Manufacturing Technology

Empower Software celebrates 21 years in business.

Empower Software have pioneered engineers’ and manufacturers’ use of labour productivity software using touch screens on the workshop floor, since commencing business in 2002. Empower Software is cloud based, an Add On and an App; manufacturing clients interface to their accounting software. Empower is supplied and supported as SaaS (Software as a Service), low cost monthly fee based. They currently have 240 manufacturing and engineering clients, mainly throughout Australia and New Zealand including US, Canada, UK, South Africa and the Philippines. There are an estimated 80,000 SME based manufacturing and engineering businesses throughout Australia and New Zealand, 80,000 businesses an estimated 30% still use manual time sheets “today” for workshop staff to manually record their jobs and times worked on each job. An estimated 60% do not track their workshop staff time on their jobs at all because manual time sheets produce information that is “too little, too late, too inaccurate and too costly to produce”. Manual time sheets cost approximately $80 per workshop staff member per week to produce; in comparison the Empower Software App is approximately $15 per staff member per week – so it is an obvious substitution to adopt technology and use the Empower Software App. Empower Software suits manufacturers and engineers who wish to replace manual time sheets, as well as those manufacturers who wish to commence tracking time on jobs for the first time, using technology. Lean manufacturing, Digital Manufacturing, Industry 4.0 are all being heavily promoted to Australasian and NZ manufacturers by government and industry groups as the means to be labour cost competitive and Empower Software “rides that wave”. Touch screens on the workshop floor and Empower deliver for 90% of manufacturing clients a 20% to 40% reduction in labour times on jobs and 20% to 40% reduction in labour cost […]

New Zealand research to fly on International Space Station

Dr Sarah Kessans. A research facility prototype developed in Christchurch will soon orbit Earth aboard the International Space Station (ISS) under a partnership between the Ministry of Business, Innovation and Employment (MBIE) and US space company Axiom Space. The facility for studying protein crystal growth in space, developed by Senior Lecturer at the University of Canterbury’s School of Product Design, Dr Sarah Kessans, in collaboration with teams from Arizona State University and Christchurch companies Asteria Engineering Consultancy and Intranel, was one of two projects selected for initial feasibility studies in 2022. “We signed a Memorandum of Understanding with Axiom last year and agreed to two feasibility studies, one of which led to Dr Kessans’ project,” MBIE Director of Innovative Partnerships Joe McKay said. “This facility could lead to major advances in medical, biotechnological, food science, and agricultural innovation and we are excited to support the next step.” Sarah’s research facility is scheduled to fly on Axiom Mission 3 (Ax-3) later this year, which will be the third private astronaut mission to the ISS. “Being able to conduct this research on the ISS is such a huge opportunity and really is critical to what we’re trying to achieve in terms of scientific innovation and future commercial outcomes,” Sarah said. “When protein crystals are grown in microgravity, they can develop into larger and higher quality crystals than what we can grow on Earth. These crystals can then be used to create high-resolution pictures of the protein’s structure. If we have a detailed picture of what virus proteins look like, for example, we can develop things like antiviral drugs and vaccines.” Current facilities for protein crystal growth on the Space Station require significant time and resources for astronauts to mix samples, set up experiments, observe growth and adjust settings as needed. By developing […]

