MEPCA August 2023

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Editor

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August 2023

In this issue of MEPCA, we highlight a new guide from the Association of Electrical & Mechanical Trades (page 7), which aims to help users of induction motors reduce their total cost of ownership (TCO).

In a totally unscientific survey I recently carried out by way of a LinkedIn poll, around a third of respondents in manufacturing roles said they don’t consider TCO when specifying or purchasing a motor. In the current economic climate, with energy use far and away the largest factor in a motor’s TCO, this figure surprised me. But what is possibly concerning about this, if it is truly representative of the bigger picture, is that reducing energy use is the largest contributor to reducing carbon emissions and achieving Net Zero ambitions. So does that mean that a third of manufacturing businesses are not considering reducing their emissions? Or are they not making the connection?

A recent conversation with a supplier of industrial equipment would back up the view that a large number of industrial businesses are still not making sustainability a focus. They confirmed that cost is far and away the driving factor in purchasing decisions, with reliability and impacts on quality and customer satisfaction often coming ahead of sustainability.

For quite some time now, the sustainability benefits of products and solutions has been a key marketing message for many vendors serving the manufacturing and engineering sector. So why is the message not getting through? Or is it being heard but simply not being viewed as important enough to rise up the list of priorities? And will we see that time come?

It’s difficult to be sure, but for the sake of future generations, I truly hope the messages start to hit home soon. Or that my assumptions are wrong.

Chris Callander, Editor

Labour challenges remain despite jobs boost in UK Regions and Nations

The number of jobs in manufacturing has grown in six of eight English regions along with Wales, highlighting the importance of the sector to hopes of levelling up across the UK by creating high skill and better paid jobs.

According to Make UK, the figures also counter the long-held narrative of an inevitable decline in manufacturing employment and show, as is happening in the US, that growing manufacturing jobs and the sector’s share of the economy is a realistic prospect given a supportive policy framework.

The findings come in the Make UK/ BDO Annual Manufacturing Outlook Report (bit.ly/MUKROR), which provides a comprehensive analysis of the contribution of manufacturing to each English region and devolved Nation. It analyses a number of metrics, including industry’s share of regional and national economies, number of jobs and share of regional/national employment, together with sectoral analysis.

However, despite the increased number of jobs across most English regions, Make UK stressed that substantial labour challenges remain. According to the latest official data, 74,000 vacancies remain unfilled, at a cost in economic output of approximately £6.5bn.

According to official data, Yorkshire & Humber saw the biggest growth in manufacturing jobs, adding 46,000 jobs in 2022 compared to 2021, bringing the

total number to 316,000, more than one in ten (11%) of the region’s workforce.

According to Make UK, this is possibly due to the growth of the Food and Drink sector post pandemic, given it accounts for almost a fifth (16.3%) of regional output. The second largest sector in the region is Chemicals which has also performed strongly in recent years, closely followed by Basic Metals.

The South West saw the second highest increase, a further 28,000 jobs bringing the total to 249,000, 8% of the region’s workforce. This was closely followed by the East of England, adding 27,000 jobs bringing the total to 228,000, 7% of the region’s workforce. The East and West Midlands, together with London and the South East, Wales and Northern Ireland also saw increases in the number of manufacturing jobs.

The report also highlights the importance of manufacturing and jobs to so-called

‘red wall’ areas where the sector occupies a substantially higher than average contribution to the regional economy.

The average regional share of manufacturing nationally in the UK is just under 10%, whereas in Wales, the sector accounts for almost a fifth of the economy, whilst it is also substantially above the

average as a share of the economy in the East Midlands (16.4%), Yorkshire & Humber (15.4%), North East (15%), West Midlands (14.4%) and the North West (14%).

However, as well as highlighting the strengths of manufacturing across regions and nations, the report also shows the challenges which still remain for levelling up and, the implications for policies to promote it. According to the most up-to-date official data available on regional manufacturing Gross Value Added (GVA), all regions and nations, apart from the West Midlands, had recovered to pre-pandemic levels of output by 2021.

Whitepaper accelerates journey to net zero

Made Smarter has launched a whitepaper to help SME manufacturers accelerate their net zero plans.

‘Decarbonisation through Digitalisation: manufacturing made smarter and greener with technology’ (bit.ly/MSDtD) is a practical guide to industry’s biggest challenge and opportunity.

The free-to-download document from

the government-backed and industry-led technology adoption programme, aims to simplify a complex and fast-evolving topic by demystifying some of the terminology and analysing the latest research.

Crucially, the whitepaper offers insights about how a variety of technologies enable manufacturing and engineering businesses to make things smarter and greener, while powering growth and creating new highly skilled jobs.

The whitepaper showcases makers who have started their decarbonisation journeys with Made Smarter, including Crystal Doors, Fylde Fresh and Fabulous, and The Cumbria Clock Company.

It also signposts manufacturers to other initiatives, including Race to Zero, a campaign led by the United Nations, and the SME Climate Hub, a non-profit global initiative that empowers companies with tips and tools, including its Business Carbon Calculator.

Guide helps motor users cut costs

The Association of Electrical and Mechanical Trades (AEMT) has published a new guide designed to help users calculate their industrial motors’ total cost of ownership (TCO). With a focus on assisting organisations to reduce costs and improve their motors’ environmental impact, the free guide can be downloaded from the AEMT website at bit.ly/AEMT_TCO.

Despite a some improvement in recent weeks, today’s energy prices are more than double the pre-2021 historic average, and forecasts suggest they will remain so for some years to come. As a result, the lifetime cost of running an electric motor is an increasing focus for many users. However, we are still some way from a motor’s TCO becoming a standard factor in most purchasing decisions.

