Editorial

Question everything, nothing is off the table

Simon Ganley, managing director, Ganley Engineering Over the past three decades I have been at the sharp end of process control. Mostly with multi-national manufacturers both in NZ and internationally. This has involved a wide variety of applications in a large number of factories. I have made a lot of very useful contacts with a lot of very clever people. I have seen a lot of amazing solutions and have also seen a lot of dumb stupidity that has cost a lot of money. So, what do the top players do with the new waves of technology becoming available because of quantum developments in computing, optics and machine control? For a start they question everything. Nothing is off the table. They only buy the best equipment available with the lowest cost of ownership. Anything bought is thoroughly tested and dissected long before it gets anywhere near a production line. They sell what they make for top dollar and have built their reputations on quality. They hate waste and they watch their costs. A lot of them have process control sensors specifically developed for what they do with custom filters and algorithms. This enables them to go to places no-one has been before with consistently made new products. And it enables us to build these new technologies into our new analysers and control sensors. It is a symbiotic world for us. Now what they do and a lot of industry doesn’t is to control what they make to the top of the specification as they make it. Probably the biggest cost to manufacturing is the price of energy. If someone is running a fluid bed drier, a tunnel oven, a fryer, a drum drier or anything that uses energy with no controls is probably over drying/ cooking and giving away enormous […]

Industry 4.0 Mobile showcase to launch at EMEX 2021 in February

Callaghan Innovation has confirmed Beca and The Employers and Manufacturers Association (EMA) as official partners to deliver the Government’s Industry 4.0 Demonstration Network – an initiative that will grow uptake of new technologies in the manufacturing sector. The partnership will bring to life a nationwide showcase of Industry 4.0 technologies that are delivering vast improvements and resilience for businesses in many sectors. This will involve real-world demonstrations of how the fusion and application of advanced technologies from robotics and automation to data analytics, mixed reality and artificial intelligence can drive productivity and enable new business models. The Government committed funding over four years to roll out the initiative. The Industry 4.0 Mobile showcase will launch at EMEX 2021 in February. Paul Linton, Callaghan Innovation’s General Manager Research & Technical Services and Commercial Businesses, says it will include a mobile Industry 4.0 showcase along with a network of site visits and ‘smart factory’ tours which will demonstrate Industry 4.0 in action. “Our aim is to help New Zealand manufacturers to transform and increase their resilience and competitiveness through the adoption of new technologies. Raising the value of their activities and businesses is especially important during times of economic uncertainty and recovery,” says Mr Linton. “This partnership is a great example of the Government working with industry experts to create exciting new opportunities for business growth and economic development. It will help prepare the country for a world where increased digital capability is key to lifting our productivity and make us more internationally competitive and future-relevant.” Industry 4.0 in action Beca will deliver the mobile showcase and bring Industry 4.0 technologies to the doorstep of manufacturers and educators across New Zealand. The EMA, part of the BusinessNZ network, will deliver a network of site visits and smart factory tours by manufacturers to […]

X5 FastMig for arc-welding productivity

Kemppi, has released its new X5 FastMig multi-process welding system for MIG, DC TIG and stick welding (MMA) as well as gouging. Designed in conjunction with professional welders specifically for steel welding, the X5 FastMig delivers a range of features to help significantly enhance arc welding productivity. Built using energy-efficient inverter technology, the X5 FastMig offers faster welding and quality welds thanks to Touch Sense Ignition, effortless operation, excellent welding ergonomics and flexible equipment setup. Faster welding, better quality welds Built to perform, the X5 FastMig features the latest in ignition technology – Touch Sense Ignition – as standard in all available models. When combined with WiseSteel software, which also comes as standard with every model, the X5 delivers precise ignition capability and stable arc control. It tackles the challenges of globular arc by alternating between short arc and spray transfer. In short-circuit transfer, it improves the arc stability adaptively, provding better out-of-position steel welding capabilities. In spray transfer mode, micropulsing of the current and voltage increases travel speed significantly. In doing so, the X5 helps to minimise the spatter produced by a traditional globular arc, as well as the need for post weld cleaning, saving the welder both valuable time and cost, while helping to deliver better quality welds. For more challenging applications, the arc control can be further optimised with optional welding programs and Wise special processes. Effortless operation Designed to be hassle-free, the X5 FastMig is very easy to operate. It features a large, graphical and impact-resistant TFT display panel that illustrates all the required information clearly and without the use of abbreviations. Welding parameters are set automatically when the user adjusts the wire feed speed. And memory channels are also available to customise and save personal settings. Easy to use, the operating basics of the X5 […]

