens, viruses

or bacteria that are resistant to UV-C,” he said.

The NIGHTINGALE unit, designed specifically for the disinfection of enclosed rooms and spaces, provides low pressure UV-C lamps in the 254nm range mounted on a robotic base. The model is fitted with hazard warning light, 360-degree cameras with AI algorithm for human detection that shuts down the UV-C system if the presence of a human is detected.

The system also uses LiDAR laser surveying to map and plan the most efficient disinfection cycle, ensuring 99.9 per cent of viruses and pathogens are destroyed.

“It’s an autonomous, robotic, remote-controlled unit that maps the

ROBOTICS

area and activates a plan based on the size of the area to maximise the disinfection of that space,” Baird said.

A version of the NIGHTINGALE unit designed to be used in planes, the AIR ANGEL, adopts the same processes but addresses the challenges of space restriction and seating arrangements.

“We required a lot more power for the AIR ANGEL, because there’s a lot more shadows present within the surfaces when you’re moving inside an aircraft, and this presents a challenge” Baird said.

“COVID cells, being lipid, are not a resilient virus, hence good hand sanitisation can destroy the virus. That’s also what UV-C does. It penetrates the outer layer and destroys the DNA and RNA to prevent the virus from actually replicating.”

As the pandemic continued to spread globally, Baird Technology and Backplane Systems used their expertise in robotics to develop a disinfection solution.

“With COVID coming in, we’ve noticed, around the globe, many companies rose to the challenge of providing equipment that could be used to disinfect buildings and so forth,” Baird said.

The safety features, programmed by a machine learning algorithm, ensure that if a human enters the room while the robot is in operation, the robot will lapse immediately.

“COVID-19 has created a unique opportunity, and we see longevity for product life cycle of both products,” Baird said.

A certified UV-C distributor and installer for Philips germicidal lamps, which Baird Technologies has successfully integrated into the NIGHTINGALE and AIR ANGEL units to provide high levels of iradiation capability to disinfect rooms within a short time.

Baird Technologies is currently building relationships with the United Arab Emirates, Oman, Egypt and the UK, the US. The Therapeutic Goods Administration has assessed and accepted the NIGHTINGALE disinfection robot as a non-medical device.

“Given the current circumstance, our value proposition is reducing exposure to risk within the workplace.

The Nightingale unit is designed specifically for the disinfection of enclosed rooms.

Within the aviation industry, we believe this is imperative for commercial airlines to protect staff and customers as well and build confidence in this severely impacted industry,” Baird said.

“Australian manufacturing is respected globally. We’re looking at moving these units out in large numbers over the coming months, and Backplane has played a huge part acting as support staff extension for Baird Technology.”

Assessing the challenges

The partnership with Baird Technology is one example of how Backplane Systems Technology has used the pandemic as an opportunity to highlight the potential of embedded industrial computing in a wide range of sectors.

The company was established in 1989 to service the needs of systems integrators. Since then, Backplane has grown to become a primary supplier of a wide range of industrial computer hardware solutions for a multitude of applications. These include defence, mining, emergency services, autonomous agriculture, robotics, rail, transportation, surveillance and utilities.

Backplane Systems Technology specialities include the supply of customised industrial PC systems,

embedded rugged controllers for in-vehicle computing and harsh environments, AI and edge computing platforms, LCD displays and panel PCs, rugged tablets and PDAs, network appliances, data acquisition and control modules.

“One of the key markets we have focused on during 2020 is our edge computing product line, incorporating GPU compute technology designed for AI, machine learning and autonomous vehicles,” Backplane Systems Technology CEO Kristy Comb said.

“Backplane Systems Technology has invested significantly in this vertical market by commissioning a white paper Computing around Artificial Intelligence and Autonomous Vehicles for Industry designed to educate and discuss the opportunities for businesses to integrate this emerging technology into applications in mining, manufacturing, rail, surveillance and road transportation.

“Our white paper has been an immense success during 2020 and generated the greatest level of engagement compared to other articles over the past six years. Backplane Systems Technology has attributed this achievement to the emerging trend in AI and autonomous applications, as well as the increase in people working from home,” Comb said.

As customers and suppliers shifted

to working from home, Backplane adopted similar technologies to stay in touch and continue providing the latest in AI hardware.

“During COVID, face-to-face meetings with clients and suppliers became a risk for local, inter-state and international travel. To combat this, we quickly adopted a ‘business as usual’ approach by utilising video conferencing platforms.

