Reliability and performance…
Hayes International – exporting to more than 90 countries
Rotorua based company Hayes International was founded by Tom Hayes in 1960 and this private company became part of the Bradbury Group of Kansas, US in 1999.
Today, the New Zealand company is internationally known as a “market leader for quality and performance” with in excess of 1,820 Hayes machines exported to more than 90 countries worldwide.
Hayes originally started producing corrugated sheet machines for roofing and cladding, however products produced by this amazing 64-year-old New Zealand manufacturer today include panel mills, purlin mills, stud mills roll-forming accessories, purlin mill accessories, auto-curvers, folding machines, coil handlers and more recently finished product handling equipment including automated purlin stacking equipment.
“In purchasing a Hayes machine our clients get the best in the industry in terms of reliability and performance which also provides them with a competitive advantage with whole of life cost, reduced machine down time and waste minimisation,” says managing director, Nick Looijen. “Ninety-percent of our business is repeat customers or direct referrals from existing customers with our principal markets being Australia, UK, USA and New Zealand.”
Okuma has been an integral part of this advanced manufacturing business with the first Okuma CNC machining centre purchased in the early 1970s. Since that time, a further 10 precision CNC machining centres and lathes have been added to the Hayes machine shop including the latest Okuma double column CNC machining centre model MCR-A5C 25 x 65 resulting in the highest precision component output and significant production benefits. The Okuma double column machine producing 5.6 metre purlin chassis sections has reduced production time of five days to one shift with complete accuracy.
“The Okuma machines provide us with complete accuracy of the highest quality standard with significant time savings making us internationally competitive,” says Looijen. “We have experienced staff and the Okuma machines are easily programmed yet we take full advantage of Okuma’s specialised training especially with new machines to ensure that we take full advantage of each machine’s capabilities.”
Engineers and apprentices under training are excited with the new machines enabling them to achieve new skills and expand their personal development.
With the advantage of an in-house design team using the most advanced software in industrial design, as well as electrical, hydraulics and engineering disciplines, the company can change designs, expand product development and more, with time savings and accuracy to provide precisely what the customer requires and expects. With more automation, the lead times are being drastically reduced in the manufacture of major plants and equipment with rapid replacement parts for worn components on roll-forming lines shipped directly to customers wherever they are in the world.
Hayes International also assists customers on upgrading their roll-forming machinery to improve efficiency, add features or update specifications. This has many advantages over purchasing a new machine according to the company, including lower up-front costs, shorter manufacturing lead time and reduced down time, providing customers with greater flexibility and options.
Upgrade options can be many and varied such as additional guards for a machine to meet local regulations when changing locations, additional punch heads for Hayes purlin mills forming stations for sloping eaves or sigma purlins, coil handling or upgrading the control system for efficiency, improved control or vision. Coil handling can be added or adapted to existing equipment and machine lines.
The company employs more than 90 staff with a strong commitment to apprenticeships – six in training at any time. It has a commendable record of staff retention with more than 20% of those staff having 20 or more years of service and offers many incentives, including safety and workplace training.
Export sales for Hayes International now represent approximately 9% with the remaining 5% to New Zealand customers.
“It is exciting for Okuma to be working together in partnership with Hayes International as the company continues to expand and develop new precision products for world markets and we look forward to the future in tandem,” says Okuma New Zealand manager, Karl Medley.
Embracing greater automation in metal fabrication and machining
Eko supplies a hybrid CNC press brake featuring dual servo motors, while Estun provides the press brake tender robot.
New Zealand manufacturers should be embracing greater automation in metal fabrication and machining, says Andrew Leabourn, managing director of Leabourn & Rose Ltd.
“The need for automation is driven by several factors: the difficulty in finding skilled labour, the imperative to enhance worker safety, the need to boost productivity, and the demand to stay competitive on a global scale” says Leabourn.
“Many argue that automation isn’t feasible for job shops or small-batch manufacturers due to economic concerns. However, I believe otherwise. In my view, the focus of automation in metalworking should be on flexible manufacturing cells”, explains Leabourn. Standalone cells automate specific metalworking processes while offering the flexibility to handle various items. As businesses grow, these cells can be interconnected to automate multiple processes in a streamlined manner.
In collaboration with Eko and Estun, Leabourn & Rose has developed a versatile press brake bending cell. Eko supplies a hybrid CNC press brake featuring dual servo motors, while Estun provides the press brake tender robot. The breakthrough for economical small-volume production is Estun’s digital robot bending workstation software. Leabourn says this advanced offline programming solution, designed specifically for the sheet metal industry, features a modular and intuitive interface that enhances robot programming efficiency. By importing a digital model of a product, the software automatically calculates the robot’s trajectory for each bending step.
Estun has also designed robots tailored for press brake bending. The company’s robots, with attributes such as a short boom and a long arm, accommodate high load capacities and a significantly larger working area, allowing them to safely handle and rotate large plates. Integrated with the Eko press brake are high-sensitivity back gauge switches that create a feedback loop with the robot. This system ensures that the plate is precisely aligned with the bending line, automatically adjusting if misalignment is detected.
Estun offers bending robots in load capacities of 45kg, 80kg, and 130kg. For example, a 40kg plate that would normally require two operators, to handle can be easily managed by a robot. Freeing up valuable staff and enhancing safety.
“At Leabourn & Rose, we pride ourselves on a 46-year legacy of delivering expert machine tool knowledge, technical proficiency and quality brands. We will not only provide the machine tools but also the expertise needed to integrate and automate your manufacturing processes. Our exceptional team will support you every step of the way,” says Leabourn.
Sponsored content: For more information visit http://www.leabourn-rose.co.nz, email info@leabourn-rose.co.nz or call 09 274 6186.
Gripping research…
Researchers build smart object to measure a robot’s squeezing force
QUT researchers, who recognised that grasping objects is difficult for robots, have built a smart object that can measure a robot’s squeezing force.
The QUT Centre for Robotics research team was led by Dr Fangyi Zhang, under the mentorship of Distinguished Emeritus Professor Peter Corke, with contributions from research assistant Maceon Knopke, and former research assistant and QUT masters student Liguo Zhu.
Zhang says robots needed to pick up all sorts of objects, soft and hard, they needed to hold them firmly, not drop them, but also to not damage them by squeezing too hard.
