Product Watch

Students get more time to learn

Southern Institute and Technology (SIT) recently installed a new Egmont Air dust extraction system to compliment their high-profile joinery workshop facility.

SIT offers a new Joinery training facility that many believe is the best in the country. The large well appointed machine-shop houses high quality, modern industrial machinery required to manufacture kitchens, furniture, doors, windows, stairs and cabinetry.

Students manufacture full-size, quality, practical projects throughout the duration of the program and have the opportunity to use a wide range of traditional and advanced computer controlled machinery. A greater emphasis on including the latest technology in the workshop makes for a real-life situation and experience.

Having experienced numerous performance issues with a previous extract system, SIT engaged Egmont Air to provide a full on-site evaluation, testing and analysis of their dust extraction system and design a new system that would suit the needs of a modern workshop.

Todd Prestidge from Egmont Air says: “We quickly identified that the primary issue was created by the existing extractor unit. The filters were clogging quickly, sometimes within days, creating excessive back-pressure and poor suction at the machines.”

Of course this had a knock-on affect, dust levels in the workshop areas were excessive where health and safety was a priority for Southern Institute and Technology. A lot of time was spent cleaning up rather than working on projects.

“It is critical that the design of a dust extraction system is balanced,” says Prestidge. “The filter, fan and ducting are all inter-related and must be sized correctly to provide on-going reliable performance.”

High-performance computer machinery such as CNC routers, speed-sanders, dimensioning saws etc, require extra-high levels of extraction to cope with fast cutting speeds, angular cutting angles, and a combination of fine particle board dusts.

The design of any dust extraction starts with the machinery. Each machine must be separately evaluated based on hood design, capture velocity, hours of use, dust volume created to specify the airflow and suction that will successfully capture the dust before it reaches the operators breathing zone or spread throughout the workshop.

As each machine is connected to the centralised ducting system, the main duct grows in diameter allowing full capacity of the extraction system to be shared and balanced between machines. A small discrepancy in ducting size can cause a large compromise in extraction if this fundamental design principle is ignored.

Egmont Air re-designed the system from scratch, while much of the existing ductwork was re-used; some critical parts were up-sized to allow proper conveying velocities and airflow distribution.

New Egmont high-efficiency fans were specified and installed to provide optimum suction levels. Each workshop area was fitted with its own fan unit and non-return valve, operating independently, so that any area could function without respect of the other. Both fans were ducted into a single Egmont Modular Filter to provide central collection of dusts.

The Egmont Modular Filter system is fitted with high filter-surface area, automatic cleaning, decantation chamber and rotary-valve for discharging high volume of dust.

Russell Finlay, programme operations manager at Southern Institute and Technology, comments how happy he is with the design of the new Egmont Air system, “its performance is exactly what we had hoped it would be, the tutors are happy and I am relieved.”

“Egmont’s extract system made an incredible reduction in airborne dust in the workshop environment,” says Finlay. “We took before and after video recordings of the dust clouds on the previous system and when compared to Egmont Airs new system the difference is dramatic.”

The Egmont Air offer a huge range of duct and flex, fans, filter and cyclones for wood-working applications and provide solutions for many timber processors, kitchen makers & joinery shops.

Egmont Air’s experience and expertise prove popular for diagnosing issues on existing dust extraction plants.

Egmont Air provides a free consultation and professional advice for any dust or fume extraction issue. Contact Egmont Air on 0800 781 200 or +64 6278 1200 or visit their website:  www.egmontair.co.nz for more information and a free catalogue.

 

 

 

 

Pneutech’s reliable oil-free compressor

Industrial Air Systems’ range of Pneutech RSCRDV oil-free series rotary screw compressors bring the highest and most reliable source of food-safe compressed air to the to the industry.

Ranging in sizes up ton 250Kw, including VSD models, the  Pneutech RSCRD range of oil-free compressors can be relied on to deliver a consistent flow of high quality, clean and economical Class-0 compressed air.

The Pneutech RSCRD-V series industrial rotary screw compressors are designed for heavy duty and demanding applications. This industrial rated oil-free compressor features a direct driven transmission, driving a world-renowned two-stage air-end, and spinning at low RPMs.

The low operating temperatures, low wear, and consequently low service requirements, results in minimal maintenance costs, over the lifetime of the machine. With a 100 per cent duty cycle, the Pneutech RSCRD oil free series compressors, promise high performance, long life and solid reliability, which makes them ideally suited to so many 24/7 production situations in the oil-free industry.