“This was particularly successful when hosting project meetings with people across different states and internationally, and as such has been adopted as a standard practice within our business.”

Backplane Systems Technology has always maintained close working relationships with international manufacturing partners, attending annual worldwide product seminars to keep abreast of new and emerging technology and opportunities.

“When international travel become difficult due to border restrictions and health risks, our annual seminars were held via an interactive video conference,” Comb said.

By embracing current industry trends and quickly adapting to the new business norm, Backplane Systems Technology has defined a clear vision for future growth throughout the COVID period and beyond. PACE OCTOBER 2020 www.pacetoday.com.au 11

AUTOMATION

Riding the wave of interoperability Why a collaboration between ifm and Asset Aware IoT exemplifies the meaning of digital transformation.

I

t started with an enquiry about a water flow meter. Now ifm Australia and Asset Aware IoT are looking at projects they can partner on in the long-term to provide real-life Industry of Things (IoT) solutions to customers.

As specialists in their respective fields – ifm in sensor technology, IoT services and automation, and Asset Aware IoT in fleet connectivity and management – the two companies share a collaborative “match made in heaven”, says Freddie Coertze, systems solutions manager and IoT business manager for ifm.

“The journey to digital transformation is not one that any company would want to take in isolation. As solution providers in this space, the collaboration between ifm and Asset Aware IoT is the perfect example of how new possibilities can come out of working together.”

John Briffa, general manager, AA Radio and Asset Aware IoT, says Asset Aware IoT and ifm share synergies on multiple levels.

“Like ifm, we have been in operation since the late 1950’s and have built our companies reputation upon the cornerstones of quality and service. With both ifm and AA Radio having these two core values in building the very fabric of each separate company, I believe our combination under this positive symbiotic relationship will generate a truly special result.

In the past, AA Radio have provided mainly voice communication to mission critical and commercial clients including governments, emergency services and general SME’s. Briffa says collaboration with ifm on IoT solutions opens new doors for the company.

“IoT has opened up the ability for us to talk at a deeper level with these customers and help them to deal with the enormous amount of data we can help them collect in a more meaningful way. This augments our

12 www.pacetoday.com.au OCTOBER 2020

IoT has opened up the ability for ifm and Asset Aware IoT to talk at a deeper level to their customers.

offering and increases our importance to each customer and will also allow us to introduce ifm to perhaps some new customers and facilitate a relationship that we can trust will be nurtured by ifm.

“Our history shows us that the experience we have gained through the radio communications section of our business and our ongoing commitment to the highest level of customer focus and quality delivery will enable us to actively participate in this relationship with ifm and deliver them enormous value as consideration for the true value they are delivering to us. Both of our companies have blue chip customer bases and the fantastic result of us working together means that all of these customers will reap the rewards of our combined hard work.”

Theo Goslett, senior engineer, AA Radio and Asset Aware IoT, concurs with Briffa.

“I couldn’t be happier with how our integration process with the ifm team has unfolded. Not only are their products and solutions manufactured to an incredibly high standard, that same level of quality is also present in the support and communication I have received from all of their team. I’m incredibly excited to see our project portfolios grow together.”

The following Q&A involved an interview with Akmal Yang, a senior sales engineer at ifm Australia, Freddie Coertze, systems solutions manager and IoT business manager for ifm Australia, and Rohan De Silva, head of Asset Aware IoT product development.

Q: How did the relationship between ifm Australia and Asset Aware IoT begin?

Akmal: I received a query from Chris Reade, Business Development Manager at AA Radio about a water flow meter in January 2020. Since we hadn’t had previous dealings with AA Radio, I contacted Chris to ask about the application. I soon realised that the scope of this project was much bigger than the need for a sensor. Consequently, I was put in contact with Rohan De Silva from Asset Aware IoT. Rohan came in to meet with myself and Freddie Coertze, who is the manager of IoT business at ifm Australia, and we presented a solution that not only incorporated the flow meter but the entire connectivity technologies for this system, as well as the possibilities

AUTOMATION

that could be available with our SmartObserver software. It turns out this was exactly the type of solution that Rohan had been looking for and would pair perfectly with the platform Asset Aware had developed.

Q: Why do ifm and Asset Aware IoT complement each other?

