Smart Manufacturing Today

D&H Steel – manufacturing in the construction game

-by Lisa van Beurden D&H Steel Construction is an Auckland-based structural steel contractor with its fingerprints over many of the largest structural steel projects nationwide. For almost 50 years it has led innovation in the steel industry, from being an early adopter of welded beams and on-the-ground erection techniques to, more recently, driving quality management systems in fabrication. The company straddles manufacturing and construction. “While we are a structural steel fabricator for the building industry, we consider ourselves a manufacturing operation as 70 percent of our work is undertaken in our workshop facilities,” says D&H Steel managing director Wayne Carson. Looking ahead at the next 12 months, D&H Steel has a very strong order book, of which some is a function of pent-up demand spilling over from COVID-related lockdowns and slowdowns, says Carson. Beyond that Carson says that there is less certainty but COVID and other market influences have led industry players to focus more on financial sustainability. “The industry is giving greater consideration to risk and making firmer decisions,” says Carson. “We have a more robust market as a result.” COVID has had other impacts. For the last few months, D&H Steel has been very disrupted by the effects of COVID, more than expected, especially around the shipping and supply of product, says Carson. As a result, the company has had to take a more conservative approach to procurement processes. “Just-in-time procurement has been shown to be very high risk across all industries so we’re having to carry higher stock levels, and having to allow for longer lead times to procure job-specific materials. “It means we need to get started on projects earlier than previously, which, in turn, means an earlier commitment from clients to get the procurement process underway.” D&H Steel has retail customers that are accelerating new […]

EcoStruxure solution meets Mataura Valley Milk’s requirements

Building the world’s best nutritional business is the ambitious goal that New Zealand dairy company Mataura Valley Milk set out to achieve in August 2016. Now the company’s milk production plant is an impressive accomplishment that comfortably justifies its early ambition. Mataura Valley Milk is now benchmarking innovation and performance for other milk plants. Situated north of Gore at the bottom of the South Island, the state-of-the-art facility was delivered on-time and within budget, an impressive achievement for a greenfield project. “To achieve our goal, we knew that choosing only the best people, partners, and infrastructure was crucial,” says Brent Robinson, Mataura Valley Milk’s Projects Manager. “The success of the project was a consequence of meticulous planning and strategy. We sought out and hired the most skilled staff; we chose construction partners with proven expertise; we purchased best-in-class plant and equipment; and we partnered with industry-leading suppliers and fabricators.” Schneider Electric was one such expert partner that delivered its EcoStruxure solution, tailored to Mataura Valley Milk’s strict requirements for a fully connected and integrated facility with real-time visibility of every process. Connectivity At Mataura Valley Milk’s core is its dedication to customers. “We must have agility around what we produce with no sacrifice of quality. Producing nutritional products is a complex, high reward approach so the plant must be nimble and our expertise unmatched. To confidently make these decisions, visibility and trust in our data is crucial” says Robinson. Schneider Electric’s EcoStruxure Plant solution delivers and provides context to live, real-time data on every process at the plant through AVEVA’s System Platform, Batch Management and Manufacturing Execution System (MES) software. In short, Mataura Valley employees receive any data they require immediately and know they can trust it. Goal Mataura Valley Milk wanted to build a business that could quickly tailor production […]

Circular Economy Awards launched in Australia & New Zealand

A new awards program, The Circle Awards, will celebrate and unite the businesses, organisations, projects and people shaping the circular economy in Australia and New Zealand. Established by The World’s Most Rubbish (TWMR) in partnership with NSW Circular, The Bravery, and Urban List, The Circle Awards aims to spotlight products and services adopting circular practices that span all aspects of our day-to-day lives. It also aims to grow awareness of the sustainable options available to more people, not just the ones who are already looking for them. In contrast to our current ‘take-make-waste’ linear model, a circular economy is regenerative by design. It’s about rethinking the entire approach in order to design out waste and pollution, keep products and materials in use and regenerate natural systems. Keeping resources in use for longer, and in a perpetual loop, or circle, reduces environmental impact and protects precious natural resources. Nick Hoskin, Co-Founder of TWMR and The Circle Awards said, “Many consumers and brands are already contributing towards a more circular world, sometimes without realising it. While we’re hearing the term ‘circularity’ or the ‘circular economy’ more than ever, the understanding of what this means, both in theory and practice, is limited.” “The Circle Awards showcases tangible examples of circularity in action, demonstrating to people that we can consume more consciously without compromising on quality, cost or experience. In fact, circular design thinking is behind some of the most interesting products and services on the market as a driving force for innovation. The result can be a far superior experience because every aspect in the process has been carefully considered to deliver the best possible outcome,” explained Nick. Importantly, The Circle Awards is here to recognise and celebrate those making progress in this space, not just those doing it perfectly or on a […]