The state-of-art German-machined and coated rotors lead to a high oil free air delivery and lower energy costs when compared with many other compressor models. The rotor casings feature generously-sized liquid cooling passages for even heat dissipation, enabling closer tolerances to be used for high compression efficiency. Non-contact, non-wearing labyrinth seals prevent bearing lubricant entering the compressor chamber.

The Pneutech RSCRD-V variable speed series rotary screw compressors offer substantial energy savings with the ability to supply a varying compressed air volume to suit the work demand. With today's increasing cost of electricity, the RSCRD-V compressors bring up to 40 per cent savings in power usage over the conventional single speed screw models.

The significant additional benefit of the directly coupled motor/air end configuration, leads to further energy savings with efficient direct transmission, low rotation speed and low heat generation.

Contact Industrial Air Systems NZ on 0800 555 018 or info@industrialair.co.nz

 

 

 

 

 

Keys to smooth operation – listening and planning

A big part of ensuring the smooth operation of a new project is clear communication between client and provider. Aurora receives excellent reviews from its clients who say they listen to client needs and maintain regular contact throughout the project and post-installation.
 
Geoff Hadwin, general manager at Cresta Mushrooms has first-hand experience as Aurora supplied and installed a metal detector for their production plant.
“Aurora listened to what we wanted and sourced the machine we needed. They then programmed it to what we wanted and installed it,” says Geoff.
“It was a complicated thing they were having to do, but they were good, and they were always very pleasant to deal with. And once the machine arrived their communication level was great.”
 
Every load of mushrooms now goes through the new metal detector to ensure no metal contaminant is passed on to the consumer, and its main benefit is that it saves a lot of product.
Cresta Mushrooms didn’t consider going with any other supplier when Aurora was recommended to them, and Aurora delivered on their high expectations.
 
“We were happy with their product, price and service, and with their performance,” says Geoff.
The Aurora quality assurance team specialises in foreign matter control and product inspection. Our German made metal detectors and checkweighers are known globally as the cutting edge in quality and technology along with the revolutionary FORCE10 magnetic separators.
 
The metal detection equipment is supplied to many industries globally, to ensure compliance with the numerous standards and best practice guidelines necessary to produce world-class product. With robust food grade manufacture, simple operation and intelligent technology, these units ensure a simple solution for a large variety of applications.
With our range of check-weighing, metal detection, magnetic separation, X-ray and metal detectable products, Aurora provides the complete product security package to protect you and your company, enabling you to add significant value to the quality of your products and brands.
 
Visit our stand #3078 at the Foodtech Packtech Exhibition, ASB Showgrounds, Auckland from 23 to 25, September 2014. Aurora will have on display a range of our Force10 Magnetic Separators and quality assurance equipment.
Our team of consultants and engineers will partner with you to provide a complete solution for your particular application to increase your product quality, brand integrity, peace of mind, and set your company ahead in its field.
Contact Aurora today for all your quality assurance requirements.
 
Phone 0800 55 77 33, email sales@aurora-nz.com or see our website www.aurora-nz.com
 
 
 
 
 
 

Traffic management is critical

Traffic management involves a systemised approach to analysing and controlling the traffic movements in and around a production or warehousing facility. Every facility should have comprehensive traffic management plan.
When you have trucks, fork lifts and other heavy machinery on site it will inevitably create the hazard of mixed traffic. This needs to be isolated, controlled or eliminated to ensure people’s safety at work.
 
Pedestrian traffic must be managed wherever there are vehicle movements in a work place – it only takes a single moment of inattention for a serious or even fatal accident to occur.
Designated pedestrian walkways, using the certified Tru-Gard barrier system, are an effective solution to ensure employees and visitors don’t stray into danger zones.
 
Doorways to warehouses, factories and loading bays are also areas that can be overlooked when it comes to safe traffic management. Ideally doorways should not have mixed traffic types and it is recommended that traffic flow is restricted to one direction.
Implementing traffic management systems not only reduces the health and safety risks on your site but it can also help with streamlining your entire production or warehousing facility. Standardisation across multiple sites also reduces the risks associated when employees move between sites.
 
Talk to us today about how we can help you reduce the health and safety risks that you are faced with in your workplace.
 
Call 0800 144 999 or visit www.tru-bilt.co.nz
 
 
 
 
 
 
 

Digital valve controllers

Emerson Process Management has introduced the Fisher Fieldvue DVC6200p series of digital valve controllers.
The DVC6200p series is an ideal solution for applications in which accessibility, extreme temperatures (up to 120°C/250°F), extreme vibration or confined space make integral mounting difficult or impractical.
 