Rohan: The synergy that’s happened between ifm and Asset Aware IoT has been serendipitous. Asset Aware IoT was launched last year when our parent company, AA Radio – which specialises in radio communications – wanted to diversify into digital asset tracking and fleet management telematics, with a focus on IoT. And we’ve developed a very opensourced platform that we are looking to connect to multiple things from sensors in multiple vehicle and other non-vehicle-based applications.

Having met with Freddie and Akmal, my colleagues and I came to realise that they have all these sensors, as well as a software solution that can solve many of our requirements. As they are a leader in their space, we thought why reinvent the wheel?

Let’s collaborate! Let’s work with ifm to incorporate their sensors and software into our platform.

Freddie: Our company was founded in the 1960s – we’re a family-owned German company that has grown and developed from making basic sensors to much more sophisticated systems with over 10,000 products in our portfolio.

In more recent years, we’ve moved into software development and dynamically into the IoT space, so we’re not just manufacturing sensors but providing tailored solutions to our customers. Having said that, we’re one of the few companies that offer a five-year warranty on all our hardware. So, we’re very proud of our history and the reputation we’ve earned for producing such robust products.

However, we’re also continuing to evolve as a company and in my role, I’m looking at how we can digitally transform our culture internally, as well as externally with customers to create solutions. Working with Asset Aware IoT is such a good fit because the collaboration matches our philosophy regarding digital transformation.

“I couldn’t be happier with how our integration process with the ifm team has unfolded. Not only are their products and solutions manufactured to an incredibly high standard, that same level of quality is also present in the support and communication I have received from all of their team. I’m incredibly excited to see our project portfolios grow together.” – Theo Goslett Q: Can you explain why this partnership exemplifies “digital transformation”?

Freddie: Digital transformation at its core is about connectivity and collaboration – it’s not about working in isolation on a project. I think our collaboration opens up many possibilities. I believe that if we at ifm want to be successful as a solutions company, we need partners like Asset Aware IoT. And as Rohan mentioned, Asset Aware has developed an open platform, where you can connect any device or any sensor to the platform and it aligns with what we’re doing. Also, their parent company, AA Radio, has such an established history and customer base in radio communications. So, with their platform, and the digital asset tracking and fleet management telematics they bring on board, coupled with our sensor technology, IoT services and automation expertise, we’ve got excellent synergy.

Q: What does the collaboration entail?

Freddie: Well, going back to the water flow meter enquiry, we came to understand that Asset Aware had their own platform. So, while we discussed our sensor options, we also provided a demonstration of how our SmartObserver software works, and how that could potentially be integrated with the Asset Aware platform to provide a holistic solution to their customer.

Rohan: We quickly recognised that ifm is a leader in their space, so instead of going on our own path with software development, we thought it logical to add their software onto our platform. What we did with SmartObserver was housed it as an application on our Asset Aware platform. Basically, it’s in this

common IoT path where everything is in collaboration. If you look at interoperability, if you look at the set standard language of the JSON format, which is a standard form of communication, here’s a real example that’s come to life very quickly because of that standardisation.

Because our two companies used the same language in development, we’ve been able to develop an end product based on that connectivity and using the same language.

Akmal: There would be a lot of labour involved in separate solution developments. Instead, we found a way to orchestrate these solutions and put them together in one common platform and this way, the end user will greatly benefit. It’s like a puzzle.

We each contribute pieces to make the bigger picture, communicating along the way as to how these pieces will fit together to achieve that goal.

Q: What are the benefits to the customer?

Freddie: The overall benefit for the customer is being able to look after their assets properly. By understanding what is happening with their assets and with the flow meters in there, they can see what the applications are doing with the flow rates. They can also remotely adjust the parameters from anywhere in the world. It’s like having this extended set of data that provides them with meaningful logic to make better business decisions. But without that data, they would never know of these benefits.

Q: In context of what’s happening with the pandemic, why is digital transformation so important?

Rohan: Because it enables remote monitoring. Everything we do in the telematics and IoT space revolves around remote monitoring. So, if a

manager is at home and has a fleet of 100 trucks, they can now monitor everything about the vehicle, the driver behavior, the sensors, the engine performance and get proactive reports when things are going wrong.

