Manufacturing Technology

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.

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 […]

Manufacturing industry crucial to the country’s economic future

The New Zealand manufacturing and technology industry is actively urging the Government to listen to and support the engine room of New Zealand’s economic recovery. The call comes after the Hutt Valley Chamber of Commerce hosted the country’s first Manufacturing and Technology Forum, focusing on economic recovery from COVID-19. Over one hundred manufacturing and technology industry representatives across the Wellington region came together to share their views and highlight areas where support was needed to foster economic growth from these industries. The Minister of Finance, the Honorable Grant Robertson attended the forum and opened the event, which was part of October’s 2020 Wellington Business Expo. CEO of the Hutt Valley Chamber of Commerce, Helen Down, said government must support the manufacturing sector to reap the benefits it can offer to the COVID-19 response and our economic recovery. The forum is part of an ongoing programme of work by the Hutt Valley Chamber of Commerce to champion the manufacturing and technology industries and advocate for them to government. “It is not only industries most obviously damaged by COVID-19, like international tourism that needs support. Manufacturing and technology industries are pivotal to our recovery and our future, they are important employers in our communities and they need government support,” she said. A panel of industry experts from a variety of manufacturing and technology companies presented their inside perspectives. The panel included Sir Neville Jordan from Endeavour Capital; Martin Simpson from Fraser Engineering; Richard Latta from Leda Extrusions and Pikes Plastics; Derek Bradley from Aurora44; Terry Carter from NZ Tube Mills; and Shane Lowe from 360 Logistics. The General Manager of Fraser Engineering, Martin Simpson, said the manufacturing sector is the engine room of the economy and can no longer be ignored. Located in Wingate, Lower Hutt, Fraser Engineering employs 120 staff and […]

Ganley Engineering process control specialists

Khamal Ganley, Gill Ganley and Simon Ganley. Assisting New Zealand companies go forward with great technology. Ganley Engineering Ltd a family company, based north of Auckland, covers all of New Zealand. They are the country’s premier suppliers of manufacturing process controls systems and have been so for the past 25 years. The company consists of Simon, Khamal and Gill Ganley, all of whom bring levels of expertise to represent NDC Technologies, exclusively, for advice, sales and service. Ganley Engineering specialises in on-line and at-line process control. Process control places NDC Technologies sensors in a manufacturing line to measure and control moisture, oil, fats, protein, brix, caffeine, nicotine and colour in real-time. The sensors talk directly to the manufacturing machinery so that levels of moisture (and other components) are automatically and instantly adjusted to the top of the specification or yield. The sensors also display exactly what is being made on trending SCADA screens so operators and management can monitor the production yields. This means manufacturing companies save a lot on power consumption, staff time, scrap, downgrade and raw materials. They also save on not having to do repetitive lab tests and having staff to run them. Companies are now able to make products they could never have economically made before. The sensors can be placed above a line, into a fluid bed drier and in a variety of other locations. They have no recalibration or maintenance schedules so are basically fit and forget. NDC have tens of thousands of these sensors controlling a wide variety of applications world-wide, including NZ. NDC Technologies is the world’s largest manufacturer of process control sensors. They work in closely with multi-nationals to develop solutions to meet specific manufacturing needs. Ganley Engineering has in the past 30 years worked with many NZ companies and developed […]

Coffee shop workers standing at the counter

For a unique shopping world: igus low-cost robot in the design of your choice

Custom design robolink robot arm ensures fast automation and a new shopping experience. From industrial use, robots are increasingly finding their way into the retail trade. There they ensure rapid automation of processes and are also a real eye-catcher. Users place high demands on design and reliability at a cost-effective price. For this reason, igus is now offering its low-cost robot – robolink DP – consisting of high-performance polymers, in custom design. Shopping and ordering online has already become part of everyday life, be it for new trousers, an SLR camera for the holidays or the sushi for dinner. Within a few minutes or the next day, the delivery service or the parcel carrier is at the door with the order – convenient and simple. But the new buying behaviour is increasingly building up competitive pressure on the stationary retail trade. Intelligent automation systems for fast shopping are in demand, in the supermarket as well as in the furniture store. Solutions can be: automatic juice dispensers, bread slicers or self-service cash registers with weighing technology, in which igus motion plastics – such as lubrication-free iglidur plain bearings and maintenance-free drylin linear guides – ensure wear-resistant movements. At the same time, retailers such as fashion houses and restaurants can develop store and design concepts that offer customers a new experience. Robots are a popular tool of choice because they are not only a real eye-catcher, but also a practical automation solution. They can give out prizes from raffles, mix cocktails or even cover a pizza with toppings. So far, expensive fun that is rarely found in New Zealand. With its igus robolink DP, Treotham now offers a new cost-effective solution, which the customer can design individually. Low-cost robots in the desired outfit Last year, igus presented for the first time its […]

Mulcahy signs with Epicor to build digital manufacturing platform and turbocharge growth

