A predictable outcome when quality meets quality

Rotational moulding power specialists Vision Plastics NZ Ltd (VPLAS) has been in business barely a year but already has captured a healthy part of the New Zealand market and exports 30 percent of its product overseas.

The company was set up by Dario Masutti and Sally Spencer after the US company they were working for closed its New Zealand manufacturing operation and laid off the employees.

“We believed we could make the business work in New Zealand based on our experience, commitment to quality and the support of colleagues we had worked with for many years,” says Mr Masutti.

Part of that commitment to quality came with the purchase of a Camfill Farr GOLD SERIES® dust collector installed by Viking Ltd , whose reputation in the dust extraction business matches that of Vision Plastics in the rotomoulding industry.

“The Gold Series is the most efficient cartridge filter on the market today,” says Viking manager Ross Metcalf.

The vertical design of the Farr cartridges provides more efficient pulsing of dust, eliminating uneven dust loading associated with horizontally mounted cartridges.

“The Hemipleat cartridges allows 100 percent of the filter media to remain open for dust capture and improved airflow. The open pleats allow for optimal pulse cleaning.

“Viking did a bang up job for us,” says Vision Plastics factory manager Ken Ritchie.

“Ross Metcalf and his crew knew exactly what they were doing and offered good advice on what was needed to ensure we were compliant,” he says.

VPLAS produces compounds of resin, pigment and speciality additives which they then grind into a range of high quality powders primarily for the rotational moulding industry, tailoring solutions to their customers’ requirements where needed.

The dust extractor pulls powder dust away from the process ensuring worker safety.

“Staggered baffles installed inside the inlet protect the filters from incoming dust and separate the larger dust particles, which fall directly into the hopper, reducing the load on the filters,” says Mr Metcalf.

Life is made a lot easier when you are dealing with quality equipment, he says.

There are quick open access door to the cartridge change out system that does not require entry into the collector. CAM operated clamp bars provide easy filter clamping and sealing.

About roto-moulding

A heated hollow mould is filled with a charge or shot weight of material, it is then slowly rotated causing the softened material to disperse and stick to the walls of the mould. To maintain even thickness throughout the part, the mould continues to rotate during the heating phase and avoid deformation during the cooling phase.

VPLAS has the exclusive AsiaPacific rights to a process which plasma treats polyethylene prior to moulding, the resulting change in the surface tension of the polyethylene creates a previously unachievable, successful bond to polyurethane foam and potentially paint and decals.

VPLAS has a strategic commitment to industry development and this process looks set to revolutionise the use of polyethylene and provide an exciting avenue for expansion of the rotational moulding industry.

This will be featured in the September issue of NZ Engineering News.

To change may be difficult – not to change can be fatal

A Christchurch engineering company that once specialised in sawmill machinery has landed a major, NZ$25 million supply contract for an Australian bulk grain handling firm that will see up to 50 new jobs created in the firm’s Christchurch manufacturing base.

Southern Cross Engineering chief executive Paul Thorn is unequivocal about the reasons for the firm’s diversification into different fields.

“Survival,’’ he says.

Sixty years ago, ‘’there was a timber mill in every small town in New Zealand,’’ he says.

Not so today, with that industry in a protracted downturn.

But the firm’s strengths – innovation, discipline, efficiency and an X-factor described by Mr Thorn as “lateral thinking” – have turned successfully to other fields, including materials handling and a foray into minerals in Australia.

Australian bulk material handler Graincorp has ordered 25 grain stackers due for staggered delivery up to November this year.

The order will see a new site developed in Hornby, Christchurch, and new employment opportunities for everything from tradesmen to assembly operators, in order to manufacture and deliver on time.

Mr Thorn says the company hopes to absorb some skilled workers from other Christchurch companies undergoing restructuring, retaining skills within the region. They are also advertising extensively nationwide.

He says Southern Cross won the contract with its innovative edge.