The purchase price of a typical industrial motor can be just 2% of its lifetime cost. So, to help end-users benefit from a greater focus on a motor’s TCO, the AEMT’s new guide outlines the variables which need to be considered when calculating the overall cost and offers recommendations for how it can be reduced. Areas covered in the guide include using variable speed drives, higher

efficiency motors and improving motor reliability.

Commenting on the AEMT’s new guide for industrial motor users, Thomas Marks, the Association’s Secretary and General Manager, said: “We have produced this guide to encourage a focus on the total cost of ownership of electric motors, to help users reduce their costs and improve their environmental impact. From initial system design right through a motor’s operational life, there is a range of ways the total cost incurred can be optimised.

“Our members are experts in advising motor users on the most efficient and effective solutions for their applications, and we want to highlight the positive impact users can have on their bottom lines and the environment.”

According to research from the World Energy Council, electric motors and electric motor-driven systems are estimated to account for almost 50% of all global electricity consumption. Alongside the potential for significant financial savings, if that consumption dropped by just 10%, that could reduce the global demand for electricity generation by 1,425TWh, equivalent to the

total amount of electricity used by India, the world’s third largest consumer.

Focusing on a motor-driven system’s TCO can help realise these benefits, and this new guide from the AEMT has been designed to support the process.

Growth of 5-7% forecast for global industrial robot market

Global economic volatility and supply chain disruptions are having a huge impact on the market for industrial robots, which has led to project delays and decreased spending on automation projects. Despite this, long-term projections remain steady, with electric vehicle (EV) manufacturing and new energyrelated applications fueling global demand for industrial robots and growth of 5-7% forecast for the sector out to 2027.

Interact Analysis has recently published updated forecasts for the industrial robot market, and they mark the most significant revisions compared to the 2022 version of the report. From 2023 onwards, the market intelligence specialist predicts investment confidence will continue to be low in the short

term, causing end-users to delay large capital investments in industrial robotics projects. In the long term, demand from new EV manufacturing lines and from service sectors such as intra-logistics will further fuel the market, resulting in an average growth rate of 5-7%, which is much higher than the precovid period.

Following a slow 2020 due to the pandemic, the industrial robot market enjoyed substantial growth in 2021, witnessing a yearon-year increase of 34.9%. The market cooled slightly in 2022 but still expanded, registering 11.9% unit shipment and 14.9% revenue growth. The pandemic helped to fuel demand for the robotics industry as companies turn to automation as a way of alleviating labour shortages. Many companies are now investing in industrial automation in order to add stability

to their workforce should future crises occur.

In 2022, China accounted for a 39.1% revenue share and 55.4% shipment share of the global industrial robot market. Interact Analysis forecasts that the Chinese market will account for over 60% of industrial robot unit shipments from 2024. The EMEA market for industrial robots was the second largest in the world, accounting for 14.8% of total shipments in 2022. The Russia-Ukraine conflict is still a significant threat to Eurozone growth prospects not only because of energy price increases but also because it pushes down business confidence, which could affect employment and investment decisions. The American market for industrial robots was estimated to be worth $2.8Bn in 2022, accounting for 19.8% of global revenues, with 55,268 units shipped.

Precision 3D LiDAR navigation and collision avoidance

SICK has unveiled a milestone advance in its threedimensional LiDAR technology with the launch of the multiScan multi-layered LiDAR sensor. The SICK multiScan combines floor-to-ceiling 360° environment perception with high-resolution navigation for reliable real-time localisation, mapping and collision avoidance in automated mobile robots (AMRs) and industrial vehicles.

Developed on the foundations of SICK’s multi-echo LiDAR technology, multiScan is a compact, lightweight and rugged 3D sensor designed to maximise vehicle availability in both indoor and harsh outdoor environments. With their broad 360° x 65° field of view and 16 scan layers, the LiDAR sensors in the multiScan100 family use ondevice pre-processing to output a dense 3D point cloud with 690,000 measuring points, complemented by a high-resolution 0° 2D

scan plane for precision navigation.

Each multiScan arrives factorycalibrated and ready for use, whether it is specified as a standard pre-configured product or using the specially-developed online configurator. Machine builders and integrators can select the features they need for their applications using the time-saving online platform with access to software apps and add-ons for easy customisation.

To enhance the 16-layer 360° horizontal coverage, the multiScan’s vertical aperture angle is configured to optimise the layers between -22.5 to +42.5°. This ensures reliable collision avoidance for objects at ground level, as well as detecting cliff edges and ramp inclinations. Objects protruding into the field of view at height, e.g. on warehouse shelving, can also be reliably avoided. The multiScan136, the first sensor to be launched in the product family, has a 360x65° field of

view and a 60m working range, with further variants available later in 2023.

Equipped with 100Mbps Ethernet, eight multifunctional I/Os and matching system plugs, the SICK multiScan is easy to integrate and saves engineers valuable time during commissioning.

www.sick.co.uk

Stereo microscope update brings improved user capability

Innovative inspection, metrology, and digital 3D visualisation solutions provider, Vision Engineering, recently announced the launch of Mantis

3rd Gen, the latest addition to its best-selling and award-winning range of ergonomic optical stereo microscopes.

Mantis is in use in tens of thousands of R&D, manufacturing and analytical sites around the world. Mantis 3rd Gen incorporates the latest developments in optics, digital cameras and fully adjustable LED lighting, to keep it at the forefront of stereo imaging.

Mantis is perfect for electronics quality inspection and rework, plus a wide range of other applications that require high-quality images and superior ergonomics. It features a unique, patented, eyepiece-less design that delivers a large, high-quality optical stereo image directly into the user’s eyes, making it more comfortable and easier to view than traditional microscopes.