One of New Zealand’s leading metal manufacturers, has signed a $1 million dollar deal with Epicor Software Corporation, a global provider of industry-specific enterprise software to promote business growth. The deal will see Epicor deliver a modern end-to-end digital manufacturing platform, allowing Mulcahy to further its digital transformation and be a leading adopter of Industry 4.0 technologies. Mulcahy is one of the country’s largest fabricated metals manufacturing company, partnering with clients in the food and dairy, materials handling, original equipment manufacturing, agriculture, horticulture, and architecture industries. From design to production, Mulcahy partners with product leadership companies helping turn their ideas and intellectual property into a reality, acting as a one-stop manufacturing partner. Innovative technologies from Epicor, which are already helping manufacturers around the world streamline their business processes and break down barriers to growth, will deliver an end-to-end manufacturing platform for Mulcahy to automate its business processes and truly embrace the benefits of the fourth industrial revolution. The solution will provide much greater visibility and traceability – from organisation wide capacity planning and scheduling, job tracking throughout the facility to scheduling machine total productive maintenance (TPM) – helping the organisation gain efficiencies. The Auckland-based, family-owned business, which celebrates 40 years this year, has grown from a small facility with five employees in Gleneden, to a 6,000 square metre plant in Avondale and a team of 140. Ongoing investment in technology is a key part of Mulcahy’s strategy, having invested in state-of-the-art machinery and boosted data capabilities to optimise business operations over the years. However, disparate legacy systems to manage finance, payroll and CAD capabilities developed over the past 20 years are limiting Mulcahy’s ability to gather consolidated data into its SQL database and draw actionable analytics from its connected machinery. With ambitious plans to […]

UX10 tablet performs in challenging work environments

Getac’ UX10 is a powerful, fully rugged tablet that’s built to thrive in challenging working environments, such as those found in the public safety, utilities, natural resources and manufacturing industries. Building on the success of Getac’s original UX10, this tablet delivers improved performance, storage, connectivity and rugged reliability in a stylish new chassis, all while retaining the same proven form factor of its predecessor. Key features include a 10th Gen Intel® Quad-core i5 or i7 processor and PCIe NVMe SSD storage technology, for up to six times faster speeds than SATA SSD, while the latest Intel® Wi-Fi 6 AX200 module ensures more stable and reliable connectivity in dense, congested environments. In addition, the UX10 boasts enhanced rugged protection, with MIL-STD-810H certification and drop resistance of up to 6-foot while in tablet mode, for added peace of mind. As well, the UX10-EX is designed to be a highly effective field services solution for engineers and technicians in the energy, natural resources and utilities industries. Incorporating the latest intrinsically safe technology, the device fully meets stringent ATEX/IECEx standards for use in Zone 2/22 hazardous and potentially explosive environments that field professionals encounter on a regular basis. Furthermore, extensive connectivity options make accessing remote tech support and uploading reports directly from the field fast and efficient, while the UX10-EX’s all-weather functionality means it can be relied on in every situation. Three key software utilities available for use alongside the UX10 are Getac’s KeyWedge Barcode Reader Utility, Getac Driving Safety Utility and Getac Device Monitoring System (GDMS)*.

The power of traceability for food and medical manufacturers

– Reinaldo Silva, Head of Digital Manufacturing and Automation at Facteon As food and medical manufacturers face stringent regulations, an ability to trace the movement of raw materials and finished product both within your facility and beyond is demanded throughout industry by manufacturers of all sizes. A variety of forces have highlighted the need for food and medical manufacturers to gain greater traceability of both raw materials and finished products within their facility and beyond. Risk One: Increasingly Globalised Supply Chains As it becomes more cost-effective and simpler to source raw materials from suppliers across the globe, manufacturers are relying on increasingly globalised supply chains. While this brings a range of benefits, such as proximity to raw materials, cost competitiveness and improved quality of raw materials, there are significant risks as the supply chain becomes increasingly complex. As a result, traceability requirements expand significantly. Simplistic supply chain approaches that focus on “one step back and one step forward” traceability become increasingly complicated and impractical when manufacturers are drawing on a globalised supply chain. Risk Two: Product Recalls Tyson Foods famously recalled 39,000 pounds of frozen chicken patties which were potentially contaminated with foreign matter in mid-2019. From business interruption and eroded profit margins to long-term damage to your brand, a product recall has the potential to harm consumers and cost manufacturers dearly. Research has also found that a mere 21% of food recalls across USA, UK and Ireland were detected by the manufacturer. In fact, regulatory bodies discovered 68% during routine or spot testing. This highlights the potential competitive advantage that can be unlocked by manufacturers taking a proactive approach to both raw material and product traceability. Medical device manufacturers are also at risk of product recalls. Research has found that a significant challenge for medical manufacturers in the event of a product recall is tracing each […]

Designing for Additive Manufacturing

Over the last six months, RAM3D have seen an unprecedented increase in both large and small companies interested in trying 3D metal printing as an alternative to other forms of manufacturing. This is possibly because they have had time to work on projects during the COVID-19 lockdown. RAM3D works closely with their clients offering them advice on how to alter the part’s design to make the part stronger, lighter, and therefore cost competitive using dedicated design for production, using additive manufacture. When designing a part for metal 3D printing, the biggest thing to consider is the material properties of the part you want to 3D print; if the mass doesn’t need to be there, get rid of it! Traditional manufacturing and design methods tend to be constrained by tool paths, machine time, material shapes and sizes. This means, if you can’t remove the material, it stays there. With AM you are less tied to these constraints allowing you to do cut outs, pockets, fillets, undercuts and even combine part assemblies, where traditionally you couldn’t. Some CAD programs even contain part optimisation for additive parts. This is a great way of reducing the part cost, while creating innovative and interesting looking parts. Where you cannot remove large surface areas or you need to keep a solid look to a part, there is the option of adding an internal lattice structure. Lattice Structures One of best ways to reduce mass without reducing too much structural integrity, is to add a lattice structure. The benefit of using a lattice over simply hollowing a part, is the lattice does not require internal support. When designed correctly, it can maintain good strength and performance. RAM3D can create a simple uniform wall thickness internal lattice structure using their Netfabb build software. This is great for those […]

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