“To find out how hard the robot is squeezing an object we built a smart object that can measure this squeezing force, how hard it is squeezed and where,” Zhang says.
“The paper tackles the difficulty in assessing robotic grasping of ‘compliant objects’ – which are objects that have an ability to yield elastically when a force is applied.
“Things like fruit or other delicate items, where precise force application is critical to prevent slippage or damage.”
Knopke says the research developed a new method to assess such compliant robotic grasping by using special (sensorised) objects that can feel and measure how much force is applied.
“A test design was proposed to use sensors and magnets to measure where and how strongly something is being touched,” Knopke says.
“The design demonstrated promising results, accurately detecting contact locations and applied forces during robotic grasping tasks, highlighting its potential for broader applications for grasping performance evaluation in robotics.
“The research included extensive testing, showcasing the effectiveness of the design in both single and multiple contact scenarios, paving the way for future enhancements.”
Zhang says the work addressed a significant challenge in robotics – measuring stress or damage to objects during handling – by providing direct assessment capabilities through innovative sensor integration.
Aussie Pumps get creative with concrete and maintenance
Discovered by the Romans almost more than 2,000 years ago, we are told they used concrete to develop the aqueducts, viaducts, dams and similar major structures that are even today impressive.
Australian Pump Industries (Aussie Pumps) is extremely conscious of the concrete industry as the company develops products that are used in the industry from the original quarry work (granite or limestone) all the way through to the final stages of the process of building cities, bridges, and tunnels.
“We all know the vital components of concrete are crushed gravel, burnt limestone (cement), sand and water. Every quarry has pumps. Not only for pump out in the event of heavy rain, but also to deal with fire hazards and even mundane tasks like machinery washdown,” says Warick Lorenz, managing director Aussie Pumps.
It’s in this area that Aussie Pumps provides everything from high pressure water blasters and steam cleaners for keeping machinery clean all the way through to fire pumps and even 4-inch and 6-inch trash pumps that can move up to 6,000 litres per minute.
Many have a water cart on site for dust suppression. By using a high-pressure Aussie fire pump on that unit, as “favoured by bushfire brigades and National Parks”, these carts can double up for fire support.
Aussie Fire Chief pumps are “high pressure, designed for long trouble-free life and are available with either Honda petrol or Yanmar diesel engine drives”.
Some models in the Aussie tanker pump range are also hydraulic drive, negating the need for petrol or diesel engines on site. The Aussie package is built with top quality pumps with extended warranties to five years.
Batch plant efficiency
Australia’s concrete industry is highly competitive with three major operators and a number of privately owned plants as well. Generally speaking, they all have the same material costs so the more successful businesses are focused on cost control and reliability. The mixer needs to arrive on the site on time.
That’s where Aussie’s self-priming centrifugal motor pumps kick in. Every batch plant has a wide range of pump applications including in the batching process, water recycling and draining sumps.
“These centrifugal motor pumps are replacing submersibles in many batch plants. The beauty of Aussie’s self-primers is that they are surface mounted. That makes service and maintenance significantly easier than submersibles due to the high visibility of the product.”
These batch plant pumps, or semi trash pumps, are available in a range from 1 ½-inch all the way through to big 6-inch pumps. The most popular are the 3-inch and 4-inch versions but all feature heavy duty cast iron open impellers, capable of passing solids in suspension. Not only that but, the company has designed in a stainless-steel wear plate to protect body wear from abrasion. All machines are supplied with silicon carbide mechanical seals.
“An added feature, popular with batch plants is a front clean out port. That enables the unit to be cleared of any blockages without the need for disconnecting pipework. It’s a gift that can speed up maintenance, saving hours”, says Aussie Pumps chief engineer, John Hales.
High pressure pumps are also available and are used for moving water for the batching process. Aussie’s range provides pumps that will deliver up to 1250 litres of water per minute and offer total head (vertical lift) up to 78 metres.
“Yes, that pump has a 22kW motor driving it, comes on a steel base plate and is delivered ready to go to work. We have optional 316 stainless steel impellers available on a number of models for particularly abrasive applications.
All together, we are pleased to see first class results in batch plants adopting the surface mounted Aussie self-priming pumps. They offer very real advantages in terms of maintenance and overall reliability, “says Hales.
Mixer washdown
Australian Pump is famous for its range of Aussie eco-clean petrol and diesel drive pressure cleaners. The machines are designed with heavy duty slow speed triplex pumps and deliver pressures up to 350 bar (5,000 psi). They can be engine drive or powered by three phase electric motors. The motors are slow speed, four pole, designed for long trouble-free operation in even the most difficult applications.
A number of Aussie high-pressure washers are out there working in batch plants on general cleaning duties, not just used on the mixer trucks but also for the plant itself.
Off site
“We’re all used to seeing mixer trucks on the roads slowly rotating on their way to a job site. It may be anything from a domestic house slab, a new base for a factory or office block or a major job in a high-rise development.”
Many of the concrete pumps used on these sites are fitted with Aussie Pumps’ hydraulic drive high pressure piston pumps and need to be cleaned out thoroughly after use – Aussie Pumps also having the cleaning solution to keep them in great shape.
EMA: Fast-track consents potential major economic boost
Projects included in the recent fast-track consents announcement are a potential major economic and housing boost for the ‘golden triangle’ economic zone, particularly for greater Northland’s inclusion in that zone north of Taupō, says the EMA.
“All three ports in the region – Northport, Port of Auckland and Port of Tauranga – have consents for expansion included in the extensive list of projects and, as all are basically funded, that means critical expansion can go ahead,” says EMA head of advocacy, strategy and finance Alan McDonald.
“Including the proposed dry dock at Northport will be a significant boost for the engineering cluster that already exists in the region, while road and rail projects included in the fast-tracking process will improve freight and road access to all three ports as well as allowing people to move more easily around the region.
“They include roading and housing projects at Tauriko heading west out of Tauranga; Cambridge to Piarere, south of Cambridge; and improved access from Hamilton in the south to State Highway 1 (SH1).”
McDonald says many of the projects had been talked about for years but little or no progress had been made.
“For example, two big projects in Auckland – Mill Rd and the East/West Corridor – have been around for decades with zero to very little progress. This may be the catalyst to finally move on these projects.
“Northlanders will also be very pleased to see the Brynderwyn bypass and the link from Whangārei to Marsden included in the roading mix.”