Manipulative, rework and restoration tasks need stereo images to allow easy handto-eye coordination and depth perception. Mantis 3rd Gen combines stereo optical images with highresolution camera options for manipulation and recording.

Mantis 3rd Gen features long working distance and excellent depth perception, now with a choice of three magnifications, making it ideal for a wide range of applications. It also now comes as standard with five different ways to illuminate a subject, giving the flexibility to adjust the lighting to get the perfect image.

In addition to its outstanding image quality and ergonomics, Mantis also features a powerful digital imaging system that allows users to capture, review, and share

high-resolution images. This makes it easy to share work with colleagues, document findings, and train new employees.

Substantial R&D has resulted in a new range of stand options to allow flexibility, stability and reduced footprint.

www.visioneng.com/mantis

SOLUTIONS FOCUS

Give your data local impact

The new DX1063 multifunction display module from ifm electronic provides a simple and effective way of displaying key data locally on a machine or process plant, making it much easier for operators to keep an eye on status when they’re away from the main operating position. To maximise its versatility, the DX1063 is compatible with most commonly used analogue input signal types. It incorporates a high-resolution TFT display that offers a wide range of colour and digital labelling options.

Measuring 48mm high x 109mm wide and just 42mm deep, the DX1063 is large enough for essential data to be read from a considerable distance but small enough to be accommodated in almost any control panel. It detects and converts voltage,

current, frequency, pulse counter and thermocouple inputs, displaying the results directly in units specified by the user. The unit is also shown, along with the signal name and location tag, so that the meaning of the displayed value is always readily apparent.

To further increase the usefulness of the DX1063, the display’s background colour can be altered according to the value of the input signal. This means, for example, that a green background could be programmed for a signal in the normal range and red for an

alarm condition. The DX1063 also has two relay outputs that the user can configure to pass alarm signals to the plant control or supervisory systems.

www.ifm.com

Work safely in potentially explosive areas

The Schmersal Group has expanded its range of optoelectronic protective devices with a series of safety light curtains/grids in Ex design. The new EX-SLC/SLG440 series is designed in the ignition protection types EX d (gas atmospheres), EX t (dust atmospheres) and EX op (optical radiation) and is therferore especially suitable for access protection of potentially explosive areas in industrial production – namely for zones 1 and 21.

There is an elevated risk of explosion in many areas of manufacturing, such as in the chemicals industry, in refineries or paint shops where flammable coatings are being used. In industries that process bulk materials, such as in the animal feed or recycling industries, as well as in sawmills and plants that process cereals and grains, there is a risk of dust explosion and the occasional formation of a potentially explosive dust cloud during normal operation.

Schmersal has developed the SLC/ SLG440 safety light curtain/grids in Ex version precisely for these applications. These devices can be installed in potentially explosive gaseous and dusty atmospheres of zones 1/21 and 2/22, category 2GD

and are used to protect hazardous areas and machine access. When one or more of the beams is interrupted, hazardous movements are brought to a halt.

The series is ATEX certified and further certification – IECEx, INMETRO and CCC Ex – are due to follow. The sensor system is accommodated in a protective enclosure made from non-breakable glass.

Ex-SLC440 safety light curtains for finger,

hand and body detection are available in versions with a resolution of 14 and 30 mm as well as ranges of between 0.3 and 20 m. Ex-SLG440 safety light curtains are suitable for access control to hazardous areas.

The waterproof and dustproof devices achieve IP66 and IP67 protection class and also have the capability to be used outside.

www.schmersal.co.uk

Mobile freedom with AGV’s Material transport in dynamic environments

The KMP 600-S diffDrive mobile platform from KUKA opens up new avenues and provides greater flexibility for production intralogistics. The automated AGV has a payload of up to 600 kilograms, needs no safety fencing enabling maximum freedom of movement and laser scanners mounted at the front and rear provide maximum safety, allowing for high speeds in all directions of travel, when cycle times require it.

KUKA Robotics UK Ltd.

T: 0121 505 9970

E: sales.uk@kuka.com

New generation of NEMA motor offers high energy efficiency and reliability

ABB has developed the new generation AMI 5800 NEMA modular induction motor to offer exceptional energy efficiency and reliability in demanding applications such as pumps, compressors, fans, extruders, conveyors and crushers. Rated for a power output of up to 1750HP, the AMI 5800 offers the capability for a high degree of modularity and customisation to suit both new-build and upgrade projects in a wide range of industries, including chemical oil and gas, conventional power generation, mining and cement, and metals. The motor opens up new options for UK OEMs looking to export customers in North America.

The AMI 5800 motor is a true NEMA design that builds on ABB’s technology leadership in the North American market to meet both electrical performance requirements and mechanical mounting

standards. A key feature is a high-strength welded steel frame typically found only in motors with larger frame sizes. This lowers stress on the motor while mitigating vibrations and resonance to ensure reliable operation in harsh conditions with a design life of 25 years or 20,000 starts.

A further important advantage of the AMI 5800 is a shorter bearing-to-bearing span compared with previous models. This innovative feature improves performance at high speeds and enables the motor to be used as a simple drop-in replacement to upgrade existing equipment.

