Manufacturers’ Monthly July 2018

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MANAGEMENT >> TECHNOLOGY >> SOLUTIONS

JULY 2018

BREAKING BOUNDARIES

INSIDE >>

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Taking additive metal manufacturing to a new level

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Highlights from the AES 2018

28

Helping manufacturers on their Industry 4.0 journey

>>

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Managing Director: John Murphy Managing Editor: Syed Shah Ph: (02) 9439 7227 syed.shah@primecreative.com.au

Inside­­ JULY 2018

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Journalist: Tara Hamid Ph: (02) 9439 7227 tara.hamid@primecreative.com.au Art Director/ Production Coordinator: Michelle Weston michelle.weston@primecreative.com.au Design: James Finlay, Blake Storey, Adam Finlay Sales/Advertising: Madhu Singh Ph: 040 2718 081 madhu.singh@primecreative.com.au Subscriptions Published 11 times a year

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36 Research & Development

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30 Soft Skills In Manufacturing

8 News@MM

32 Industrial Chain Drives

20 Industry Focus

33 Compressors@MM

39 Endeavour Awards 2018 Preview

24 AES Conference 2018

34 Risk Management

41 MEGATRANS 2018

28 Issues & Insights

35 Safety & Control

43 What’s New

4 Editor’s Comment

Copyright Manufacturers’ Monthly is owned by Prime Creative Media and published by John Murphy. All material in Manufacturers’ Monthly is copyright and no part may be reproduced or copied in any form or by any means (graphic, electronic or mechanical including information and retrieval systems) without written permission of the publisher. The Editor welcomes contributions but reserves the right to accept or reject any material. While every effort has been made to ensure the accuracy

37 Events@MM

of information, Prime Creative Media will not accept responsibility for information published.

The opinions expressed in Manufacturers’ Monthly are not necessarily the opinions of, or endorsed by the publisher unless otherwise stated. © Copyright Prime Creative Media, 2018 Articles All articles submitted for publication become the property of the publisher. The Editor reserves the right to adjust any article to conform with the magazine format.

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Behind the cover Additive manufacturing has long been viewed as a process that could disrupt the way products are designed, manufactured and distributed. This month, we highlight an even more disruptive process that the inventors say could challenge the very core of traditional metal manufacturing processes in the not-too-far future.

Titomic Kinetic Fusion, developed by Titomic, uses a robot arm to spray titanium powder particles onto a scaffold at supersonic speeds of around 1 km/s – so fast that when they collide, they mechanically fuse together.

Born out of a study by CSIRO to capitalise on Australia’s rich titanium resources, the technology has already

grabbed the attention of Tier-1 companies in the aerospace and shipbuilding industries. Fincantieri Australia – one of the shortlisted bidders for The Future Frigates SEA 5000 program – recently signed a deal with Titomic to investigate potential applications of the technology in shipbuilding.

We have also covered in this issue insights from the Australian Energy Storage Conference and Exhibition (AES 2018) and interviewed key energy players about their current and future investment plans in Australia.

The general message across the board at the event is for manufacturers to resort to clean energy solutions and manage their energy costs prudently.

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MANAGEMENT >> TECHNOLOGY >> SOLUTIONS

JULY 2018

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INSIDE >> 20

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Selecting the right compressor for your manufacturing needs

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Manufacturers’ Monthly JULY 2018 3

Comment

SYED SHAH – Managing Editor, Manufacturers’ Monthly

Let’s print out the future

A

dditive manufacturing, or 3D printing as it is commonly known, has come along in leaps and bounds over the past 12 months. A couple of decades ago, 3D printing was probably a distant pipe dream (together with grandiose dreams of robot automated factories) but at National Manufacturing Week (NMW) 2018, these 3D businesses were out in full force. And taking in orders by the dozens. Back in the day, it did draw the crowds but not the dollars. What a different story it is today.

Now, it is a serious contender in the primary industry space as a game changer. This is epitomised by Titomic, a company that has invested in the world’s biggest 3D metal printer. When we, at Manufacturers’ Monthly, caught up with Jeffrey Lang, CTO and co-founder of Titomic at NMW 2018, we almost didn’t believe what he told us about what his company had just achieved.

Typically, metal 3D printing is a tool-less manufacturing method that can produce fully dense metallic parts in short time, with high

4 JULY 2018 Manufacturers’ Monthly

precision and uses layer-by-layer printing technique. Features of additive manufacturing like freedom of part design, part complexity, light weights, part consolidation and design for function are garnering particular interests in metal additive manufacturing for aerospace, oil and gas, marine and automobile applications.

Titomic’s metal 3D printer, however, uses mechanically fusing technology instead of the conventional layer-by-layer printing technique. Interestingly, the technology was developed via a study

by Australia’s own CSIRO because the federal government wanted to capitalise on the country’s rich vein of titanium.

Throughout NMW, a familiar term was floated around transition.

There has been a significant increase in chatter over the past 18 months about Industry 4.0 and what it means to manufacturing. Still, in 2018, a lot of people are intimidated by the idea of Industry 4.0, not so much because they don’t know what to do, or see no value, but they don’t know where to

start. Futuremap, an idea born from three industry bodies – the AMGC, IMCRC and the Entrepreneurs Programme – is designed to help companies make the transition via a series of workshops. These workshops are designed to develop relationships between research institutes and industry for mutually beneficial outcomes. Not one, but three rounds of futuremap trial workshops were run during NMW 2018 and it met great interest from manufacturers.

They especially target SMEs, who usually don’t have huge R&D budgets – if they have them at all – and help them navigate the pitfalls of Industry 4.0 as they make the transition to digitisation as painless as possible.

Elsewhere, our journalist Tara Hamid was out and about in Adelaide in May covering the Australian Energy Storage Conference and Exhibition (AES 2018). As expected, the dominating theme was the expanding role renewables are having on the Australian energy landscape. The near future indicates that fossil

fuels are still going to play a leading part in the country’s energy needs, but solar and wind power, and the associated battery storage requirements, are making headway as their market share increases.

Keynote speaker, Sanjeev Gupta from GFG Alliance, touched on why renewables were so important. While there is debate about the pros and cons of both types of generation, Gupta didn’t mince his words when it came to the main reason his company was investing in the technology.

He believes renewables are a key ingredient to lower his various companies’ power bills. As any manufacturer knows, power costs are a huge dent in a company’s revenue.

Gupta claims that about one third of costs related to steel production are taken up by paying for energy needs. His key point was that it is important for companies to take charge of their own energy needs. He believes renewables are the answer in that regard.

Certainly, an action-packed issue we have here to keep all our valued readers entertained.

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Comment

INNES WILLOX – Chief Executive, Ai Group

Continued growth and opportunities, but still much to do

F

or quite a while now Ai Group’s monthly performance indices – the Australian PMI, the Australian PSI, and the Australian PCI– have pointed to sustained expansions across the manufacturing, services and construction sectors respectively.

It is very encouraging that, both across these industrial sectors and within them, the expansion is broad-based.

There are patches of weakness of course. These include the more consumer-facing sub-sectors of the services sector, the apartment building sub-sector in construction and some of the smaller traditional manufacturing sub-sectors.

But beyond these areas, businesses have been reporting healthy levels of activity and employment growth. They also have been reporting steady growth in new orders pointing to the continuation of positive conditions in the near term.

Our surveys are also suggesting a gradual pick up in wages and in input costs and significantly lesser growth in selling prices. This accords with our economics team’s view that the growth in aggregate profitability has been concentrated in the mining and financial sectors and that beyond these areas profits have been improving but at a modest pace.

Looking beyond the more immediate conditions, we are increasingly getting reports from Ai Group members and other businesses about difficulties in finding skilled staff. And alongside this, businesses are also reporting growing pressures on wages and salaries.

Particularly in upstream segments of the manufacturing sector, we are also hearing about the pressures on businesses from high electricity and gas prices.

The reports of outright difficulties obtaining supplies of gas have abated – at least for now.

6 JULY 2018 Manufacturers’ Monthly

While not wanting to get too alarmist about it, businesses highly reliant on gas – whether as feedstock or as a source of energy – have been facing existential questions over the past few years.

And at a fundamental level these questions remain unanswered.

And while of somewhat less urgency, very profound questions are being asked by energy-intensive manufacturers more generally as a long-standing source of cost advantage has been all but eliminated.

But building on the generally positive current conditions and despite the areas of stress I have mentioned, there appears to be a distinct sense of opportunity among our members.

There is clear scope for improvements in productivity and competitiveness from the further application of digital technologies to production and distribution.

Businesses are switching on to Industry 4.0, curious about its possibilities and applications in their own businesses. It is an area in which Ai Group has a growing presence – alerting and informing members and bringing businesses and others together to progress this important area.

Businesses are well and truly switched on to the opportunities presented by the growth in the Asian economies and the tremendous surge underway in Asia’s share of the global middle class. There has been a palpable increase over the past decade in the number of Australian businesses looking for opportunities, sealing deals and servicing customers to our north and north west.

There is also a deepening of conversations between Australia’s researchers and research institutions and the business community. The differences in cultures and a range of other barriers to more widespread cooperation are not going to disappear overnight but it is very

We are pleased to be able to say that most businesses are reporting very good conditions. clear that over recent years we have made important initial strides in the right direction.

No doubt others could identify other elements in this but my sense is that there would be widespread agreement with the sense of opportunity we are experiencing across the business community.

There appears so much to look forward to and so much potential for our country.

When it comes to community attitudes towards business, however, the picture is different. To be blunt, business seems never to have been more on the nose across the broader Australian community.

Last month at our National Executive Advisory Council meeting in Canberra, Ai Group members had a heartfelt discussion about these issues. It seems strange to us that, just as we are sensing such potential for our country – potential that business has a clear role in realising – the mood of the country has become almost anti business.

Of course, there is a recognition that there are plenty of examples of businesses undermining our own standing. The Financial Services Royal Commission is unveiling its share of these. And at the same meeting we had the head of the ACCC, Rod Sims, making some very strong points about some instances of bad behaviour. And we can all recall some high-profile reports of underpayment of employees.

But it is more than just these instances – important as they are. Rather, it seems there is a much more widespread sense of dissatisfaction and distrust of the business sector. And it goes beyond the business sector and seems to be part of the well-documented broader sense of cynicism and distrust in the community.

Of course, this is not confined

to Australia but seems to be linked to a broader sense of dissatisfaction and disenchantment with “the establishment” across the developed world.

Part of the puzzle for us is that in Australia’s case we have had a long period of growth without recession and without the associated surge in unemployment. Nor has there been an increase in job insecurity. And real living standards have increased broadly across the household income distribution. Admittedly in the past few years this has been at least as much about jobs growth as it has been about increases in real wages.

While it is puzzling, it seems to us that there are clear risks with this mood of disenchantment, distrust and dissatisfaction. One of them is the fertile ground it prepares for people, organisations and parties who seek political advantage by stirring dissent and a sense of division. And they are building support for policy directions that, while they may have populist appeal, in reality would undermine business confidence, investment and our role in job creation.

And so today, not for the first time, there are mixed messages from business.

We are pleased to be able to say that most businesses are reporting very good conditions. We have been investing more and employing more people, and we are seeing a widespread engagement by businesses in areas of very strong opportunity for Australia.

But there is growing concern that this sense of opportunity is far from universal and indeed, the mood of dissatisfaction and distrust in the broader community has the potential to undermine our ability to realise these opportunities. manmonthly.com.au

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News@MM South Australian companies cut steel for cruise ship blocks As part of Fincantieri Australia’s local operations start-up, the company announced in June that the first steel has been cut in South Australia for three cruise blocks.

The cruise ship block contracts were awarded to MG Engineering and Ottoway Engineering in March. The Australian steel will be integrated into the cruise ship superstructure for one of Fincantieri’s international projects.

MG Engineering was awarded a contract for the construction of two blocks that sit on port and starboard sides of the ship and will be dedicated to accommodation areas. The block constructed by Ottoway Engineering will be located in the central part of the ship and will be dedicated to technical zones where emergency generators are located.

An estimated 1,000 sqm of Australian steel will be used and all three blocks will be constructed and

delivered by mid-2018, according to Fincantieri Australia sources.

Construction is expected to employ approximately 40 – 50 local workers across the two South Australian sites.

Fincantieri Australia is one of the few companies tendering for Australia’s next major naval program – the SEA 5000 Future Frigates program.

The company has undertaken the cruise ship block initiative as well as other test orders for mechanical equipment, work-force preparation and qualifying Australian supply chain to ready itself for the construction of nine frigates for the Royal Australian Navy in Adelaide in 2020.

As part of Fincantieri’s commitment to transferring technology and its expertise in commercial shipbuilding to Australian businesses, its representatives will also be on site at MG Engineering and Ottoway Engineering to share best practices

with Australian technicians. This includes sharing methods and fabrication sequences, familiarising engineers of the company’s technical drawings and supporting the cutting and production process.

Building the cruise ship blocks locally allows the company to establish and strengthen its relationships with local suppliers and understand their capabilities. It is part of the company’s detailed Industry Plan,

which is focused on maximising local industry participation and helping Australia become autonomous in the design, construction and export of vessels, including the material and equipment within.

