THE FIRST commercial installation of printed solar panels in Australia was completed in August, with the University of Newcastle wrapping up the process for Chep Australia.

In one day, the Chep team installed 200sqm of the material, made by printing electronic ink onto sub-millimetre plastic sheets, with double sided tape on the roof of its warehouse in Beresfield, Newcastle.

With a production cost of less than $10 per square metre, printed solar panels are much more affordable than other commercially available solar technologies.

The university also believes the technology should soon be widely available for the broader market. 

Professor Paul Dastoor, from the School of Science and Mathematics at the University of Newcastle said, “This is the first commercial uptake of printed solar in Australia, most likely the world. It’s an historic step in the evolution of this technology and another example of private enterprise and community leading the charge in the adoption of renewables.

“Our printed solar cells are now considered to be at the top of the technology readiness tree.

“Those working in technology development use a NASA developed Technology Readiness Level or TRL system to determine how evolved our solutions are, with 1 being the lowest and 9 the highest,” Prof. Dastoor said. “We are now rated TRL 8 and essentially considered green lit.

“On the University’s lab-scale printer, hundreds of metres of material can be produced per day, however upgrading production to a commercial-scale printer would increase this output to kilometres. No other renewable energy technology can be manufactured as quickly.

“The low cost and speed at which this technology can be deployed is exciting as we need to find solutions, and quickly, to reduce demand on base-load power – a renewed concern as we approach another summer here in Australia.”

Prof. Dastoor said due to the low cost of upgrading and replacing the panels, they may be provided as a service rather than an ownership based model.

“One of the most common questions I’m asked is when will people be able to buy this on shelves at Bunnings,” Prof. Dastoor said.

“Unlike most centralised or de-centralised energy infrastructure, which requires a substantial upfront investment, printed solar might resemble something more akin to a mobile phone plan.

“In future, we expect users might sign onto this energy solution in a similar way to a mobile phone plan, where you determine your usage requirements, pay a monthly service fee, but never need to ‘own’ the infrastructure. The service provider installs and upgrades your service for you as the technology continues to develop.

“This is quite a step change in how we’ll think about energy provision and energy markets in the near future.”

The panels are printed using roll-to-roll printing, and could one day provide printers in the country with an entirely new revenue stream, according to a report by Australia’s ProPrint online magazine.

www.newcastle.edu.au

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MANUFACTURERS Australia-wide are being assisted to take immediate steps to manage their energy consumption through a new industry initiative that has already saved some companies 25 percent in gas usage.

The Clean Energy Finance Corporation, the Energy Efficiency Council and the Australian Industry Group have launched Australian Manufacturing: Gas Efficiency Guide in an effort combat escalating energy costs and record gas prices.

A meat processing plant used the guide’s techniques to save $45,000 per month by cutting gas use by 21 percent, after upgrades to its boiler and steam facilities. A building products manufacturer saved $42,000 a year by installing a new control system on its boiler.

The guide examines the energy needs of a wide range of manufacturers, from food and beverage production to metals fabrication, printing and furniture manufacturing. 

The guide identifies a range of proven technologies with the potential to cut gas consumption by 25 percent. In the majority of cases, up front investment costs were $50,000 or less, with the costs recovered within just five years.

“Gas prices have risen substantially, and leading Aussie manufacturers are investing in energy efficiency to take control of their energy costs,” Energy Efficiency Council CEO Luke Menzel said. “The good news is that these projects are delivering benefits well beyond energy savings: operational life of equipment is increasing and maintenance costs and emissions are going down.

“This guide catalogues the learnings from leaders on gas efficiency so they can be leveraged across the entire manufacturing sector.” He said the guide was a comprehensive resource identifying practical and proven strategies to deliver energy and cost savings across manufacturing operations.

If the initiatives were all implemented at once, they would reduce greenhouse gas emissions by as much as 10 million tonnes a year, equivalent to taking more than two million passenger vehicles off the road, or meeting the electricity needs of 1.5 million homes.

“It is no secret that manufacturers are relatively large energy users. The good news is that clean energy solutions can make a very real and positive difference,” Clean Energy Finance Corporation CEO Ian Learmonth said.

“An initial investment of $50,000 or less can be recovered within just five years, producing lasting benefits for the business. By switching to more efficient equipment and cheaper renewable energy, manufactures can improve their competitiveness as well as cut greenhouse gas emissions.”

The guide says major improvements can be achieved through: Fuel shifting from gas to solar thermal, solar PV, bioenergy and low emissions electricity; equipment maintenance improvements; operational optimisation; replacement of old equipment with more efficient, newer equipment; and smart redesign to improve industrial processes.

The guide describes key planning requirements when embarking on efficiency initiatives including the key skills required, financial considerations and available financing options

“Australia’s manufacturing sector has confounded doubters in recent years by expanding strongly,” Ai Group CEO Innes Willox said. “The sector has the potential for even greater growth amidst a new industrial revolution that is transforming industry yet again.

