Starting Jan. 1, 2023, you may be able to invest more, thanks to the Internal Revenue Service increasing benefit limits for 401(k) and other qualified plans. Below is a summary of the changes:

Highlights include:

• The 401(k) and 403(b) Maximum Annual Elective Deferral Limit has increased to $22,500.
• The Catch-up Contribution Limit for individuals aged 50 or older has increased to $7,500.

To make it easy to explain these changes with employees, please click here for a flyer that summarizes the 2023 and 2022 limits.

For the full details on the limit changes, click here to visit the IRS website.

For more information, contact Joe Trybula at joe@printers401k.com or 800.307.0376.

By Liz Stevens, writer, Plastics Decorating

Credit card use may abound, and cryptocurrency might be up (unless it’s down again), but there’s no substitute for cold, hard cash. Around the globe, the banknote, the bill and the note remain wildly popular and eminently trusted. Wherever there is cash, there will be counterfeiters and, in turn, anti-counterfeiting technologies with increasing sophistication. Here are the top five technologies – venerable or brand-new – that give counterfeiters headaches.

1. Polymer substrates

Credit the Australians for creating the first polymer substrates for currency. Back in the day (1966), Australia switched to decimal currency, printed a raft of new banknotes and experienced an astounding rate of counterfeiting. Dave Solomon, a young scientist employed by the nation’s science group CSIRO (Commonwealth Scientific and Industrial Research Organisation), rose to the challenge of creating a currency that would foil the counterfeiters – by making a banknote that could not be successfully photographed for reproduction. Solomon’s idea was to embed something into the bills – an optically variable device (OVD) – that photography simply could not capture.

Solomon et al. created several visible security features, including banknotes with colors that changed and images that moved when the banknote was rotated, colors that would change in response to pressure, holograms and photochromic compounds. Solomon then offered up a polymer substrate to hold these new features – an impossible-to-commercially-source substrate that could be made opaque for printing but that also could have transparent areas in which to float some of the new features.

Australia went all in, and over the years replaced its currency with the new banknote substrate and security features. Now dozens of countries have adopted polymer banknotes, which are touted as being less costly, longer-lived and more hygienic than paper/fiber banknotes, along with their superior security features.

While Solomon is known in banking for his polymer banknotes, he is known more widely in the science realm as the guy who proved that one can control the structure of polymers, thus rewriting the theory of radical polymerization and developing the nitroxide mediated living radical polymerization method.

2. Laminated banknotes

The Banque de France, that country’s central bank, recently signed an agreement with 300-year-old Portals Paper in the United Kingdom to license Portals’ multi-layer banknote technology, EverFit.

EverFit is built around a special cotton/polymer-based high security paper core, which is printed with traditional paper/fiber security features and then laminated on each side with a highly adhesive film on an exclusive machine – the NotaLamina.

Benefits of lamination include the ability to wipe the surface clean and an extended circulation life for the notes. The makers also point to superior resistance to ink abrasion, which is characterized as a common problem in polymer banknotes.

3. Money with moving pictures

While the Harry Potter books and films made moving pictures in picture frames and newspapers seem like an everyday thing, Lebanon’s new 100,000-pound banknote is touted as the first banknote to contain CINEMA, a moving image effect embedded into the polymer substrate of the bills. The technology was developed by CCL Secure (the Australian manufacturer behind the Guardian polymer now used for almost all polymer-based banknotes) and Rolling Optics, a Swedish company that specializes in 3D imagery.

In the Lebanese banknote, the moving image effect is combined with a 3D effect, creating a sense of depth and movement in the areas with these features – a background area where the date changes from 1920 to 2020 and appears to move. CCL Secure also added another feature, dubbed Vivid, that creates an optically variable device containing a tree that is white under normal lighting but that changes to full color when viewed under UV light.

4. High praise for holograms

Firms in France and Russia earned awards in 2021 from the International Hologram Manufacturers Association for their banknote security features.

SURYS of France earned an award for best origination for its Plasmogram Reverso banknote, a new application of hologram technology on a polymer substrate. Three effects are seen in the notes: a set of distinct colors on the front of the note that turn into shades of gold on the back of the note; each color shifts when the banknote is tilted; and when one holds the note up to a light, a third set of colors becomes visible.