“We broke the paradigm,’’ he says of the design for the mobile stacker, which receives grain from trucks post-harvest and transfers it into storage bunkers.

Existing arrangements had issues with safety, operability and efficiency. Southern Cross’ machine is unique.

It can be transported from bunker site to bunker site – is easily assembled and disassembled – conforms to Australian road regulations – is four wheel drive enabling it to operate in extreme terrain – it is self-propelled with its own electrical generator and controlled by one operator.

The mobile stacker has a throughput capacity of up to 700 tonnes per hour, far exceeding anything currently in use.

It can also operate in temperatures up to 50C.

An Australian engineer who has worked in New Zealand for more than 20 years, Mr Thorn is also clear on why a New Zealand firm was able to trump Australian competitors for the coveted Graincorp contract.

Price was an obvious factor, he says, but then “we can build 40 per cent cheaper again in China.’’

“Innovation is the key. One of the unique things is we design/manufacture/ install and commission. We’re not a consultancy.

“We market as a one-stop shop – we have a workshop and our designers have a pragmatic view of the world because the workshop guys feed back to the designers about some aspects of design.’’

He also believes a uniquely Kiwi “understated arrogance” drives New Zealanders to do better and never rest on their laurels, as opposed to the more overt Australian self belief.

The current order for 25 grain stackers is due progressively by November, a tight time frame which will see double shifts running in the company’s Christchurch sites – is the result of a carefully cultivated relationship with Graincorp over several years. It is not expected to be the last and the firm is expecting a repeat order, as well as marketing the product further afield, such as in North America.

In another recent project, Southern Cross completed a belly dumping woodchip truck receiving facility at a Victorian port for Graincorp, a project which led to the request for a prototype grain stacker.

Mr Thorn says Southern Cross’ outside-the-box approach to the operating issues with current grain stacking arrangement won it the contract.

A prototype was trialled in Canterbury, then in Australia under conditions replicating an Australian harvest.

Thorn says Southern Cross – 100 staff strong and with offices in Christchurch, Auckland, Melbourne and Brisbane – isn’t small, but neither is it the largest firm in Australasia. They make that size work to their advantage.

“We have to keep ahead on innovation. We can’t afford to waste money on patenting … we change and develop to keep ahead of the competition.’’

Next up for the firm is a continued and growing involvement in the Australian minerals sector.

A project to upgrade plant at a quarry in Kullnara, New South Wales, where rock is crushed, graded and screened for use in concrete, roads and rail ballast has been a huge learning curve, he says.

“There were lots of lessons. The potential is huge. The client is a large competitor in the industry and was very happy.’’

Further mining/quarrying work is inevitable.

For a company founded in 1955 on servicing the timber industry, mining and grain handling seem a long way from its roots.

Mr Thorn says Southern Cross is still deeply involved in solutions for timber processing, but diversification into other industries is ensuring the company’s future.

Tasman Machinery releases new desktop 3D printer

Tasman Machinery has released Stratasys’ new ‘Mojo’ desktop 3D printing system, which promises to make 3D printing much more accessible to companies by lowering the threshold for adopting the technology. The printer includes features aimed at making 3D part-making more intuitive and seamless.

Tasman Machinery used the opportunity to introduce the high-end additive manufacturing technology at Austech in May with the running of Stratasy’s flagship Fortus 3D Production System, a Fortus 400mc.

“We have generated huge interest in our high-end machines like the 3D Fortus production system, which is finding more and more advanced applications for users. At the other end of the application scale we celebrated the worldwide release our latest FDM 3D printer, The Mojo, which is going to be a game changer in the industry,” managing director Dermid McKinley says.

While the Fortus 400mc 3D Production System can be used as a full production machine, producing everything from assembly jigs through to end-user parts to replace injection moulded and CNC machined components, the new ‘Mojo’ desktop printer now brings the possibilities of 3D printing right to the desktop, provided the part can fit within the unit’s build envelope of 127 x 127 x 127 mm.