Earlier inMay, Fincantieri Australia signed a Memorandum of Understanding (MoU) with the University of Adelaide to develop a collaborative program of education and research co-operation.

Building the cruise ship blocks locally allows the company to establish and strengthen its relationships with local suppliers and understand their capabilities.

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3D printed orthotics business gets AMGC support The Advanced Manufacturing Growth Centre (AMGC) has announced that it is supporting a collaborative project led by iOrthotics, a Queensland-based company specialising in design and manufacture of custom-made orthotic devices.

The AMGC will provide $195,250 in co-funding to support iOrthetics’ expansion into global markets with the use of HP Multi Jet Fusion 3D printing technology. iOrthotics is a fast-growing maker of custom orthotic shoe inserts that correct biomechanical issues. The podiatry and orthotic business is pioneering the next wave of 3D printing technologies with ambitious plans to expand its reach into the United States, UK and Canada.

The company currently supplies to 75 clinics across Australia and has new opportunities in several international orthotic laboratories. Seizing this potential for increased export growth and revenue requires digitising its operations and scaling up production.

“On each occasion, I like to reinforce the message that Australian manufacturers must compete on value and not on cost; and we are excited to be supporting iOrthotics, a manufacturer who is doing just that,” said Dr Jens Goennemann, managing director of AMGC. “iOrthotics is leveraging a network of expertise including its supply chain and University of Queensland to provide superior medical devices, and by building on its technical leadership and

taking that globally,” he said.

The collaborative project uses iOrthotics’ relationship with machine provider HP, as well as local reseller Evok3D, which is sharing technical support. University of Queensland will provide invaluable material science, testing and validation expertise in developing iOrthotics’ superior new products and processes.

“We do need help to facilitate what we are doing, or we simply cannot afford the investment to innovate,” Dean Hartley, iOrthotics general manager said.

“It is the network and industry knowledge AMGC is able to provide which can help a business such as ours that is in its growth and early commercialisation stage.”

Hartley adds that digitising operations, including the entry system for clients, tracking jobs via barcoding, and optimising orthotic design for manufacture, is essential to scale internationally. iOrthotics moved to 3D printing in 2015, using fused deposition modelling (FDM) and cutting 1.4 kilograms of waste for each pair of orthotics made compared to older milling methods. A bank of 20 printers enabled 3,300 pairs of orthotics annually to be produced.

With R&D and their new HP printer purchased last year, iOrthotics can produce 24,000 pairs annually requiring less post-processing and reducing over 30 tonnes of plastic landfill waste.

20 The company currently supplies to 75 clinics across Australia and has new opportunities in several international orthotic laboratories.

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News@MM New lithium processing plant to launch in WA Battery material company Neometals has moved ahead with plans to build a lithium hydroxide refinery in a 40-hectare site in a new industrial estate at West Kalgoorlie in Western Australia.

The state land will be leased by the city of Kalgoorlie-Boulder to help secure the development of the lithium facility.

The agreement provides Neometals with a two-year option over the site (with provision for an additional two-year extension). During this time, Neometals will undertake engineering studies as part of a feasibility study for the refinery.

The proposed Kalgoorlie Lithium Refinery will have an initial 10,000tpa lithium hydroxide production capacity.

Lithium concentrate feed will come from Neometals’ offtake option from the Mount Marion Lithium Operations, in which the company has a 13.8 per

cent project ownership stake.

State government agencies, including the Department of Planning, Lands and Heritage are working collaboratively with the City of Kalgoorlie-Boulder to facilitate the development of this strategic industrial site.

Neometals CEO Chris Reed said the strategy to move Neometals downstream towards lithium chemical production is part of a broader evolution of the company’s lithium business arm.

“The aim is to develop a closed loop lithium ecosystem with access to the lithium raw material source, value adding for use in the battery supply chain and ultimately, recycling of spent batteries,” he said.

The Western Australian Government recently committed provisional funding for the Minerals Research Institute of Western Australia, to support

of the Kalgoorlie Lithium Hydroxide Facility will put the Eastern Goldfields of Western Australia at the forefront of this growing resource industry.

“When completed, the Kalgoorlie Lithium Hydroxide Facility will produce a battery-quality lithium product suitable for use in the lithiumion battery industry,” she said.

development and manufacturing of technology metals and renewable energy sources.

Meanwhile, WA Lithium last month signed an agreement to enter into an Option to Lease with LandCorp for a selected site in Kwinana.

Western Australia land minister Rita Saffioti said the development

The proposed Kalgoorlie Lithium Refinery will have an initial 10,000tpa lithium hydroxide production capacity.

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News@MM DexKo Global expands into chassis manufacturing in Australia

All parties in the MoU have mentioned that the integration will allow them to better serve their customers in the region with additional quality products.

DexKo Global, a global supplier of highly engineered trailer running gear and chassis assemblies and related components, has announced signing a definitive agreement to acquire G&S Chassis and Hume Caravan and Camping Accessories to expand its Australian operations.

G&S Chassis and Hume Caravan

and Camping Accessories are Australian family-owned businesses for chassis manufacturing and supplying a diverse range of accessories used by leading caravan manufacturers nationally.

“We are excited to welcome the G&S Chassis and Hume teams to the DexKo organisation. These

acquisitions allow us to expand into chassis manufacturing and to supply an even more diverse range of products in Australia through the integration of two leading businesses,” said Fred Bentley, CEO at DexKo Global.

According to DexKo Global, the transaction has the endorsement of the Inturrisi family as the owners of G&S Chassis and Hume, including Rob Inturrisi who will remain within the business as general manager, along with many other members of the Inturrisi family.

“At G&S Chassis and Hume, we are very proud of the legacy we have built for over 40 years. Becoming part of the DexKo family will allow the business to continue to grow with the backing of the industry leader,” said Rob Inturrisi.

“I am confident that uniting with DexKo will be very beneficial for both our customers and employees.”

Harald Hiller, global president and

CEO of AL-KO Vehicle Technology said, “We continue to add strong brands to our global portfolio and offer additional quality products to our customers.”

He said that this integration will further expand the company’s core business, which will allow them to service their customers as a systems supplier with an even “broader range of solutions”.

“I am excited by the opportunity to integrate G&S and Hume into the DexKo organisation,” said ALKO’s Australian managing director, Peter Mannfolk. “I look forward to the already successful G&S and Hume businesses continuing to service customers, whilst adding the additional support of AL-KO in Australia and the global chassis manufacturing expertise of DexKo to take chassis manufacturing in Australia to new heights.”

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News@MM Queensland to get billion-dollar wind farm The Queensland state government has given the development approval for up to 195 wind turbines at Clarke Creek, 150 kilometres north west of Rockhampton.

Queensland Minister for State Development, Cameron Dick, said the $1 billion Lacour Energy wind farm project would involve approximately 350 jobs during construction.

“In addition to building the turbines, associated infrastructure will include substations, temporary workers’ accommodation, staff and operational facilities and powerlines,” Dick said.

“This means jobs for the region over the project’s 36-month construction period and more clean energy that our state can tap into.

Queensland Energy Minister Dr Anthony Lynham said the new wind farm was part of Queensland’s $20 billion pipeline of energy projects – with projects worth almost $4.5 billion underway.

“Queensland is focused on reaching its 50 per cent renewable energy target by 2030, with more than 20 projects currently either underway or financially committed, creating over 3500 construction jobs across the state.

“And as we progress to a

Queensland is focused on reaching its 50 per cent renewable energy target by 2030, according to their state government.

renewable future, the Palaszczuk Government continues to deliver reliable supply and our two-year guarantee that electricity prices will not rise above inflation.”

“Lacour Energy has worked closely with the department to assess acoustic impacts of the wind farm as well as impacts on fauna and vegetation,” he said.

“The Queensland Government looks forward to bringing more job-

creating, economy-boosting projects to central Queensland.”

Once constructed, the wind farm will be one of the largest in Australia, according to the Queensland government website.

Director of Lacour Energy, Mark Rayner said the Clarke Creek wind farm would have a power output of more than over 800 megawatts of electricity.

“It is a unique renewable energy

project which combines excellent wind and solar resources at a location directly adjacent to the backbone of the Powerlink 275 kV transmission network,” Rayner said.

“The wind farm development approval is a significant milestone for the project. We look forward to completing the feasibility study by the end of the year so that construction can begin early next year,” he said.

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The new ‘laser cell’ in our SA engineering facility will have the highest-power laser beam used for laser cladding in the Southern Hemisphere. We already operate the three most powerful lasers in this industry in Australia. These are supported by many other processes and technologies, such as HP HVOF, all supported by our own well-equipped metallographic

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News@MM Australia’s ECT collaborates with India for the future of steel Environmental Clean Technologies (ECT), a Melbourne-based company focusing on commercialisation of new coal and iron-making technologies, has signed an agreement with India’s national lignite and iron ore authorities, to help scale up and commercialise ECT’s technologies.

The Project Agreement, signed with NLCIL (India’s national lignite authority) and NMDC (India’s national iron ore authority) will focus on commercialising ECT’s two proprietary technologies: Matmor and Coldry.

According to ECT, Matmor is the world’s first and only lignite (brown coal)-based primary iron making technology capable of replacing metallurgical coal and high-grade lump iron ore with lower-cost alternative raw materials thanks to its unique, hydrogenbased chemistry and furnace design.

Coldry is a unique, zero-emission, lignite upgrading technology capable of producing a solid fuel for use in power generation, industrial thermal applications and as a feedstock to higher-value downstream products such as hydrocarbon liquids, gas, fertiliser, chemicals, chars, activated carbon, hydrogen and steelmaking via the Matmor technology. Coldry solid fuel is significantly less CO2 intensive than lignite.

The project entails two phases, commencing with a $35 million R&D phase funded by the Indian partners, which aims to scale-up ECT’s Matmor and Coldry

technologies to deliver an integrated pilot plant capable of producing two tonnes of metal per hour.

Following successful R&D outcomes, phase two involves commercial expansion, targeting an integrated steel making facility with a proposed capacity of 500,000 tonnes per annum and an estimated cost of $300 million.

The partners will then assess opportunities for global commercial expansion based on market assessment at that time.

Senior executives and directors from NLCIL, NMDC and ECT executed the Project Agreement in the presence of India’s High Commissioner in Canberra on May 30.

ECT Chairman, Glenn Fozard said the agreement followed four years of effort by ECT to work out the process with NLCIL and NMDC to take the two technologies through the scale-up process.

“Today marks a significant milestone on the journey which, all going to plan, will see the commissioning of our Coldry-Matmor pilot plant in India by the end of 2019,” Fozard said.

NLCIL’s director of projects and planning, Selvakumar noted, “We want to use our lignite for alternative purposes. We want to dry the lignite. Coldry is a good technology for transforming lignite. When discussing lignite use with NMDC, we saw the opportunity to work together to achieve iron ore reduction as well, adding higher value to our resource through new applications.”

Phase two involves commercial expansion, targeting an integrated steel making facility.

18 JULY 2018 Manufacturers’ Monthly

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HELP SHAPE THE FUTURE Unique opportunity to co-locate and partner with Australia’s leading University

University of Melbourne Fab Lab Powered by the University of Melbourne, a global leader in the knowledge economy, and developed in partnership with Lendlease, Australia’s leading innovation precinct is destined to attract industry, government, entrepreneurs and researchers to its unique knowledge-sharing ecosystem.

Unparalleled student experience is at the heart of the FABLAB @ CCI project, and we are also offering the opportunity to interact with the broader innovation precinct, local business, start-ups and the wider research community.

The Fab Lab will be accommodated in approximately 1,140sqm across the ground floor and basement. This space is currently at First Fit stage so the successful partner has the unique opportunity to define the layout, specify the equipment and manage the flow of activities through this innovative space.

The Fab Lab brief requires the following capabilities: • General fabrication areas • Woodworking space • 3d printing capability • Laser studio • Finishing/paint shop • Support space • Open plan office space • Maker area • Test area • Print studio • Display space (street facing) • General workspace • Storage space • Kitchen area We are open to all business model options from self-sustaining outsource models, to industry partnerships and corporate sponsorships, all the way through to community-led Fab Lab opportunities and hackerspaces.

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As part of this exciting new ecosystem, Melbourne School of Engineering at the University of Melbourne is seeking expressions of interest from industry and community to run, operate and/or partner with us to deliver a state of the art Fabrication Laboratory including a sizeable makerspace.

Industry FOCUS Titomic Kinetic Fusion: Breaking the boundaries of additive manufacturing Additive manufacturing company, Titomic, has launched what it refers to as the world’s largest and fastest 3D metal printer. Tara Hamid looks at the revolutionising metal printing technology, in conversation with Titomic founding director and CTO, Jeffrey Lang.

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HE world’s largest 3D metal printer has a build area 9 metres long, 3 metres wide, and 1.5 metres high. But it’s not just that size that makes it impressive. It’s the technology behind it, enabling it to print objects much bigger than current industry metal 3D printers and finding applications in areas

where traditional manufacturing has limitations and no other additive technology has gone before.

The patented process developed

by Titomic at their Melbourne-based facility goes by the name of Titomic Kinetic Fusion and produces load-bearing 3D forms from fusing metallic powder feedstock sprayed

at supersonic speeds.