According to ABB’s Stephen Clabburn, UK Sales Manager, Large Motors & Generators: “We have engineered the AMI

5800 motor to meet customer requirements for high energy efficiency and reliability, as well as sustainable manufacture and use. Its modular design in terms of cooling methods, bearings, shaft extensions and terminal boxes also provides the flexibility to match the North American installed base. This makes the AMI 5800 ideally suited for upgrading existing installations and next-generation designs, no matter how harsh the environment is. From a UK perspective, for UK OEMs exporting to the North American market, ABB can now support you locally with this new generation of NEMA designs that build on our already extensive NEMA range.”

new.abb.com

Decentralised frequency inverter gains extended power range

NNORD DRIVESYSTEMS specifically developed its decentralised NORDAC ONSK 300P frequency inverters for the requirements of horizontal conveyor technology in intralogistics and warehousing. The inverters are characterised by an integrated Ethernet interface, IIoT capability, full pluggability and a compact design. Now, the power range of the NORDAC ON has been extended to 3kW.

The NORDAC ON frequency inverters are part of the NORD modular system and can be optimally combined with the manufacturer’s motors.

The drives can be used over a wide speed range and thus allow for variant reduction, for example in large intralogistics systems. The NORDAC ON is now designed for power ranges of up to 2.6kW – the NORDAC ON+ for up to 3kW. Both have integrated Industrial Ethernet interfaces. The communication protocols, for example Profinet, EtherNet/IP or EtherCAT, can

be easily set via parameters. Firmware updates can also be implemented via Ethernet. This makes the NORDAC ON/ ON+ frequency inverters optimally suited for integration into IIoT environments. The equipment also includes a diagnostic interface, M12 connections for sensors and actuators and, with the NORDAC ON+, an additional protocol-based encoder interface that is well protected against interference.

The space-saving decentralised inverters can be perfectly integrated into conveyor systems, significantly reducing wiring efforts compared to centralised frequency inverters. Its pluggable connections make the NORDAC ON/ON+ an economical, plug-and-play solution for intralogistics applications. The inverters are suitable for

direct motor mounting or for wall mounting.

As with all NORD frequency inverters, the NORDAC ON/ON+ is equipped with a powerful PLC for functions close to the drive. It can process data from connected sensors and actuators, initiate control sequences and communicate drive and application data to the control centre, networked components or cloud storage.

www.nord.com

Its time for a more coherent vision for UK industry

Over the past fifteen years, there have been fifteen different Secretaries of State responsible for industrial strategy (when combining the various different iterations of ministries and departments now housed under the current Business Secretary), who together have launched six different plans for growth. And the Whitehall department responsible for managing industrial policy has been re-organised and re-named five times in that same period.

This endless chopping and changing masks a myriad of other remit reforms, the most prominent examples being the bouncing back-and-forth of higher education and skills policy (including apprenticeships) between the education and business departments. The same can be said for energy policy. While trade has sometimes been the responsibility of the business ministry and, at other times, of its own bespoke trade department.

When it comes to industrial strategy, the UK government has commitment issues.

As a new report launched recently by Make UK shows, many businesses are warning that a habitual short-term focus on quick fixes and political publicity stunts from successive governments is impeding economic development.

One of the main problems is a lack of commitment. In the same way, erratic parenting is poor practice, too often, new government schemes are announced with great fanfare, only to be abandoned or forgotten almost immediately. Though initiatives like Freeports or the Northern Powerhouse can be well intentioned and well designed, such policies need to be part of a broader and more coherent vision. Inconsistency in public policy breeds uncertainty in private industry. That prevents businesses from planning effectively, so

instead of incentivising investment, it incentivises intransigence.

This tendency to focus on shortterm tactics at the expense of long-term strategy is understandable, given the pressures of electoral cycles and the need for quick wins. But short-sightedness stifles success. Instead of constantly changing direction depending on the latest economic indicators or political pressures, an effective industrial strategy requires investing in education and training, infrastructure, and innovation, even if the benefits may not be felt for years or even decades.

Of course, a long-term industrial strategy is not without its challenges. It means making difficult decisions about where to allocate resources, what to prioritise and what to sacrifice. It requires the political will to take risks. Yet the alternative, as we are now seeing, is stagnant productivity, increasing inequality, and low or zero economic growth.

A modern industrial strategy will require a significant, game-changing shift in the way policymakers approach business and economic policy.

The first step must be to agree on our industrial and economic ambitions. Over the last few years government’s approach to international trade has been to prioritise the quantity of our new partners rather than the quality of those relationships. Attachment theory is instructive about how to form more productive partnerships. It is imperative we set clear expectations from the start about what we wish to gain in future trade deals, as well as what we’re willing to give in return. Make UK has proposed establishing a Royal Commission on Industrial Strategy to help determine a cross-party consensus on these

issues. That knowledge should then inform and underpin all economic policymaking.

A strategic approach also means sticking to the plan. One option might be to reestablish the independent Industrial Strategy Council to oversee and guide industrial strategy. The Cabinet Office could then be given responsibility for working across government, business, trade unions and other stakeholders to agree on firm goals and targets and put in place policies and practices to monitor progress and ensure accountability across all levels of government and industry.

The UK needs a stable policy environment to support businesses and workers and create the conditions for sustained growth. Through a long-term industrial strategy, we can build an economy that works for everyone, now and into the future.

Stephen Phipson, CEO of Make UK, explains why the association has proposed establishing a Royal Commission on Industrial Strategy.

Taking battery production to a new level

Bosch Rexroth, a leading provider of automation solutions, explores the future of battery production.

The demand for batteries is skyrocketing, driven by the rapid growth of electric vehicles (EVs), renewable energy storage systems, and portable electronic devices. As the battery industry evolves, manufacturers face the constant challenge of adapting to changing requirements and staying ahead of the competition. To succeed in this dynamic landscape, battery production processes must become more flexible, transparent, and intelligent. This is where Bosch Rexroth, a leading provider of automation solutions, comes in.