“The number of manufacturers producing end-use parts through additive manufacturing is relatively small, but the number of organisations considering doing this is large,” Mr McKinley says. “The new Mojo 3D desktop 3D printer is now virtually affordable for anyone, and includes features aimed at making 3D printing more intuitive and seamless, much like using a traditional desktop 2D printer.”

Like other 3D printers from Stratasys, the Mojo unit builds parts through fused deposition modelling (FDM) – a process that creates resilient plastic parts out of durable and strong ABS thermoplastic.

Applications of FDM therefore extend beyond prototyping to include functional tools, fixtures and end-use parts.

The Mojo comes with a print pack which includes PrintWizard software that allows users to design products and print. The print wizard imports the CAD model and steps the user through decisions related to orientation and scaling, as well as the number of pieces to be built in the cycle.

A hardware innovation intended to further simplify the process is the integration of material spool and print head into a single package (the ‘QuickPack’ engine). Thanks to this design, loading material into the Mojo unit is a straightforward step that is similar to snapping an inkjet cartridge into an office paper printer.

“This product is just another indication that 3D printing is ready to move into the mainstream,” Mr McKinley says. “For a person or organisation who wants a 3D Printer that can work right out of the box and producing professional grade models, the Mojo is very attractive.”

For more information:
Visit: www.tasmanmachinery.com.au

Wind turbine for domestic use

A $368,000 grant from the Ministry of Science and Innovation’s Technology Transfer Voucher scheme will allow a revolutionary single-blade wind turbine designed for domestic use by Dunedin’s Powerhouse Wind Limited to be developed for production and sale in partnership with Otago Polytechnic.

Co-funded by the Ministry and investment being raised by Powerhouse Wind, the project will see Powerhouse Wind work with Otago Polytechnic to develop its innovative Thinair turbine from a promising field test prototype into a fully-developed product ready for market.

Traditional wind turbines are constructed with multiple blades attached to a fixed hub; Thinair’s patented single-blade teetering hub design allows the blade’s angle to change in response to variations in wind speed. As a result, it makes more efficient use of strong and gusty wind, is protected from damage in extreme wind and is considerably quieter than traditional turbines.

“Until recently, reliable turbines for smallscale wind power generation have not been available,” explains Powerhouse Wind Director, Bill Currie.

“Household wind power generation has largely been limited to turbines built, installed, and maintained by enthusiasts. We have used our experience and expertise to develop a wind turbine purpose-built for use in a domestic environment, aimed at providing a customer experience similar to that offered by existing home appliances.”

Mr Currie says that Powerhouse Wind “wanted a product that works like any other appliance and can satisfy customer expectations – that is easy to use and comes with a manual. We now have a machine good enough to prove that it works. We would then like the opportunity to take it to pilot production and sales.”

Otago Polytechnic’s research and development centre, Innovation Workspace, will manage the project, which involves the review and further development of the turbine’s mechanical, electrical, electronic and software components. It will also work with Powerhouse Wind to establish and monitor test sites across New Zealand and help create commercial market opportunities.

“Powerhouse Wind has a long-standing relationship with Otago Polytechnic,” says Innovation Workspace Manager, Eva Gluyas.

“Our track record is one of creating successful commercial solutions and we’re thrilled the company has chosen to work with us again. We have extensive project management and design capabilities, and a great development workshop facility. We also offer strong connections with the industrial and manufacturing sectors throughout Otago and New Zealand.”

Powerhouse Wind’s directors and partners believe this joint project is a great opportunity to create an expertise base.

“While there will be many challenges, the combination of a startup company with prototyped technology, an academic institution with great expertise and development resources, and the very capable engineering suppliers in Dunedin and New Zealand, creates a vehicle that can make the remaining development to market for Thinair rapid and thorough,” says Mr Currie.

That market is far reaching. As well as opportunities for domestic users in New Zealand, Mr Currie says the technology is of huge benefit to developing countries as well.