The world of remote monitoring and remote control of different things is massive; whether it’s a machine or a truck, you can have more visibility or control the inputs with IoT like turning generators on/off remotely, and so on. That’s where Asset Aware complements ifm because ifm does the sensor side but that only makes up part of the picture. Asset Aware IoT provides all the other analytics to help paint the whole picture, which has a lot of benefits for the customer. And the customer has increased visibility through the one application, which is ifm’s SmartObserver.

Q: What does the future look like as project partners?

Freddie: From the first time I spoke to Rohan, I felt our companies had a similar vision of IoT development.

We have an openness that enables us to collaborate easily. We’re also working towards a common goal, which is to help our customers in their digital transformation. I feel like the sky’s the limit in what we can achieve, not just in Australia, but globally, as partners.

Akmal: While both ifm and Asset Aware’s parent company, AA Radio, have been around for a long time and have their own sets of customers, where it gets exciting is that we both started to move towards a non-traditional market with our IoT solutions and package offerings. It’s a match made in heaven because Asset Aware IoT have solutions that we want to integrate our ifm technologies with and vice versa.

Rohan: Together, we are riding that space of interoperability. Of making the connected world a reality. You know, we’ve developed a real-life future forward solution through collaboration. The future looks grand because there’s so much more that’s going to come out of this. With the reach of ifm working in 72 countries and with the reach of our extended Asset Aware IoT team in Florida, Mexico, and all of South America, we are truly looking at the global picture in terms of project scope. PACE OCTOBER 2020 www.pacetoday.com.au 13

ACTUATOR SYSTEMS

OZmist fosters local innovation in dust prone environments LINAK actuators play a key part in the automated sprayers by Victoria-based manufacturer, OZmist, who is paving the way for high-pressure misting systems within a range of environments.

I

n many areas of the world, dust clouds can pose a severe challenge on the factory floor. The Australian enterprise OZmist, based in Wangaratta in the north-east corner of Victoria, has driven innovation into new and uncharted territory and developed a solution applicable across many trades.

Being locally owned and operated, innovation is at the company’s core.

With 20 years of experience, the company has maintained a proactive approach to R&D and have shown the ability to adapt current designs to suit different environments for their applications. OZmist is continuously looking at ways to design new products, or to modify existing ones, and LINAK actuators play a central part.

“Our first mist cannon is unique and comprises a tandem-wheel trailer fitted with a 2,000L aluminium tank, highpressure pump and fan, which throws mist 50 metres. All run from a generator that is fitted to the draw bar,” said Dean McDonald, director of OZmist.

“With 2,000 litres of water on board, the trailer can be towed by most SUVs.” Dust is a major issue, particularly in some rural Australian working environments. It not only affects the

A LINAK actuator is a key component in OZmist’s mist cannons.

air quality for workers, but also the wider community as plants and crops tend to suffer as well. According to McDonald, this is the motivation for many customers to invest in its products.

If companies are doing the right thing, they also follow the requirements of the Environment Protection Authority (EPA) and the local councils.

Built to work in harsh environments

Mist cannons typically operate through the use of a pump, which transfers water from the onboard tank and pumps it at a high pressure through rings of nozzles at the outlet of the cannon. A fan blows millions of tiny water droplets, which exit the nozzles, to create a mist.

Although mist cannons have been used as a mister at large concerts or gatherings to cool patrons, they are traditionally designed for dust suppression in harsh environments.

This includes mining, demolition, excavation, road building, and for concrete plants where the millions of water droplets from the fan attach themselves to the dust particles and drop them to the ground.

A LINAK actuator is a key component in these mist cannons as it is used to lift and lower the outlet of the cannon to adjust the throwing distance of the mist.

Finding the right partner

In 2018, OZmist developed their first mist cannon for dust control. Today, it manufactures two variations of the product, both using LINAK actuators.

During the design process, OZmist needed a heavy-duty, robust, reliable, and water-resistant actuator that it could build into its system.

“The actuator is subjected to a huge amount of vibration and has to be able to lift the heavy cannon as well as 14 www.pacetoday.com.au OCTOBER 2020

Mist cannons are traditionally designed for dust suppression in harsh environments. withstand life outdoors and in very dusty environments,” McDonald said.

“The LA36 fits ideally into the system due to its programmable configuration, robust construction and reliability in these harsh environments.

LINAK account manager, Ron Diocera, said OZmist needed a reliable dust suppression system and local support.

“We believed in their system as a solution to an ongoing issue of airborne hazardous dust in the industry, which is a major risk to the health of workers,” he said.