The mix of fast-track projects also includes a number of new renewable energy projects such as wind and solar and renewing consents for existing hydro schemes.
“Given the recent issues caused by higher energy prices and the demands on generation capacity to further electrify the economy, these new fast-tracked projects have increasing significance,” says McDonald.
“The importance of new and expanded quarries is often overlooked but we can’t build new infrastructure without them.”
McDonald says a couple of significant projects that will benefit Auckland public transport had also been overlooked in the general reaction to the fast-track list.
“There are consents granted to alter 42 rail crossings around the Auckland network, which will greatly enhance capacity on the commuter network, and a fast-track for the Northwest Busway.”
‘Life-changing opportunity’ thanks to Manaaki scholarship
Jeron Gwaite’e was the first in his family to pursue tertiary study, thanks to the Manaaki scholarship programme that he credits for securing “a life-changing opportunity”.
Thousands of students from developing countries apply for the Government-funded Manaaki scholarships each year, with fewer than 500 making it through the competitive selection process.
The three-year scholarship covers tuition fees, a living allowance, travel, and setup costs, allowing Gwaite’e to leave his home country for the first time and study in New Zealand within the civil engineering programme at Unitec. After graduating in 2022, he secured a role as a graduate construction engineer for the Ministry of Foreign Affairs and Trade (MFAT) at the New Zealand High Commission in Honiara.
Gwaite’e believes the credibility of the scholarship was key to his success.
“When the MFAT position was advertised, being a Manaaki scholar graduate was a requirement. I used my Unitec experiences to support my application,” says Gwaite’e.
Gwaite’e acknowledges the support of Unitec’s teaching and support staff throughout his studies.
“They were approachable and interactive,” he says. “Massive credit to my final-year project supervisor, Don Houghton, who guided me through my development project. Unitec’s student support team regularly checked on the welfare of international students, which was especially helpful during Covid. The Pacific Centre and Student Support & Scholarships team were welcoming and supportive, making my Unitec experience fantastic.”
Sophie Aleke Fa’avae, the New Zealand scholarships and youth guarantee lead at Unitec, says Gwaite’e stood out as a positive, enthusiastic student and an inspirational role model: “We’re looking for students who can represent their countries with pride. Jeron’s vitality and success have inspired others to follow the same path.”
New CoroCut 2 with RF geometry for secure high-precision profiling
Sandvik Coromant, a manufacturer of cutting tools and tooling systems, has launched CoroCut 2 with RF geometry, designed for secure and high-precision profiling. Additionally, grade GC1205 is introduced for parting and grooving operations in aged nickel-based HRSA components, offering enhanced process security and consistent tool life.
Sandvik Coromant continues to upgrade its long-established CoroCut 1-2 parting and grooving concept. With improved stability, greater flexibility and significant productivity gains, CoroCut 2 is proven to be a true companion in many workshops.
CoroCut 2 eliminates the trade-off between chip control and achieving a superior surface finish. This tool provides flawless edge line quality and superb chip-breaking capabilities, ensuring secure machining with high surface integrity results.
“The -RF geometry combines a sharp edge with a high-precision chip breaker, making it ideal for finishing operations in ISO S materials where chip control can be an issue”, says Fredrik Selin, product application specialist at Sandvik Coromant. “With this tool, we can meet the highest demands from the aerospace industry”.
To achieve superior chip control for small depths of cuts, the chip-breaker geometry must be positioned close to the cutting edge. This is now possible thanks to a unique, in-house developed patented technology. With this innovation, the chip breaker can be placed precisely where it needs to be to get the job done — while maintaining a sharp insert edge.
“With the -RF geometry, you can expect top process security, even in the most challenging materials. The -RF geometry also offers superior tool life due to the new technology, which results in higher quality and more consistent performance.”
Grade GC1205 is the most recently developed grade for machining aged nickel-based HRSA materials. It features a hard, fine-grained substrate, the latest PVD coating technology and optimised edge-line integrity providing increased flank wear and notch wear resistance, superior edge-line security and reduced flaking.
“For our customers, this translates into possibilities to run the inserts at higher cutting speed and additionally, it ensures consistent and predictable tool life, while reaching the required surface integrity demands for critical aerospace components”, says Martin Saunders, global product application specialist for turning at Sandvik Coromant.
Another important factor for all parting and grooving applications is stability. The main challenge is to keep the insert in place to minimise all forms of insert movement. The solution is our well-established rail interface that provides a more precise insert position and makes the insert resilient against side forces put upon it, ensuring stability in all operations.
The power of clever design – cutting carbon in engineering
OPINION by Troy Coyle
For engineers, carbon reduction is not only a priority but also an opportunity. With the right strategies, significant cuts to embodied carbon in construction projects are within reach, enabling the sector to meet national carbon reduction goals.
The good news is that these solutions are not hypothetical—they’re already being tested in real-world scenarios, as highlighted by a recent study funded by the building research levy (through BRANZ) and heavy engineering research levy (through HERA). Aimed at reducing construction waste and embodied carbon while enhancing the circular economy, a research output has been a design hierarchy which provides practical guidance for cutting emissions in low-rise commercial buildings by more than 50% through smart design and material selection.
How small design changes can lead to massive carbon savings…
Within this HERA led project, a case study from Christchurch was used that featured conventional construction practices: a steel-concrete composite flooring system, concrete shear walls, and steel moment-resisting frames. Using this as a baseline, we explored design variations, including low-carbon steel, hybrid steel-timber flooring, and eccentrically braced frames. Each tweak resulted in significant carbon reductions, showing that even minor design modifications can make a big difference.
Key takeaways for engineers to consider
Overall, the results showed that steel, timber, and concrete all have roles to play in reducing embodied carbon, depending on how they are combined and for what purpose. Hybrid steel-timber designs, for example, offer strong performance while lowering emissions. Additional concepts were also noted that engineers could consider to make significant impact.
- Design for disassembly: Use reversible connections in flooring systems to enable material recovery and reuse at the building’s end of life.
- Seismic resilience: Optimise designs for seismic resilience. For example, steel frame designs can extend a building’s lifespan and reduce carbon-heavy repairs.
- Material substitution: Substituting conventional materials with low-carbon alternatives like low-carbon steel and concrete can reduce embodied carbon by up to 70%.