Krypten Research and Production Company of Russia earned an award for innovation in holographic technology with its 3D-GRAM CONTRUST Security Patch. The patch is a photopolymer-based security feature that can be used on paper/fiber and polymer-based banknotes. The company used the feature in its sample piece – a banknote featuring Dennis Gabor, Nobel Prize winner for his invention and development of the holographic method, and Albert Einstein, Nobel Prize winner in physics for the discovery of the law of the photoelectric effect.

5. Singles, deuces, fivers, sawbucks, Jacksons and C-notes

Banknotes in the US feature a constantly evolving set of security features. One security feature is actually the absence of a material: starch. While most paper sold globally contains starch, the substrate for US currency never includes starch. This makes for an easy test for counterfeit bills: mark the note with an iodine-based ink and watch for the result. If the mark turns yellow, there is no starch and the bill is genuine; if the mark turns dark blue, the bill is a starch-laced fake.

US currency is not made with polymer substrates; it is made from a blend of fibers that include linen and cotton. But it does have very fine bits of red and blue polymer threads that are pulped into the substrate as a security measure.

American cash also has color-shifting ink in places, such as the numerals and the “bell in an inkwell” on a 100-dollar bill that change color when a bill is tilted. And our bucks have an invisible vertical security stripe that glows pink under UV light.

Polymers, laminates, UV light-revealed changes, moving pictures and holograms. These are just a few of the security features of modern-day currency that keep counterfeiters lying awake at night.

There is a hot new trend in mentoring gaining steam across a spectrum of industries, from advertising to engineering to manufacturing. Reverse mentoring is not just a hot trend; it is a bright, practical approach to bringing newbies up to speed on a new job while capitalizing on the smarts and insights that they bring to the company. But really, reverse mentoring is not really a new trend – it was implemented at least 25 years ago at General Electric.

“Reverse” mentoring is actually a misnomer. Learn-teach mentoring or give-take mentoring might be more apt ways to describe this concept. The crux of it is that, rather than only pairing young, new employees with older, veteran workers solely for the newbie’s benefit, companies make a practice of creating a reciprocal mentoring dynamic in which veterans impart traditional knowledge to newbies and the newbies share their unique knowledge with veterans.

It is apparent why companies seek to have veteran employees pass on knowledge to the new workforce. Gen Z, however, has valuable knowledge, experience with the latest technologies and communication methods, and insight into the mindset of industry’s youngest consumers and clients.

How and when to do the mentor pairing is up to each company, based on its need to pass on company culture, industry expertise and operational insight, and dependent upon its need to educate its workforce on the latest technologies and perspectives.

Companies might choose to pair new workers with veteran workers to quickly impart industry and operations info to the newbies, and then later ask for a role reversal so the newbies can show the veterans around the latest in technology and share Gen Z cultural values. Or companies might pair the veterans and newbies with the aim of simultaneous sharing/teaching by each mentor.

Here are the top five reasons to consider reverse mentoring.

Mind the gap

The knowledge gap between Gen Z and Baby Boomers is getting wider by the day, whether the knowledge in question is the consumer technology savvy that seems to come so effortlessly to Gen Z or the trove of industry and business knowledge that Baby Boomers have accumulated over long careers. The longer one waits to close the gap, the larger the span that must be covered.

The Great Retirement

Baby Boomers are going to retire. Having their body of knowledge in a three-ring binder (or nowhere at all) will not cut it. Manufacturers can do double duty on capturing that vital Baby Boomer knowledge by allowing a Gen Z newbie to learn the ropes from a veteran, and also to record on-the-go with the latest digital tools – smartphone-based notes, audio Q&A, video interviews and demonstrations.

But what do they want?

The client base is skewing younger, and it is imperative to understand them, including their wants and needs. If a company pairs a young new worker with someone in the C-suite, the newbie can learn about management by osmosis and the executive can gain insight into the Gen Z consumer. Beyond understanding product preferences, executives can gain insight into how much Gen Z values sustainability, a strong corporate ethos and community buy-in from the companies and brands that they patronize. The C-suite also can learn first-hand what kind of employer traits appeal to Gen Z, for informing future hiring campaigns.

Stay just a little bit longer

Having Gen Z employees mentor Baby Boomers can keep the Boomers on the job longer. For manufacturers that are implementing automation and digital tools, younger employees can help older ones gain proficiency with the new technologies, allowing veterans to feel more comfortable and confident with the new innovations that will, invariably, make their jobs easier.