Circular product stewardship: Starting with design

By Barbara Nebelwww.thinkstep-anz.com/ In the transition to a circular economy, New Zealand first needs to address its continued reliance on a linear take-make-waste model. For organisations looking to take meaningful action, taking responsibility for the end-of-life of their products with product stewardship can be a key part of the solution. With proponents ranging from successful businesses to new industry and governmental initiatives, it is safe to predict that product stewardship is here to stay and ready to play a pivotal role in the circular transition. Starting with the waste problem during this process is a common tactic but the best approach starts at the beginning with product design. In fact, UK based Waste and Resources Action Programme (WRAP) found that 80% of the environmental impacts of modern products are determined during product design and development. Incorporating product stewardship into product design will provide more circular solutions for end-of-life decisions, minimise waste in the process and ultimately, speed up the transition to a circular economy. This is exactly what Utility Electric Vehicle (UEV) company UBCO has set out to do. Starting with product stewardship Focused on a largely electronic product with a high capacity lithium-ion battery, UBCO identified end of life processes and product stewardship as their defining sustainability issues. For UBCO, tackling these issues head on starts with design. UBCO’s product design approach utilises life cycle thinking to consider the entire value chain – from the raw materials and the energy used to create the product, through to the packaging, distribution, use, maintenance, and eventually recycling, reuse, recovery, and final disposal. “It would have been easiest to have battery and electronics in a big block of resin to make it waterproof – but that would prevent any product stewardship approach in future”, says Timothy Allan, CEO and Managing Director of […]

ABB Ability Liquid Routing Library launched for food and beverage production

Process automation technology provides customers with optimal routing and ‘cleaning-in-place’ to increase efficiency and reduce costs. ABB has launched ABB Ability Liquid Routing Library which is a control engineering inventory for food and beverage manufacturers and those in other liquid related industries, including tank farms, pharmaceuticals and chemical resin plants. The new digital application draws on ABB Ability System 800xA, the most powerful Distributed Control System (DCS) automation platform in the market and will support routing and cleaning in place (CIP) functionalities needed for liquid-led production. It can be used wherever products are transported, stored or processed in tanks and lines and is particularly relevant to dairy, brewing, sugar, mills and edible oil application programming. Ready-made objects including libraries, typicals, and templates for product routing, with recipe-based CIP, track and trace, preventive plant maintenance, Excel-based bulk data tools are made available for customers through the library. Functionalities include alarm handling, alarm propagation between different units, queue handling for online production changes, control and supervision of process objects, interlocks and transfer of product and equipment settings like product codes, unit names and unit states. ABB Ability Liquid Routing Library will support food and beverage customers in their digitalisation journey. Customers are driving innovation in process automation, digitalising their production sites for greater speed, consistency and quality and Liquid Routing Library is an important piece of this jigsaw. Having a complete library for product routing, with ready-made objects and templates will allow users greater visibility and understanding of what is happening at each stage of the process. We know that routing and cleaning in place support are vitally important in food and beverage plants. This is built-in and at-any-stage ABB support from experts or additional documentation is available. Operators will be able to diagnose issues quicker than before and have solutions ready, […]

How RAM3D became the largest independent metal AM service in Australasia

New Zealand company operates seven metal AM systems Though it may best be known for the Kiwi bird, Lord of the Rings and its inspirational Prime Minister, New Zealand has another claim to fame in the additive world: it is home to the largest independent metal 3D printing service in the Southern Hemisphere: RAM3D. Founded in 2008, the Tauranga-based company has had an interesting journey over the past decade, partaking in metal AM’s transition from a one-off custom prototyping solution to an industrial production process. This journey in itself is interesting, as RAM3D played a vital role in the evangelisation of metal 3D printing in its part of the world—a role that many service providers have played. In short, 3D printing metal parts for customers was only part of its job in its earlier years, it also had to focus on raising awareness of AM, educating on DfAM and facilitating the shift from prototyping to production. “In our very early days the perception of 3D metal printing really was that it was just for one-off, custom part prototyping,” explained Gilly Hawker, RAM3D Marketing Manager. “Its real benefits, in terms of improved part functionality, part integration, weight reduction, cost effectiveness and so on, just weren’t widely recognized. We did have to play our part in improving general market awareness and helping to rectify any misconceptions.” One of the big milestones in the company’s evolution has been its partnership with Renishaw, which began in 2014, when the UK-based metal AM company supplied its newest system to RAM3D. At the time, the machine provided the flexibility and openness that RAM3D was looking for, as it had the skills to optimize the AM process for its customers’ applications. “We had lots of ideas of our own on optimising our manufacturing process, and this machine gave us the freedom […]

Hydraulink optimises pipe safety for McConnell Dowell’s Watercare record length project

New Zealand construction leader McConnell Dowell Constructors Ltd has selected the quality hydraulic hose, fittings and 24/7 service backup of Hydraulink to optimise the safety of New Zealand’s longest pipe jacking project. The Hunua 4 watermain project, commissioned and managed by Watercare Services Ltd, is a 31km pipeline through South and Central Auckland to help meet growing demand, increase the system’s capacity, ensure uninterrupted supply, and provide resilience to natural disasters. Watercare, an Auckland Council-controlled organisation, engaged McConnell Dowell to design and construct Section 11, the final section of the pipeline, from Market Road to the Khyber Pass Reservoir. A strong emphasis was placed on minimising disruption to communities along the pipeline route. Using mainly micro-tunnelling methods, McConnell Dowell constructed a 3.5km watermain using a tunnel boring machine (TBM) to drive and install 2,500mm ID jacking pipes between six shafts, before lining the tunnel with a 1,575mm OD steel pipe. The pipe jacks are the longest ever completed in New Zealand. McConnell Dowell recently (July 2020) celebrated the completion of the second drive of Section 11. McConnell Dowell’s TBM broke through at Khyber Pass Rd, setting a record of 1,216 metres for the longest single drive in the southern hemisphere by a TBM greater than 3 metres diameter. McConnell Dowell utilised a world-class TBM from Germany – a 55-tonne Herrenknecht – to excavate the 3m diameter tunnel required. To minimise community disruption, 80% of the pipeline construction was trenchless, and McConnell Dowell selected an alternative pipeline route that moved construction away from residential areas and ecologically sensitive sites. Hydraulink has more than 400 service outlets throughout New Zealand, Australia, and Pacific Islands, which bring essential hydraulic hose, fittings and safety-compliant and traceable service expertise to industries requiring prompt, quality 24/7 service either on or off site. Hydraulic hoses are like […]