Unlike conventional metal 3D printers that print layer-by-layer using metal powders melted at extreme heat, the Titomic Kinetic Fusion process involves a 6 axis robot arm spraying titanium powder particles onto a scaffold at supersonic speeds of around 1 km/s

– so fast that when they collide, they mechanically fuse together.

“We are challenging the traditional core of manufacturing,” Jeffrey Lang, Titomic’s founding director and CTO told Manufacturers’ Monthly.

“While most metal printing processes use an electron beam laser

Titomic 3D metal printer’s build area is 9 metres long, 3 metres wide, and 1.5 metres high.

20 JULY 2018 Manufacturers’ Monthly

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IndustryFOCUS to melt the metal, there is no melting involved in our process. Therefore there are no heat-related distortions and the materials retain their properties.

“This also means that we are not limited by size. Because melting metals in the conventional 3D printing processes causes them to oxidise, the conventional metal 3D printing needs to take place inside a vacuum chamber. Lack of melting in our process means that we are not limited by size,” he said.

The differentiating factors do not stop there. Titomic’s process is also much faster than conventional 3D printing and of course a lot faster than the traditional subtractive methods, minus the material wastage associated with the latter.

“Depending on the complexity of the metal parts, we can deposit between 20-45 kilograms of metal per hour. That’s just with one spray head. We are working on a new system where we could operate a series of robots that connect multihead robots. That would enable us to deposit up to 200 kilograms of material per hour.

“To put that into perspective, the normal 3D printers can usually deposit about one kilogram in 20 hours. So we are really bringing volume into the additive manufacturing market,” Lang said.

As with all new processes, the technology needs to go through a validation process before being adopted in industries such as aerospace. But there are other industries, which Titomic is already working with to produce parts.

Lang says early adopters could benefit through gaining a competitive edge, besides saving considerably on both time and material wastage.

“Airbus, for example, uses 50 tons of titanium a day in raw materials to produce just 8 tons of parts by traditional subtractive manufacturing,” Lang said.

That’s about 90 per cent of material going to waste in the machining process. According to Lang, that leads to one of the major problems faced by both Boeing and Airbus: long lead times required to machine titanium parts, contributing manmonthly.com.au

to as much as 10 years backlog of production.

“If we could make those parts as near net shape components, that is to create the final shape of the part and then add just a little bit extra burden of the material on it, we could reduce that machining time in some instances by 80 per cent.

“We are not saying this technology can jumpstart now and replace the current aerospace process. But our process is currently one of the most significant processes that those aerospace companies are looking at. We have come up with additional solutions to remove a small amount of porosity to achieve aerospace grade.

“For one of the aerospace components, which can be up to $4 million in cost, we can reduce production time from 200 hours down to 6 hours,” he said.

Where did it all begin?

The Titomic Kinetic Fusion technology was born from a study by CSIRO – the Commonwealth Scientific and Industrial Research Organisation – as the Federal Government searched for a way to capitalise on Australia’s rich

titanium resources.

“The Federal Government did a study in 2007 with this idea that while Australia is not a large resource of titanium, we have a large amount of mineral sands that contain titanium.

The government wanted to find ways to utilise that resource instead of just selling it off, like we always do in Australia,” Lang said.

“I was invited to be a part of the project and look at the ways by which we could use large volumes of titanium powder. We started thinking about how to develop titanium powder from that vast resource and build a whole industry around it.”

While doing the research, Lang and his colleagues found the existing additive manufacturing processes to be very restrictive in terms of size and quantities, “We were looking for something that we could use in an industrial scale,” he said.

Then they came across the Cold Spray coatings process. “Why hasn’t anyone ever used this for additive manufacturing?” they wondered.

Cold Spray process was developed in Russia around 30 years ago. It was rendered as a coating technology for doing very high-level metal coatings,

including putting linings on jet engines in aerospace. It was also extensively used in Asian countries for manufacturing scratch-proof rice cookers and high-level frying pans with copper-coated bases. “What no one had realised was the potential applications of the process in additive manufacturing,” Lang said.

“We haven’t found any scientists who can clearly explain the theory behind the process, but the technique is currently being reviewed at the army labs in the USA. The US Army has already validated the process for doing aluminium repairs on aircraft wings, etc. There are also a couple of big global companies using the technology for defence applications,” he added.

Lang and his colleague and co-inventor, professor Richard Fox, explored incorporating Cold Spray onto a scaffold to build a 3D object.

The co-inventors requested that CSIRO patent and license the technology to their composite sporting goods company, Force Industries. Titomic was established in 2014 to commercialise this technology.

Titomic currently has the exclusive rights to commercialise CSIRO’s

Titomic founding director and CTO, Jeffrey Lang, and Titomic chairman, Philip Vafiadis, at the launch of Titomic’s 3D metal printer in Melbourne.

Manufacturers’ Monthly JULY 2018 21

Industry FOCUS

Kinetic Fusion process involves a 6 axis robot arm spraying titanium powder particles onto a scaffold at supersonic speeds. proprietary and patented process for the application of cold-gas dynamic spraying of titanium or titanium alloy particles onto a scaffold to produce a load-bearing structure.

Infinite potentials Titomic’s technology is not limited to 3D printing. Their process also finds applications in seamless coating for large industrialscale parts, as well as in creating advanced composite materials by fusing dissimilar materials together.

“Probably the most exciting advantage of Titomic Kinetic Fusion process is that it enables us to fuse dissimilar materials that could not be fused in any other way. This puts us at the forefront of pioneering new smart materials that can be specifically designed for different components and parts,” Lang said.

The aerospace industry is currently the largest customers of titanium alloy products. “Airbus is sticking with carbon fibre while Boeing is moving towards super alloys. So Airbus is looking at ways for metallisation of the carbon fibre.

We are currently working with a couple of Tier 1 companies from the aerospace industry who are looking to develop carbon fibre parts with titanium middle structure,” Lang said.

Defence is another sector where Titomic’s technology finds relevance.

“In the past, the idea of protecting our land vehicles from explosives, land mines and bullets was simply 22 JULY 2018 Manufacturers’ Monthly

to use thicker plates. With smart materials, we can significantly reduce the weight of those vehicles. Using kinetic technology, we can fuse a hard material such as titanium with a layer of light material like aluminium to produce a multi-layer material with superior properties,” Lang said.

“Similarly in the containment or pressure vessels, say for the submarine hulls, we currently have hulls with 200 to 400mm-thick sections using monomaterials. Using hybrid composite metals, we could reduce that thickness down to 50mm with even higher compressive yield properties,” he said.

Shipbuilding is a major industry Titomic is targeting. In mid-May, Titomic signed a Memorandum of Understanding (MoU) with Fincantieri Australia – a division of Italian shipbuilder Fincantieri. The company is one of the shortlisted bidders for The Future Frigates SEA 5000 program. As part of the MoU, over the next 12 months, Titomic will investigate how its industrial scale advanced manufacturing process can be effectively used in Fincantieri Australia’s manufacturing process.

“The shipbuilding industry is currently using 50-year old technologies. Nothing much has changed in that area over the past years. Our machine can be installed on a gantry system to coat the whole hull of the ship. That shows the significant scale of what we can do.”

Lang said.

Titomic’s technology also finds applications in the mining and the

oil and gas industries in laying continuous pipes or coating the existing pipes and valves.

“While setting up a mine, one of the main costs is related to pipe welding. Customers are excited around the potential for Titomic to produce pipes on demand and on site at large lengths.

“The pipes in the oil and gas industry are in very abrasive environments. When they pump up the oil, there is a lot of sand and grit in the oil. We are working on new materials to harden the insides of valves, extending the lifespan of the parts up to ten times,” Lang said.

On the smaller, commercial goods side, Titomic has already worked with two famous US-based sports equipment manufacturers for production of bicycle frames and golf equipment. There is also interest from international design houses for manufacture of luxury titanium suitcases.

Cost-competitiveness of 3D printing with titanium While 3D printing of titanium has unique applications, particularly in making complex-shaped parts, Lang says with time, the technology will catch up with traditional manufacturing processes when it comes to cost.

“The nitrogen and electricity costs for running the machines are not very high. Our biggest cost restriction at the moment is the cost of metal powders,” Lang said. “Titanium powder can be prohibitive for high volume, low value industries.”

He believes the cost will come down, however, as more and more applications are developed for titanium, increasing demands.

“When you look back at 150 years ago, the most expensive material in the world was aluminium. And that is now only $2-3 per kilogram.

Things change based on demand.

The demand for titanium powder in Australia hasn’t been great until Titomic came along. Now we are in the position where we are securing the supply chain from larger suppliers,” he said.

Lang is also leading negotiations with a few key countries including Russia, which currently controls most of the world’s titanium supply.

Despite the small hurdles which will be overcome with time and ingenuity, including validations and perfecting the manufacturing process – particularly in posttreatment and finishing of the parts, Lang is excited about the opportunities the technology offers.

“One common reaction that I get whenever I speak to engineers and industrial designers is that they say they couldn’t sleep for nights after our conversation as their minds came up with new, exciting ideas about possible applications of this process,” he said.

“These are exciting times. We started the whole project with the view of developing sovereign capabilities for Australia. But the technology does not benefit just one country,” he said. “It’s about securing a better future for all humanity and future generations on this planet.”

Titomic founding director, Jeffrey Lang, and new CEO, Gilbert Michaca, pose with the spray gun of Titomic’s metal 3D printer.

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AES CONFERENCE 2018 Solutions for a sustainable future in energy storage Running 23-24 May in Adelaide, the Australian Energy Storage Conference and Exhibition (AES 2018) saw the biggest names in energy storage come together to showcase their latest technologies and processes. Manufacturers’ Monthly reports.

A dominant message in the conference was the need to prepare Australia for the inevitable transition to renewable energy and the available solutions.

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HE fifth edition of the Australian Energy Storage (AES) Conference and Exhibition held in Adelaide, revolved around the central theme of “Storing Energy for a Sustainable Future.”

More than 60 leading companies in the Australian and global energy storage industry exhibited their newest technologies.

The conference sessions focused on the latest developments in

24 JULY 2018 Manufacturers’ Monthly

lithium batteries, flow batteries, hydrogen storage, silicon thermal storage, compressed air storage, flywheel energy storage, inverters, lead acid batteries, pumped hydro, hybrid system providers, and energy management.

A dominant message in the conference sessions was the need to prepare Australia for the inevitable transition to renewable energy and the available solutions to do so in the most sustainable way.

South Australian Minister for Energy and Mining, Dan van Holst Pellekaan, reaffirmed this message in his welcome address: “The level of attendance [in the conference] is a testament to the importance of storage in the energy transition. It is not a choice of whether to increase clean energy, but how to do it. The transition is underway and the transition will continue.

“You can not pursue such a high take-up of variable renewable

energy without it being paired with a growth in storage and interconnection,” van Holst Pellekaan said.

Tackling high energy costs: GFG Alliance’s model Keynote speaker, GFG Alliance chairman Sanjeev Gupta discussed his company’s plans and ambitions for investing in various sectors in Australia, noting that all of those investments were reliant on being manmonthly.com.au

AESCONFERENCE 2018

able to effectively lower the energy costs through renewable energy generation and storage.

He mentioned plans by GFG Alliance to invest in establishing a bank for the mid-corporate companies (with turnover ranging from $50-$500 million), expanding the mine acquisitions across Australia and investing in nonferrous minerals and expanding his steel production and scrap steel and scrap aluminium recycling business (Green Steel and Green Aluminium).

Underpinning all those investments, he said, would be the company’s investments in energy.

“Energy is a great cost in all of our business sectors. In steel production, about a third of our cost is in energy.

“Since we came here, from having the lowest energy costs in the world, Australia quickly became one of the highest energy cost countries in the world,” he said.

At the same time, he said, energy consumption in Australia is expected to grow with the evolution of domestic economy, and strengthened by the entry of international investors, such as GFG Alliance.

To tackle the issue, he described GFG Alliance’s solutions as threefold: taking control of their own energy generation; pairing energy generation with load balancing mechanisms; and developing renewable energy solutions for the wider society.

While Gupta’s company had earlier committed to building 1GW of large-scale solar-plus-storage in and around Whyalla, he said the scope of GFG’s investments in renewable energy across Australia could increase to as much as 10GW – keeping in line with the company’s industrial growth.

Gupta also confirmed plans to enter into electric car production with iStream, a light-weight car designed by UK’s Formula One

manmonthly.com.au

GFG Alliance chairman, Sanjeev Gupta, discussed his company’s plans and solutions to the high energy costs in Australia. designer Gordon Murray.

“The design uses F1 technology, but at the opposite end of the scale – making competitive cars for $20,000 to $30,000. The car has a light frame as it uses tubular chassis rather than the traditional chassis. It also uses composite panels. So, it’s a much lighter car and therefore well suited to the electric car technology.

“That is the car which we will invest in both Australia and India.

We are looking at setting up a plant in the next two-three years, either in South Australia or in another part of the country, subject to what conditions are best for production,” he said.

He also hinted at future plans to enter lithium battery production and battery recycling.

“Australia has the best material resources, both in terms of energy and minerals. But unfortunately it has failed in capitalising on them.