Applying this to your work
HERA’s Circular Low Carbon Design Hierarchy is a valuable tool for engineers looking to achieve meaningful carbon reductions. It’s important to consider not just material selection, but the entire lifecycle of a building, from cradle to cradle, when making design decisions.
One key finding is the importance of keeping Life Cycle Assessment (LCA) tools up-to-date to include the latest low-carbon materials. Without these updates, assessments may skew in favour of one material over another, missing out on the actual carbon savings newer materials offer. Staying informed about these options is essential for engineers looking to make impactful changes in their projects.
Get started with free resources
Engineers are key players in driving carbon reduction in construction. By applying circular design principles and embracing low-carbon design, the sector can make significant strides toward sustainability goals.
Our work at HERA demonstrates that reducing carbon isn’t just possible—it’s practical and achievable with the tools and knowledge available today. So, the next time you’re specifying materials or designing a building, consider how small changes could make a big difference. After all, cutting carbon is not only about the future; it’s about what we can achieve today with clever, thoughtful design.
For more details, check out HERA’s Low Carbon Circular Design Hierarchy here. If you’d like a poster version for your office, please get in touch with our customer experience manager, Rebecca Symonds.
For more information on the research, listen to our latest podcast.
I also offer free in-house training for practitioners (minimum numbers required). Please get in touch with me at troy.coyle@hera.org.nz to discuss further.
BIO: Dr Troy Coyle brings more than 20 years’ experience in innovation management across a range of industries including materials science, medical radiation physics, biotechnology, sustainable building products, renewable energy and steel. She is a scientist with a PhD (University of NSW) with training in journalism and communications
Bonfiglioli solutions put power into metal working industries
Australia and New Zealand’s metal working industries are integral to the country’s economy, supplying other key sectors ranging from defence and transport to construction and infrastructure. It also provides employment, with the steel industry, for example, employing around 120,000 Australians.
With Australia poised to become a green superpower, driving the global reduction in emissions, the metal working industry will continue to play an important role. As part of its Future Made in Australia plan, the Government is prioritising the green metals industry, specifically the production of low emissions iron, steel, alumina and aluminium.
“As a long-standing manufacturer of solutions for the metal sheet handling industry, supplying innovations that meet the sector’s changing requirements, Bonfiglioli is well-positioned to support customers,” says Martin Broglia, MD of Bonfiglioli Australia and New Zealand.
The company offers an extensive portfolio of dedicated solutions for metal cutting, bending and punching, as well as metal forming and shaping.
Metal plate rolling and profile bending solutions
Bonfiglioli supplies a wide range of planetary hydraulic or electric gearmotors with controls, ensuring optimal performance in metal plate rolling or profile bending applications.
The 300 Series roller drive, featuring a wide range of ratios and reinforced output shaft bearings, handles shock loads up to 2,000,000Nm. It delivers exceptional torque control. “With its modular design, flexible input options, multiple output configurations and accessories, this drive is a great option for heavy duty metal plate bending,” says Broglia.
The company’s BX Series asynchronous IE3 three phase motor, meanwhile, offers reliable, balanced and robust performance as well as energy efficiency.
“This is a complete solution, with a power range up to 355 kW and rotor balancing,” says Broglia. “It features thermal protection and ventilation, as well as anti-corrosive paint coatings, IP56 protection and anti-condensate heaters. It’s available with built-in brakes for all power options and sizes”.
Bonfiglioli’s Active Cube Series premium frequency inverters are also ideal for use in metal plate rolling or bending applications, enabling highly customisable drive control and higher productivity. With a power range up to 1200 kW, it delivers advanced brake control, multi drive synchronisation and torque control. “This inverter is easily installed and has energy recovery braking functionality – sending recovered electricity back to the grid,” explains Broglia.
Dedicated customer service
Broglia reiterates that it’s not just Bonfiglioli’s portfolio that sets it apart, but also the company’s global network and commitment to customer support and service.
“Though our international network, we ensure that customers can enjoy Bonfiglioli’s top quality solutions anywhere. We have invested in our local presence, expanding our Sydney and New Zealand facilities to meet the growing demand for our solutions and services,” says Broglia. “Our dedicated services, co-engineering expertise and after-sales support continue to make us one of the metal working sector’s most sought-after partners”.
NMIT aeronautical engineering programme takes flight in Nelson
In response to a domestic and global shortage in aviation engineers, the Nelson Marlborough Institute of Technology (NMIT) has extended its aeronautical engineering programme.
A refreshed certificate programme, developed in consultation with national industry partners, is kicking off in Nelson in 2025, complementing NMIT’s popular Woodbournebased programmes. This means budding engineers can choose both their location and their time commitment – with either a one or two-year programme available – before embarking on a career in aviation, ultimately helping to address the shortfall in aviation engineers.
NMIT has a proud history as New Zealand’s only tertiary institute training future aeronautical engineers. Current programmes are all based at Woodbourne Airbase, and a close relationship with New Zealand Defence Force and the commercial aviation industry has meant NMIT’s programmes have grown and developed according to the needs of the industry and learners.
The programmes have an excellent reputation with aircraft maintenance engineers in the aviation industry in New Zealand and abroad. The updated Level 3 Certificate in Aeronautical Engineering means students can complete their qualification in one year. They can then choose to continue into the Level 4 Certificate programme or enter the workforce. The first Nelson-based cohort in the updated Level 3 Certificate programme will begin in February 2025.
A newly fitted-out hangar-style building on NMIT’s Hardy Street campus offers what NMIT describes as world-class specialist equipment. With the choice of either Nelson or Woodbourne to study in 2025, word has already spread, and the programme is gaining a lot of interest, with the February intake almost full.
The programme equips students with core aircraft maintenance skills such as using aeronautical engineering tools, adhering to safety protocols, and performing aircraft repairs and overhauls. It also delves into aircraft systems, the role of human factors in engineering, and the importance of teamwork. It attracts learners already in the aviation industry who want to level up their skills, as well as those wanting to pursue a career in aviation in New Zealand or overseas.
Reid Carnegie, curriculum area manager for aviation says the programme ticks a lot of boxes.
“We’ve historically seen high demand for the two-year Certificate, and we’ve been looking at ways to expand and update the programme. We know aviation engineers are highly sought-after and it’s crucial we keep meeting the needs of the industry. After listening to our industry partners, including Air New Zealand, we’re confident this new format and additional location will prove very popular,” says Carnegie.