Food and beverage led economic recovery highlights the importance of Foodtech Packtech show in 2021

Locally and globally the environment, freight, food safety, traceability and security are becoming increasingly relevant to consumers and governments. As people ask where their food came from, food and beverage manufacturers need support and expertise to ensure that they meet the demands of buyers and legislators alike. It is times of intense change where a trade show spanning decades provides vital support to the industry by showcasing new technology, products, solutions and know-how. Meeting industry specialists is essential to helping you innovate and stay relevant through New Product Development and Process Improvement. Running from April 13 to 15 at ASB Showgrounds the co-located Foodtech Packtech and Materials, Handling and Logistics Expo give visitors the opportunity to meet over 200 new and existing suppliers in packaging, ingredients, logistics, machinery, technology and much more. Whether you are looking to take your new plant food solution the rest of the world, launch the family’s secret sauce or ensure that your multimillion-dollar global company is keeping up-to-date, this show will help you achieve your goals. Packed with features the event is a one-stop shop, with two shows key to the food and beverage industry under one roof. You will meet new and existing suppliers, as well as industry experts, and associations, so you can help New Zealand kick start the economy. Seminars With 32 seminars and workshops across three days, you are connected with the experts and answers to your most pressing food processing, manufacturing, packaging, sustainability and distribution questions. Business Growth Hub The show’s Business Growth Hub is supported by the Food Innovation Network, Auckland Unlimited, NZ Food Awards, Callaghan Innovation, New Zealand Trade & Enterprise and New Zealand Institute of Food Science & Technology Inc. You can book a one-on-one session at https://www.foodtechpacktech.co.nz/visitor-information/business-growth-hub/. Digital Lean Introductory Workshop A Digital Lean Introductory Workshop […]

We’re big coal users

-Editorial, March issue NZ Manufacturer Its common to sling the mud at Australia about its coal mines, reliance on coal and exports to South Asia nations. But it’s something else to realise that New Zealand has been importing coal at levels not seen in 14 years. million tonnes were imported into New Zealand last year, much higher than the combined total for 2018 and 2019. Why is this happening? Because the Government three years ago banned exploration for natural gas. We even had a climate – change emergency in December last year with coal imports 41 percent higher than in December 2019. Food for thought? The 2018 ban on companies exploring for natural gas has caused this spike. New Zealand’s manufacturing sector saw a slower rate of expansion during February, according to the latest BNZ – BusinessNZ Performance of Manufacturing Index (PMI). The seasonally adjusted PMI for February was 53.4 (a PMI reading above 50.0 indicates that manufacturing is generally expanding; below 50.0 that it is declining). This was down 4.6 points from January. PMI Time Series Table National Indicies Feb 2020 Oct 2020 Nov 2020 Dec 2020 Jan 2021 Feb 2021 BNZ – BusinessNZ PMI 54.1 52.2 54.9 48.3 58.0 53.4 Production 54.9 51.9 55.4 52.4 59.3 57.3 Employment 51.5 52.3 51.3 49.8 56.1 49.8 New Orders 56.2 53.2 56.7 50.5 62.8 56.2 Finished Stocks 53.5 49.3 59.5 45.3 52.9 51.2 Deliveries 53.6 49.1 51.6 45.0 48.8 47.6