The way I see it [with battery

production], we are again heading towards exporting the lithium material to China and other places such as Korea or Japan, without adding much value.

“There is a clear and great opportunity for us to take charge of this change in the world order where batteries will become a key part of our lives. Both battery production and battery recycling are clear opportunities and we will try to get involved in them,” he said.

In a conversation with Manufacturers’ Monthly, he encouraged manufacturers in all sectors to take benefit of renewable energy to bring down costs.

“If you have a warehouse processing, you can easily apply rood-top solars and batteries. The key is to bring the cost of these things down. At the moment, the costs are quite high, and one of the reasons is the cost of finance and how long it takes to amortise it,

because many businesses cannot, or will not, amortise these plants over a long period. They want to pay them back in much shorter periods,” he said.

Admitting that not all companies can follow suit with GFG Alliance’s integrated model to generate their own renewable energy, he recommended that companies look for energy generators who can offer renewable energy at competitive rates – an example being GFG Alliance’s recent deal with Neoen to supply power to Laverton steel works in Victoria.

“Where some other company has a cheap form of generation, we buy from them. It all depends on what is the best opportunity available,” he said.

Flow batteries as a solution Another keynote speaker, Simon Hackett, non-executive director and technology evangelist-Redflow Limited, spoke about the advantages

Manufacturers’ Monthly JULY 2018 25

AES CONFERENCE 2018

Redflow non-executive director, Simon Hackett (left), Victron Energy sales manager, Philip Crotty (centre), Kokam vice president, Ike Hong, and general manager Australian Operations, Jon Pemberton (right), discussed their companies’ latest technologies. of flow batteries over conventional batteries such as lithium ion and leadacid batteries.

Redflow’s ZBM2 Zinc-Bromine flow battery is the first small-scale application of flow batteries, making them ideal for use in residential, telecommunications, commercial and industrial and even grid-scale energy storage.

“Unlike conventional batteries, flow batteries don’t lose their output capacity with ageing. All other types of batteries wear out with time and the more you use them, their capacity diminishes with age. That’s something we are used to and we think that’s a normal thing with a battery. It may be a normal thing with conventional batteries, but not with flow batteries,” Hackett told Manufacturers’ Monthly.

“Flow batteries can also be completely charged and discharged.

They have no concept of reserved capacity. They also don’t suffer from what is called as thermal runaway.

In lithium batteries, one of the consequences of their high energy storage capacity is that capacity also governs the thermal runaway.

But a major advantage, Hackett said, is the recyclability of flow batteries, making them a better choice for the environment compared to lithium and lead-acid batteries. “All 26 JULY 2018 Manufacturers’ Monthly

components of Redflow batteries can be either recycled or re-used,” he said.

“One of the things that we need to be careful about as we move into a sustainable energy future, replacing base-load power with dispatchable generation, is not to follow saving the environment from coal with destroying it with an environmental disaster around recycling enormous quantities of conventional batteries,” he said.

In the near future, Auckland-based Hi-Tech Solutions will be deploying Redflow’s ZBM2 batteries to build advanced hybrid energy storage systems that will deliver reliable power to multiple remote sites in a Pacific Island nation.

“It’s actually a multi-island telecommunications and digital TV network. The smaller sites will have two or three batteries, and the bigger sites will have up to 60 batteries installed in a container case.

“The New Zealand company chose Redflow’s battery for its resiliency, recyclability, fire-resistance and lighter weight compared to acid batteries,” he said.

Battery inverter-charger for large-scale storage projects Other exhibitors launched new products, allowing delegates to be the first to see ground-breaking

technologies in the market. Victron Energy was one of these companies, showcasing MultiPlus-II series of battery inverter-chargers.

Victron Energy sales manager, Philip Crotty said the MultiPlusII converters use old, long-proven design methodology, but offer that at competitive costs through adoption of modern manufacturing methods and new components.

The MultiPlus-II is a 48-volt inverter-charger that readily connects with a range of energy storage systems, from lead-acid and lithiumbased batteries to zinc-bromine flow batteries. The unit is easier to install than earlier models with AC connections accessible via a single plate on its base. The 18-kilogram MultiPlus-II draws just 11 watts of standby power, less than half that used by the model it supersedes.

“We have designed this model specifically for on-grid energy storage systems, but it can also be used in offgrid and micro grid connections,” he told Manufacturers’ Monthly.

He cited as one of the most popular applications of their system helping optimise existing diesel generators.

“Diesel generators are used in many remote sites, such as in mining applications. The diesel generators are built for the maximum load, but

quite often the load is way below the maximum. In this situation, the efficiency is very low and it causes quicker wear out.

“If you have a battery, instead of running the generator 24 hours a day, you can run it for two to three hours a day at peak efficiency and fill up the battery. And then, those variable loads can be taken out of the battery,” he said.

As with all Victron inverterchargers, the MultiPlus-II is a transformer-based system, which can immediately deliver backup power if the grid drops out. This includes startup supply for high-demand devices, such as air conditioners and freezers.

On the utility side, Crotty said Victron Energy’s controllers are also used to smooth out the grid in distributed power generation.

High power/low energy battery technology Ike Hong, vice president and head of power solutions division, Kokam, explained the theory behind high power/low battery technology and how to choose the right battery technology for each application.

“To install the battery storage system, you need to define two different numbers: the capacity – which is determined by what is the manmonthly.com.au

AESCONFERENCE 2018 single largest loss of load on the system – and the battery energy, which is to do with how long you are going to operate the system. The C-rate is the ratio between energy and power.

“Energy applications requiring energy to be provided over a long period of time with long recharge times favour lower C-rate battery technologies; whereas power applications that require energy to be provided over a short period of time with fast recharge favour the high C-rate battery technologies,” he said.

Kokam is currently providing battery solutions to multiple industries, including electric buses, electric passenger cars, electric tram and the railway industry, yachts and submarines, as well as military vehicles, missile defence systems and aircrafts, Hong told Manufacturers’ Monthly.

While Kokam has found a niche market in the off-grid mining sector, with six projects completed in Australia – the latest being a 30MW lithium battery storage project for Alinta Energy in the Pilbara region of Western Australia – Hong said his company is also looking at expanding into the local market for utility-scale energy storage systems.

Kokam provides a range of lithium ion/polymer battery solutions to customers in over 50 countries.

According to Hong, his company is now planning to open office in Australia, considering the exponential growth in demand for battery solutions.

“When we came here three to four years ago, there were only a few small pilot projects, whereas now, there are so many big projects and everyone wants to put storage systems everywhere. So, it’s a very good time for us to ramp-up the scale of our business here,” he said.

Thermal energy storage systems Dr Kevin Moriarty, executive chairman of 1414 Degrees discussed his company’s unique thermal energy storage system (TESS) and how it can be utilised to deliver clean heat.

1414 Degrees’ technology uses the latent heat properties of silicon to store and recover high-temperature heat and electricity. Silicon’s high melting point (1414° Celsius)means it can hold much more energy than other phase change materials.

Moriarty noted that while 1414 Degrees had initially planned to use the technology to compete with battery storage systems, an approach he referred to as “naïve, considering that the batteries would do that a lot better.”

In its current approach, however,

Where some other company has a cheap form of generation, we buy from them. It all depends on what is the best opportunity available.

1414 Degrees is focusing on providing energy in the form most used in the world – heat.

“We had underestimated the demand for clean heat. Since we changed our approach, we have had many companies come to us who said around two-third to 95 per cent of their energy needs are heat related.

They said we want to install solar panels on the roofs of our factories to replace gas, because gas is expensive,” he said.

Noting that about 50 per cent of the European Union’s energy consumption is in heating/cooling, Moriarty said estimates based on data from the Federal Government showed that about a third (33.5 per cent) of energy use in Australia is in the form of heat, while electricity consumption is less than a third (27.1 per cent). The remaining consumption is in transport.

1414 Degrees is currently developing joint ventures to commercialise its technology, including a 10MWh TESS device to be deployed at Pepe Ducks processing

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plant and a biogas energy recovery and storage project for the Glenelg Wastewater Treatment.

Moriarty pictured a future where renewable generation will replace gas for industrial heat.

“The worldwide market for heat is much larger than electricity. In the future, the renewable generation will feed the grid and that electricity will be used to supply the industries with efficient electricity and heat.

“We are not going to compete with batteries. We want to operate at a much bigger scale and the end result should be that we can use the existing grid infrastructure, rather than using distributed storage solutions, to lower costs and increase efficiency,” he said.

Returning to the issue of sustainability, Moriarty said the problem with using a wrong solution is that you can end up with negative consequences down the road.

“Batteries are not the solution for bulk storage. It has to be something else, and we think we’ve got one of them,” he concluded.

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Manufacturers’ Monthly JULY 2018 27

Issues & INSIGHTS Future-proofing the Australian SMEs with futuremap The Advanced Manufacturing Growth Centre, Innovative Manufacturing CRC and Entrepreneurs’ Programme are jointly taking futuremap, a business diagnostic tool developed

by IMCRC, to market to help SME manufacturers on their journey to the Industry 4.0 transition. Manufacturers’ Monthly reports.

The futuremap program helps SME manufacturers map the current state of their businesses and their future aspirations by comparing them against 13 key areas.

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USTRALIAN manufacturers across the country have an opportunity to get on board with the transition to what is referred to as the fourth industrial revolution (Industry 4.0) and to assess the current state of their businesses with regards to the benchmark characteristics for advanced manufacturing.

The futuremap workshops, jointly developed by the Advanced Manufacturing Growth Centre (AMGC), the Innovative Manufacturing CRC (IMCRC) and the Entrepreneurs Programme, are designed specifically for Australian SME manufacturers to help foster cooperation among research and industry.

According to the AMGC managing director, Jens Goennemann, this

28 JULY 2018 Manufacturers’ Monthly

industry engagement program using futuremap intends to achieve three main objectives: first, to help Australian manufacturers get an insight on the opportunities and challenges of digital and advanced manufacturing; second, to act as a mirror for the participants to analyse the current state of their business and compare this to where they aspire to be in two years’ time; and third, to help businesses understand where they can seek assistance on their transition to digital manufacturing.

“The futuremap workshops provide an opportunity to share with the participants outcomes from AMGC’s research on the advanced characteristics of globally successful businesses, as well as to connect and build relationships

with manufactures throughout the country,” Goennemann told Manufacturers’ Monthly.

As part of the workshop, the participants answer a number of questions that help them map the current state of their businesses and their future aspirations by comparing them against 13 key areas to become an advanced and digital manufacturer. At the end of the session, participants receive an immediate online assessment report, showing their current state in all of the 13 key areas, as well as their aspirations and ambitions going forward. The report also connects the participating SMEs with further educational materials and access to a broad eco-system of supporting government organisations and programs.

“This is a confidential exercise, which means the companies continue to own their data. These futuremap workshops act as a marketplace, to connect the businesses with other like-minded companies, as well as to the relevant organisations and growth centres.

If, for example, the outcome of the self-assessment tool indicates that a business would like to become more globally competitive within the next two years, we would connect the company to representatives from Austrade. If a company would like to have a holistic review of their business strategy, they can connect with a representative from the Entrepreneurs’ Programme,” Goennemann said.

The first series of the futuremap workshops were held in parallel with the National Manufacturing Week from May 9-11. The AMGC, the IMCRC and the Entrepreneurs’ Programme plan to hold similar

workshops throughout the country over the next 12 months to reach out to a broader audience, not just in the metropolitan areas, but also in the regional areas.

“I would like to see that those who participate become part of our constituency and form an on-going relationship with our state directors in their journey to become part of the transformation in manufacturing,” Goennemann said.

Insights from the workshop The first series of futuremap workshops were held in Sydney from May 9-11, over three breakfast events running parallel to the National Manufacturing Week.

The workshops received a positive feedback and strong participation from the manufacturers.

The program complements the outcomes of the research by AMGC on building resiliency in the manufacturing sector and helping Australia transition into smart, highvalue and export-focused industries.

According to Goennemann, AMGC’s study of over 3,000 globally successful manufacturers showed that to be globally competitive, these companies did not need to be cost-competitive. Instead, he suggested models where companies can compete on value rather than on cost.

“Australian manufacturers cannot only compete globally in terms of cost. Rather, they need to compete on value, rather than on cost,” he said.

“Manufacturing is more than just production,” he said. “That’s because some things come before you produce and some after. In fact, there are manufacturers today who do everything except production. manmonthly.com.au

Issues& INSIGHTS The futuremap workshops have received positive feedback and strong participation from the manufacturers.

You can do something before, in research and development or design, or do some thing after in sales and services. You can still produce something and combine service on top of that.”

Fred Eske, sector directoradvanced manufacturing, the Entrepreneurs’ Programme, explained the role of his organisation in offering support to businesses and encouraged participants to seek guidance from

manmonthly.com.au

the programme’s advisers.

The Entrepreneurs’ Programme is the Australian Government’s flagship initiative for business competitiveness and productivity.

The programme offers support to businesses through four elements: accelerating commercialisation, business management, incubator support and innovation connect.

David Chuter, managing director and CEO of IMCRC, took a closer look at Industry 4.0, the wave of

technological advances sweeping the world of manufacturing, and how Australia can capitalise on the resulting opportunities.