Kayasand receives backing from NZGIF to reduce carbon emissions from concrete

Kayasand, a distributor of premium sand manufacturing technology, is opening its first V7 high-technology manufacturing demonstration plant in New Zealand, which uses waste products such as recycled glass, concrete and slag, and turns them into premium sand for concrete. Kayasand has received the backing of New Zealand Green Investment Finance (NZGIF) via a $3.5 million equity investment. The green investment bank was established to accelerate investment that helps reduce greenhouse gas emissions. A further $1.8 million of private investment has been secured alongside the NZGIF investment bringing the total raise to $5.3 million. Natural sand supplies are becoming harder to access and traditional concrete manufacturing processes, including the impacts of sand dredging on coastlines such as Pakiri, 100km north of Auckland, are not sustainable over the longer-term. Dr Bram Smith, Kayasand General Manager, says “Our technology can reduce or in cases eliminates the need for natural sand dredging. It uses by-products and recycled materials such as quarry crusher dust and recycled glass to manufacture a sand of such quality that it makes stronger concrete than natural sand when mixed with cement. Our goal is to reduce carbon emissions from concrete production by up to 20% using this method.” Kayasand technology is used in over 300 plants across Japan, China, India, and Australia. The picture shows a V7 plant in Japan. NZGIF Chief Executive, Craig Weise, says the deal is an important step and is a boost for the construction sector and consumers who are eagerly looking for more sustainable building materials. He says, “Auckland’s infrastructure requirements alone are projected to be $26 billion over the next decade and if New Zealand is going to meet its CO2 emission reduction targets, we need to find alternative manufacturing and building methods. We are delighted to invest in Kayasand to help deliver its […]

NZ start-up FabriBotics poised to revolutionise metal manufacturing

FabriBotics, a new manufacturing start-up based in Tauranga, New Zealand, has developed technology in large-scale metal additive manufacturing. The company’s proprietary technology allows for the production of custom metal parts ranging from 1kg to 1000kg in size, using a variety of weldable materials, including stainless steel, aluminium, steel, and bronze. Founders Mike Fry and Ben Jackson began working on the 3D printing (Wire-Arc Additive Manufacturing, or WAAM) technology during an MBIE-funded research program at TiDA Ltd. The start-up has secured pre-seed investment from KiwiNet to further develop the technology and business. The applications for FabriBotics’ technology are vast with the ability to produce custom, large metal parts applicable across many industries, with 1kg to 1 tonne being the target size. Industries include heavy industry, power generation, marine, mining, agriculture, food processing, transport, and architecture. The technology offers a cost-effective solution for creating complex shapes and reducing the costs of machining. Using additive manufacturing to produce near-net-shape billets, the technology minimises material waste and maximises the efficiency of the manufacturing process. The technology also eliminates the need for expensive tooling required for traditional casting methods, making it an attractive option for replacing one-off cast components. Furthermore, the technology enables extensive repair options for broken metal products, offering a sustainable and economical alternative to replacing entire components. New Zealand is ideally placed to benefit from FabriBotics’ technology due to its long supply and logistics chains, high cost of labour and low value of metal waste. The ability to produce custom and niche metal parts on-shore will provide a much-needed solution for industries that currently have limited options for prototyping, spare parts and repairs. Commenting on the launch of FabriBotics, newly appointed Commercialisation Director Iain Hosie says “The potential for FabriBotics’ technology to revolutionise metal manufacturing in New Zealand is immense. With the ability […]

HERA recognises leading Metalminds at Future Forum Awards

In the picture: Innov8taiao (steel is sustainable) Award. The heavy engineering industries’ top innovators and changemakers were recognised at the HERA Future Forum Nation Dinner on 5 May 2023 at the Christchurch Art Gallery Te Puna o Waiwhetū. Sponsored by New Zealand Steel, the awards celebrated the significant impact that individuals and teams are making across Aotearoa, honouring outstanding projects, innovations, and research that demonstrate leading vision and contribute to success within their respective industries. Dr Troy Coyle, HERA’s CEO, says, “I would like to congratulate the winners, finalists, and scholarship recipients for 2023. All of the work they do across the country invaluably contributes to the success of the industry and nurtures the values that will ensure we are servicing a better tomorrow. It is a privilege to acknowledge longstanding dedication, alongside new leaders and up and coming talent.” The 2023 award winners are: Keith Smith Memorial Award – Geoff Bird, Structural Technical Development Manager at Beca. Geoff’s contribution to the industry is a longstanding one, supporting HERA’s Structural Division in 1983 and moving on to become the Structural Manager of New Zealand Steel in 1992, where his work became instrumental in the widespread use of structural steel in multi-story buildings. Geoff is a significant knowledge benefactor for the industry, participating in HERA’s Steel Research Panel and SCNZ technical working groups. He is also an honorary lifetime member of the Structural Engineering Society (SESOC) and a Fellow of Engineering NZ. Next Gen Leadership, Leading Metalmind Award – Mike Ryan, GM of Operations at Farra Engineering. Mike impressed the judges with the breadth of projects for which he was able to achieve the seemingly impossible, as a result earning the informal title ‘guru of solving crazy engineering problems for the hydro industry’. His problem-solving work at the Burrinjuck Hydropower Station […]