Additive Manufacturing: Re-thinking how we use materials in a circular economy

By Dr. Jim Goddin, Technical Director of Circular Economy at thinkstep-anz. The circular economy presents a more economically sustainable and lower-risk alternative to the highly wasteful, linear, take-make-dispose economy. The regenerative model proposed by the circular economy shows that when the things we make are designed to last, their economic value can be recovered for the benefit of the business. If delivered well, the circular economy can also provide significant environmental and social benefits. The circular economy presents key opportunities for products that rely on advanced manufacturing processes such as Additive Manufacturing. Additive Manufacturing (AM) — sometimes called 3D printing or near-net-shape manufacturing — is the process of building a part layer by layer through selectively fusing (or sintering) the material using a laser or electron beam. This layer-wise process delivers design freedoms that are unavailable in more traditional manufacturing techniques. World-leading AM collaborations are incorporating Life Cycle Assessment principles when developing AM processes and parts, including the €18M (NZD $30M) AMAZE project — Europe’s largest and most ambitious metal additive manufacturing research project. Many AM projects also have a strong focus on resource efficiency. Metrics, such as the Material Circularity Indicator (MCI), enable us to gauge resource efficiency and in turn, quantify how circular products are. How then might AM be promoted based on circularity? Recovering manufacturing value in a circular economy The circular economy is estimated to represent a $NZD $7.5T global economic opportunity. This massive economic value stems from the reduction of supply risks and the recovery of value that is currently lost through products which are designed inefficiently, under-utilised, or which otherwise go to waste. Recovering materials through recycling is a prominent part of the circular economy and serves an essential purpose in reducing waste. However, recovering raw material value only accounts for a tiny portion […]

Launch of Aisle Master Order Picker: Aisle Master-OP

Combilift’s new Aisle Master-OP (AME-OP) is a pioneering stand-on electric powered model that combines the advantages of a narrow aisle articulated forklift and an order picker for versatile operation in warehousing applications. The development of this model was influenced by customer feedback – as has often been the case with Combilift’s innovations – as well as the recent soaring growth of e-commerce. “Customers already using the Aisle Master for space saving, storage and efficiency in their warehouse asked if we could redevelop the Aisle Master to meet their ever-growing demand for order picking customised orders”, said Combilift CEO Martin McVicar. Research & Development carried out in 2019 & 2020 has created the Aisle Master-OP. The main feature of this unit is the step-through operator compartment which has design copyright protection (European Design Registration No. 002676809-0001) across multiple markets worldwide. The low floor height of just 280mm (11”) enables convenient, single step access from both sides of the truck which speeds up order picking compared to the operator having to get on and off from a seated position. The AME-OP truck has all the key advantages of the conventional Aisle Master – indoor/outdoor, for loading/offloading and for stock replenishment at other times during shifts when order picking is complete. The Aisle Master-OP is available in a number of variants, with lift capacities from 1,500kg to 2,500kg, lift heights up to 12.1m and can operate in aisles as narrow as 1650mm. It features a patented chain steering system (EU Patent No. 3008008), which allows the truck to articulate more than 205°, with an inline drive motor and front drive axle assembly, all of which enable narrower aisle operation. The multifunctional programmable joystick control lever in the operator compartment, which includes controls for the hydraulics and traction, is adjustable to enable comfortable and ergonomic working conditions for operators of all sizes. The Operator Presence Detection floor pad engages the parking brake automatically when the operator steps off the truck to carry out Order Picking. The AME-OP is now a production model within Combilift, with units currently in build for customers in the United States and in New Zealand – one of which is Sorted Logistics based in Christchurch New Zealand, a third-party logistics provider and freight forwarder who will be receiving eight AME-OP units shortly. This is a major innovation in the warehousing sector and the versatility to use the one Aisle Master for multiple applications – narrow aisle operation, truck to rack handling, bulk picking and item order picking – will result in strong demand for this new product […]