As the next step, from 2026 the Level 4 Certificate will become a one-year qualification in block course format, meaning learners can either study fulltime or continue working throughout the year and attend one-week blocks of learning as they work towards the Certificate.
Reliability and performance…
Hayes International – exporting to more than 90 countries
Rotorua based company Hayes International was founded by Tom Hayes in 1960 and this private company became part of the Bradbury Group of Kansas, US in 1999.
Today, the New Zealand company is internationally known as a “market leader for quality and performance” with in excess of 1,820 Hayes machines exported to more than 90 countries worldwide.
Hayes originally started producing corrugated sheet machines for roofing and cladding, however products produced by this amazing 64-year-old New Zealand manufacturer today include panel mills, purlin mills, stud mills roll-forming accessories, purlin mill accessories, auto-curvers, folding machines, coil handlers and more recently finished product handling equipment including automated purlin stacking equipment.
“In purchasing a Hayes machine our clients get the best in the industry in terms of reliability and performance which also provides them with a competitive advantage with whole of life cost, reduced machine down time and waste minimisation,” says managing director, Nick Looijen. “Ninety-percent of our business is repeat customers or direct referrals from existing customers with our principal markets being Australia, UK, USA and New Zealand.”
Okuma has been an integral part of this advanced manufacturing business with the first Okuma CNC machining centre purchased in the early 1970s. Since that time, a further 10 precision CNC machining centres and lathes have been added to the Hayes machine shop including the latest Okuma double column CNC machining centre model MCR-A5C 25 x 65 resulting in the highest precision component output and significant production benefits. The Okuma double column machine producing 5.6 metre purlin chassis sections has reduced production time of five days to one shift with complete accuracy.
“The Okuma machines provide us with complete accuracy of the highest quality standard with significant time savings making us internationally competitive,” says Looijen. “We have experienced staff and the Okuma machines are easily programmed yet we take full advantage of Okuma’s specialised training especially with new machines to ensure that we take full advantage of each machine’s capabilities.”
Engineers and apprentices under training are excited with the new machines enabling them to achieve new skills and expand their personal development.
With the advantage of an in-house design team using the most advanced software in industrial design, as well as electrical, hydraulics and engineering disciplines, the company can change designs, expand product development and more, with time savings and accuracy to provide precisely what the customer requires and expects. With more automation, the lead times are being drastically reduced in the manufacture of major plants and equipment with rapid replacement parts for worn components on roll-forming lines shipped directly to customers wherever they are in the world.
Hayes International also assists customers on upgrading their roll-forming machinery to improve efficiency, add features or update specifications. This has many advantages over purchasing a new machine according to the company, including lower up-front costs, shorter manufacturing lead time and reduced down time, providing customers with greater flexibility and options.
Upgrade options can be many and varied such as additional guards for a machine to meet local regulations when changing locations, additional punch heads for Hayes purlin mills forming stations for sloping eaves or sigma purlins, coil handling or upgrading the control system for efficiency, improved control or vision. Coil handling can be added or adapted to existing equipment and machine lines.
The company employs more than 90 staff with a strong commitment to apprenticeships – six in training at any time. It has a commendable record of staff retention with more than 20% of those staff having 20 or more years of service and offers many incentives, including safety and workplace training.
Export sales for Hayes International now represent approximately 9% with the remaining 5% to New Zealand customers.
“It is exciting for Okuma to be working together in partnership with Hayes International as the company continues to expand and develop new precision products for world markets and we look forward to the future in tandem,” says Okuma New Zealand manager, Karl Medley.
Embracing greater automation in metal fabrication and machining
Eko supplies a hybrid CNC press brake featuring dual servo motors, while Estun provides the press brake tender robot.
New Zealand manufacturers should be embracing greater automation in metal fabrication and machining, says Andrew Leabourn, managing director of Leabourn & Rose Ltd.
“The need for automation is driven by several factors: the difficulty in finding skilled labour, the imperative to enhance worker safety, the need to boost productivity, and the demand to stay competitive on a global scale” says Leabourn.
“Many argue that automation isn’t feasible for job shops or small-batch manufacturers due to economic concerns. However, I believe otherwise. In my view, the focus of automation in metalworking should be on flexible manufacturing cells”, explains Leabourn. Standalone cells automate specific metalworking processes while offering the flexibility to handle various items. As businesses grow, these cells can be interconnected to automate multiple processes in a streamlined manner.
In collaboration with Eko and Estun, Leabourn & Rose has developed a versatile press brake bending cell. Eko supplies a hybrid CNC press brake featuring dual servo motors, while Estun provides the press brake tender robot. The breakthrough for economical small-volume production is Estun’s digital robot bending workstation software. Leabourn says this advanced offline programming solution, designed specifically for the sheet metal industry, features a modular and intuitive interface that enhances robot programming efficiency. By importing a digital model of a product, the software automatically calculates the robot’s trajectory for each bending step.
Estun has also designed robots tailored for press brake bending. The company’s robots, with attributes such as a short boom and a long arm, accommodate high load capacities and a significantly larger working area, allowing them to safely handle and rotate large plates. Integrated with the Eko press brake are high-sensitivity back gauge switches that create a feedback loop with the robot. This system ensures that the plate is precisely aligned with the bending line, automatically adjusting if misalignment is detected.
Estun offers bending robots in load capacities of 45kg, 80kg, and 130kg. For example, a 40kg plate that would normally require two operators, to handle can be easily managed by a robot. Freeing up valuable staff and enhancing safety.
“At Leabourn & Rose, we pride ourselves on a 46-year legacy of delivering expert machine tool knowledge, technical proficiency and quality brands. We will not only provide the machine tools but also the expertise needed to integrate and automate your manufacturing processes. Our exceptional team will support you every step of the way,” says Leabourn.
Sponsored content: For more information visit http://www.leabourn-rose.co.nz, email info@leabourn-rose.co.nz or call 09 274 6186.
Gripping research…
Researchers build smart object to measure a robot’s squeezing force
QUT researchers, who recognised that grasping objects is difficult for robots, have built a smart object that can measure a robot’s squeezing force.
The QUT Centre for Robotics research team was led by Dr Fangyi Zhang, under the mentorship of Distinguished Emeritus Professor Peter Corke, with contributions from research assistant Maceon Knopke, and former research assistant and QUT masters student Liguo Zhu.