To meet the evolving demands of battery production, manufacturers need flexible and intelligent solutions. Bosch Rexroth recognises this need and is at the forefront of delivering innovations that address these requirements. By providing open interfaces, all components, modules, and system solutions from Bosch Rexroth are designed for optimum connectivity. This connectivity allows for seamless integration and communication between different parts of the production process, reducing complexity and increasing overall productivity and availability.

One key aspect of flexibility is the ability to scale and adapt production capacity according to market demand. Bosch Rexroth’s solutions offer flexible expansion options, allowing manufacturers to have a broad scope for action. Whether it’s ramping up production to meet growing demand or quickly reconfiguring production lines for new battery designs, Bosch Rexroth enables manufacturers to respond swiftly and efficiently.

Furthermore, transparency is crucial for optimising production processes and ensuring quality control. Bosch Rexroth’s solutions provide real-time monitoring and data analytics capabilities, allowing manufacturers to gain valuable insights into their production operations. By harnessing the power of data, manufacturers can identify bottlenecks,

optimise efficiency, and proactively address potential issues. This level of transparency ensures that battery production remains at its peak performance, meeting the highest standards of quality and reliability.

In the complex world of battery production, a comprehensive understanding of the entire value stream is essential. Bosch Rexroth brings not only its expertise in automation solutions but also its deep knowledge of battery production processes. Starting at the earliest stages, Bosch Rexroth’s automation solutions optimise the electrode and cell manufacturing processes. By leveraging their expertise in precision engineering and control systems, this ensures the highest levels of accuracy and consistency in these critical stages. This attention to detail sets the foundation for high-performance batteries.

Moving downstream, Bosch Rexroth’s solutions extend to battery module and pack assembly. These solutions enable manufacturers to streamline assembly processes, reducing cycle times and increasing overall efficiency. With the company’s automation solutions, manufacturers can achieve the precision, speed, and reliability necessary to meet the demands of modern battery applications.

Moreover, Bosch Rexroth’s commitment to the entire value stream extends to end-of-line testing. As batteries become increasingly

complex and safety-critical, stringent testing procedures are essential. The company’s solutions provide comprehensive testing capabilities to ensure the quality and reliability of batteries before they reach the market. This means manufacturers can have confidence in the performance and safety of their products. The future of battery production demands flexibility, transparency, and intelligence. With its focus on innovation and connectivity, Bosch Rexroth is well-positioned to meet these evolving requirements. By delivering open interface solutions, Bosch Rexroth reduces complexity and increases productivity and availability. The flexibility of its solutions allows for easy scaling and adaptation to market demands, giving manufacturers a competitive edge. Additionally, Bosch Rexroth’s comprehensive expertise in battery production processes makes it an ideal partner for the entire value stream, from electrode and cell production to module and pack assembly, and end-of-line testing.

In a rapidly changing industry, partnering with Bosch Rexroth empowers manufacturers to take their battery production to new heights. Manufacturers can navigate the complexities of battery production with confidence, ensuring high-quality, reliable, and innovative batteries for the future.

www.boschrexroth.co.uk

BATTERY PRODUCTION OF THE FUTURE

Forging ahead on the fast track: Clever solutions for industrial automation

For more information: sales@boschrexroth.co.uk www.boschrexroth.com/en/gb/industries

Insulation against supply chain instability

With

disruptions to supply chain operations set to

remain through 2023 and beyond,

Stephen Hayes, Managing Director at automation and control technology specialist Beckhoff UK, looks at how manufacturers can increase the stability of their supply chain.

The impacts of supply chain disruption are becoming all too familiar – shortages, inflation, factory closures, goods waiting at ports to be unloaded, and so on.

These disruptions have a huge impact on a business, and not a good one. From shipping delays to complete stoppages of production, supply chain disruptions leave manufacturers with financial losses, customer dissatisfaction, reputational damage and increased costs.

Therefore, it is crucial that businesses gain a clear understanding of what a supply chain disruption is and how it can affect their operations before implementing the necessary measures to protect themselves against any uncertainties.

Diversification strategy

Some might say a diversified supply chain is simply a variety of supply and manufacturing channels to meet business needs, but it is much more than that – it is the heart of supply chain resilience.

Manufacturers should minimise risk and increase agility by developing a flexible risk management strategy that involves multiple suppliers, the reimagination of manufacturing and distribution networks, and the use of redundant and multimodal logistics methods.

In fact, well known food manufacturer Kellogg Co realigned its sourcing strategy and distribution network in the wake of packaging bottlenecks during the COVID-19 pandemic. As the region’s Korean supplier ran short due to shipping delays, Kellogg Co found an alternative supplier in New Zealand, which was based closer to home and reduced transportation costs.

Technological enhancements

Research from KPMG has revealed that over 50% of firms believe increased digitisation and automation will increase the resilience of their supply chains, with real-time tracking and monitoring systems able to offer insights into inventory levels, production progress and shipping statuses.

Tracking systems can provide data to help manufacturers improve supply chain management by showing inefficiencies and unnecessary expenses. Plus, tracking systems can also alert supply chain managers to any problems during the supply, production or delivery process, helping businesses to act quickly before product is damaged or wasted.

Returning to the aforementioned example, Kellogg Co uses software to review disparate sources of data relating to various demand signals. When it senses a disruption, or a pattern that might lead to a disruption, it

provides a recommendation on how to avoid it. This helps the company to adjust and prevent an out-of-stock issue from occurring, days to weeks in advance.

Leveraging these software tools is crucial for proactively managing disruptions and building more resilient supply chains. That’s why software, such as Beckhoff’s PC-based control systems, plays a crucial role in ensuring scalability and modularity when quick adjustments in production and the integration of alternative suppliers are needed.