“We’re seeing an explosion of opportunities with this thing called the Internet of Things (IoT),” said Chuter. “Fifty billion connected devices – it’ll just keep growing. If you look at emerging technology trends, the IoT is the single biggest investment opportunity the world has seen. IoT is forecast to attract more than $1.4 trillion globally by 2021. So what are the opportunities for Australian manufacturing in this?

“The second largest investment trend is in robotics, forecasted at US$225 billion ($294 billion) by 2021. As manufacturers we’ve had robots in factories for decades.

But those robots have been behind cages and cost at least a quarter of a million dollars. It’s disruptive, but nowhere nearly as disruptive as cobots, little robots that work alongside people, doing things that people probably shouldn’t be doing.

What could that do in your business to free up opportunities?” he asked.

He mentioned artificial intelligence and the computing power as the next big emerging and disruptive technologies. “That investment continues unabated, faster, quicker, at lower costs. It’s game-changing,” he said.

Chuter also spoke about the concept of servitisation as a sales

strategy to help manufacturers maximise their profits.

Citing examples of companies such as Rolls-Royce, Microsoft, Apple and Michelin tyres, he demonstrated how international companies are coming up with selling models that enable them to sell services rather than simply selling products, thereby maintaining an ongoing relationship with their customers.

Throughout the session, Chuter invited the participants to reflect on their current state with complete honesty and to ask themselves how much they were prepared for adopting the new trends and where they thought they would be standing in two years’ time.

“Why two years? Because one year passes very quickly. Three years is a horizon that’s a bit beyond most peoples’ planning. So, we have set a goal of two years. You may not change the world in two years but you may be well on the journey in certain areas.

“The idea of futuremap is to help you and point you in the direction, or help you point yourselves in the direction where you think you need to invest your resources,” he said.

To connect with the three organisations, please visit: Advanced Manufacturing Growth Centre – amgc.org.au Innovative Manufacturing CRC – imcrc.org Entrepreneurs’ Programme – business.gov.au

Manufacturers’ Monthly JULY 2018 29

Soft SKILLS IN MANUFACTURING Soft skills, maximum results Rum Charles, principal consultant at the Australian Institute of Soft Skills Training (AISS Training), explains to Manufacturers’ Monthly how the companies could benefit from soft skills training programs for their staff.

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T is no secret that automation and artificial intelligence (AI) are changing the business landscape.

It is no longer just the manual tasks that are being handled by robots.

They are also increasingly capable of accomplishing activities that include cognitive capabilities, such as making tacit judgments, sensing emotion, or even driving.

A survey by the World Economic Forum predicts that by 2020, AI, robotics and automation will lead to the disappearance of 7.1 million jobs in 15 of the world’s major industrialised nations.

But, there are certain traits and skills that robots cannot and will never replace. Human skills, or “soft skills” are what make humans such an important part of any company and what set companies apart from their competitors.

According to a report by McKinsey Global Institute, titled “A future that works: automation, employment, and productivity,” humans are still much stronger at skills such as logical reasoning, creativity, coordination, identifying social and emotional states and moving around diverse environments.

Realising this fact, companies are becoming ever more aware of the importance of soft-skills training for their staff, as the main strategy to remain competitive and boost their productivity and growth.

Manufacturers’ Monthly reached out to Rum Charles, principal consultant at the Australian Institute of Soft Skills Training (AISS Training), on the importance of soft skills.

“The biggest problem that Australian companies are going to face in a few years – and which many are struggling with right now – is running out of appropriately skilled people in their workforce who can communicate the company’s value propositions to customers and prospective customers.

Because irrespective of how good

30 JULY 2018 Manufacturers’ Monthly

In order to be a smart nation focusing on smart and niche manufacturing, collaboration and communication play a key role. your products are, if you don’t have people with good presentation and communication skills, then you’re going to struggle to get your product to market,” Charles said.

He pointed out that while the focus has been on upskilling workers with technical skills and redirecting academic studies towards STEM, Australia has a real problem – basic people to people communication skills are very low.

“Young people coming out of trade schools or university have had little to no training in soft skills, and many people already in the workforce have not updated their skills in many years. They need to realise that communication and creative thinking skills are central to the survival of every business today, he said.

In order to be a smart nation focusing on smart and niche manufacturing, collaboration and communication play a key role.

“In terms of leadership skills in Australia, there’s a massive deficiency because we haven’t been training our business leaders of the future, particularly in manufacturing.

“Without a customer-centric strategy, retaining customers becomes harder – particularly when you don’t have the soft skills to keep them engaged with you,” Charles pointed out.

It always costs a lot more to gain a new customer than keep an existing one, and many manufacturing

companies find themselves in financial difficulties if they loss a big customer and the loss of two will see some close their doors for good.

Reducing the companies’ risk due to unpaid invoices through credit control training Even if companies realise the importance of soft skills training for their sales team, not enough of them realise the most critical department is their accounts receivable department.

“No invoices paid, no cash flow,” according to Charles.

“If you ask companies whether they have trained their accounts receivable staff, most will answer “no”. In addition, most companies don’t even have a dedicated accounts receivable staff member. The task is often handled by inexperienced people who perform all sorts of other tasks simultaneously and like with most things people don’t like doing, it gets left to last, if done at all.

“This has resulted in many companies struggling with cash-flow, being left with large amounts of outstanding invoices that are in the 90-day plus category. Through our credit-control training, we can help the companies reduce their outstanding invoices over 60 days, by up to 20 per cent or more in some cases.

“We achieve this by training the accounts receivable staff and giving them the confidence and skills to ask customers for overdue payments, whilst

maintaining an excellent relationship with the customer. We see credit control as part of a healthy customer service dynamic. We also train them on the necessary attitude and voice skills required to have impact on the phone, as well as the negotiating skills that can help them through difficult situations,” he said.

“The strategy I would recommend is a very simple one – send them to us (AISS Training) for up-skilling.

We believe in equipping our clients with professionally trained accounts receivable people. If you don’t have a professionally trained accounts receivable team, it is likely that you will always have the risk of large amounts of outstanding money,” said Charles.

All in a day’s work Charles said that the time needed to turn that around in terms of skills, is a single day. “No long drawn out training, send us your staff for a day, we send them back changed and ready to collect outstanding invoices.”

AISS Training offers interactive training courses, as well as tailored, in-house training, ranging from customer service to credit-control and leadership training. As a facilitator, Charles has worked with multiple organisations such as Deloitte, EY, BHP, Haymes Paint, as well as government institutions and many SMEs, providing soft-skill training via interactive engaging training sessions.

“Through our one-day and twoday training courses, we help people gain the required soft skill and the confidence to succeed in their roles,” Charles said.

“By giving the staff an enjoyable training experience, we help organisations thrive in these competitive times.”

AISS Training Tel:1300 766 067 Web: aisstraining.com.au manmonthly.com.au

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Industrial CHAIN DRIVES Staying ahead of the curve Gates Australia’s PolyChain GT Carbon belts are suited for use in machine tool, roller chain, small conveyors and compact drives where space is a problem.

Manufacturers’ Monthly reports.

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NDUSTRIAL chain drives in manufacturing plants are under a lot of stress. Transmission roller chains have to handle heavy loads, high speeds and temperatures, volatile materials and other demanding environmental conditions.

Sometimes, they simply can’t handle those things.

Re-tensioning and lubricating the roller chains can be quite timeconsuming, costing businesses in downtime. Some drives even fail only a few months into their lifetime, requiring expensive replacements.

All of these add up to the cost of the businesses.

That might have been acceptable in the past. “That’s how we’ve always done it,” business-owners would say.

But, according to Gates Australia, that doesn’t cut it anymore, especially when there’s a better option available.

A better alternative Building on decades of experience in creating optimum solutions for belt drives in both automotive and industrial applications, Gates Australia has introduced PolyChain GT Carbon belts, which are well equipped to handle the demands of any manufacturing environment.

PolyChain GT Carbon is Gates’ most powerful synchronous belt and is designed for optimum performance on hig- torque, low-speed drives often seen in industrial applications.

An excellent alternative to chain drives, PolyChain offers many benefits to any business.

The body and teeth of PolyChain GT Carbon are constructed using a lightweight polyurethane compound, which is specially blended to adhere to the cords and fabric. Carbon fibre tensile cords provide extraordinary power-carrying capacity, as well as exceptional flex fatigue life.

Combined, these factors mean PolyChain GT Carbon has the 32 JULY 2018 Manufacturers’ Monthly

strength to withstand shocks and surge loading and is virtually immune to abrasions. Being much lighter than steel chain, PolyChain GT Carbon also reduces overhung loads.

Additionally, the new PolyChain GT Carbon has power ratings up to 30 per cent higher than the company’s earlier versions of PolyChain and a service life up to three times longer than conventional roller chains.

Similarly, pulley life for PolyChain is up to 10 times longer than roller chain sprockets.

By eliminating the need for constant re-tensioning, lubricating and removing the links, the belts increase the production efficiency and save businesses valuable time.

PolyChain GT Carbon belts are maintenance-free. They do not require lubrication or oil baths (a hazard for any food handling environment) or re-tensioning every few months. They will not stretch during service. They offer 400 per cent greater capacity than High Torque Drive (HTD) belts, five per cent energy savings over V-belts, and 99 per cent efficiency for the life of the drive.

PolyChain GT Carbon is inert to most acids, chemicals and water, making it an ideal solution for wet environments – unlike roller chains, which can rust, potentially contaminating food-handling spaces.

The belts operate on Poly Chain GT pulleys and do not require any adaptation of existing GT2 applications.

Specifications The belts come in a range of pitches.

This range includes both short and extended custom lengths to suit a variety of manufacturing purposes.

Short-length versions of the belt in five metres and eight metres are suitable for industrial markets requiring a short centre distance but high-density power and offer all the

PolyChain GT Carbon has a service life up to three times longer than conventional roller chains. benefits listed above.

PolyChain GT Carbon is also available in the 19-metres length to handle longer drive centre distances, while delivering high-power capability, long life and freedom from maintenance. PolyChain GT Carbon offers a 96 per cent weight saving versus traditional, comparable transmission roller chains.

Extended length manufacturing capability allows for custom belt lengths with any tooth count – within the minimum and maximum length range.

All PolyChain GT Carbon belts are operational in temperature extremes of minus 54°C to 85°C and can be used for applications in general manufacturing, food and

beverage, timber, agriculture, oil and gas, cement and more. They are suited to a range of different environments, from food production to fans and pumps.

PolyChain GT Carbon also offers reduced width drive conversions for existing roller chain applications, and over 120,000 possible ratio combinations, making it easy to switch the drives. The space-saving, weight-saving, time-saving and money-saving drives offer a long and reliable service life.

Company: Gates Australia Phone: (03) 9797 9688 E-mail: Southpacsales@gates.com Web: www.gatesaustralia.com.au/ PolyChain manmonthly.com.au

Compressors @MM Energy savings through the right compressor Manufacturers’ Monthly speaks to Matthew Gray, business line manager, Industrial Air, Atlas Copco Compressors on their latest offerings and the energy issue for the manufacturing sector in 2018.

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OVING into 2018, Atlas Copco Compressor’s strategy was to reach out to as many opportunities within the industrial market and engage more deeply with customers to service the needs of manufacturers.

Matthew Gray, business line manager, Industrial Air from Atlas Copco told Manufacturers’ Monthly that the company plans to help educate users that it is not just about supplying (or buying) a compressor.

“It is often easy to replace like-forlike kW sized compressors, or to select a compressor on the recommendation of a peer based on something that has worked for them in the past, or based on a catalogue-like compressor supplier. In many cases, users of compressors do not understand what is truly needed to make their operation as efficient or as functional as they need to,” said Gray.

Gray explained that one of Atlas Copco Compressor’s biggest value propositions is that they don’t just stop at the selection and supply of a compressor, but they make sure that value continues to be delivered to the customer even after the sale.

Tackling the energy equation The value of the Atlas Copco Compressor products is in the energy efficiency that it gives the user.

“If we can find the most energyefficient tool for manufacturers today that offers you an opportunity to save year-on-year and wholeof-life costs on that equipment – then you’re going to jump at it,” said Gray.

He emphasised that it is the goal of the company is to find the right compressors and associated equipment that will save users as much as possible on operational costs, and on maintenance associated down-time or loss of productivity. manmonthly.com.au

“Today, for the industries that we serve, it is all about being adaptable. People drive a lean operation, which means that they are looking at shorter start-up and set-up, and change-over times in their manufacturing. This creates an increased variable demand on their manufacturing utilities. One of which, is air. So, old-school practice of using fixed speed compressor that chugs away in the corner and feeds a machine that is turning out thousands of pieces per batch just doesn’t happen today. These days, having the most efficient variable speed compressors that turn down to a fraction of their maximum speed is critical for manufacturers to stay competitive,” Gray said.

He explained that to achieve the quick turn-arounds today, there needs to be a variability in the air supply and in other utilities – that’s where the savings are really going to come from.

the IoT for remote monitoring and data gathering and analysis, cuts across most advanced factory floors.