Kemppi adds Pulse model to X5 FastMig welding range

Leading international welding equipment manufacturer, Kemppi, has released its latest addition to its range of X5 FastMig welders – the new X5 FastMig Pulse. The X5 FastMig Pulse multi-process welding system has been specifically designed for steel, aluminium and stainless steel welding in industrial environments. The machine delivers a range of features that help significantly enhance arc welding productivity. Built using energy-efficient inverter technology, the X5 FastMig Pulse offers faster welding and quality welds thanks to Touch Sense Ignition, effortless operation, excellent welding ergonomics, flexible equipment setup and is industry 4.0 ready. Faster welding, better quality weldsA high-performing machine, the X5 FastMig Pulse features the latest in ignition technology – Touch Sense Ignition – as standard. When combined with WiseSteel software, which is also included in the X5 FastMig Pulse, it delivers precise ignition capability and stable arc control. The X5 Pulse tackles the challenges of globular arc by alternating between short arc and spray transfer. In short-circuit transfer, it improves the arc stability adaptively, providing 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 Pulse 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 steel, stainless steel and aluminium applications, the arc control can be further optimised with optional MAX welding programs and Wise special processes. Effortless operationDesigned to be hassle-free, the new model can be quickly set up thanks to Weld Assist.This feature guides the welder to set the right parameters for each application so they can start welding faster. The X5 Pulse is also very easy to operate. It features a large, graphical and […]

Cost effective automation

Low Cost Automation reduces the barriers to getting started with automation and gives special assistance to small and medium-sized companies in increasing their competitiveness. To this end, motion plastics specialist igus has built up a broad network of 55 robotics providers and 40 integrators over the past three years – and new partners are constantly being added. As a result of continuous developments and product innovations, affordable robotics has become especially interesting for small and medium-sized companies. And the number of offers on the market is increasing. For instance, igus Low Cost Automation represents a broad portfolio of articulated arm, linear, delta and SCARA robots. Product modularity means that single components or individual complete solutions can be assembled according to the build-or-buy principle. The focus is always on a low entry-level price and quick payback. This is where igus high-performance plastics play to their strengths. They are tribologically optimised and especially durable, lightweight, lubrication-free and maintenance-free, and cost-effective to produce. The most cost-effective solution that works Over the past three years, igus has built up a broad, constantly growing partner network. As part of the LCA partner programme, the motion plastics specialist works with integrators who provide customers with additional expertise, experience with end customer projects, and joint project experience. Igus started with seven partners around two years ago, and now have almost 100. In order to refer interested parties to competent integration partners in their area, they are constantly expanding their network. Together, they can offer customers a wide range of automation solutions – focussing on applications with a total investment volume of less than €45,000. Typical services include integrating a control system into existing machines, setting up and commissioning robots, evaluating safety measures or, if there is simply no capacity, providing the capability of assembling machines on site. Experience Low Cost Automation […]