If veteran gurus are paired with newbies full of initiative, energy and technical expertise, the resulting synergy can lead to great ideas for improving various aspects of operations. Needs identified by veterans can be addressed with the fresh technologies that Gen Z uses every day. Seeing one’s suggestions for continuous improvement put into practice with cutting-edge technology can make one feel invigorated and appreciated. Maybe it’s not quite time to retire after all.

The secrets to success

Having Baby Boomers mentor Gen Z employees will deliver more than operational knowledge to them. There is more to success in a career than technological, industry and operational knowledge. Baby Boomers can share important company lore and hard-earned wisdom that can help Gen Z workers leapfrog to a higher plane of expertise and acumen.

Understanding a company’s origins, its history and the reasons behind its culture are valuable to any Gen Z employee who wants to climb the company’s career ladder. Absorbing a few lessons about what crises arise in the business and at the company, and how one can meet and navigate those trying times, can give a newbie knowledge and tools to lean on when the inevitable crisis occurs. Baby Boomers can help Gen Z understand the value of industry networking and in-person relationship building, for connecting with clients and suppliers in ways that spawn solid business connections.

Companies can use reverse mentoring to help veteran workers embrace the latest methods and gizmos, to assure that a deep industry and operations knowledge base is successfully bequeathed to a new generation, to impart company history and culture to new workforce members, to offer newbies a valuable leg up with sage career advice, and to gain insight into what the young sprouts desire in career, products and brands. It’s an idea worth trying, and it is the proverbial win-win.

For a TED Talk on this subject, “ What baby boomers can learn from millennials at work – and vice versa,” visit https://www.ted.com/talks/chip_conley_what_baby_boomers_can_learn_from_millennials_at_work_and_vice_versa.

Manufacturing.gov is a national manufacturing portal, a gateway to the wide and deep array of federal government initiatives, programs and resources that exist to support, strengthen and advance all aspects of manufacturing in the US. Here are the top five things to know about this massive resource.

1. The reach of the umbrella

Under the Manufacturing.gov umbrella, there are a slew of institutes, programs and partners.

Sixteen manufacturing innovation institutes connect government and academia with major manufacturing corporations. These groups work on R&D projects for the industry, test new technologies and create new products.

Manufacturing-oriented programs are aimed at upping the nation’s ability to compete with advanced manufacturing. Programs include the Investing in Manufacturing Communities Partnership, which encourages communities to develop economic development plans to attract manufacturing and supply chain investments; MForesight, an alliance created to allow private-sector input for guiding R&D priorities in advanced manufacturing technology; and the National Robotics Initiative, which accelerates the development and use of cobots.

Partners include the Departments of Agriculture, Commerce, Defense, Education, Energy and Labor, as well as NASA, the National Institute of Standards and Technology (a research lab focused on enhancing industrial competitiveness), and the National Science Foundation (supporting research, education and workforce training for advanced manufacturing). It truly is a big umbrella.

2. Cybersecurity

Manufacturers can take advantage of many cybersecurity resources through Manufacturing.gov, such as MForesight’s publication, “Cybersecurity for Manufacturers: Securing the Digitized and Connected Factory.”

There also is a host of information about the business value of strong cybersecurity as well as cybersecurity risks and threats, and case studies created by the National Cyber Security Alliance that illustrate the varied potential of cybersecurity threats.

Also available is the Association for Manufacturing Technology’s short article, “IT and OT: Finding Common Ground – Cybersecurity for Digital Manufacturing,” written by Benjamin Moses on the divide between OT (operational technology) and IT (information technology).

3. Smart manufacturing

Manufacturers interested in exploring and embracing smart manufacturing (aka, Industry 4.0) will be interested in MForesight’s “Smart Manufacturing: A Primer for Small Manufacturers.”

Mforesight soon will commence a new project, Smart Manufacturing for Small and Medium Manufacturers, citing recent surveys showing that small and medium-sized manufacturers (SMMs) have made little progress in implementing the technology. In consultation with manufacturers, consultants and technology providers, this project will match technology solutions with specific “pain points” typically encountered on the shop floor of SMMs and provide a practical path forward.