“Our compressors can be connected back to the customer via mobile devices and can provide reports to tell them whether or not that machine could be optimised further or run out of capacity (inhibiting an operation), or if it is due for a service,” explained Gray.

Gray then said that the concept of variable speed drive (VSD) technology is not fully understood.

“Users need to understand more about VSDs because they are all not equal. Users should ask manufacturers to talk through the differences between VSDs. At the moment, there’s a lot of manufacturers with a lot of different pieces of equipment, compressors or otherwise, that really promote VSD, however many don’t deliver the energy savings that you expect

to achieve from a quality built VSD,” said Gray.

“It’s important that people do their research on VSD drives because they are definitely not all equal and having the term broadly written in your spec may not necessarily be saving you the expected levels of savings,” said Gray.

Atlas Copco builds their controllers in-house. In terms of energy, Gray explained that the Atlas Copco Compressors VSD Plus machine will turn down to below 20 per cent of its maximum power.

“To put that in perspective, the 100-kilowatt machines will turn down and run like a 20-kilowatt machine at its lowest speed. Bolt-on like VSDs will generally only turn down to 40 or 50 per cent of their maximum power, so the differences you can gain in energy savings is really quite considerable if you select a quality, purpose-built, VSD,” Gray explained.

The reliability in connectivity and quality Atlas Copco prides itself in building reliable, trouble-free machines, which are not easy to find elsewhere in the market.

“You can reverse engineer a lot of things in today’s market, but you can’t reverse engineer quality of design. That is why we spend a lot of money on research and development – to make sure that our machines, continue to improve with every version released,” said Gray.

He explained that a break-down is one of the most significant issues in a manufacturing facility because it leads to the loss of productivity, which is difficult to recover. Atlas Copco manufactures compressors through design and extensive testing with the aim to eliminate that issue.

Gray also added that the use of

The value of the Atlas Copco Compressor products is in the energy efficiency that it gives the user.

Manufacturers’ Monthly JULY 2018 33

Risk MANAGEMENT Manufacturing is a soft target for cyberattacks Paul May, operations engineering manager, FM Global, urges manufacturers to be on their toes when it comes to securing their networks and to take nothing for granted.

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If you see this text then your files are no longer accessible, because they have been encrypted,” read the message on the computer screen. “Please follow the instructions and send $300 of Bitcoin to the following address.”

With these words, a Cadbury’s factory in Tasmania was forced to close for three days in June 2017 when parent Mondelez International’s entire global IT network was knocked out by the Petya ransomware attack.

With 500 employees and 50,000 tonnes of chocolate produced a year, the impact was significant – and not just on Aussie chocolate lovers.

To date, Cadbury’s is one of the unlucky few manufacturers in Australia to have been hit so hard by a cyberattack. But our data suggests it may just be the tip of the iceberg.

Counter-intuitively, manufacturing has proven to be one of the sectors most vulnerable to cyber risk. The reasons why suggest there’s much more pain to come.

A shifting risk landscape As one of the world’s largest commercial property insurers, this is just one of several worrying cyber-risk trends we’ve observed. Australian manufacturers, and businesses in general, should be paying closer attention.

The rise of indiscriminate attacks, like last year’s WannaCry and NotPetya, is one of the reasons why manufacturers are among the most impacted by cyber threats in recent years, according to our loss data. Due to the global interconnectedness of business operations, such untargeted attacks spread easily throughout the system. The Cadbury’s shutdown in Tasmania was part of a worldwide shutdown of Mondelez International.

The fact that these untargeted strikes are resulting in the greatest damage, negates the argument relied on by some business leaders. They say their business isn’t interesting 34 JULY 2018 Manufacturers’ Monthly

to potential attackers so they don’t need a comprehensive cyber-risk strategy or insurance policy. Yet although a targeted attack strikes fear into the hearts of executives and risk managers, the risk of becoming collateral damage should not be underestimated.

Cyberattacks are increasing in number, roughly doubling every year since 2015. The financial impact to business is also on the rise, jumping 62 per cent between 2016 and 2018.

These attacks are also becoming more physical in nature, damaging property as well as disrupting operations. Imagine a wind turbine that gets hacked and spins out of control, causing millions of dollars in damage. As recently as 2015, there had been only two such recorded cases but tangibly destructive outcomes are now increasingly common.

Manufacturing under threat Financial services companies were previously the most likely to be hit by cyberattack but when Petya struck in 2016, FM Global’s loss data shows that two-thirds of those affected were in manufacturing.

And it’s not just smaller or less sophisticated companies that are threatened. Our loss data shows large multinationals were badly impacted, with one major client taking 75 days to get operations back online.

Access to valuable intellectual property is one reason why the manufacturing industry is a target.

But the main reasons for this spike in attacks are structural. Network access has been at issue in about 40 per cent of cases we’ve dealt with.

Ageing industrial control systems that monitor equipment are also to blame, along with poor patching discipline and easily guessed passwords.

Physical security has proven to be another reason why manufacturing is a soft target because people can walk into some facilities without checks. Globally, almost two-thirds

Physical security has proven to be another reason why manufacturing is a soft target.

of the physical security deficiencies we’ve found have been in this sector. As companies become more technologically sophisticated, implementing more robotics and automation into their manufacturing processes, the attack surface will grow.

Resilience beats compliance The threat landscape is evolving rapidly and cyber risk must be considered a business issue, not an IT or legal one. It’s a matter of ensuring resilience, not just compliance. This is because the extent of losses is determined largely by how long it takes your businesses to get back to normal – you can’t predict an attack but you should be prepared to respond.

There are three key aspects to managing cyber risk in the manufacturing sector – physical security, industrial control systems and information security. Boards and leadership teams looking to ensure their businesses are protected effectively must implement products, processes and educational initiatives

taking each of these areas into account. These should be reinforced with appropriate insurance coverage based on a holistic view of cyber risk.

Our threat intelligence indicates that Australia is a medium-risk country when it comes to the potential for targeted cyberattacks. In March, the UK and US governments issued a first-of-its-kind warning that Russian state-sponsored cyber actors were trying to access devices that control internet traffic.

Australian intelligence agencies joined their counterparts in the US and UK, advising that about 400 Australian businesses were among those targeted.

There’s a lot more than chocolate bars at stake when risk gets overlooked. Manufacturing accounted for about seven per cent of Australia’s total economic output in 2016. It employs close to a million workers, making it the sixth largest employer.

Cyberattacks are increasingly indiscriminate but the same approach cannot apply to risk management strategies. manmonthly.com.au

Safety &CONTROL Bosch Australia: Creating value through diversification Bosch Australia is setting a good example of driving value through diversification. With years of experience in vehicle technologies, the company has now entered the world of trailer safety and control.

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OSCH Australia recently launched an innovative trailer safety system that combines “on trailer” Anti-lock Braking System (ABS) and sway mitigation technology to improve safety of towing trailers, caravans and camper trailers.

The Trailer Safety Control system is the first in an expanding portfolio of systems to improve trailer usability and road safety for Australians and the global market. The product, first launched in late 2018 is under development and will be manufactured at Bosch’s Clayton facility.

Bosch has been a leader in automotive safety systems such as anti-lock braking and stability control for 40 years. The Trailer Safety Control system will be for fitment to caravans and trailers equipped with electric brakes and towed by passenger vehicles.

The system shows how Bosch Australia is diversifying into new products and markets including the global caravan and trailer sector, building on 30 years of local automotive engineering expertise.

“Our extensive vehicle safety systems experience is carried over into the Trailer Safety Control system, making it a system you can rely on,” Mark Jackman, the head of Bosch Australia’s Vehicle Safety Division said.

“Despite the end of volume passenger car production in Australia over the past year, Bosch Australia’s 200-strong automotive engineering team is busier than ever,” said Gavin Smith, president of Bosch Australia, “Trailer Safety is a great example of how to apply existing capability to an adjacent and attractive niche with global potential.”

Trailers and caravans are a large market segment in Australia. But trailers can easily become unstable manmonthly.com.au

and cause accidents when braking, swerving, overtaking, driving in high winds or on difficult roads. In 2016, loss of control accounted for 30 per cent of caravan accident claims, with over-steering and fishtailing among the main causes.

Many people have experienced nervously following a trailer that has begun to sway and would appear that at any moment it could fishtail out of control. Worse still, is the feeling of a loss of control while negotiating the twists and gradient of the road with a trailer in tow. Both circumstances can be stressful, and for both driver and surrounding traffic, potentially very hazardous.

Bosch Australia appointed as global Centre of Competence for Trailer Safety The Australian Vehicle Safety Systems engineering team identified the need for a solution to this problem. This

prompted an innovation idea and subsequent R&D project in 2014.

The parent company acknowledged the local engineering capability and market opportunity, which led to the establishment of a Bosch global Centre of Competence for Trailer Safety in Australia by 2015.

The launch of the first system, an active safety system, will aid accident prevention by incorporating ABS, sway mitigation and other valueadding functions, for new caravans and trailers with electric brakes.

It has the potential to reduce the number of trailer related incidents by up to 45 per cent. Furthermore, the comfort of knowing that the system will automatically intervene when necessary at the first sign of instability or wheel lock, will help alleviate driver stress levels while towing.

Mounted to the trailer’s chassis, the system comprises an Electronic Control Unit (ECU) with integrated

motion sensor, and wheel speed sensors. These sensors determine the movement of the trailer and the speed of each individual wheel, respectively.

The brain of the system, the ECU, will be manufactured at Bosch’s production facility in Clayton.

DexKo Global provides its expertise With the support of DexKo, a global supplier of highly engineered trailer running gear, chassis assemblies, related components and the parent company of both Dexter and AL-KO VT, Bosch is in the final stages of development, readying the TSC system for sale.

The system will be offered initially in Australia and the US. In these two markets alone, there are approximately 1 million new trailer registrations annually (including caravans), and 12 million registered trailers.

Testing of Bosch Trailer Safety Control at the Australian Automotive Research Centre (AARC).

Manufacturers’ Monthly JULY 2018 35

Research &DEVELOPMENT Powering innovation through collaboration The University of Melbourne is inviting industry and community partners to help run a state-of-the-art fabrication laboratory, part of a new innovation precinct being developed at the heart of Melbourne CBD. An artist’s impression of what the Carlton Connect innovation precinct will look like.

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HE University of Melbourne is undergoing infrastructural expansions. Apart from developing a seven-hectare second engineering campus at the former site of Holden factory in Fishermans Bend and refurbishing and expanding its existing schools of engineering and IT to almost double their capacities, the university is also building a new innovation precinct near its existing Parkville campus.

The project, known as the Carlton Connect Initiative, is transforming a former hospital site into a mixeduse innovation precinct with the aim of bringing together industry, government, entrepreneurs and researchers to work on innovative projects.

With a total area of 28,700 sqm, the master plan for the Carlton

36 JULY 2018 Manufacturers’ Monthly

Connect innovation precinct dedicates spaces for multiple activities including indoor and outdoor public spaces, co-working spaces, accommodation and retail spaces for visiting academics and post-graduate students, a start-up hub (Third Spaces) and an equipped fabrication laboratory (Fab Lab).

The site will also be home to Science Gallery Melbourne, which aims to invite young learners to creatively explore the collisions between art and science.

The Melbourne School of Engineering at the University of Melbourne is currently seeking expressions of interest from industry and community to run, operate and/ or partner with them to deliver the state-of-the-art fabrication laboratory, as a place to test ideas

and manufacture prototypes prior to launching new products.

The University of Melbourne is pursuing a number of objectives through the establishment of Fab Lab, according to professor Andrew Western, director of infrastructure for the Melbourne School of Engineering.

“First of all, the lab will help our coursework students, the engineers of the future, develop the skills and understanding of workshop and manufacturing processes. The facility will also provide the students working on building new devices a place where they can build their own prototypes,” he said.

“The laboratory will also provide partner organisations based in the precinct a facility where they can either build their own prototypes or have prototypes built for them by the organisation running the Fab Lab. Finally, we might also have the general public coming in and utilising the space,” he added.

The Carlton Connect initiative builds on the success of LAB-14, an on-site prototype launched by the University of Melbourne in 2015 to test the concept of a new innovation precinct in Carlton. In its two-anda-half years of operation, Lab-14 attracted more than 40,000 visitors to its programs, including events, seminars, exhibitions, workshops and roundtables.

Early works on the development of Carlton Connect began in November 2017, in a partnership between the University of Melbourne and Lendlease construction group.

The precinct is being developed at the former Royal Women’s Hospital building, located across the road from the university’s Parkville campus. Construction is expected to complete in 2020.

“This is right on the Swanston Street, in the heart of Melbourne, and right next door to the university.

It will be a very visible space.

We also hope it will play a role in inspiring future students of STEM (Science, Technology, Engineering and Mathematics) in general,” Professor Western said.

Professor Western said the University of Melbourne School of Engineering is open to all business model options proposed by thirdparty partner organisations.

“We are open to proposals from either a model where the University provides the facilities and someone else operates those; right though to a model where an organisation might design and fit-out the area with their own facilities. We are early enough in the project development process for that flexibility to still exist,” he said.

The Fab Lab will be accommodated in approximately 1,140 sqm across the ground floor and basement of the precinct. This space is currently at First Fit stage so the successful partner has the opportunity to define the layout, specify the equipment and manage the flow of activities through this innovative space.