Zhang says robots needed to pick up all sorts of objects, soft and hard, they needed to hold them firmly, not drop them, but also to not damage them by squeezing too hard.
“To find out how hard the robot is squeezing an object we built a smart object that can measure this squeezing force, how hard it is squeezed and where,” Zhang says.
“The paper tackles the difficulty in assessing robotic grasping of ‘compliant objects’ – which are objects that have an ability to yield elastically when a force is applied.
“Things like fruit or other delicate items, where precise force application is critical to prevent slippage or damage.”
Knopke says the research developed a new method to assess such compliant robotic grasping by using special (sensorised) objects that can feel and measure how much force is applied.
“A test design was proposed to use sensors and magnets to measure where and how strongly something is being touched,” Knopke says.
“The design demonstrated promising results, accurately detecting contact locations and applied forces during robotic grasping tasks, highlighting its potential for broader applications for grasping performance evaluation in robotics.
“The research included extensive testing, showcasing the effectiveness of the design in both single and multiple contact scenarios, paving the way for future enhancements.”
Zhang says the work addressed a significant challenge in robotics – measuring stress or damage to objects during handling – by providing direct assessment capabilities through innovative sensor integration.
Aussie Pumps get creative with concrete and maintenance
Discovered by the Romans almost more than 2,000 years ago, we are told they used concrete to develop the aqueducts, viaducts, dams and similar major structures that are even today impressive.
Australian Pump Industries (Aussie Pumps) is extremely conscious of the concrete industry as the company develops products that are used in the industry from the original quarry work (granite or limestone) all the way through to the final stages of the process of building cities, bridges, and tunnels.
“We all know the vital components of concrete are crushed gravel, burnt limestone (cement), sand and water. Every quarry has pumps. Not only for pump out in the event of heavy rain, but also to deal with fire hazards and even mundane tasks like machinery washdown,” says Warick Lorenz, managing director Aussie Pumps.
It’s in this area that Aussie Pumps provides everything from high pressure water blasters and steam cleaners for keeping machinery clean all the way through to fire pumps and even 4-inch and 6-inch trash pumps that can move up to 6,000 litres per minute.
Many have a water cart on site for dust suppression. By using a high-pressure Aussie fire pump on that unit, as “favoured by bushfire brigades and National Parks”, these carts can double up for fire support.
Aussie Fire Chief pumps are “high pressure, designed for long trouble-free life and are available with either Honda petrol or Yanmar diesel engine drives”.
Some models in the Aussie tanker pump range are also hydraulic drive, negating the need for petrol or diesel engines on site. The Aussie package is built with top quality pumps with extended warranties to five years.
Batch plant efficiency
Australia’s concrete industry is highly competitive with three major operators and a number of privately owned plants as well. Generally speaking, they all have the same material costs so the more successful businesses are focused on cost control and reliability. The mixer needs to arrive on the site on time.
That’s where Aussie’s self-priming centrifugal motor pumps kick in. Every batch plant has a wide range of pump applications including in the batching process, water recycling and draining sumps.
“These centrifugal motor pumps are replacing submersibles in many batch plants. The beauty of Aussie’s self-primers is that they are surface mounted. That makes service and maintenance significantly easier than submersibles due to the high visibility of the product.”
These batch plant pumps, or semi trash pumps, are available in a range from 1 ½-inch all the way through to big 6-inch pumps. The most popular are the 3-inch and 4-inch versions but all feature heavy duty cast iron open impellers, capable of passing solids in suspension. Not only that but, the company has designed in a stainless-steel wear plate to protect body wear from abrasion. All machines are supplied with silicon carbide mechanical seals.
“An added feature, popular with batch plants is a front clean out port. That enables the unit to be cleared of any blockages without the need for disconnecting pipework. It’s a gift that can speed up maintenance, saving hours”, says Aussie Pumps chief engineer, John Hales.
High pressure pumps are also available and are used for moving water for the batching process. Aussie’s range provides pumps that will deliver up to 1250 litres of water per minute and offer total head (vertical lift) up to 78 metres.
“Yes, that pump has a 22kW motor driving it, comes on a steel base plate and is delivered ready to go to work. We have optional 316 stainless steel impellers available on a number of models for particularly abrasive applications.
All together, we are pleased to see first class results in batch plants adopting the surface mounted Aussie self-priming pumps. They offer very real advantages in terms of maintenance and overall reliability, “says Hales.
Mixer washdown
Australian Pump is famous for its range of Aussie eco-clean petrol and diesel drive pressure cleaners. The machines are designed with heavy duty slow speed triplex pumps and deliver pressures up to 350 bar (5,000 psi). They can be engine drive or powered by three phase electric motors. The motors are slow speed, four pole, designed for long trouble-free operation in even the most difficult applications.
A number of Aussie high-pressure washers are out there working in batch plants on general cleaning duties, not just used on the mixer trucks but also for the plant itself.
Off site
“We’re all used to seeing mixer trucks on the roads slowly rotating on their way to a job site. It may be anything from a domestic house slab, a new base for a factory or office block or a major job in a high-rise development.”
Many of the concrete pumps used on these sites are fitted with Aussie Pumps’ hydraulic drive high pressure piston pumps and need to be cleaned out thoroughly after use – Aussie Pumps also having the cleaning solution to keep them in great shape.
EMA: Fast-track consents potential major economic boost
Projects included in the recent fast-track consents announcement are a potential major economic and housing boost for the ‘golden triangle’ economic zone, particularly for greater Northland’s inclusion in that zone north of Taupō, says the EMA.
“All three ports in the region – Northport, Port of Auckland and Port of Tauranga – have consents for expansion included in the extensive list of projects and, as all are basically funded, that means critical expansion can go ahead,” says EMA head of advocacy, strategy and finance Alan McDonald.
“Including the proposed dry dock at Northport will be a significant boost for the engineering cluster that already exists in the region, while road and rail projects included in the fast-tracking process will improve freight and road access to all three ports as well as allowing people to move more easily around the region.
“They include roading and housing projects at Tauriko heading west out of Tauranga; Cambridge to Piarere, south of Cambridge; and improved access from Hamilton in the south to State Highway 1 (SH1).”
McDonald says many of the projects had been talked about for years but little or no progress had been made.
“For example, two big projects in Auckland – Mill Rd and the East/West Corridor – have been around for decades with zero to very little progress. This may be the catalyst to finally move on these projects.