The best things come in small packages

Transponder-coded guard locking for small doors and flaps Treotham’s new, compact Euchner CTM transponder-coded guard locking provides process and personnel protection in the smallest of spaces, making it the perfect solution for securing small doors and flaps. The real bonus is that, at only 120 x 36 x 25 mm in size, the switch is especially easy to integrate into packaging machines. Typical applications include case packers and dosing, filling and sealing machines. The innovative ball actuator supported on an elastomer bearing can even secure doors with extremely small pivoting radii. What’s more, it also guarantees the highest degree of protection IP69. The switch’s special hygienic version makes it particularly suitable for the demanding food and pharmaceutical industries. The CTM provides reliable Cat. 4/PL e safety door protection according to EN ISO 13849. Thanks to its different product variants and interfaces, the switch offers the right solution for every user and is well-suited to Industry 4.0 applications because of its IoT-compatible communication with IO-Link. Maximum safety throughout the packaging process The diverse Euchner safety solutions can be perfectly integrated into modular systems to protect people, machines and products in the packaging sector. The product range comprises guard locking devices and access management systems as well as products such as door detectors, door locking systems and pendant stations. For all of its products, Euchner guarantees exacting quality far exceeding the requirements in standards and laws. Customers can rely on Euchner products with over 60 years of safety engineering expertise.

NDC sensors control manufacturing at the front line

-Simon Ganley Most customer food complaints relate to colour. Too dark is considered to be over cooked or baked. Too light is perceived to be underdone. You wouldn’t believe just what people complain about. But businesses have to take complaints seriously and it costs to deal with them. So now a lot of food manufacturing companies are adding colour to the other parameters they measure and control, saving a lot of money by doing so. There is a good chance that a biscuit you buy in NZ will have had the manufacture controlled by colour rather than moisture. The measurement was developed in NZ with NDC and is being rolled out world-wide. This saves a manufacturer a fortune in power consumption, scrap, waste, staff time and raw materials. And dealing with complaints. Next time you eat fries at top quality franchised restaurants, they will have had the manufacture controlled with moisture, oil, colour, bed depth and temperature – all on the one NDC sensor that sits above the fryer. Coffee is another application. The top brands of coffee have NDC sensors controlling the colour, moisture and caffeine. They also control tea. Sugar is another application that is being developed at the moment. NDC controls the manufacture of pretty much all the sugar made and sold in NZ. “Wet” sugar moisture can be controlled to 0.1% on-line and dry sugar to 0.006%. But customers are alert to shades of brown that creep into refined sugar. Strangely the colour we see in sugar isn’t brown. It is actually in the blue/green part of the spectrum. Lactose is another product that downgrades with shades of brown and manufacturers of quality products build NDC sensors into the fluid bed driers to maintain top yield prices. When we talk about product control with colour, we […]

Get your carbon diet on track: 5 steps to carbon reporting

– Barbara Nebel, CEO thinkstep-anz Is reducing your carbon emissions on your list of New Year’s resolutions? Want to put your business on a carbon diet, but not sure how? Whether you are new to carbon measurement or looking to make an ambitious pledge to further reduce your emissions, the following five steps offer inspiration for tackling your carbon in 2021. This can be taken as a step-by-step guide or a reference for your company’s next carbon initiative. The reality is that reducing your carbon emissions is no longer an option — it’s as essential to a healthy planet as good nutrition is to a healthy body. The 2015 Paris agreement united 195 of the world’s governments in committing to limit global warming to well below 2 degrees Celsius. At thinkstep-anz, we believe the actions of businesses will be instrumental to achieving this goal. Keep in mind that the carbon strategy you choose will depend on your business goals and who you share your carbon reduction plan with. 1. Start with a no-frills approach If you are new to this, we recommend starting with a no-frills approach. Internal carbon reporting should be your first step. Focus on aligning the actions you take with your organisation’s values and be carbon conscious. At the early stages, there is no need to communicate externally, nor is it necessary to get your targets externally verified or reviewed. However, it is always a good idea to follow best practice and get guidance from internationally recognised standards. The Greenhouse Gas Protocol (GHGP) provides the most widely used greenhouse gas accounting standards in the world. 2. Demonstrate best practice If you want to gain some recognition, stand out among your peers for your carbon reporting, or even fulfil a membership requirement, you will need to demonstrate best […]

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