The Fab Lab brief requires it to have certain capabilities; including general fabrication areas, a woodworking space, 3D Printing capability, laser studio, finishing/ paint shop, a support space, an open plan office space, maker area, test area, print studio, street-facing display space, general workspace, storage space and kitchen area.

This is a unique opportunity for a partner organisation to work with the University of Melbourne students on their innovative projects, as well as interact with the broader innovation precinct, local business, start-ups and the wider research community.

Interested parties can send an email to fablab-cci@unimelb.edu.au to receive an EOI pack, which must be completed and returned by 1 August 2018. manmonthly.com.au

ARBS 2018 Changing and evolving in the right direction The event was a bold step in the direction of never seen before technologies for the HVAC, refrigeration and building services industry. Manufacturers’ Monthly reports.

Mitsubishi were out in force at the show featuring many of their key products at ARBS 2018.

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HE Air-Conditioning, Refrigeration and Building Services exhibition (ARBS 2018) held in Sydney on May 8-10 saw more than 300 exhibitors showcase their products and services.

According to the chairman of ARBS, Ian Hopkins, the industry is continuing and changing in response to new demands and pressures from economic, government and private sectors. With that in mind, the offerings and the services rendered at the event needed to be tailored in response to these demands.

Because of this, a key addition to the event was the IBTech@IRBS segment, a new smart building precinct that was packed with innovative products and solutions which featured a series of displays, presentations and hands-on sessions.

Its introduction recognised the growing impact of data and technology on the HVAC, refrigeration and building services industry.

Industry veterans headline the show Several industry stalwarts were present at the show. That included Mitsubishi Heavy Industries manmonthly.com.au

who had a strong presence in the exhibition, showcasing products for both commercial and residential applications.

Mitsubishi were featuring their new Airzone VAF-ducted zoning solution, their new PAC In-ceiling cassette, the RAC Hi-Wall and Q-Ton system which has been used for certain food and beverage manufacturing environments.

Greg Piggott, Mitsubishi Heavy Industries technical sales manager was describing the split AC system that was suitable for both commercial and industrial applications.

“This outdoor unit hooks up to the indoor unit and can have multiple indoor units connected to one outdoor unit. This one starts at 22 kW in capacity and it also comes in smaller sizes of up to 11.2 kW.,” Piggott told Manufacturers’ Monthly.

He said its best feature is that it has horizontal blow instead of vertical discharge because it is usually installed in places where ceilings are low like at carparks. “So, if you have a top discharge, the air cannot get circulated properly and our horizontal blow feature makes the product very attractive to the

market,” Piggott said.

He also added that the capacity can’t be decided based on the space area alone.

“This is because it depends on the heat load of the space and what the space is being used for. Because of this, you can’t relate the kilowatt to the square metre area. In residential applications you can do that, but not in commercial,” Piggott said.

The process is that the architect designs the space. Then, they will give it to a consulting engineer, after which, they will then calculate the heat load for that area. It will only be after this that Mitsubishi will be given the heat load and then they will decide the unit to match that heat load.

Their Airzone VAF ducted zoning solution, which is a new control unit, allows users to use one outdoor unit with multiple indoor units and control temperature in each area individually.

“The unit helps reduce energy because you can control each individual zones very precisely. So, that means that you are not running your cooling where you don’t need

to,” said Piggott.

Across the hall, Samsung, also stretched its muscle with its mini-VRF system. The small-scale system for small out-door units is suitable for hotels, residential, and commercial spaces, according to the Samsung engineers that were on site.

Pump specialists, Victaulic, had their new vibration isolation pump drops which is a single SKU manufactured pump drop-unit that connects the pump to a header.

The company mainly serves the HVAC, industrial mining, fire-protection, oil and gas scene internationally.

David Ellis, regional manager, Victaulic, said, “Typically we would sell each component separately, as separate units, but, what we are doing now is that we are about to launch a new Brisbane branch and we are about to sell these as prefabricated units rather than separated parts.”

“Because prefabrication is where the market is heading, prefabricating and doing as much work as possible off-site. We are just entering that area as well.”

David Ellis, regional manager, Victaulic.

Manufacturers’ Monthly JULY 2018 37

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2018 NOMINATIONS NOW OPEN Sponsors

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EndeavourAWARDS 2018 Endeavour Awards 2018 to showcase manufacturing sector’s great achievements Manufacturers’ Monthly is proud to hold the premier night for recognising the achievements of the manufacturing sector – the Endeavour Awards.

T TICKETS, NOMINATIONS & INFO Contact Lauren Winterbottom Events Manager, Prime Creative Media event.organiser@ primecreative.com.au 03 9690 8766 Nominations & Tickets Nominations are now open.

Visit endeavourawards.com.au to nominate and for updates.

Tickets are also currently on sale (the Early Bird rate is $185 + GST for a ticket or $160 + GST for a table of 10). To buy tickets, click the ‘GET TICKETS’ button on the Endeavour Awards website, under the Awards Night tab.

When Thursday 12 July 2018 Where Showtime Events Centre, 61 South Wharf Promenade, South Wharf, Melbourne.

Time 6:30pm-11pm Dress Code Cocktail/lounge suit manmonthly.com.au

HE Endeavour Awards 2018 will be held on Thursday 12 July 2018 from 6:30pm-11pm at Showtime Events Centre, 61 South Wharf Promenade, South Wharf, Melbourne.

The Awards are a chance for all involved in manufacturing across Australia to celebrate the many successes within the industry, share these successes with a broader audience, network, and learn more about Australian manufacturing’s movers and shakers.

Last year, the 14th edition of the Endeavour Awards was held during the National Manufacturing Week 2017 and saw an increase in the number of quality sumbissions and finalists for all categories compared to the previous editions. This year has added a new category – Best Industrial IoT Application.

In Australia and globally, manufacturing is being disrupted by the Internet of Things (IoT). The convergence of technologies like sensors, automation, intelligent robotics, embedded electronics and their internet connectivity is enabling the integration of data across manufacturing functions and supply chains.

The inclusion of this category in the Endeavour Awards 2018 is in line with recent efforts by the Advanced Manufacturing Growth Centre (AMGC) to help Australian manufacturers retrofit their machinery with IoT sensors and communications.

This year we will continue to help in telling the story of your industry’s importance, and of the innovators who ensure that Australian manufacturing thrives.

Last but not least, we would like to thank our category sponsors BESTECH, SICK, SEW Eurodrive , BECKHOF, VEGA, B&R and NMW. Some changes have been made

to the award categories since last year’s awards:

Safety Solution of The Year Technology Application Award – Sponsored by BECKHOFF This category is suitable for those looking to submit successful applications for new technology in manufacturing processes.

Environmental Solution of The Year This category recognises manufacturers who have successfully implemented solutions designed to reduce the environmental impact of their manufacturing operations.

Best Industrial IOT Application – Sponsored by B&R Automation This Award recognises the best uptake of smart factories implementing Industrial Internet of Thing (IOT) applications.

– Sponsored by SICK Safety is of the utmost concern and this category highlights the unique products, solutions and programs implemented by or developed for manufacturers.

Exporter of The Year This category is for companies who have successfully entered or are developing an export market with a new or existing locally-made product.

Australian Industrial Product of The Year – Sponsored by VEGA This category aims to highlight new, innovative Australian-made products designed for industrial applications and turn the spotlight on the people who design and build them.

Most Innovative Manufacturing Company Award – Sponsored by SEW Eurodrive

Outstanding Start-up Award– Sponsored by NMW

This award recognises a manufacturer in Australia that has thought “outside the box” to implement a new business idea.

This category seeks out notable start-up manufacturers – the future of our industry depends on them.

Global Supply Chain Integration of The Year

Manufacturer of the Year

Many Australian companies have developed unique expertise and/ or components that allow them to plug into global supply chains.

Tell us about your projects and the talented people who make them happen.

From the numerous entries received, one trailblazer stands out for outstanding innovation in the areas of technology, management and product development. This award aims at recognising that outstanding manufacturer.

– Sponsored by BESTECH

Manufacturers’ Monthly JULY 2018 39

NOMINATIONS NOW

OPEN For more information, please go to

www.prospectawards.com.au Sponsors

Megatrans 2018 MEGATRANS2018 Wrap Up The inaugural MEGATRANS2018 held in Melbourne from 10-12 May, brought together Australia’s supply chain and logistics industry under one roof for the first time.

MEGATRANS is now firmly placed as a must-attend networking event in the logistics and supply chain events calendar.

U

SED by many businesses as an opportunity to launch new products, communicate with others in the industry and to network with delegates and exhibitors alike, the first-ever MEGATRANS2018 was hailed as a great success for the industry.

Attended by senior leaders, decision makers and business owners, this was the first time in Australia where the premier freight, transport, logistics and supply chain management organisations could be found together under one roof.

It was a rare opportunity for all modes of transport and logistics to get together and discuss common concerns such as productivity, safety and efficiency, MEGATRANS is now firmly placed as a must-attend networking event in the logistics and supply chain events calendar.

Ministerial breakfast briefing To mark the official beginning of the show, MEGATRANS2018 hosted a breakfast briefing where business leaders, influencers and government manmonthly.com.au

came together to discuss the latest developments and opportunities for logistics and transport in Australia.

Kicking off the discussion was Luke Donnellan MP, Victorian Minister for Ports, Roads and Road Safety. Commended for his commitment to the logistics industry and the greater community, Donnellan offered his vision for the future of freight and logistics in Victoria.

He congratulated delegates for their hard work in establishing Victoria as the freight capital of Australia and spoke of the significant investments that the Government will be delivering in rail, ports and infrastructure.

These include $4.3 million to better roads in Victoria and $500,000 to review truck licences in order to keep heavy vehicle driving as an attractive career option.

Raising the profile A common theme across the three days was the need to raise the profile of the industry and the

contribution it has to GDP and the community. This was stressed

by Michael Kilgraff, CEO of the Australian Logistics Council (ALC).

“People don’t understand how their food gets there. It’s important for us to have these kinds of conversations with consumers and policy makers about how our industry works,” Kilgraff said.

Kilgraff spoke of Australia’s growing population and said there is a need to build a city the size of Canberra every year to deal with the projected increase in population and that this will place a huge task on our freight and logistics networks. Efficient supply chains create efficient economies and Kilgraff spoke of the importance of engaging with consumers, policy makers and industry to create a productive and efficient freight network.

An ageing fleet The influence of technology and what that means for Australia’s fleets was discussed. With Tony McMullan, CEO of the Truck Industry Council, presenting the case for a fleet refresh in Australia.

He informed delegates that the average age of a truck in Australia is 14.9 years and fleets are getting older each year. According to McMullan, current fleets are not as safe, environmentally friendly, nor productive as they could be.

McMullan referenced a study from Monash University that found that 104 lives could be saved if more advanced technological safety systems were implemented into fleets. He also found that a failure to modernise fleets and to introduce technology will have an impact on the industry’s ability to realise these safety advances.

Freight and liveability Caryn Anderson, executive general manager, strategy and business

development for the Port of Melbourne spoke of the need to better integrate all modes of the supply chain, both domestically and internationally.

The Australian logistics industry accounts for 8.6 per cent of GDP and contributed $131.6 billion to the Australian economy in 2013.

According to Anderson, freight drives the liveability of a city and with Australia’s projected growth, it is more important than ever that all aspects of the supply chain work together.

Networking opportunities As the entire industry gathered in one place, many businesses used the opportunity to showcase their latest products and developments, as well as to engage with potential business partners and suppliers.

Feedback echoed by all delegates and exhibitors alike was that MEGATRANS is a well-needed event for the Australian logistics and supply chain industry. A common message was that having the entire industry in one location for three days presented networking opportunities that have never been realised in the industry before.

For sensor, networking and control systems supplier, ifm, the show was a great chance to connect with the right people. “This is different to any other show we have exhibited in that it is specific and targeted. The delegates are the right people who want to know how they can improve their processes,” Glenn Thornton, national product and brand manager at ifm said.

Commenting on the success of the event, Simon Coburn, show director said: “It has been great to hear all the feedback from the industry and to realise that this was a much-needed event for the logistics and supply chain sector. We look forward to working with you all on the next MEGATRANS event.”

Manufacturers’ Monthly JULY 2018 41

PACKAGING, WRAPPING & LABELLING For many operations, the final steps of packaging, wrapping and labelling their goods can turn into a bottleneck. These final processes can also affect the quality of a product in the hands of the consumer.

In August 2018, we will speak with companies providing solutions to every level of manufacturing operation.

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.

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booking deadline: August 2018 manmonthly.com.au

MANAGEMENT >> TECHNOLOGY >> SOLUTIONS

JULY 2018

BREAKING BOUNDARIES

INSIDE >>

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All the highlights from AES 2018

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Helping manufacturers on their Industry 4.0 journey

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Selecting the right compressor for your manufacturing needs

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What’sNew

Brought to you by

Great absorbing performance rubber vacuum pad The latest vacuum pad from SMC is the ZP3P which is designed to offer optimum absorbing performance and efficient handling. It features a blue coloured, silicone rubber pad that prevents wrinkles and is compliant with the FDA regulations. The bright blue colour makes it easy to spot during contamination inspections, making it ideal for the food and medical sectors.