“Northlanders will also be very pleased to see the Brynderwyn bypass and the link from Whangārei to Marsden included in the roading mix.”
The mix of fast-track projects also includes a number of new renewable energy projects such as wind and solar and renewing consents for existing hydro schemes.
“Given the recent issues caused by higher energy prices and the demands on generation capacity to further electrify the economy, these new fast-tracked projects have increasing significance,” says McDonald.
“The importance of new and expanded quarries is often overlooked but we can’t build new infrastructure without them.”
McDonald says a couple of significant projects that will benefit Auckland public transport had also been overlooked in the general reaction to the fast-track list.
“There are consents granted to alter 42 rail crossings around the Auckland network, which will greatly enhance capacity on the commuter network, and a fast-track for the Northwest Busway.”
‘Life-changing opportunity’ thanks to Manaaki scholarship
Jeron Gwaite’e was the first in his family to pursue tertiary study, thanks to the Manaaki scholarship programme that he credits for securing “a life-changing opportunity”.
Thousands of students from developing countries apply for the Government-funded Manaaki scholarships each year, with fewer than 500 making it through the competitive selection process.
The three-year scholarship covers tuition fees, a living allowance, travel, and setup costs, allowing Gwaite’e to leave his home country for the first time and study in New Zealand within the civil engineering programme at Unitec. After graduating in 2022, he secured a role as a graduate construction engineer for the Ministry of Foreign Affairs and Trade (MFAT) at the New Zealand High Commission in Honiara.
Gwaite’e believes the credibility of the scholarship was key to his success.
“When the MFAT position was advertised, being a Manaaki scholar graduate was a requirement. I used my Unitec experiences to support my application,” says Gwaite’e.
Gwaite’e acknowledges the support of Unitec’s teaching and support staff throughout his studies.
“They were approachable and interactive,” he says. “Massive credit to my final-year project supervisor, Don Houghton, who guided me through my development project. Unitec’s student support team regularly checked on the welfare of international students, which was especially helpful during Covid. The Pacific Centre and Student Support & Scholarships team were welcoming and supportive, making my Unitec experience fantastic.”
Sophie Aleke Fa’avae, the New Zealand scholarships and youth guarantee lead at Unitec, says Gwaite’e stood out as a positive, enthusiastic student and an inspirational role model: “We’re looking for students who can represent their countries with pride. Jeron’s vitality and success have inspired others to follow the same path.”
New CoroCut 2 with RF geometry for secure high-precision profiling
Sandvik Coromant, a manufacturer of cutting tools and tooling systems, has launched CoroCut 2 with RF geometry, designed for secure and high-precision profiling. Additionally, grade GC1205 is introduced for parting and grooving operations in aged nickel-based HRSA components, offering enhanced process security and consistent tool life.
Sandvik Coromant continues to upgrade its long-established CoroCut 1-2 parting and grooving concept. With improved stability, greater flexibility and significant productivity gains, CoroCut 2 is proven to be a true companion in many workshops.
CoroCut 2 eliminates the trade-off between chip control and achieving a superior surface finish. This tool provides flawless edge line quality and superb chip-breaking capabilities, ensuring secure machining with high surface integrity results.
“The -RF geometry combines a sharp edge with a high-precision chip breaker, making it ideal for finishing operations in ISO S materials where chip control can be an issue”, says Fredrik Selin, product application specialist at Sandvik Coromant. “With this tool, we can meet the highest demands from the aerospace industry”.
To achieve superior chip control for small depths of cuts, the chip-breaker geometry must be positioned close to the cutting edge. This is now possible thanks to a unique, in-house developed patented technology. With this innovation, the chip breaker can be placed precisely where it needs to be to get the job done — while maintaining a sharp insert edge.
“With the -RF geometry, you can expect top process security, even in the most challenging materials. The -RF geometry also offers superior tool life due to the new technology, which results in higher quality and more consistent performance.”
Grade GC1205 is the most recently developed grade for machining aged nickel-based HRSA materials. It features a hard, fine-grained substrate, the latest PVD coating technology and optimised edge-line integrity providing increased flank wear and notch wear resistance, superior edge-line security and reduced flaking.
“For our customers, this translates into possibilities to run the inserts at higher cutting speed and additionally, it ensures consistent and predictable tool life, while reaching the required surface integrity demands for critical aerospace components”, says Martin Saunders, global product application specialist for turning at Sandvik Coromant.
Another important factor for all parting and grooving applications is stability. The main challenge is to keep the insert in place to minimise all forms of insert movement. The solution is our well-established rail interface that provides a more precise insert position and makes the insert resilient against side forces put upon it, ensuring stability in all operations.
The power of clever design – cutting carbon in engineering
OPINION by Troy Coyle
For engineers, carbon reduction is not only a priority but also an opportunity. With the right strategies, significant cuts to embodied carbon in construction projects are within reach, enabling the sector to meet national carbon reduction goals.
The good news is that these solutions are not hypothetical—they’re already being tested in real-world scenarios, as highlighted by a recent study funded by the building research levy (through BRANZ) and heavy engineering research levy (through HERA). Aimed at reducing construction waste and embodied carbon while enhancing the circular economy, a research output has been a design hierarchy which provides practical guidance for cutting emissions in low-rise commercial buildings by more than 50% through smart design and material selection.
How small design changes can lead to massive carbon savings…
Within this HERA led project, a case study from Christchurch was used that featured conventional construction practices: a steel-concrete composite flooring system, concrete shear walls, and steel moment-resisting frames. Using this as a baseline, we explored design variations, including low-carbon steel, hybrid steel-timber flooring, and eccentrically braced frames. Each tweak resulted in significant carbon reductions, showing that even minor design modifications can make a big difference.
Key takeaways for engineers to consider
Overall, the results showed that steel, timber, and concrete all have roles to play in reducing embodied carbon, depending on how they are combined and for what purpose. Hybrid steel-timber designs, for example, offer strong performance while lowering emissions. Additional concepts were also noted that engineers could consider to make significant impact.
Applying this to your work
HERA’s Circular Low Carbon Design Hierarchy is a valuable tool for engineers looking to achieve meaningful carbon reductions. It’s important to consider not just material selection, but the entire lifecycle of a building, from cradle to cradle, when making design decisions.
