Smart Manufacturing

Developing zero-carbon aquaculture through data science

A collaboration led by Victoria University of Wellington has received $13 million in funding to help New Zealand transition to a zero-carbon society by applying data science to the aquaculture industry. “New Zealand’s greatest opportunity to transition to a zero-carbon economy while improving livelihoods and wellbeing is to develop our aquaculture industry using data science,” says Professor Mengjie Zhang from the University’s School of Engineering and Computer Science, who will lead the collaboration. The University is working with Plant & Food Research, Cawthron Institute and University of Otago researchers on the Ministry of Business, Innovation and Employment-funded project. Professor Zhang says, “Through this project we aim to develop innovative data science, artificial intelligence (AI), and machine learning techniques that will enable the aquaculture industry to keep growing efficiently and at large scale, producing high-quality, low-carbon protein for New Zealand and the world without compromising the environment.” The collaboration will develop data science tools to optimise the farming of Greenshell™ mussels and finfish in open ocean farms. “Collecting and incorporating various types of data through this project will unlock significant advantages for the aquaculture industry,” says Professor Zhang. “Farm managers can use these data to drive decision-making when responding to climate challenges, managing disease, improving production yields, and farming sustainably at scale.” The research team is aiming to develop innovative evolutionary and statistical learning techniques for use in the aquaculture industry, Professor Zhang says. “These learning techniques will help create better AI, which can be used to expand the capacity of the mussel and finfish farms,” he says. “This is an area in which Victoria University of Wellington scientists are leaders and can bring significant expertise to the table. “It is exciting to see data science becoming more integrated into New Zealand’s growing aquaculture sector to allow for more precise decision […]

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Robotics Plus wins ANZLF Trans-Tasman Innovation and Growth Award

Robotics Plus, a world-leading robotics and automation company developing innovation to unlock new levels of productivity in some of the world’s most labour-intensive food and fibre value chains, has won an ANZLF Trans-Tasman Innovation and Growth Award. The awards celebrate innovation, growth and impact of emerging businesses in Australia and New Zealand. Robotics Plus was founded in 2013 by Steve Saunders and Dr Alistair Scarfe with a simple goal in mind: to improving the quality, productivity and sustainability of the horticultural and other primary industry supply chains. The company’s R&D efforts focus on automation, vision, robotics and AI, to solve the growing challenges in the primary industry globally such as: labour shortages, sustainability for growers and producers, pollination gaps and yield security. Steve Saunders, Chairman and Founder of Robotics Plus, says: “It’s an absolute honour for the team to receive an ANZLF Trans-Tasman Innovation and Growth Award. It is validation of the hard work of a lot of people over a number of years and celebrates our innovation, culture and diversity. “Receiving such a prestigious award provides a valuable opportunity to showcase Robotics Plus to the world. We would like to recognise our fantastic partners and collaborators in the commercial, research and Government sectors, without them this would not be possible.” Robotics Plus CEO Dr Matt Glenn says the company is experiencing strong growth on the back of increasing demand for its world-first platform technologies. “Over the last 18 months Robotics Plus has launched two commercial products, entered the US and European markets, completed a US$10M Series A investment with Yamaha Motor Company and grown from a team of 12 to over 50. We also have a number of new products in the pipeline and expect our growth to continue at the same rate for the foreseeable future. “We’ve been able to […]

ThinkTop revolutionises valve sensing and control units

Alfa Laval has unveiled a refreshed, rethought version of the Alfa LavalThinkTop, the company’s best-selling valve sensing and control unit for hygienic valves used in the dairy, food, beverage, brewery and pharmaceutical industries. The Alfa Laval ThinkTop V50 and V70, the second-generation of premium control units, have been reengineered to meet customer needs while incorporating the latest advances in technology. “We have listened carefully to what customers want from a valve sensing and control unit,” says René Stietz, Product Management Valves & Automation, Hygienic Fluid Handling, Alfa Laval. “The changes we’ve made to the ThinkTop are highly responsive to customer needs and therefore highly relevant – for instance, faster and more intuitive setup without compromising durability and reliability.” Reengineered to meet customer needs For the first time, the rethought Alfa Laval ThinkTop offers customers fast and intuitive setup and commissioning; enhanced 360° LED visual status indication, a repositioned Gore Vent, a more compact and aesthetic design, burst seat clean functionality, and a QR code for easy online access to support materials and direct support. Fast and intuitiveThe new auto setup feature offers manufacturers quick, easy commissioning – up to 90% faster than the previous generation. Plus, the live setup feature coupled with true valve recognition ensures the perfect match during any-and-all setups. Adaptable and smartThe new ThinkTop fits on any Alfa Laval valve, making it perfect for all retrofits. What’s more, it is smart. It features 24/7 self-diagnostics, checking and remedying operations when required, and an enhanced 360° LED visual status indication so that operators can clearly see the valve status no matter where they are on the production floor. Durable and reliable The new ThinkTop is as long-lasting and dependable as the first generation. However, repositioning the Gore Vent makes the ThinkTop more durable and more reliable than before, […]