“There are currently two billion people in the world without electricity. It doesn’t take much to make a huge difference. A single turbine would provide for five households, for example.”

The Ministry of Science and Innovation’s Technology Transfer Voucher scheme is designed to create lasting partnerships between companies and research providers, and improve access to expertise and development resources for companies developing commercial technologies.

Otago Polytechnic is one of the scheme’s 14 accredited research and development partners.

Kiwi innovation is nothing new – it was alive and well decades ago

When 76 year old John Tippett tells you he is about to retire after more than half a century in the business, people just smile quietly. Few believe this extraordinary graduate of the School of Hard Knocks is capable of standing by and watching while others turn out the swivel fittings for which Swivel Consultants are renowned.

Wife and partner Marie has been alongside him for 53 years every step of the way, operating machinery and bringing a fresh perspective to complex engineering tasks and is often called on by John and others in the industry.

Nearly 40 years ago, John Tippett made a radical decision. He bought a Czechoslovakian made TOS lathe which had been turned down by the original customer because it was metric, borrowed space from a friend, kept his day job and worked at night with Marie on “everything and anything”.

“I worked on the machine until the early hours, went home for a couple of hours sleep and then off to my day job,” he says.

The company grew and a couple of years later the fl edgling J & M Tippett Engineering was looking for a new machine. John went to Melbourne to and came back $100,000 lighter and the proud owner of a Mazak CNC lathe, reputedly the first to be put to work in a jobbing shop. A couple of years later a Micro Turn CNC lathe was added to the scheme of things.

During the ensuing years, special machines and projects for various customers were completed using the CNC machines and the employees.

In 1987, a major customer failed to make payments and the domino effect sent the business down and the Tippetts back to square one.

Adversity became the mother of invention and John and Marie started toying with the notion of making cast or stainless steel swivels. In those days vehicles used hoses which created a health and safety issue with limited ability to withstand back pressure.

John went back to working for wages but in the evenings the pair developed the now well known ”Z” swivel. “It was a matter of trial and error – we got the first ones to swivel ok but they pinched our fingers.”

It is pretty much history from there.

Today Swivel Consultants NZ Ltd make a wide range of swivel fittings, mainly from stainless steel but some in mild steel. Protected by patents, copyrights and registered designs (Aus) they are in wide use in engineering applications in Australia, the Pacific and New Zealand.

“We use off the shelf seals and components so maintenance is no problem,” says John.

Angular swivels may be more compact to fit in confined areas, such as the hose reels as used on fire appliances where space is at a premium. Both straight and angular swivels can be made to suit different applications and with different threads. Swivel joints manufactured for fluid handling, rotary and circulating hoses offer flexibility in hoses with any fluids.

“There are no internal parts or protrusions to slow the fl ow, no circlips and no snap rings,” says John.

The Gallagher brand stamped with DMG/Mori Seiki 5-axis flexibilty

Gallagher, the company renowned for its innovation in electric fencing and access control systems, is enhancing engineering capabilities following the purchase of a new 5-axis tooling machine from DMG/MoriSeiki.

Gallagher has adopted lean philosophies across the group and this translates in a focus on the greatest possible quality tooling in the least possible time.

“Our extensive industry experience and market knowledge enables us to identify future industry trends and we adapt our activity accordingly,” says business unit manager John Amis.

“To remain competitive on price and to maintain its reputation in the engineering environment the company needed to make an investment in new tooling machinery.

“And we have done that with the purchase of an DMG/MoriSeikiDMF 180 5-axis machining centre.”

Mr Amis says that during the due diligence process his team considered three main areas of requirement of the investment.

“First, the centre must integrate within our proven process of approach to manufacture. Familiarity with the latest Heidenhaim controller, software compatibility and posting code to name a few – we knew they would be seamless with this machine.

“Second was the consideration of oneset machining that the superb extra axis machining offers. This one set solution can be applied simply and sensibly with the DMF180 machine and will offer further optimisation of skilled labour.