More sustainable and productive steel turning with new carbide inserts

A recent survey by OpenText found that 92% of manufacturers consider corporate social responsibility (CSR) to be important for their overall reputation in the markets. Even though steel turning is, by nature, a waste producing process, it is possible for manufacturers to improve their sustainability without compromising process security — even against the unprecedented challenges of COVID-19. Here is a different approach to steel turning. According to the 17 Global Goals for Sustainable Development set out by the United Nations (UN), manufacturers are expected to minimise their environmental impact while going further than just optimising energy use. Although CSR is important to companies,manufacturers waste between 10% to 30% of material in their machining processes, with a typical machining efficiency of below 50%, which includes at the design, planning and cutting phases. So, what can manufacturers do? The UN’s goals recommend two main avenues that take into account such factors as a growing population, finite resources and the linear economy. The first is to address these challenges with technology. Industry 4.0 concepts — like cyber physical systems, big data or the Internet of Things (IoT) — are frequently cited as being the way forward for manufacturers seeking to reduce waste. Yet, this does not allow for the fact that most manufacturers are yet to apply modern machines with digital capabilities to their steel turning operations. Most manufacturers are aware of how important the choice of insert grade is for making steel turning more efficient and productive; and how this affects overall performance and tool life. However, many are missing a trick by not considering the whole tooling concept; everything from advanced inserts, tool-holders and easy-to-adopt digital solutions. Each of these factors can help to make steel turning more sustainable by reducing energy consumption and minimising waste. Reduced cutting speeds Manufacturers face […]

igus unveils world’s first urban bike made from recycled plastic

No maintenance, no corrosion- the igus:bike sets new standards in sustainable mobility With its expertise in plastics for movement, Treotham is making the concept and components available to all bicycle manufacturers on the new igus:bike platform. The first model should be available by the end of the year. The world is drowning in plastic waste. The huge piles in landfill sites are growing fast. Some of this plastic ends up in the ocean, enters the food chain, and becomes a danger to marine, animal and human life. Therefore it is most urgent to move away from the traditional linear economic model and migrate to a fully circular economy. To help this transformation, igus the motion plastics specialist has been developing and investing in ideas for recycling plastics for many years. The company recently presented a world first: The concept of a robust, durable urban bike made entirely of plastic, from frame to bearings to toothed belt. One special feature of this new bike is that the recycled version will be primarily made of reused plastics originally “single use”. “The plastic in rubbish dumps around the world is becoming a valuable resource,” explains Frank Blase, igus CEO. He first had the idea of a bicycle, now known as the “igus:bike”, on a beach while on holiday. In conversations with employees of a bicycle rental company on the beach, he found out about their major problems with beach bikes. These were continuously exposed to sand, wind and saltwater and sometimes only lasted three months before they had to be replaced. Maintenance and replacement are often expensive and time-consuming in this industry. “The igus:bike does not rust.” The igus:bike is easier to own than any other bike. Owners can leave the single-speed bike outdoors in all weather and clean it in seconds with […]

Cosmed Group – a byword for innovation, efficiency, quality and respect

For Cosmed Group, the upheaval of the last two years has been unexpectedly good for business. Based in East Tāmaki, it’s the leading New Zealand-owned contract manufacturer (OEM and ODM) for the skincare, cosmeceutical, cosmetic, baby care, hair care, pet care and personal care industries. Co-founder, Dr Olga Garkavenko, says the pandemic came into this world unexpectedly and changed the way society operates. “This has caused a lot of businesses to rethink their strategy. Not only are the established successful brands switching to us, but there’s also many new players too,” she says. Dr Garkavenko’s core strength is in Biotechnology R&D, but she says it is a team effort all round. “I’m proud of all of our dedicated and enthusiastic team members. We have more than 100 years of combined experience across all the services. “This includes Cosmetic Science Research, Ingredient R&D, Business Management, Quality Management, Environment Management, GMP Production, Cosmetic Care, Personal Care, Health Products, Consumer Products, Supply Chain, Engineering and Customer Services”. Who and what About eight out of ten of Cosmed’s clients are based in New Zealand. Most of these clients want help in developing formulation of their own brand, ensuring quality across each stage of the process. Cosmed Group creates a unique business package for each client, including VI Design, packaging solutions, product IP issues and registration. Sustainability and ethical sourcing A big selling point for Cosmed’s products are that they are made in New Zealand which has a good reputation overseas for its natural and sustainable products. The demand for natural ingredients in cosmetics is on the rise globally, and environmental issues are growing in importance, making sustainability, ethical sourcing and their related labelling schemes more prominent. Changes in consumer behaviour and lifestyles are also creating openings for natural ingredients. Cosmed Group is BioGro NZ […]

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