Smart Manufacturing Today

Luminescence sensors get a performance upgrade

New generation, new features: Treotham’s photoelectronic luminescence sensors by Wenglor combine innovative features and proven performance values for reliable detection of luminophors. In addition to an IO-Link interface, the two new models P1PA001 and P1PA002 also have a teach-in button for intuitive configuration. New features at a glance. The world speaks IO-Link – and the new Wenglor luminescence sensors from Treotham are no exception. The standardised communication interface makes it easy to configure parameters, output intensity values, operate condition monitoring or set on and off delays. Simply via IO-Link. But the sensor housing has also been given a functional facelift: A central teach-in button and two LEDs on the top of the sensor ensure a simple operating concept. If the button is held down for two or five seconds, objects can be taught in statically or dynamically. To teach in the sensor remotely, you can use the intuitive wTeach2 configuration software. “This makes the entire installation, configuration and maintenance easier”, says Wenglor product manager Stefan Reetz. “There are fewer elements on the sensor than before, and they can do more. Everything else can be conveniently adjusted via IO-Link 1.1.” The technology is housed in Wenglor’s tried-and-tested 1P housing (50 × 50 × 20 mm). An extended working range of between 30 and 90 mm and a small light spot diameter, combined with a high switching frequency of 2,500 Hz ensure an enormous performance range. Receiving ranges between 420 and 750 nm (P1PA001) and 570 and 750 nm (P1PA002) round off the new generation. Making the invisible visible Luminescence sensors emit UV light at a certain wavelength. If the emitted light strikes a luminescent object, it reflects within a visible wavelength range in accordance with the luminescent substance mounted. The sensors use this effect to make markings on labels visible, for example. Your advantage: These markings remain invisible to the human eye. Particularly when packaging […]

Multi-Million dollar decarbonisation initiative set to boost wool exports

A new multi-million dollar decarbonisation initiative at one of the country’s largest wool product manufacturers is set to reduce emissions by up to 30% and help boost wool product exports. According to EECA (the Energy Efficiency and Conservation Authority), industrial heat processes accounts for around a third of New Zealand’s overall energy use. An estimated 60% of production heating is fossil-fuelled.[1] The sustainability initiative is part of a multi-year programme to reduce production related carbon emissions and improve operating efficiency at wool carpet manufacturer Bremworth. The first stage of the decarbonisation pathway is a $2.1 million project for the Napier wool yarn spinning plant to transition from natural gas process heat to electric heat pump technology. The initiative is designed to improve the energy efficiency of manufacturing processes, by detailed process heating measurement, minimising waste heat and optimising the heating system configurations and technology to meet future production volumes. Production efficiencies from the use of the technology in the yarn making process are expected to help boost exports for markets where demand for New Zealand made wool carpet attracts a premium price point. The project will also reduce emissions at the facility saving up to 1,500 tonnes of CO2 per annum. Scientific estimates suggest a radiata pine tree absorbs one to two tonnes of CO2 in one year – meaning 800-1500 trees would be needed to match the annual emission savings from the installation of the new technology.[2] Greg Smith, Bremworth CEO, says the increased efficiency of the new technology will help lower operating overheads, as well as boosting production and exports. He says the design of the technology will require a specialised team of engineers and contractors to build and then install high temperature heat pump technology of up to 800kW capacity at their Hawke’s Bay facility over a […]