One key finding is the importance of keeping Life Cycle Assessment (LCA) tools up-to-date to include the latest low-carbon materials. Without these updates, assessments may skew in favour of one material over another, missing out on the actual carbon savings newer materials offer. Staying informed about these options is essential for engineers looking to make impactful changes in their projects.
Get started with free resources
Engineers are key players in driving carbon reduction in construction. By applying circular design principles and embracing low-carbon design, the sector can make significant strides toward sustainability goals.
Our work at HERA demonstrates that reducing carbon isn’t just possible—it’s practical and achievable with the tools and knowledge available today. So, the next time you’re specifying materials or designing a building, consider how small changes could make a big difference. After all, cutting carbon is not only about the future; it’s about what we can achieve today with clever, thoughtful design.
For more details, check out HERA’s Low Carbon Circular Design Hierarchy here. If you’d like a poster version for your office, please get in touch with our customer experience manager, Rebecca Symonds.
For more information on the research, listen to our latest podcast.
I also offer free in-house training for practitioners (minimum numbers required). Please get in touch with me at troy.coyle@hera.org.nz to discuss further.
BIO: Dr Troy Coyle brings more than 20 years’ experience in innovation management across a range of industries including materials science, medical radiation physics, biotechnology, sustainable building products, renewable energy and steel. She is a scientist with a PhD (University of NSW) with training in journalism and communications
Bonfiglioli solutions put power into metal working industries
Australia and New Zealand’s metal working industries are integral to the country’s economy, supplying other key sectors ranging from defence and transport to construction and infrastructure. It also provides employment, with the steel industry, for example, employing around 120,000 Australians.
With Australia poised to become a green superpower, driving the global reduction in emissions, the metal working industry will continue to play an important role. As part of its Future Made in Australia plan, the Government is prioritising the green metals industry, specifically the production of low emissions iron, steel, alumina and aluminium.
“As a long-standing manufacturer of solutions for the metal sheet handling industry, supplying innovations that meet the sector’s changing requirements, Bonfiglioli is well-positioned to support customers,” says Martin Broglia, MD of Bonfiglioli Australia and New Zealand.
The company offers an extensive portfolio of dedicated solutions for metal cutting, bending and punching, as well as metal forming and shaping.
Metal plate rolling and profile bending solutions
Bonfiglioli supplies a wide range of planetary hydraulic or electric gearmotors with controls, ensuring optimal performance in metal plate rolling or profile bending applications.
The 300 Series roller drive, featuring a wide range of ratios and reinforced output shaft bearings, handles shock loads up to 2,000,000Nm. It delivers exceptional torque control. “With its modular design, flexible input options, multiple output configurations and accessories, this drive is a great option for heavy duty metal plate bending,” says Broglia.
The company’s BX Series asynchronous IE3 three phase motor, meanwhile, offers reliable, balanced and robust performance as well as energy efficiency.
“This is a complete solution, with a power range up to 355 kW and rotor balancing,” says Broglia. “It features thermal protection and ventilation, as well as anti-corrosive paint coatings, IP56 protection and anti-condensate heaters. It’s available with built-in brakes for all power options and sizes”.
Bonfiglioli’s Active Cube Series premium frequency inverters are also ideal for use in metal plate rolling or bending applications, enabling highly customisable drive control and higher productivity. With a power range up to 1200 kW, it delivers advanced brake control, multi drive synchronisation and torque control. “This inverter is easily installed and has energy recovery braking functionality – sending recovered electricity back to the grid,” explains Broglia.
Dedicated customer service
Broglia reiterates that it’s not just Bonfiglioli’s portfolio that sets it apart, but also the company’s global network and commitment to customer support and service.
“Though our international network, we ensure that customers can enjoy Bonfiglioli’s top quality solutions anywhere. We have invested in our local presence, expanding our Sydney and New Zealand facilities to meet the growing demand for our solutions and services,” says Broglia. “Our dedicated services, co-engineering expertise and after-sales support continue to make us one of the metal working sector’s most sought-after partners”.
NMIT aeronautical engineering programme takes flight in Nelson
In response to a domestic and global shortage in aviation engineers, the Nelson Marlborough Institute of Technology (NMIT) has extended its aeronautical engineering programme.
A refreshed certificate programme, developed in consultation with national industry partners, is kicking off in Nelson in 2025, complementing NMIT’s popular Woodbournebased programmes. This means budding engineers can choose both their location and their time commitment – with either a one or two-year programme available – before embarking on a career in aviation, ultimately helping to address the shortfall in aviation engineers.
NMIT has a proud history as New Zealand’s only tertiary institute training future aeronautical engineers. Current programmes are all based at Woodbourne Airbase, and a close relationship with New Zealand Defence Force and the commercial aviation industry has meant NMIT’s programmes have grown and developed according to the needs of the industry and learners.
The programmes have an excellent reputation with aircraft maintenance engineers in the aviation industry in New Zealand and abroad. The updated Level 3 Certificate in Aeronautical Engineering means students can complete their qualification in one year. They can then choose to continue into the Level 4 Certificate programme or enter the workforce. The first Nelson-based cohort in the updated Level 3 Certificate programme will begin in February 2025.
A newly fitted-out hangar-style building on NMIT’s Hardy Street campus offers what NMIT describes as world-class specialist equipment. With the choice of either Nelson or Woodbourne to study in 2025, word has already spread, and the programme is gaining a lot of interest, with the February intake almost full.
The programme equips students with core aircraft maintenance skills such as using aeronautical engineering tools, adhering to safety protocols, and performing aircraft repairs and overhauls. It also delves into aircraft systems, the role of human factors in engineering, and the importance of teamwork. It attracts learners already in the aviation industry who want to level up their skills, as well as those wanting to pursue a career in aviation in New Zealand or overseas.
Reid Carnegie, curriculum area manager for aviation says the programme ticks a lot of boxes.
“We’ve historically seen high demand for the two-year Certificate, and we’ve been looking at ways to expand and update the programme. We know aviation engineers are highly sought-after and it’s crucial we keep meeting the needs of the industry. After listening to our industry partners, including Air New Zealand, we’re confident this new format and additional location will prove very popular,” says Carnegie.
As the next step, from 2026 the Level 4 Certificate will become a one-year qualification in block course format, meaning learners can either study fulltime or continue working throughout the year and attend one-week blocks of learning as they work towards the Certificate.
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