Anagenix purchase Vitaco manufacturing facility

Cutting edge nutraceutical ingredients company Anagenix has purchased Vitaco’s Avondale-based nutritional product manufacturing facility. The seven-figure deal includes all assets at the site and acquiring the premises’ 10-year lease. New Zealand-owned Anagenix manufactures and markets high-quality scientifically-formulated ingredients used by health supplement and nutraceutical manufacturers. Its products are locally grown kiwifruit and boysenberry-apple powders, gently processed from non-GMO whole fruits, to retain a high level of bioactivityThe company’s products are also BioGrow NZ organic certified, halal and kosher. Announcing the deal, Anagenix Managing Director Chris Johnson says Anagenix has experienced significant growth in recent years, with that trend set to continue despite Covid-19. Most of the company’s products are exported to the United States, Europe and Asia, where New Zealand-grown and manufactured natural health product ingredients command a premium. Mr Johnson commented that company’s stand was inundated at a recent European (virtual) trade show: “Whole fruit products that have great science portfolios around them, including clinical trials, are really taking off. “Our growth is such that Anagenix is now backwards integrating so that we can better manage all stages in our manufacturing supply chain, thus enhancing our products’ consistency and quality.” Mr Johnson says acquiring the manufacturing facility will enable Anagenix to triple its fruit drying and ingredient processing capacity over the next two to three years.

Carpentry graduate aims to inspire more wahine into trades

WelTec carpentry graduate, Sarah Clark, wants to start a company that champions female tradies. Sarah is currently employed by Tonks Residential, a local construction company, as an apprentice builder. Sarah was introduced to the company while she was completing her Level 3 carpentry programme at WelTec in Lower Hutt, as part of her Māori and Pasifika Trades Training (MPTTS) scholarship. The scholarship supports students from entry into study, right through to employment, and an important part of this journey is to get work experience – which in Sarah’s case led directly to her first apprenticeship. Loving her new job at Tonks, and succeeding at it as a young female – has inspired Sarah to want to create an environment that supports and encourages women into the trades. Carpentry is often considered a man’s job, but Sarah believes that seeing other women succeed in the trades could make it a more accessible career path for young women. “My aunt is an electrician so the idea of being a woman in the trades was not unusual for me when I was growing up. I definitely believe that the more young girls see females in the trades, the more common it will become,” explains Sarah. “Just getting the word out there that I am working in construction as a young female, and that the team I work for embraces and encourages me, might help someone to see it as a viable option for themselves.” Sarah grew up in Lower Hutt, living with her grandparents and attending Sacred Heart College. She completed year 13 but knew that she didn’t want to spend more time ‘sitting in a classroom’. “I knew that I wanted to be doing something in the outdoors, and so when a WelTec advert popped up on my social media, I thought […]

The truth about counterfeits

~ Why you can never eliminate the risk of counterfeits entirely ~ According to the latest data from the Organisation for Economic Cooperation and Development (OECD), the trade in counterfeit goods now represents 3.3 per cent of global trade. Unfortunately, this figure is on the rise, even as overall trade has declined. Here, John Young, APAC director at obsolete parts supplier EU Automation APAC, offers his verdict on the scale of the problem in the Asia Pacific region and what manufacturers can do to limit the risks. Counterfeiting in industry Counterfeiting is not a new problem, but the current growth of this phenomenon is driven by many novel factors, such as the convergence between industry and IT and new technologies like 3D printing. Most people have some familiarity with this problem in the world of consumer goods, but industrial equipment is not immune to the risk. In the world of industrial parts, fakes are often even harder to detect. Take an industrial motor as an example. The outer casing or housing of the counterfeit part may look perfectly fine. Even on the inside, there is very little way of detecting a counterfeit through a simple visual inspection. Counterfeited industrial parts are usually manufactured from poorer quality material. This reduces the life cycle of the part, increasing the risks of unplanned downtime and raising whole-life costs when unexpected failures occur. Unfortunately, there is often little way to know definitively if the broken part was genuine or not. Genuine parts will have been through a rigorous and standardised process of testing. Fake parts, on the other hand, do not benefit from this validation and verification process. Labelling is one way of stamping products in a way that can demonstrate their authenticity, but unfortunately modern technology makes these labels much easier for scammers […]

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