Company Profile – Oasis Engineering, Tauranga

Industry 4.0 – Just do it! Oasis Engineering began as the maintenance division of the Gisborne Oasis soft drink brand, before moving to Tauranga and becoming known for its close-tolerance machined parts in difficult to work materials, including stainless steel and titanium. They now make parts for every major compressed natural gas (CNG) company in over 40 countries. Oasis and its team of 30 manufacture precision stainless steel machined and assembled components, primarily for the natural gas industry. We recently caught up with Kevin Flint, General Manager of Oasis, to hear how their Industry 4.0 journey has been progressing. Can you tell us a bit about your background and your role at Oasis? I am the General Manager of Oasis Engineering Ltd. From Blackpool in the UK, I have been in the manufacturing industry for over 30 years. I emigrated to New Zealand in 2006 and I’ve been employed at Oasis Engineering since 2007. I have a degree in Mechanical Engineering, a Masters in Product Development, and am a Fellow of the Institute of Mechanical Engineers (UK). My first professional role was to design Automated Production Machines and write the PLC programs. Industry 4.0 has been in my blood since I began my professional career. Can you tell us what Oasis Engineering do? We are a manufacturing company based in Tauranga with 30 employees. We design and manufacture products for the CNG (Compressed Natural Gas) Industry, Hydrogen Refuelling Industry, Food and Dairy Industry. Currently, 80 per cent of our products are exported to over 20 countries, but mainly the USA and Canada. When did Oasis begin their Industry 4.0 journey? I first became aware of Industry 4.0 after Oasis Engineering was bought by German company, Elaflex Hiby GmbH in April 2017. They have a factory similar to ours in Plettenburg […]

Serious about sustainability? Delve into your supply chain!

-Barbara Nebel, CEO thinkstep-anz Supply chains are ‘having a moment’ – and not an easy one. As a manufacturer, you’re likely to be facing supply chain challenges due to Covid-19 and global unrest. The current situation highlights the critical role supply chains play in manufacturing. Read on to learn how Kawerau-based manufacturer Essity Australasia (formerly Asaleo Care) is future-proofing its supply chain, with benefits to its business, the natural environment and local communities. Zooming out: the global picture and SDG12 But first, let’s start with the global picture. The United Nations’ Sustainable Development Goals (SDGs) recognise that supply chains play a critical role in creating a more sustainable world. In fact, supply chains have their own SDG. It’s SDG 12: Responsible Consumption and Production, and it’s linked to many other goals in the SDG framework. Why the link? Because, by purchasing responsibly, manufacturers can have positive impacts far beyond their own businesses. For example, by ‘buying local’, they can help build sustainable cities and communities (SDG11). By using renewable energy, they can contribute to affordable and clean energy (SDG7) and promote climate action (SDG13). Essity Australasia: SDG12 in action Essity Australasia is a good example of SDG12 in action. The manufacturer produces personal care and hygiene products and is the only New Zealand manufacturer of toilet and hand towel tissue products. The company is serious about understanding and managing its environmental and social impacts, including through its supply chain. Understanding the sustainability of its supply chain Essity Australasia uses Life Cycle Assessment (LCA) to review the environmental impacts of its products across their life cycles. LCAs measure the impacts, including carbon emissions, involved when the manufacturer makes its personal care and hygiene products (using resources like trees, water and energy and services like transport). They also calculate the impacts involved […]

Zero carbon steel on market

“What Gets Measured Gets Managed” – Peter Drucker By Dr Troy Coyle, CEO, HERA In Aotearoa New Zealand, there are a lot of conversations being had around carbon in the built environment, with our Ministry for Business, Innovation and Enterprise having developed two emissions mitigation frameworks under the Building for Climate Change Programme. These include proposed requirements in the Building Act and Code relating to carbon reductions. From this month, certified zero carbon steel will be available in the New Zealand market through a robust offsetting program. The program, Hōtaka Whakakore Puhanga Waro, has been independently developed and is based on verifiable data. HERA is the facilitator of the program and has partnered with social enterprise Ekos, a leader in environmental financing, to administer the offsetting process. The program will give the option for specification and use of zero carbon steel through offsetting determined on the basis of a robust underlying carbon calculator. New Zealand has committed to a net zero carbon target by 2050. Steel and iron production is the single largest industrial source of CO2 emissions in New Zealand, representing 55% of industrial emissions and around 5% of total gross emissions[1]. As we are all aware, carbon is primarily used in the steel-making process as a reductant, rather than an energy source – counter to how steel is often portrayed in the media. Although there is research into alternative reductants (e.g. hydrogen), currently no commercially viable alternative exists for coal, so until an alternative is developed, offsetting plays an important role in steel’s decarbonisation journey. The zero carbon steel program has been developed to provide independent and robust carbon offsetting rules and a preference for the offsets to be focused on the planting of native trees to provide additional biodiversity and human capital benefits to New Zealand society. […]

EMEX is back!