“The third requirement is met by the flexibility that is offered by true 5-axis machining, which eliminates a high percentage of time-consuming machining strategies."

Features that clinched the deal for John Amis and his team at Gallagher

Table dimensions:
We envisaged that work for the Group will require a table that is 1500mm long and is capable of supporting a weight tooling-plate of this size.

The machine needed a wide door opening which allows us to load larger and heavier pieces with the aid of a forklift.

The DMF 180 has a table dimension of 2100mm x 700mm and supports up to 1500kg. The integrated C axis table can swing work pieces of up to 1000mm.

Spindle speed/feeds:
Development in carbide has allowed for distinctly faster and accurate machining. The introduction of the DMG MoriSeiki machine has shown precisely the gains that are available from increased spindle speeds.

Any new machine should not be considered without a minimum of 15,000rpm spindle speed.

Global trends are showing that tool making machining has moved to a technique (HSS) high speed machining which needs this level of speeds.

This technique is basically lighter cutting but increased machining feed rates which reduce pressures from the cutting carbide, extending carbide life and reducing the wear and tear on the machine. Most importantly it increases accuracy while improving machining efficiency.

The DMF 180 is equipped with an 18000rpm, 35kW spindle producing 130Nm of torque.

Software compatibility:
At present, the output of the machining code software is posted in a language recognised by Heidenhain controllers. Heidenhain is a market leader – only one of two for quality processing of 5-axis code.

Our technicians are familiar with the Heidenhain controllers – if required they are able to go to the controllers and give it instructions that it can understand – offline programming.

Tooling and automatic tool changer:
As high-speed machining becomes the industry norm, we are seeing the limitations of the traditional low-speed tool-holders at spindle speeds in excess of 8,000rpm.

Fully balanced HSK tools have been developed by the need for tool holders to match the high machining speeds required for the modern carbide productivity in reducing cycle times.

HSK spindles clamp tools combined with shrink-fit offer more security at higher speeds due to its retention system which has a more accurate face clamping, combined with the arbour diameter.

At high spindle speeds, the older tool clamp systems are ineffective resulting thermal and centrifugal imbalance. This does impact on carbide tool life through lack of rigidity impacting on increased consumable costs.

“The main cost economies come in savings in labour costs for set up and a reduction in EDM activity,” says Mr Amis.

Saving energy in compressor rooms

The latest ES 16 central controller by Atlas Copco can be connected with a maximum sixteen compressors.

The device offers one central point of control for an entire compressed air network as it retrieves and processes information coming from the compressors, dryers and other measurement equipment.

The result is a dependable and efficient network and thus helps to save on average ten percent energy. Compressors and dryers can be connected to the ES 16 controller by means of a widely used CAN network. The device stores all machine and sensor data up to one week. This allows users to see graphs and trends for analysis on the ES user interface or for longer period, they can optionally consult them through the Internet.

With the optional control feature, the ES 16 controller regulates the air net pressure by starting/stopping the different sizes of machines and selecting their optimal operating points. Furthermore, it helps to keep the air net pressure on the lowest possible level in order to gain additional energy savings. For example: lowering the air net pressure by 1 bar reduces not only the energy consumption by seven percent but also air leakages by 13 percent. Atlas Copco experts calculate ten percent energy savings in average for compressors with variable speed drives (VSD) and turbo compressors.

TheES 16 controller provides additional possibilities to increase the control and visibility in the compressor room for other equipment like pumps, valves, vents.

Optionally adding flow meter and dew point meter, users can be sure that the compressed air production continuously provides the required amount of quality air with high effi ciency and reliability.

“Customers want to continuously reduce their production costs without jeopardizing the availability of compressed air. Moreover, environmental awareness calls upon industrial facilities to limit CO2 emissions by reducing their energy consumption,” says Tamas Bakos, product marketing manager, oil-free air division.

For more information:
Visit: www.atlascopco.com