SMC has extended its range of vacuum pads with the ZP3P that stands out from the crowd due to its enhanced design for stable adsorption and handling.

The ZP3P features a thin and soft pad skirt, with reduced leakage and a strong grip, so that it’s ideal for working with thin workpieces that deform during adsorption.

The flat shape of the vacuum pad with a central stopper creates a surface that does not damage or deface the product and prevents wrinkles on thin materials such as vinyl and film.

Highly adaptable, it can work with the trickiest of workpieces that are uneven, soft, variable or ultra-thin, such as film-wrapped products, without leaving traces of any wrinkles.

In addition, the pad design of the ZP3P is suitable for a wide range of applications such as film packaging, palletising, printing and labelling. There are seven different types of adapters for customers to choose from and the option of a buffer.

Company: SMC Australia Phone: (02) 9354 8222 Web: www.smcworld.com

Signal splitters with flexible solutions Acromag have recently released the new uBSP signal splitter/duplicator. The uBSP acts as a carrier for the microBlox line of plug-in signal conditioning modules to drive two scalable 4-20mA or 0-10V control outputs and an auxiliary 5V third output from a single input.

Users can select from more than ten miniature signal conditioning modules to process inputs from RTDs, thermocouples, two-wire transmitters as well as a variety of current, millivolt, or voltage sources. The interchangeable input modules snap into the uBSP carrier which provides input and output terminal blocks plus a USB port for easy software configuration from a Windows PC or Android mobile device.

This modular, programmable approach provides an extremely flexible solution to many complex signal splitting applications. The uBSP signal splitter’s USB port allows users to customise the I/O ranges, scaling, and other operations driven by the inserted microBlox signal conditioning module. The configuration software is free, and a common mini-B USB port eliminates the need for expensive proprietary cables or adapters to connect with a PC, smartphone, or tablet.

With the plug-in microBlox modules, users can change the input type quickly and inexpensively as requirements change. 1500V isolation safely separates the input from each output circuit to prevent damage to other instruments from surges. Two-wire transmitter input modules provide field excitation for the transmitter. RTD input modules support two, three or four wire sensors with excitation, linearisation, lead-wire compensation, and break detection functions.

Thermocouple input modules support types J, K, R, S, T and E with linear or non-linear output.

To ensure reliable performance, units are highly immune to electrical noise and operate from 40°C to 75°C. Power sources from 6-32V DC are supported to simplify battery and solar-powered applications. Units mount securely on a DIN rails with 25g shock and 4g vibration resistance. Hazardous location approvals are pending for UL/cUL Class 1 Div 2 and ATEX/IECex Zone 2 standards.

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Company: Metromatics Phone: (07) 3868-4255 Web: www.metromatics.com.au

Manufacturers’ Monthly JULY 2018 43

What’s New Fastest response with the new Optidew range The new Optidew range from Michell Instruments offers the fastest response to changes in humidity of any chilled mirror instrument on the market.

Michell’s engineers have developed a unique, hybrid mirror to provide a fast response to changes in temperature and humidity, while also improving the drift-free accuracy of the fundamental chilled mirror technique by 25 per cent to ±0.15°C. The mirror is highly resistant to corrosion from acids and other contaminants, and, during rigorous testing, outlasted other mirrors based on traditional designs. Customers will be offered three choices of sensor: single and dual stage cooling, plus a dual-stage sensor which is designed specifically for use in harsh, demanding applications such as control of metallurgical processes. This harsh environment sensor is capable of operating in temperatures up to 120°C. It’s not just the sensor that Michell’s engineers have improved: the control unit has also been re-designed with a new case design and improved firmware. The new Optidew has two formats – the Optidew 501 wall mounted unit, and the Optidew 401 bench top instrument. Both are available with a full colour touch screen HMI for easy local operation and interrogation. The Optidew 501 is also available as a transmitter, without a screen, for integration into a DCS, or an environmental monitoring system such as the adaptive Rotronic Monitoring System (RMS).

Michell also offers PC-based software for data capture and graphing. The transmitter version also includes a multi-colour LED indicator which clearly displays the instruments’ status for operators to view locally.

The Optidew 501 and 401 both have two 4-20mA outputs and offer a choice of digital communications. The wall mounted Optidew 501 has Modbus RTU over RS485 as standard, with an optional Ethernet connection and SD card slot for data logging. As a bench top unit, the Optidew 401 has a wider range of communications as standard: RS485, USB and SD card data logging. Customers

can also choose to have an Ethernet connection if required.

Typical applications for the Optidew include environmental control for engine testing, climatic control in clean rooms and environmental chambers and monitoring the coating process in pharmaceutical and confectionary manufacture.

The Optidew 401 is also an excellent chilled mirror reference instrument to validate humidity probes when combined with a humidity generator and calibrated to ISO 17025 standards in one of AMS’s UKAS, NVLAP, JCSS, or SGS accredited labs.

Company: AMS Instrumentation and Calibration Phone: (03) 9017 8225 Web: www.ams-ic.com.au

DuroTech enhances durability for high-use applications Enerpac has introduced the DuroTech series air-driven power unit for enhanced durability and flexibility in high-cycle industrial applications and work holding tasks.

The DuroTech low pressure power units, which utilise air pressure between 90 and 110 psi (6.2 – 7.6 Bar), incorporate a number of features designed to extend product life and ease of maintenance.

A feature of this product is the reciprocating, dual ram piston pump. Every time the piston moves, it creates flow. This means less reciprocating motion compared with single ram systems, which leads to more flow and a longer life. In addition, DuroTech pumps are fully serviceable, require no air lubrication, run cool and produce reduced noise levels, making them ideal pumps for workholding tasks.

Company: Enerpac Phone: (02) 8717 7200 Web: www.enerpac.com.au

Key features of DuroTech pumps include: • Extremely durable pump element • Four-station DO3 manifold with cover plates for unused stations • Air filter/regulator with built-in air pressure gauge and adjustable hydraulic pressure • 6.8 litre all metal reservoir with easy-access drain plug • Easy-to-read oil level sight glass • Heavy-duty construction, including steel reservoir and protective steel shroud • Long-life, fully serviceable air motor • Dual pump action offers high oil capacity and smooth flow • On-demand stall/restart operation automatically maintains system pressure • Requires no air lubrication • Reduced noise level (75dBA)

44 JULY 2018 Manufacturers’ Monthly

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Brought to you by

Compact 6-axis robot and hollow force sensor Epson has launched the new N6 compact 6-axis (vertically articulated) industrial robot and the SH250LH, a new force sensor with a hollow design.

These robots perform tasks in tight spaces efficiently because of their “folding” arm. The N6 has a longer arm (1,000 mm) and can handle higher payloads (6 kg) than Epson’s previously released N2. The N6 is ideal for loading/unloading small electronic products and automotive parts into/from test equipment. It is also perfect for shelving/unshelving medical products and much more. It has a smaller installation footprint than earlier 6-axis robots and can reach a wider range of places, from the top shelf to the bottom. These features increase productivity and the efficiency with which factory space is used.

Taking advantage of the N series’ folding arm design and a long (1,000 mm) arm, the N6 can access locations that are higher than those that can be reached by the N2 and by Epson’s 900-mm class 6-axis robots (the C4L and C8L). Users can exploit these features by laying out factory shelves and equipment vertically instead of horizontally to enable the N6 to use previously wasted vertical space. Even with an arm length of 1,000 mm, the N6 can reach objects at the same height as the C8XL, Epson’s 1,400-mm class 6-axis robot.

Company: Epson Phone: (03) 9563 0115 Web: www.epson.com.au

High-performance switches with tailored Ethernet connections Lapp’s Etherline brand offers tailored Ethernet connections for its Etherline Access high-performance switches, with the right product available for virtually every sector. For robotics, for example, there is the Etherline Torsion.

This Cat. 7 cable for transfer rates of up to 10 gigabits per second is specially designed for flexible applications in which the cable is twisted up to 180° per metre, and can perform this motion at least five million times.

The Etherline Access M05T and M08T managed switches come with five or eight RJ45 ports, making it very easy to construct redundant networks.

The switches support all relevant protocols like HTTP, Telnet, EtherNet/IP, Modbus/TCP, IPv6, and many more. The devices also have two redundant energy supply ports to ensure maximum reliability.

They are highly resistant against vibrations and impacts, meeting the strict IEC standards for industrial components. With its outstanding reconfiguration time of under 20 milliseconds, the Etherline Access managed switch is faster than the error detection reaction times of the system controllers.

Configuration and diagnosis tools are also important features for users.

These cover the web-based configuration interface, statistics counters, e-mail alerts and further port settings. The Etherline Access switches enable standardised diagnosis of different network nodes via Simple Network Management Protocol (SNMP), and are also capable of port mirroring.

Causes of network failures, such as cable damage or the detection of a disconnected or incorrectly connected Ethernet cable, can be quickly identified. The devices have a relay output that can be used to define warning messages via a web interface. The Etherline Access Configurator is also available for configuration.

Lapp also has two “unmanaged” switches in its product range: Etherline Access U05T and U08T. They offer similar performance but come without the configuration options. These switches are suitable for collecting

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and distributing signals from the connected components. Just like their bigger brothers, the switches do not have fans and therefore require no maintenance.

Company: Lapp Australia Phone: 0447 152 982 Web: www.lappaustralia.com.au

Manufacturers’ Monthly JULY 2018 45

What’sNew Wireless pressure gauge app enhances convenience and safety Emerson has announced their new Plantweb Insight application for wireless pressure gauges that displays data in an easy-to-understand dashboard for maintenance leads and instrumentation and electrical (I&E) personnel. An entire suite of Plantweb Insight applications collectively helps users quickly make sense of plant data and drive overall enterprise profitability.

This Industrial Internet of Things (IIoT) application delivers field data from a fleet of wireless pressure gauges as frequently as once per minute. By keeping operators updated on changing conditions remotely, the app allows personnel to make fewer manual rounds and minimise their exposure to hazardous areas.

The gauge itself, the industry’s first WirelessHART pressure gauge, utilises their existing Rosemount pressure sensor technology to deliver reliable pressure readings. It provides up to 150x overpressure protection compared to traditional gauges using bourdon tube technology, and two layers of process isolation for a safer field environment. The gauge, which has a 10-year life, also reduces maintenance costs by eliminating common weak points found in mechanical gauges.

The new application is the latest addition to Emerson’s Plantweb digital ecosystem, a scalable portfolio of technologies, software, and services that take advantage of IIoT innovations to extend the benefits of automation beyond process control to the entire enterprise, improving operations, strengthening decision-making, and institutionalising best-practices.

Easily integrated with a variety of WirelessHART gauges and remote field sensors, Plantweb Insight applications combine continuous, real-time data provided by Emerson’s Pervasive Sensing strategies with predictive analytics

to give maintenance and operations personnel actionable, up-to-date process information in any location, improving reliability, safety, production, and energy management.

Company: Emerson Process Management Phone: 03 9721 0200 Web: www.emerson.com

Space-saving colour measurement system of liquid paint For paint manufacturers, measuring the colour of liquid paint has been a lengthy and difficult process. The paint is typically applied to the test area, which is then measured only after the paint has dried-off to achieve reliable measurement results.

When the results are unsatisfactory, the container has to be remixed and blended or even disposed. This process requires a significantly long waiting time until a new measurement procedure can be started.

Bestech Australia has introduced the colorCONTROL ACS7000, high-speed inline photospectrometer, and the optoNCDT 1420, laser triangulation sensor, to enable real-time and high-precision colour measurement of liquid paint directly in the production process. This system eliminates the need of waiting for the paint sample to dry, therefore, significantly reduces production times and increases production efficiency.

The spectral distribution of the reflected light greatly influences the colour measurement technology, where even changing the measuring distance by 0.05mm will vary the measurement results.

However, the distance accuracy with which paints can be filled into the sample container can be tolerated to ±2mm. This is where the optoNCDT 1420 laser triangulation sensor plays role to readjust the distance of the colour sensor from the object to achieve high measurement accuracies.

The colorCONTROL ACS7000 utilises ACS circular sensors, which eliminates error from the change in direction of sensor view. As both sensors are compact, Bestech, partner of MicroEpsilon, offers integrated and space-saving solutions for in-line colour measurement.

46 JULY 2018 Manufacturers’ Monthly

Company: Bestech Australia Phone: (03) 9540 5100 Web: www.bestech.com.au

manmonthly.com.au

LFP Inox: THE CLEAN SOLUTION FOR LEVEL MEASUREMENT

Lowering costs and offering new ideas: The hygienic LFP Inox level sensor is opening up new horizons in the food, pharmaceuticals, and packaging industries. According to the principle of guided radar, the LFP Inox functions almost independently of the properties associated with the liquid to be measured. The intelligent assembly concept offers maximum flexibility. The LFP Inox comes with a high enclosure rating of IP 69K and fulfils the requirements specified in current hygiene certification such as that provided by EHEDG. Reliable. Hygienic. Flexible. We think that‘s intelligent.

For more information, please visit www.sick.com/LFPInox or call 1800 334 802.