Beyond meat? The market for meat substitutes is way overdone

Paul Wood AO Adjunct Professor in Biotechnology, Monash University Meatless burger maker Beyond Meat has just reported quarterly earnings of US$67.3 million – much better than market expectations of US$52.7 million. It is now forecasting sales of US$240 million for the 2019 year, nearly three times that of 2018. But the company is yet to make a profit, let alone one big enough to justify its current market valuation of about US$13 billion. Since it listed on NASDAQ in May, its shares have surged more 700%. Investors’ enthusiasm reflects high hopes in the future fortunes of a company promising to put the sizzle into a meat substitute. Interest is booming in plant-based meat substitutes and lab-grown meat alternatives. The appeal is summed up by Beyond Meat’s mission statement: “By shifting from animal to plant-based meat, we are creating one savoury solution that solves four growing issues attributed to livestock production: human health, climate change, constraints on natural resources and animal welfare.” How realistic is this? The data suggests not very – that meat alternatives might play a positive role but in no way are going to save the planet. Investment appetite Predictions about the market potential for plant-based or lab-made meat vary. A lot of it appears to be only slightly better than sheer guesswork. One prediction, by the well-known Barclays, is that the market could be worth US$140 billion, or 10% of the US$1.4 trillion meat market, in the next 10 years. It’s such projections that have fuelled investors’ appetite for companies working on ways to make plant-based protein look and taste like meat. There’s Impossible Foods, for example, whose burger “bleeds” beetroot juice and is the meat (substitute) in Burger King’s Impossible Whopper. The privately held company has reportedly raised more than US$500 million, and is valued at US$2 billion. Other players in […]

Cooling tower optimisation

Food and beverage production requires a large range of temperatures. This means that plants must have effective cooling systems to deal with the excess heat. Removing the excess heat from the system requires a cooling tower, however, traditional designs require frequent maintenance. Food and beverage manufacturers understand that the industry is becoming a constant production environment, especially with the expansion of technologies like cold supply chains. Businesses, therefore, require equipment that can work constantly. However, when producing for long periods of time machines tend to overheat, meaning that to become a constantly working operation cooling systems must also work twenty-four hours a day. Heating, cooling and pasteurising are all common steps in food and beverage. Each one of these steps either directly or indirectly produces large quantities of heat. Managing this heat is a priority, because otherwise equipment may be damaged through overheating. As such, it is important to have a cooling system that is reliable, requires minimal maintenance and can extract heat at a sufficient rate. How to optimise cooling Traditional fans generally use 1500 rpm induction motors that connect to a driveshaft that connects to a gearbox, the gearbox then connects to the fan. This makes the system prone to breakdowns as there are many moving parts, also gearbox maintenance is time consuming and, due to the environment, oil leaks are common. To combat this, modern cooling fans need motors that can be mounted directly onto the fan, while being able to resist the conditions within the cooling tower. Many of these traditional motors can be replaced with more efficient permanent magnetic motors that can be directly installed onto the fan. This reduces the amount of parts in the system, limiting the risk of breakdowns. They are also compact compared to traditional cooling tower motors, reducing the space […]

HRS brings packaged solutions for pasteurisation and sterilisation

Pasteurisation and sterilisation are now so well established that it is impossible to contemplate the production of many food and drink products without using these important techniques. Both pasteurisation and sterilisation involve the use of heat, usually in a way which does not affect the fundamental characteristics of the product (in other words, it doesn’t cook it). However, while sterilisation seeks to completely eliminate any micro-organisms which may be present in the product (and so typically uses higher temperatures or longer treatment periods, and is therefore more likely to have an effect on the product’s characteristics), pasteurisation reduces the microbial load by a significant factor (for example by5-logs), which in normal circumstances reduces them to a level at which they do not pose a hazard. While simple plate heat exchangers may still be suitable for the pasteurisation of simple fluids such as milk and fruit juices, more textured and viscous products, such as cooking sauces, creams and curds, require different solutions in order to maintain their quality and texture. In order to meet this diverse range of requirements, HRS Heat Exchangers has created its Thermblock packaged pasteuriser/steriliser for food products for aseptic filling, as well as any other filling or packing method. Depending on specification and the intended use, Thermblock uses the most appropriate HRS tubular heat exchanger to deliver effective and efficient thermal treatment. All HRS Thermblock systems allow for full adjustment of the heating-holding-cooling cycle of the product, so that it can be tailored to your product/s and method/s of working. They can also be used as HTST (High Temperature, Short Time) units, subjecting the product to high temperatures for a short time to minimise potential side-effects, such as organoleptic changes or nutritional losses). There are three models of HRS Thermblock: HRS Thermblock DTA Series This features a double tube […]

Skills needed to remain competitive

-Doug Green, Publisher Every now and again we step outside the square and have a good, long look at what we are doing. So it should be with manufacturing. Specifically, to enhance the awareness of just what it is the modern New Zealand manufacturer does. Part of that, of course, is to recognise the contribution manufacturing brings to the New Zealand economy. The design, original concept processes that add so much to what is eventually made and finds its way on overseas markets. Manufacturers are modernising their technologies, equipment, systems and infrastructure consistently and applying that sophistication to their materials and production in an effort to create jobs and reduce energy costs. The jobs themselves are changing too. New, modern ways of manufacturing require highly-skilled workers. The current Government, to this end, needs to sought out what kind of ITOs will be in place to skill the workforce to play a key role in competitiveness on local and world markets. Developing talent is a real challenge and the changing nature of manufacturing is making it harder for talent to keep up. Government needs to invest more in manufacturers, their suppliers and interested stakeholders to create workforce development programs that train and equip workers with the right skills to remain competitive.