“Traditionally they would have some hydraulics in it to actuate the cannons.

But with the electric actuators, the whole system includes a power pack, hoses and the actuator itself.

“It’s a lot simpler, maintenance free and a lot easier to install. That gives a lot of value to OZmist, and to their customers as well. They don’t have to worry about servicing the hydraulics systems.”

Local suppliers is essential

As the only Australian manufacturer making these types of mist cannons, OZmist prides itself in sourcing local suppliers to assist them in further innovation and improvements.

“There is nothing worse than having a machine on site that no one can fix or parts are on the other side of the world,” said McDonald. “Building them from scratch in Australia allows us to be in control of quality and the end product that the consumer receives.”

Technical support from LINAK also played a large part in the decision making as communication and feedback was important to the final product.

“If we have a failure, we all want to know why so we can fix it,” said McDonald, who speaks directly into central LINAK cornerstones – to provide precise and reliable adjustment of various industrial applications and to work with customers to ensure the right solution for their product. PACE

NEW PRODUCTS

Modbus compatible thermal mass flow meters With the addition of the Modbus communication protocol to its new ST80 Series, recently enhanced ST51A/ST75A Series, and ST100 Series and multipoint MT100 Series, Fluid Components International (FCI) now provides the industry’s broadest selection of Modbus compatible thermal mass air/gas meters.

For Modbus-based measurement and control systems, with air or gas flow rate components, FCI can now provide an optimal, highest value flow meter solution matched to the application. FCI thermal mass flow meters with Modbus I/O are available for line sizes from 6 mm to the largest of stacks and ducts, and every size in-between. They are designed to measure the flow of air and more than 200 different gases, including inert and hydrocarbon-based, in both pure and mixed compositions.

Thermal mass air/gas flow meters are direct mass flow measuring, have no moving parts to foul or clog, and require no routine maintenance that achieve lowest installed cost and superior service life.

installation criteria. The instruments are inherently dual function and can provide flow and temperature measurement, as well as totalised flow, outputs over the Modbus connection.

The Modbus option for all five FCI model series flow meters meets the EIA/TIA-485 standard. Transmission is via RTU or ASCII with standard MS (16 bit), standard LS (16 bit) or Daniel extensions (32 bit). They’re ideal for use with PLCs, large SCADA systems or DCS systems.

In addition to Modbus, FCI’s thermal air/gas flow meters also provide 4-20 mA, analogue outputs, pulse outputs, and/or other digital bus communications of HART, Foundation Fieldbus, Profibus-PA and Profibus-DP. AMS Instrumentation & Calibration Pty Ltd (03) 9017 8225 www.ams-ic.com.au

FCI’s family of Modbus compatible thermal flow meters range from small, compact models to high feature, high performance, high accuracy models. Models are available that carry global agency approvals for Ex installations, both Div.1/Zone1 and Div.2/Zone 2 types.

Four of the series’ carry independently evaluated SIL compliance (IEC 61508) ratings for use in safety instrumented system applications.

All FCI thermal flow meters are available in a vast choice of process connections to ensure compatibility with virtually any piping and

Operational visibility enables optimised business outcomes Available from Control Logic is Red Lion’s award-winning Crimson 3.1 family of “Data Stations” and operator touch interface panels for multi-vender cloud connectivity. With a growing list of 300 industrial built-in protocols including the newly released MQTT, SQL and OPC connectors, its user-friendly and always free platform provides companies with a smart yet economic option when deciding to transform business decisions to the cloud.

Built from the ground-up and developed for over 15 years, the Crimson 3.1 configuration platform offers proven industrial reliability with simplified drag and drop development. It solves the remote firmware, configuration and version tracking problem that Linux OS boxes fail to overcome. Additionally, its compatibility with other manufacturers such as ABB, Emerson, Rockwell Automation, Schneider and Siemens, makes the Red Lion Crimson 3.1 platform a desirable option.

The Crimson 3.1 platform exposes PLC and machine data beyond the operational environment, enabling enterprise business systems to a smooth transition of direct access to reliable real-time and historical operational data using MQTT. “This can dramatically simplify system architectures, increase scalability and accelerate data integration initiatives with no additional hardware or expensive software customisation required,” says Paul Bunnell, Red Lion’s product management director for automation products.

Control Logic 1800 557 705 www.controllogic.com.au

OCTOBER 2020 www.pacetoday.com.au 15

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