“However, energy costs loom as one of the most significant headwinds to seizing this opportunity. We’re pleased to support this practical approach to helping manufacturers address these challenges.”

Mr Willox said manufacturing was vital to the Australian economy, contributing around $100 billion (6.2 percent) to Gross Domestic Product (GDP) annually and supporting nearly 900,000 jobs, or around 7.4 percent of total employment.

Australian manufacturers are also the most energy intensive in the OECD, and account for around 40 percent of Australia’s total natural gas consumption.

Australian manufacturers have been hit hard by volatile gas prices. The guide aims to help reduce their reliance on gas by identifying a range of initiatives that can deliver meaningful efficiency gains. For each initiative it provides upfront costs, payback periods and estimates the market readiness for manufacturers adopting the initiative.

The guide demonstrates that the gains available to manufacturers are significant and can go well beyond cost and emissions savings. For example, decreasing the heat load on industrial systems can reduce maintenance costs on large plant assets such as boilers.

Manufacturers can also improve the life expectancy of plant equipment from reduced operating hours and thermal stresses.

Further gains can be made in water consumption and treatment costs, with efficiency improvements in steam system and heat recovery operations. The guide shows manufacturers how they can take greater control of energy, and improve workplace safety and comfort, with technologies such as smart meters, energy management systems, and implementing more precise process controls.

The initiatives can be implemented at the design stage for new projects, or as a retrofit to existing equipment and systems. Many can be implemented through changes in practices and management.

www.aigroup.com.au

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A VICTORIAN business will be the first in the world to commercially develop one of the strongest fibres in existence – a product with applications in the aviation, automotive, aerospace, power, electronics and health industries.

BNNT Technology has received a $1.4 million Advanced Manufacturing Growth Fund grant to help produce its Boron Nitride Nanotubes on an industrial scale.

So far the super fibres have only been produced in small laboratory-scale quantities. 

Federal Minister for Industry, Science and Technology Karen Andrews, said BNNT was one of 15 small and medium-sized businesses that will receive grants in the second and final round of the Advanced Manufacturing Growth Fund.

“These grants will help companies transition from traditional, heavy processes to advanced manufacturing of higher value products, creating new opportunities and new jobs,” Ms Andrews said.

“Nearly $19 million is being distributed in Victoria and South Australia to help industries adjust in the two states most affected by the closure of vehicle manufacturing.

“This is expected to result in an additional investment of $45 million from the successful businesses.

“These businesses show the potential of Australian manufacturing: our firms and our workers can make high-tech, high-value products that can compete in a global market,” Ms Andrews said.

“These grants are an example of business and government working together to ensure that our nation is at the cutting edge in the rapidly evolving manufacturing sector.”

Other successful applicants in the second and final funding round include South Australian companies Micro-X and Bickford’s and Victorian company Rutra. 

Micro-X is a manufacturer of novel x-ray products for medical and security applications. The grant to Micro-X is to help develop locally produced components.

Bickford’s is a beverage manufacturer. The company will use the grant to help develop a liquid batching process that will enable faster flows and greater volume flexibility in production.

Rutra’s project will use 3D digital manufacturing in the production of custom-made orthotics in its Footwork Podiatric Laboratory.

Companies which received funding in the first round of grants have already started buying advanced manufacturing equipment and designing and preparing their factories for the changes.

For example, Redarc Australia, a defence supplier in South Australia, is already installing equipment it has purchased.

The Federal Government’s $47.5 million Advanced Manufacturing Growth Fund was established in the 2017-18 Budget as part of a $100 million package to support advanced manufacturing.

www.business.gov.au/amgf-grant-recipients.

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ITALIAN helicopter manufacturer Leonardo has selected Fisherman’s Bend in inner Melbourne as the site for its Australian helicopter repair and overhaul facility.

Defence Minister Christopher Pyne said the facility will be capable of servicing Australia’s Multi-Role Helicopter, Taipan, as well as foreign military and certain civil helicopter main gear boxes.

“The facility will commence operation in mid-2020 and employ at least 15 technical staff for 30 years or more, with 25 or so staff employed indirectly,” Mr Pyne said. 

“Previously we had to send the gear boxes back to Italy for maintenance – now we’ll be able to do that work here, faster and cheaper, while transferring skills and know-how to Australian industry.”

Mr Pyne said the Federal Government was investing about $16 million in the facility, with a similar amount being committed by Leonardo. It is said to be the only facility of its kind in the southern hemisphere, and is expected to generate new opportunities for local defence industries in the regional aerospace market.

“This project is a true win-win situation for both Defence and local defence industry, creating more defence industry jobs in Victoria and leading to greater helicopter availability for operations,” Mr Pyne said.

www.defence.gov.au

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