The critical role of IIoT in the future of food processing

Michael Cahill, Rockwell MES Technical Consultant As the old adage goes, an ounce of prevention is worth a pound of cure. New Zealand food companies, that often produce high value-add product that is exported around the globe, value their brand and reputation. Things are changing. Customer expectations for food safety and quality are unprecedented. Expectations from regulatory authorities are increasing to meet ever growing market regulation. Demand for high safe products is driving growth at an unprecedented rate. The reality is the number of food recalls has been steadily increasing over the last decade, according to FSANZ’s 2009-2018 reporting. The lack of visibility in the early stages of production is leading to an increased amount of inedible product and is posing serious food safety compliance risks. With headline after headline, product traceability from paddock to plate is becoming more and more important. Any deviation in quality in the product line will involve significant wastage and financial burden on the organisation. A sustainable approach to maintain the highest standard of production quality is sought to meet these customer, regulator and growth challenges. Connecting the dots The rise of the Industrial Internet of Things (IIoT) has emerged as a solution to this problem. IIoT platforms and advanced analytics now enable users to fuse multiple data sources to provide contextually relevant historical and real-time data. Add in AI and machine learning and food manufacturing is more predictive and intelligent than ever before, giving workers uncanny insight into how to solve issues and predict problems before they happen. The problem isn’t a lack of data but a lack of connectivity from food companies. IIoT has provided the tools to better verify quality, establish batch genealogy and capture meaningful processing data from beginning to end. It’s now the job of manufacturing plants and farms to […]

Manufacturing – A year in review

-Dieter Adam, Chief Executive, The Manufacturers’ Network. It is the time again to look back on the year that was – how did our manufacturing sector do, and what were the major developments that impacted our sector in another year of political change, both in New Zealand and around the world? Internationally, issues around trade have dominated much of the economic headlines, with the trade war between the USA and China, but conflict between the USA and Europe not far behind – not to mention Brexit, the trade implications of which appear to be just as uncertain as the question of whether it’ll actually happen or not. While these trade disagreements have not yet had a major impact New Zealand exporters, they remain as a downside risk if they start impacting the wider flow of goods and supply chain which our companies are involved in. The exchange rate experienced some depreciation throughout this year, however, much of this has been eroded over the last month. While 2018 has experienced a more favorable exchange rate than the highs experienced in 2014 and 2016, it remains systemically higher than the average of the previous decade, with the AUD cross-rate remaining as the biggest concern. Domestically in 2018, we have seen a number of policy changes which will impact our sector. The improvements made to the Government’s R&D policy, increasing the proposed tax credit rate to 15% while halving the eligibility threshold to $50,000, have been a good step forward, and the move to use a committee for monetary policy decisions at the Reserve Bank makes solid sense. On the downside, the Employment Relations Amendment bill has been moving through the parliamentary process largely unchanged, with the only material concession being a weakening of the requirement to participate in collective bargaining by introducing […]

Alternative protein reports published

The Ministry for Primary Industries (MPI) and Plant & Food Research have released their joint report: The evolution of plant protein – assessing consumer response. The report was commissioned to assess consumer responses to protein and highlight the potential impacts to the New Zealand agricultural industry. New Zealand’s social, environmental, and economic well-being is linked to New Zealand’s ability to supply the rest of the world with protein. New Zealand’s animal-based protein export revenue alone accounts for 60% of New Zealand’s total primary exports. This demand will grow as the global population is set to increase to 8.1 billion by 2025. “This is the very first exploratory piece of work MPI has done in this area. The report explores how consumers have become more aware of the long-term impacts of food production and signals change for traditional animal protein producers. “The findings will inform our work programme to support primary sector resilience in the face of these impacts and changing consumer habits. “The report also includes opportunities to create value through a point of difference for traditional New Zealand products,” says Jarred Mair, acting deputy director-general for policy and trade. “In order for New Zealand to retain a competitive edge in our primary exports, we want to ensure we are looking ahead at what the future consumer might demand in our products and what opportunities are available for our sector,” says Dr Jocelyn Eason of Plant & Food Research. To assess where markets are heading in the next 5 years the report analysed consumer responses to plant-based proteins released in the United States and consumer attitudes to proteins in China. Our research has shown that wealthy western economies such as the US will require an innovative product that meets consumer needs. Key findings of the report include: Progress towards new protein […]

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