4. Workforce development

For manufacturers, workforce development is a perpetual effort. To attract the next wave of job candidates to a facility, some manufacturers participate in Manufacturing Day, an annual event that takes place on the first Friday of October.

The Hollings Manufacturing Extension Partnership (MEP) is the go-to resource for putting on a Manufacturing Day event at a plant, and also provides companies with services and access to public and private resources to enhance growth, improve productivity, reduce costs and expand capacity. Visit MEP’s website to find a local MEP Center.

To learn about 30 programs and initiatives on workforce development for advanced manufacturing, see MForesight’s publication, “AMERICA’S NEXT MANUFACTURING WORKFORCE: Promising Practices in Education and Skills Building,” at http://mforesight.org/projects-events/mfg-workforce/.

5. Apprenticeship program

The Department of Labor is ready to help manufacturers set up apprenticeships through its Registered Apprenticeship Program. This program comes with some attractive incentives, including technical assistance at no charge, state tax credits and recruiting incentives (such as incentives involving veterans eligible for GI Bill benefits).

The program allows manufacturers to dive into apprenticeship at their own level of advancement – at the exploring, building, partnering, registering or launching stage.

To learn more, visit www.apprenticeship.gov/apprenticeship-industries/advanced-manufacturing.

Energy independence is on the minds of many US manufacturers, not to mention politicians, the energy sector, auto owners and homeowners. Electric vehicles are making inroads, showing that change can be adopted and implemented. Gas and oil companies are widening their market by moving into the geothermal industry and geothermal is becoming more attractive since its sites can also be good sources for lithium and other in-demand minerals. Wind energy is maturing, with siting guidance that zeroes in on the best locations. Solar panels now are commonplace, as is feeding into the grid. Combined heat and power are evolving as a means to extract more benefits from heat and power generation. Here is a look at the top five sources of renewable energy for manufacturing.

Combined Heat and Power

Combined heat and power (CHP), aka cogeneration, is used to produce electricity and thermal energy on-site, reducing a plant’s requirement for electricity from the grid. The fuel source for cogeneration can be natural gas or a waste product that can be combusted for energy. CHP systems come in five main flavors: reciprocating engines, gas turbines, microturbines, fuel cells and boiler/steam turbines.

The US Army and the Army National Guard have installed CHP systems. Cooper Tire & Rubber has added a combustion turbine to one of its Oklahoma plants, and Michelin/American Synthetic Rubber now uses a boiler/steam turbine in a Kentucky plant. Owens Corning opted for microturbines for its Delmar Insulation Plant in New York. Industrial complexes and large corporate campuses sometimes go for district energy systems with centralized plants to serve multiple sites.

For more information on combined heat and power, visit the US Department of Energy’s Better Buildings Solution Center at https://betterbuildingssolutioncenter.energy.gov/chp/about.

For info about CHP technical assistance offered by DOE, see https://betterbuildingssolutioncenter.energy.gov/sites/default/files/attachments/CHP%20TAPs%20Flyer%20June%202021_0.pdf.

Geothermal

The earth’s internal heat can be tapped to take advantage of geothermal energy and heating/cooling. With this technique, holes are bored into the ground – either deep vertical shafts or a configuration of shallow horizontal tunnels – which access the consistent temperature found beneath the surface. With a consistent temperature of, say, 50 degrees, plant operators can take advantage of the relatively chilly 50 degrees in the hot months to achieve initial cooling for processes or environmental cooling. That same 50 degrees is relatively toasty in the winter and makes a start toward warming a plant’s environment or its processes.

Microsoft jumped on geothermal for its campus expansion in Seattle and has drilled a large number of geothermal wells connected to heat pumps, chillers and thermal energy tanks. VILPE Oy, a Finnish plastics manufacturer, uses one geothermal system to cool its plant but uses another in a different way: to store the waste heat generated by its production machinery during hot months for later use in cold months.

For some geothermal basics, visit https://www.energy.gov/eere/geothermal/geothermal-basics.

Solar

The use of solar energy has become commonplace in America. Rooftop solar panels are found from factories to remote cabins, and feeding one’s excess energy back into the grid is no longer confined to techno wonks. Solar power can be used immediately to generate electricity, or the power can be stored in batteries (or thermal storage) for later use. There are many options for storage, integration into businesses, and transmission onto the electrical grid.