No matter the event or issue, supply chain stability can only be possible with software like this, coupled with the right operational changes. The past few years have shown us that disruptions in the supply chain are inevitable and costly, but like Kellogg Co, restructuring and automating processes can reshape companies faster than you might imagine.

www.beckhoff.co.uk

Revolutionising perimeter guarding

Safety technology provider Euchner has introduced the Euchner MGB2 – a solution designed to revolutionise perimeter guarding.

With its advanced features, including operator interfaces, RFID trapped-key systems, Key-InPocket and LOTO compatibility, the Euchner MGB2 is set to transform safety standards, minimise downtime, and optimise operations within many industries.

The MGB2 is engineered with a primary focus on personnel and equipment safety. Employing a combination of cutting-edge technology with fieldbus connectivity, the innovative system prevents unauthorised access, provides traceability and protects operators from hazardous zones. When the guard is opened, the advanced design ensures that machinery and equipment come to a safe stop, effectively reducing the risk of accidents and injuries. When short-term interventions are needed, e.g., lining up a pallet, the system allows for easy operator access, albeit with other safety measures in place. With the MGB2, businesses can rest assured that their perimeter guarding is fortified with state-of-the-art technology, providing utmost safety and security.

Flexibility and adaptability

One of the standout features of the Euchner MGB2 is its exceptional flexibility and adaptability to diverse industrial environments. Thanks to its modular design, the system can be seamlessly integrated with existing control system infrastructure, minimising disruption during installation. Moreover, the device can be easily customised to meet specific requirements, ensuring optimal performance and compatibility across assembly lines, logistics centres, and warehousing facilities, to name a few. This adaptability allows organisations to standardise the hardware specification making the MGB2 an invaluable investment for the factory of the future.

Safety over fieldbus

The Euchner MGB2 offers seamless integration into factory fieldbus networks, including popular protocols like PROFIsafe and Safety over EtherCAT (FSoE). This compatibility enhances the system’s functionality and enables efficient communication between the MGB2 and other devices on the network. By leveraging the capabilities of fieldbus networks, manufacturing sites can optimise their safety systems and streamline their industrial processes.

The MGB2’s integration with the factory networks allows for real-time transmission of safety-related data over the fieldbus network. This enables rapid response and precise coordination between the guarding system and other connected devices, such as programmable logic controllers (PLCs) or human-machine interfaces (HMIs). Safety signals, status information, and diagnostic data can be seamlessly exchanged, providing a comprehensive view of the system’s performance and enhancing overall safety management.

The MGB2 facilitates increased operational efficiency. Safety-related functions, such as guard locking and emergency stop functionalities, can be coordinated and synchronised with the fieldbus network, ensuring that the safety measures are seamlessly integrated into the overall automation process. This integration minimises response times and optimises the coordination of safety-critical actions, leading to improved productivity and reduced downtime.

Another advantage of the MGB2’s integration with the Fieldbus is simplified system configuration and monitoring. The fieldbus network allows for centralised management and control of the guarding system, eliminating the need for separate wiring and dedicated safety relays. This

reduces installation complexity, saves time, and lowers maintenance efforts. Additionally, the integration enables comprehensive monitoring of the MGB2’s status and performance in real-time, enhancing predictive maintenance and facilitating prompt troubleshooting.

Moreover, the MGB2’s compatibility with Safety-Fieldbus systems ensures compliance with international safety standards. PROFIsafe and Safety over EtherCAT are widely recognised and accepted protocols for safety communication in industrial automation, adhering to the requirements of IEC 61508 and IEC 61784-3. By utilising Safety Fieldbus, the MGB2 provides businesses with confidence that their safety system meets the highest standards of reliability and performance. www.euchner.co.uk

Inductive sensors with a rotatable head and quick mounting system.

• Rotatable sensing face in 5 different positions without the need of additional tools

• Bracket with push unlock system for easy and quick mounting or replacement

• Flush or non-flush mounting

• Extended sensing distance: 22 mm to 40 mm

• Antivalent output (NO+NC): NPN or PNP

• 4 corner visible LEDs with diagnostic functions

• Operating temperature: -25°C to +80°C

• IP67, IP68 and IP69K

IRC40 Series:

Improve baking efficiency and consistency

Bühler, a leading producer of commercial food equipment, including baking ovens, employs Vaisala technology in its Meincke Turbu ovens, including Vaisala’s dew point/temperature probes and industrial transmitters. Morten Bøgild and Christoffer Bay, Senior R&D Engineers at Bühler’s biscuit business unit in Denmark, explain.

Environmental concerns and rising energy prices are driving demands for improved efficiency across all industries.

This is particularly the case in food production and especially in processes involving baking ovens, which can run at temperatures of up to 325°C. Bühler’s cuttingedge Meincke Turbu indirect-fired convection ovens aim to increase efficiency in line with the company’s strategic commitment to help its customers make substantial savings in energy, water, and product wastage.

One customer was using natural gas at an average annual cost of €10 million before ordering the ovens, but with accurate humidity measurements, a reduction in gas consumption of as much as 20% was achieved.

Consistent, reliable quality

The advantages of accurate monitoring are explained by. By measuring the humidity levels inside the oven, you can control the process to maintain a consistent baking profile, even with fluctuations in other factors like ambient conditions or ingredient quality. This enables a more consistent product in terms of spread, thickness, colouring, and other important quality parameters, thereby minimising wastage.

An oven with built-in measurement technology gives our customers the opportunity to control the humidity of their ovens themselves, as well as the temperature, which can be particularly valuable for those producing multiple products with different baking profiles.