Industries such as pulp and paper, and metal and mining have typically preferred to isolate valve-mounted instruments from harsh environments. With the remote mount version of DVC6200p, only the valve position feedback is mounted on the control valve, while the remainder of the digital valve controller can be mounted more than 90m away in a less severe or more accessible environment.
The remote valve mounted feedback unit uses the patented Fieldvue linkage-less, non-contact feedback technology in which physical contact has been eliminated between the valve stem and the instrument. With no linkage to wear, loosen, corrode or vibrate, the feedback unit can withstand a plant’s operating extremes.
 
With over one and half million units installed worldwide, Fieldvue digital valve controllers prove highly suited to difficult process environments where they provide unmatched valve operation. 
Using the best of Profibus PA, the DVC6200p series provides a wealth of alerts, trends, and diagnostics to allow for visibility and control, The DVC6200p supports enhanced device description (EDD) files that allow for quick and easy configuration.
The Fieldvue DVC6200p digital valve controller is certified to Profile 3.02 for Profibus PA devices by the PROFIBUS Nutzerorganisation a.V (PNO).
 
The DVC6200p is offered with CSA, IECEx, ATEX and FM hazardous area approvals as well as other certifications/approvals. It is also listed in the Lloyd’s Register for industrial, marine and offshore use.
 
Reader-enquiry #140906
 
 
 
 
 
 
 
 
 

High Speed Pneumatic Multipliers

Hytools NZ Ltd has a new range of Air Torque Multipliers with a speed advantage to the twin motor handle coupled with new gearbox designs deliver an ideal balance between robustness, speed and weight.

Where clients need a higher run down speed but also controlled torque up this tool does both. Industries to benefit from the TLSM range are Oil & Gas, Mining, Transport, Steel Construction and Manufacturing.

  • Fast run down speed
  • Quiet less than 85 db
  • Non Impacting
  • Square Drive is quickly and easily replaceable
  • Bi-Directional
  • Soft Start Trigger
  • For safety gearbox can rotate independently so reaction forces are not transmitted to operator

Contact: 0800 00 2195 or email: info@hytoolsnz.co.nz

 

 

 

Chemshed keeps chemicals safe

The days of leaving chemicals and other hazardous materials on a shelf or in a locked cupboard in your business, workshop or garage are over. 
 
From panel beating to farming, manufacturing to maintenance, the regulations around the storage of flammable and corrosive liquids are causing industry across the country to take a fresh look at the way these products are stored.
Common sense and best practice tells us we should store these chemicals in approved safety cabinets, where they are isolated from other incompatible substances, protected from misuse and contained in the event of a spill incident.
 
That’s where the Chemshed cabinets come in. Successfully combining compliance and practicality, their unique design provides the user with a unit that is the most secure, sound and approved solution on the market today. Packed with features like double skinned walls, 150mm sumps, galvanised shelving and sequentially closing doors, these cabinets very quickly turn that storage nightmare into a crisp, efficient and safe work zone.
 
Civilquip is the national importer of Chemshed, and with distributors right across the country, there’s bound to be a supplier not too far away. 
 
Contact Civilquip on 0800 688 844 for your nearest dealer or find us online at www.civilquip.co.nz 
 
 
 
 
 
 
 

Variable speed drives

The AC30V family of AC variable speed drives has been designed to provide users with exceptional levels of simple open loop control for pump, fan and general purpose applications through to closed loop process line applications. 
Their flexible and highly modular construction enables a wide range of communications and I/O modules to be easily added 
as required.
 
The AC30V drive has been designed with simplicity in mind, but this doesn’t compromise its functionality. Integrated macros for a range of applications and PLC functionality enables more capable users to create sophisticated control that would previously have required a separate PLC.
 
Ease of programming is a key feature of the AC30V, with a multiline operator interface and a ‘set-up wizard’ to take you through the application commissioning in a clear and concise manner, making expert drive knowledge or reliance on programming manuals redundant for the majority of applications.
 
Product features include safe torque off (STO) to SIL3, internal DC choke to reduce line harmonic to IEC/EN61000-3-12, rated for operation in temperatures up to 50˚C, control of either AC induction or permanent magnet servo motors and optional integrated EMC filter to C2 first environment. 
 
Contact ph 09 574 1744 or email nzmktg@parker.com
 
 
 
 
 
 
 
 

Milk cooling crucial for export dairy industry

With standards for milk and milk products becoming more stringent, business owners and farmers need quality cooling options to keep up the important dairy industry’s contribution to the Australian and New Zealand economies.
The dairy industry’s customers, for example those in the Asia/Pacific region, are demanding 100 per cent assurance of the milk quality from the moment it leaves the cow to when the end-user purchases the product. That means strong control over the quality of the milk as it is being taken from the cow, then onto the on-farm storage, pick-up and transportation to the processing plant phases.
 