It’s been a while for a trade show that has so much history. Through determination and persistency, the organisers, XPO Exhibitions and the loyal exhibitors – some who have been coming to the show for years – have put their foot down and made the 2022 version possible. As a visitor, you will be sharing in the 40th anniversary of the show. Technology changes so quickly, 40 years seems a long, long time ago. At EMEX 2022 you will experience the best of manufacturing technology equipment and services to assist your company in its growth, future development. And of course the industry seminars, well worth a visit to the show alone. Discussions and buying decisions around Industry 4.0, Lean Manufacturing, Green Hydrogen, Supply Chain, Machine Tools, Cyber Security, Renewable Energy, Robotics & Automation, Additive Manufacturing will be made. All key areas for manufacturing businesses and their way ahead. Some of the exhibitors include on Stand 3021 Eurotec Ltd who have been supplying and supporting premium European technology solutions to the New Zealand Industrial, Electrical, HVAC, and Refrigeration industries for over 36 years. The Eurotec team will be exhibiting the Orbis range of Electric Vehicle Chargers, Eaton Variable Speed Drives, the Testo range of measuring instruments and Infrared Technology. Materialise’s software solutions for Metal 3D Printing will be on display on Stand 1037. Treotham will be presenting their new range of products for the first time on Stand 2048, The whole range is suitable for a variety of industry sectors – from mining to railways and theatres. The diverse range includes flexible cables, accessories, chains, bearings, connectors, flexible conduits, safety products, sensors, position controls, gear boxes, linear units vacuum technology, clamping systems, pneumatics and conveyor components. Whether you are an engineer, consultant, fitter and turner, business owner or production manager, EMEX […]

IoT helps glass manufacturer disrupt industry with four-day supply delivery

New Zealand glass manufacturer, Architectural Glass Products (AGP), has deployed Internet of Things (IoT) technology from Pollin8 and Thinxtra for around-the-clock tracking of its products and delivery trolleys, ensuring it avoids losing assets, and bolstering its industry leading customer service. AGP was founded in response to market demand for high quality glass that can be manufactured and delivered in short timeframes. Established in 2019, the company has become the nation’s largest manufacturer of insulated glass units (IGUs). It currently operates a four-hectare, highly automated factory in Hautapu on the North Island. AGP owns over 1,750 purpose-built delivery trolleys, worth NZ$3,000 each, to transport its fragile, high-value glass products. To reduce the risk of these assets going missing and ensure their efficient return to the facility, AGP installed low-cost IoT tracking devices from NZ’s Pollin8, which communicate over Thinxtra’s 0G Network. This allows the manufacturer to track assets in real-time so they can be retrieved efficiently to maintain its four-day order-to-delivery service. “Before AGP came to market, the time from ordering the glass to delivery was unpredictable, and customers never quite knew specifically when their products would arrive. We have completely disrupted the market by delivering in four days,” said Gene Sanford at AGP. “Having Pollin8 and Thinxtra’s joint IoT solution in place from the start has proved central to our ability to deliver this level of service. Rather than resorting to the time consuming task of counting assets on a map with a basic GPS solution, we have a dashboard and data that inform us which customer has the trolleys and how long they have had them, enabling us to quickly take action to maintain our high service levels. “Our customers’ cash flow can be improved significantly knowing their supply will be delivered on time; getting our assets back quickly […]