The Vaisala DRYCAP dew point and temperature probe DMP6 is designed for in-line humidity measurement at very high temperatures and a wide dew point range.

It has a passive cooling function that draws heat away from the probe to reduce the temperature to within the sensor’s optimal range, making it ideal for the extreme environment of an industrial baking oven. This robust technology enables Bühler to offer its customers more accuracy and flexibility when setting up their ovens. In addition, the DMP6 measurement probe can be connected to a Vaisala Indigo500 series transmitter, which enables real-time data visualisation and probe configuration.

The monitoring of moisture levels also helps to shorten the time needed to bake the perfect product. When baking cookies, an oven typically operates with a dewpoint of 60–70 °C, but the Meincke Turbu ovens allow the humidity level to be higher. Consequently, there is less cold air to heat up because when the moisture content is regulated, less air exchange is necessary. In addition, a dryer oven requires higher temperatures to achieve the same heat transfer, while excessive humidity can damage the oven –so with a higher moisture level that is kept consistent and within safe limits, thanks to accurate monitoring, substantial reductions in customers’ energy bills can be achieved.

In addition to reduced gas consumption, the conveyer carrying the baked goods can also move through the ovens at a faster rate because the products are ready sooner, resulting in a more efficient throughput.

Bühler is at the forefront of the fourth industrial revolution in its industry, incorporating smart technology into existing automated production facilities to improve performance through enhanced monitoring, reporting, and artificial intelligence techniques. The market has slowly embraced this transition, and by recognising the efficiency benefits of having more accurate data and knowing how to use

it, Bühler is driving real change in the industry. Humidity measurements provide one of the most important insights when it comes to making the baking process more efficient and building an understanding of how heat flow within the oven contributes to final product quality.

Vaisala is the ideal partner for Bühler, helping customers to achieve ambitious efficiency targets. This is because the sensors are easy to calibrate and use and robust enough to withstand extreme conditions.

Flemming Bøge of Brdr. Jørgensen Instruments, Vaisala’s partner in Denmark, worked closely with Bühler to help identify the ideal solution; and guidance from Vaisala’s own application experts on how to calculate humidity values was also beneficial. This greatly benefited the technicians, who use the equipment daily.

Even before Vaisala was chosen as a preferred supplier, customers were specifying the company’s equipment in their orders. With an increasing demand for digitalisation and AIenabled functionalities, this need is only going to increase. vaisala.com

Draw-wire sensors offer larger measuring ranges

To better serve applications in mobile machinery for the measurement of boom and support positions, MicroEpsilon has expanded its wireSENSOR WPS-MK88 and wireSENSOR WPS-K100 series of draw-wire sensors with larger measuring ranges and CANopen interface.

The wireSENSOR K100 series of draw-wire displacement sensors measure distance and position precisely, combining high performance for outdoor use with an excellent price/performance ratio. The series now offers a larger measuring range of up to 8m, as well as a CANopen interface for all measuring ranges up to 8m, making the sensors ideal for off-highway vehicles, mobile machinery, mobile cranes and lifting technology. The compact K100 series is protected by a glass fibre-reinforced plastic housing, as well as separate drum and spring

spaces, making the sensors extremely robust (IP69K) against external influences.

The MK88 series of draw-wire sensors has also been expanded with a larger measuring range of up to 6m, as well as a CANopen interface for all measuring ranges up to 6m. The MK88 is specially designed for

mobile applications in series, such as mobile cranes and mobile working platforms. The combination of compact size, robustness and price makes the sensors unique, offering new potential in design and cost optimisation.

www.micro-epsilon.co.uk

Raw power at rural biogas plant

When Edward Vaughan decided to diversify into renewable energy at his fifth-generation family farm in Sychtyn, North Wales, he could have been tempted perhaps to have built as big an anaerobic digestion plant as possible, but his attention to the economies of scale has paid off, thanks in part to a Powerfeed unit from Borger.

The Welsh biogas plant, from which an impressive 80% of clean, renewable energy is exported, has slotted right into the existing land at JB & E Vaughan, rather than the farm having to change to accommodate the new technology.

“Seven years ago, it was all completely new, but you learn by your mistakes and have to get to grips with the learning curve quickly,” said Edward. “The price of energy wasn’t the main driver then. We’d just reached a point where it made sense to diversify, control our costs and not have all our eggs in one basket. A decade ago, we’d invested in a 250kW wind turbine, and moving forward with a biogas plant that could require plenty of extra work; we wanted simplicity but with maximum output.”

Producing grass silage and spring barley on the 850-acre farm, Edward also has his 300-strong beef herd to look after, plus 1200 sheep. So, part of that wish for simplicity and, importantly, easy maintenance, came in the form of investing in an automated Powerfeed unit from Borger, to convey the organic feedstock of crops, manure and chicken litter.

“We did our homework properly, visiting farms to see the Borger unit in operation and find out why it had been so strongly recommended,” added Edward. “Feedstock for biogas will always cause wear and tear on equipment, so we also wanted a UK company that wouldn’t keep us waiting for spare parts when needed”.

The Powerfeed set-up, which includes a Borger rotary lobe pump, can integrate into an existing biogas system at an appropriate point in the pressure pipe system to convey the feedstock into the flow pipeline. It is

a closed system, so it prevents odours from escaping and prevents gas leaks. Only light agitation in the tank is required, so power consumption is kept to a minimum.

“Price-wise, it was competitive”, added Edward. “We also wanted to work with a company where we could fine-tune equipment to suit our needs. After seeing how the process worked for our feedstock, we worked with Borger to slightly modify the Powerfeed so that it could operate in reverse as well as forwards. When needed, this helps keep everything moving better and prevents any blocking.”