When milk is taken from the cow, its temperature is 35 degrees. The longer it remains above 4’C, the greater the bacterial growth and the more unsafe it becomes to process. The timing to cool the milk below 4’C is critical to the quality of the product, and after a very short time it actually becomes worthless.
 
According to the Australian Department of Agriculture, Fisheries and Forestry, milk must be cooled within two hours of milking at no more than six to eight degrees depending on collection date. The temperature control system must maintain the temperatures to no more than 10 degrees during transport.
This highlights why the milk cooling system needs to be correctly sized and selected in the first place and then checked and serviced at regular intervals. One of the key components of this is making sure the plate heat exchanger can maintain the heat load efficiently and effectively at the correct temperature.
 
Milk coolers should be chilling the milk to within 2 degrees of their cooling water supply temperature or you are just throwing money into energy bills. The cooler the milk enters the vat storage, the cheaper it is to keep cool and the better the quality of the milk.
If the plate heat exchanger isn’t working properly, either it is sized incorrectly, or your herd has increased in numbers and thus the cooling duty has changed, or simply the milk cooler has become fouled with various contaminants that will cause a reduction in flow and/or inefficient cooling. The cooling system will then need to work much harder to cool the milk, again hurting the farmer in energy costs, and finally the milk quality will, not might, be compromised simply from not being chilled and stored cold enough.
Dairy farmers would be advised to get a dual bank exchanger that Sondex can provide. And remember “the taller the plate the cooler the milk” - the old adage of just add more plates is long dead and gone, science clearly shows that the longer the thermal length of the heat transfer plate the longer the resonance time in contact with milk, this is what will give you virtually instant cooling of the milk together with chilling it down to the required storage temperature while reducing your energy bills.
Sondex can also assist in designing and creating specific heat transfer equipment that can cover all the producer and processor’s milk cooling/heating needs.
 
The penalties for non-compliance can be quite large for businesses across regional Australia and New Zealand. If the milk is found to be not at the required temperature or have high bacteria counts, individuals are advised to correct the fault. If after this warning the problem is not fixed, there can be serious consequences - such as excluding the producer’s milk products from supply and removal of declaration of compliance.
 
This industry is full of fine margins, which is why it is so important to have your heat transfer system in top shape. If you are unable to pinpoint the faults in the heat exchanger it may pay to contact Sondex who can also offer professional technical advice.
 
For more information contact: 07 348 6339 or email miguel@sondex.co.nz
 
 
 

Push together water pipes that can take the strain

As New Zealand’s leading producer of quality frozen convenience foods, Leader Products have been experiencing ever increasing demand from their customers.  This demand has been driven by increased sales of their existing products, as well as the development and introduction of new ones. This has put strains on their current production capacity.  To meet this growth, they 
have been adding new equipment to their plant in Otahuhu in Auckland.
 
Most recently, they installed a new Retort Pressure Cooker.  The unit need a water supply connected to it.  The water supply would be taken from an existing galvanised steel line in the roof cavity above the processing factory.  
Using a pipe system that could be installed without welding and the need for hot work permits was important for Leader, as the walls and roof are made of flammable polystyrene sandwich panels, typical in food processing plants.  Access in the roof cavity was very confined in places, adding further challenges to the installation.  
 
Leader Products selected Kembla’s KemPress stainless steel piping system for the extension.  Being made of 316L stainless steel, it met food their food safety requirements. The weld-free press fit jointing system eliminated both the fire risk around their polystyrene sandwich panels, as well as the time and need to complete the hot work permits.  The range of KemPress Stainless fittings, including the BSP threaded unions, made it simple to connect the Kempress piping system to the existing galvanised steel water line via a ball valve.  The Kempress Stainless system’s compliance with standards AS 5200.053 and AS3688 gave Leader the peace of mind that the system was reliable and robust.
 
Leader Products own engineering team undertook the installation of the KemPress piping system.  The actual pipe installation took less than a day, and it was completed with no leaks.  Leader’s Engineering Manager, Richard Crabb noted that this helped them recover some lost time on the installation due to other issues that can often occur when commissioning new plant equipment, ensuring they met their production start deadline.
 
Leader Products engineering team found the KemPress piping system easy and quick to install, with Richard Crabb commenting that “we will use the product again as we continue to add to our plant capacity”.
As demonstrated at Leader Products, Kembla’s KemPress stainless steel press fit piping system has proved itself numerous times to be a quick and easy system to install, yet still being an extremely robust and reliable system.  Especially for use in food and beverage processing where plant operation time is critical to meet customer demands.
 
For more information contact: 09 274 0111 or email sales@kembla.co.nz