Power your future with clean, renewable energy

-Barbara Nebel, CEO thinkstep-anz Every manufacturer needs reliable, affordable energy. The electricity you use, the thermal energy or coal that powers your boilers, the liquid fuels that run your vehicles – energy is one of your business’ most important resources. So, let’s take your energy requirements a step further. Adding ‘clean, renewable energy’ to the list will make your manufacturing operations less dependent on fossil fuels and help avert climate catastrophe. Include a ‘resilient source of energy’ and you’ll help your business withstand potential energy shocks as geo-political tensions grow. Reliable. Affordable. Clean. Renewable. Resilient. That’s a lot to ask of an energy source! Or is it? In this article we show you how to get started – and where to look as you become more ambitious. 1. Start with the UN’s Sustainable Development Goals (SDGs) The 17 SDGs aim to end poverty, protect the planet, promote prosperity, and ensure peace for all. All 193 UN member states, including New Zealand, have adopted the goals. Based on our thinkstep-anz research, the Climate Change goal (SDG 13) is the top sustainability priority for companies in New Zealand and Australia – and maybe for your manufacturing business too. For many manufacturers, SDG 7 (Affordable and Clean Energy) will be another critical goal. SDG 7 and SDG 13 share some common targets: encouraging energy resilience, moving away from fossil fuels, and improving access to clean energy. Tackling either goal is a win for your business, our planet and its people. Operational efficiency + sustainable action together! Windmill on grass field during golden hour. Photo credit: Karsten Würth on Unsplash. 2. Understand your energy consumption 100% renewable energy is SDG 7’s holy grail. The share of renewables in New Zealand’s total primary energy supply is currently around 40% (MBIE, 2020). We’re not where we […]

How Tidy International helps float Kingfisher’s boats

When the Mason family bought into a Tauranga-based manufacturer of catamaran-hulled boats, the business management software being used included TidyEnterprise and Xero, critical to the co-ordination and control of their production and supply. After steadily maturing the workflows over the course of the year that followed the Mason family involvement, Kingfisher Boats today enjoys a software system that provides accurate stock and Work-in-Progress reports, with further developments in the works to accelerate overall business efficiency, optimise production processes and deliver company-wide data visibility. Kingfisher Boats is both designer and builder of the Kingfisher range of quality aluminium vessels with catamaran hulls sold through an approved marine distributor network. This growing New Zealand business, with its workshop facilities based in the city of Tauranga, happens to be located in the same city as Tidy’s international headquarters. Kingfisher has built up a solid range of marine-craft products for over 19 years, including commercial and recreational vessels ranging from 3m to 18m in length. Laura Mason, General Manager of the company, comments “what sets Kingfisher Boats apart is our focus on alloy catamarans. We’re unique in producing metal cats under 6 metres with a single engine – delivering a more stable platform in a compact package.” Situation Upon joining the business, Mason soon recognised opportunities for enhancing the manufacturing processes. Applying experience she gained in the automotive industry, with its long history of process standardisation and optimisation; from the production-line efficiency made famous by Henry Ford to Toyota’s Kaizen methodology of continuous improvement, Mason sought to advance the somewhat unstructured approach characteristic of smaller businesses towards a defined and repeatable model. Mason emphasises, “this does need to be differentiated depending on the boat we’re manufacturing. When we’re doing a multimillion dollar 18-metre vessel, there’s a lot of customisation so repeatability isn’t important. But […]

The sky’s the limit for growing Hutt Valley manufacturer

A high-tech design and manufacturing company based in the Hutt Valley is taking on the world while nurturing the region’s young talent. Times-7 designs and manufactures radio frequency identification antennas, otherwise known as RAIN (UHF) RFID. Founded in 2006,the company has established itself as a leading company in the global RFID market, exporting its products worldwide. Jos Kunnen, CEO and Managing Director, is committed to sustainable manufacturing in the Hutt Valley, saying, “this is the perfect place to be with other businesses around us that can support our growth and ambitions.” As uncertain as the future seemed when Covid-19 emerged, Jos says demand has skyrocketed due to an expanding market for RFID products. “We export almost everything we make, so we rely heavily on what happens in the rest of the world, especially North America and Europe.” When the first wave of covid-19 hit the US and Europe, projects stopped because no one could install products in retail stores, factories, or warehouses. Orders slowed, and supply chains became stressed and unpredictable. “Many companies suddenly realised they were not accurately tracking their inventory. They had to figure out how much stock they had but couldn’t get into their warehouses to check due to lockdown. They needed automation, so the demand for RFID products soared.” Last year, Times-7 celebrated its 15th year in business and is well-positioned for growth. Before Covid-19, companies were already piloting or deploying RFID; however, they realised they needed to speed up the implementation process. “This has driven demand. We are a part of a global RAIN Alliance group, and there are reports of others in our industry also experiencing significant growth. For context, the annual number of UHF RFID tagged items has risen from 21 billion to 28 billion over the last year. “All these tags need […]

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