Home decor manufacturer MCS Industries, Inc., added a roof-mounted solar power generating system to its new Palmer Township, Pennsylvania, distribution facility. The 894 kW system will provide most of the power required for the 500,000-sq.-ft. operations plant. In Petaluma, California, research consumables manufacturer Labcon North America gets one third of the factory’s electricity from 3,000 solar panels which produce 870 kW.

The Nature Conservancy has released a solar (and wind) project siting map to help identify the most effective places to deploy solar energy systems with the least disruption to wildlife.¹ The federal government makes it attractive to businesses to invest in solar energy, via investment tax credits.²

Wind

Depending on one’s locale, wind turbines for generating electricity may be nearly as common as telephone poles or may be an infrequent sight. Utility-sized wind turbine farms tower over the landscape in geographies with strong, consistent winds and home-sized turbines spin where farm windmills once stood. In between are turbines sized for industrial facilities and for grouping to create distributed wind systems for industrial parks or small communities. Turbines come in the horizontal-axis form and in a variety of vertical-axis models.

Triad Recycling and Energy Corporation, Tonawanda, New York, has two horizontal-axis turbines on 120-foot towers. The first turbine offset 100% of the company’s electricity consumption and the second turbine was added to offset 50% of the electricity consumption for a facility expansion. Spirit AeroSystems Inc., Wichita, Kansas, a manufacturer of aerostructures, converted to 100% wind-generated electricity. The company’s energy comes from 62 wind turbines at the Flat Ridge 3 wind farm, allowing Spirit to buy clean electricity from regional utility company Evergy.

Get the DOE’s Small Wind Guidebook at https://windexchange.energy.gov/small-wind-guidebook.pdf.

A Smorgasbord

The Department of Energy’s National Renewable Energy Laboratory offers REopt: Renewable energy Integration & Optimization, a web-based tool that allows users to evaluate the economic viability of a mix of distributed photovoltaics, wind, battery storage, combined heat and power, and thermal energy storage. It can be an aid for identifying system sizes and strategies, and for estimating critical load durations for systems.

To access REopt, visit https://reopt.nrel.gov/tool.

The energy source(s) best suited for any company will depend upon the location’s availability of wind, solar and geothermal, as well as other considerations like whether the source is best used in new construction projects or can be added to an existing site. Federal, state and local regulations apply, but so do federal, state and local incentives.

References

1. Kelsey Misbrener, “The Nature Conservancy releases low-impact solar project siting map,” solarpowerworldonline.com. 02/08/2022. https://www.solarpowerworldonline.com/2022/02/nature-conservancy-low-impact-solar-siting-map/.

2. “Guide to the Federal Investment Tax Credit for Commercial Solar Photovoltaics,” US Department of Energy. January 2021. https://www.energy.gov/eere/solar/articles/residential-and-commercial-itc-factsheets.

During National Safety Month, which concluded at the end of June, Stamford, Connecticut-based Goodway Technologies reminded facility managers of the importance of understanding explosion and fire risks in the work environment. The combustive power of airborne particles, such as dust, is astounding and can be a threat to a number of different industries.

“Understanding how to identify and prevent risks in your production environment is critical for any plant manager or maintenance personnel,” said Frank Intrieri, vice president at Goodway Technologies. “A combustible dust explosion can be extremely devastating, which is why it’s important to take the proper steps to reduce potential hazards and concerns.”

Goodway Technologies has outlined 10 easy tips on how to help prevent dust explosions:

1. Most dusts are combustible. According to the Occupational Safety and Health Administration (OSHA), any solid that can catch fire can become explosive when turned into dust.
2. Provide access to all hidden areas of a plant or facility. Make sure that every horizontal surface in a plant can be accessed, including ductwork, beam and joist surfaces, and the area above suspended ceilings in order to assess dust buildup.
3. Regularly inspect for dust. OSHA inspectors look for accumulations of 1/32 of an inch, which is about the thickness of a standard paper clip. Immediate cleaning is necessary when a layer of that amount covers a surface area equal to 5% of the floor area.
4. Clean at regular intervals. Put a plan in place to conduct timely cleaning. Work cycle dust should be removed concurrently with operations and not be allowed to accumulate. Be mindful of dust dispersion during housekeeping.
5. Move dust collectors outside. Dust collectors with a volume of greater that 8 cubic feet should be located on the exterior of a building to limit risks.
6. Ensure electrical wiring and equipment is approved for dust hazard conditions. OSHA also recommends “The use of proper electrical equipment in hazardous locations is crucial to eliminating a common ignition source.”
7. Only use certified industrial vacuums for explosive material pickup. Essential in hazardous dust environments, “explosion proof vacuums” approved for Class II conditions don’t produce sparks.
8. Control ignition sources. Post “No Smoking” signs. Control static electricity by bonding and grounding equipment. Provide personal protective equipment, as needed, not only as a protective barrier for the employees, but also to prevent the ignition from static electricity.
9. Perform regular preventative maintenance on equipment. Equipment in bad repair is a common cause of ignition.
10. Train employees to recognize and prevent hazards. Proactively train new employees before they start work and again periodically, to refresh material, or when they are reassigned. In addition to understanding safe work practices relating to their tasks, employees should also know the overall plant programs for dust control and ignition source control. Develop a company culture of safety by encouraging employees to report unsafe practices. If fine dust, powders, or other flammables are used in the facility, think about using these tips and to start your preparedness.

“There are a variety of options when it comes to industrial vacuums and it is also important to make sure you are using the appropriate equipment for the application and materials that are being picked up,” said Intrieri. “Goodway Technologies offers a selection of industrial vacuum cleaners for different applications and needs, which are outlined in our Industrial “Explosion Proof” Vacuum Buying Guide. Our team of experts can also help determine which is the best solution that meets the necessary classifications required for your plant.”

A hazardous, or classified, location is defined by the National Electrical Code (NEC) as a working area with a risk of explosion or fire due to the presence of flammable gases, vapors, dust, or ignitable fibers in the air. Electrical sparks, arcs or hot surfaces may cause gases and other airborne particles to ignite, resulting in injury, loss of life and property damage.

The NEC uses a class/division/group system to identify the different risk levels.

• Class defines the kind of hazardous material present in the area.
• Division defines the likelihood that a hazardous material may be present in sufficient quantities to ignite or explode.
• Group more clearly defines the specific type of hazard in the atmosphere.

Goodway Technologies further breaks down the classifications in their buying guide which can help you to understand an area’s explosion and fire risk. In addition to knowing the potential risks and hazards in a facility, it is also important to have the correct maintenance tools, especially when purchasing industrial vacuum cleaners to clean or pick up hazardous materials.

While this information can be used as a reference, plant and facility managers need to discuss best practices with their safety officer or maintenance personnel before selecting equipment. NEC Article 500 also will provide information on how to choose the correct enclosures to keep people and property safe.

For more information, visit www.goodway.com.

A series of free roadshows in selected cities across North America, organized by Labelexpo Global Series, will give label, packaging and commercial printers a sneak peek into the technology on show at Labelexpo Americas 2022 later this year.

The roadshows will take place in Cincinnati, Ohio; Orange County, California; and Toronto, Canada, and are only open to printers, end users and trade press. The roadshows are supported by Gold sponsors HP, Epson and ABG and Silver sponsor Xeikon.

The roadshow kicked off in Orange County on July 20, hosted by Fullerton College. Working closely with the Printing Industries Association of Southern California (PIASC), this roadshow provided insights on the workforce issues surrounding the labels and package print industries. Printers also heard about trends and case studies throughout the one-day conference program.

The Cincinnati leg of the roadshow takes place on July 28 and will be hosted by Haney Packaging. Haney Packaging describes itself as a “packaging micro-factory,” providing a one-stop shop from pack development to prototype, test marketing and everything in between. Micro factory customers have access to what Haney describes as “the industry’s largest library of recyclable and compostable packaging solutions.” The roadshow will include a tour of Haney’s impressive facility, while supplier partners will cover industry trends, end-user case studies and specialist technical subjects in the one-day conference program.

The final leg of the roadshow takes place in Toronto on August 3 at the High Park Brewery. Roadshow delegates will hear about their partnership with a local designer and printer to develop a new identity for the brewery which includes their community links and commitment to sustainability. This will complement a core program focusing on trends and key technology advances in label printing.

For more information or to register, visit www.labelexpo-americas.com/labelexpo-roadshows.