Edward built a filling hopper to supply the organic matter to the Powerfeed, which is designed with an auger shaft that also breaks down the feedstock and compresses it towards the press channel. This leads to the flushing unit, which is connected to the flow pipeline. The clumps that form in the press channel have the effect of a selfrenewing seal. The substrates obtain a larger surface area, removing trapped air.

Every two and a half to three hours, 2.5 tonnes of organic matter at JB & E Vaughan is fed through by the automated system for the biogas plant, which has primary and secondary tanks (both 1200m3). The farm also benefits from two boilers, which bring the total power output up to 450kW. Once again, that important planning and economies of scale came into play as the existing infrastructure for the wind turbine

helped minimise gas-to-grid connection costs for the exported energy.

“The plant produces plenty of power,” continued Edward. “But with the Borger Powerfeed as part of the set-up, we also benefit from the very good quality digestate we get from the end of the process. We add farmyard manure to our feedstock, which might not produce that much gas but is very good for the biology. Our soil is so much healthier. We no longer have to buy fertiliser, which, as all farmers know, has had a huge increase in price. This has become a big part of us keeping our costs under control. Also, the low pH of the fertiliser at around four to five meant that what we were adding was really too acidic, whereas the biogas digestate at a pH of around 7.8 acts more like an alkaline.”

www.boerger.com

Massive expansion of KSB chemical pump series K

SB SE & Co. KGaA has added 19 sizes to its MegaCPK type series. Users can now choose from 55 sizes with more than 78 hydraulic systems for these standardised chemical pumps. The available materials of grey cast iron, nodular cast iron and cast steel, stainless steel, as well as duplex and special alloys, such as titanium and Hastelloy, result in an extensive range of applications. Fluids that require heating or cooling can also be handled.

The pumps are characterised primarily by their high output per size and their low energy consumption. Not only does this save on electricity consumption, but it also reduces the user’s initial investment. KSB’s developers have placed particular emphasis on good suction behaviour, with a low NPSH value, to minimise the risk of cavitation. This enables smooth and stable pump operation

even under difficult operat¬ing conditions. It also ensures a high degree of reliability and improves the availability of an entire system.

By using the finite element method (FEM), a calculation method for the simulation of solids, the developers were able to achieve a high degree of strength and rigidity of the installed components while at the same time optimising the use of materials. After optimising all hydraulic contours using computational fluid dynamics (CFD), the improvements were verified in extensive test set ups.

The new seal chamber design allows the installation of gland packings, all common mechanical seals compliant with EN 12756, and many cartridge-type mechanical seals. Fully confined casing gaskets and minimised axial thrust ensure long service life. To control and monitor operation, the

pumps can be equipped with speed control, vibration and bearing temperature measurement and operating point monitoring.

In line with KSB’s common practice for industrial pumps, every pump is supplied to the customer with the impeller diameter trimmed exactly to the duty point. Impeller trimming, combined with the large range of pump sizes, helps ensure that the pump’s energy consumption is kept to the minimum necessary, even when run at a fixed speed.

www.ksb.com

Energy savings that resonate

Teledyne FLIR, a specialist in intelligent sensing solutions for defence and industrial applications, explains how its equipment is enabling ultrasonic imaging to cut costs for international industry.

Renowned across central and southeast Europe for its steel forging factories, Acciaierie Bertoli Safau SpA (ABS) has been immersed in metallurgy for over 200 years.

ABS has two core production sites, one located in Cargnacco, Italy, and one in Sisak, Croatia, as well as a cutting-edge research centre in Metz, France, in which it carefully hones its centuries-old craft.

ABS steel is mainly used in the automotive industry, where it has a broad range of applications throughout the supply chain of creating and maintaining vehicles.

Whether it’s wire rods, ingots, rolled billets, forged bars or rotoforged products, each unique process requires carefully controlled heat to activate the chemical reactions that change ore into the extraordinary.

In the intense environment needed to mould steel (which melts at temperatures above 1200°C), it’s no surprise that it can take considerable supplies of energy to create sufficient heat as the ore is slowly melted, purified and recast into the desired shape and form.

Cutting-edge tech

With energy prices rising across Europe, ABS is taking action to actively cut maintenance costs across the board – with the help of cutting-edge technology from Teledyne FLIR.

ABS’ Udine factory has a direct supply of electricity from the Italian power grid to drive an induction furnace which is used to melt ore and recycled materials into shaped steel. The site receives electricity through an on-site substation, and uses compressed air extensively throughout the production process to power many manually repetitive operations – such as moving sections of a metal bar that has been cut to length into bundles, or coiling operations.

The compressed air systems run through the entire length of the production operation with hundreds of couplings, filters and actuators – each with the potential to

leak. For such energy-intensive industries, even the most minute air leak can lead to substantial energy wastage, costing more to power the machinery optimally and driving up production costs with every m³ of air lost.

This is where inventive solutions provide a unique line of defence for locating and sealing air leaks and keeping the facility at maximum efficiency.

By using the FLIR Si124 acoustic camera, ABS can detect and isolate compressed air leaks, corona and partial discharge throughout the production facility and substation, enabling engineers to ensure a reliable and uninterrupted energy supply while simultaneously managing their compressed air system before air loss can begin to negatively impact their energy bill.

Acoustic imaging is specifically designed to enable operators to see the energy lost through air leaks by transposing an image based on the inaudible ultrasonic vibrations picked up by the 124 cutting-edge acoustic microphones in situ, even in loud industrial environments, which can often mask maintenance issues.

So, whatever the size of the air leak, it can be instantly flagged and fixed.

Daniele Guastamacchia, Head of Maintenance Engineering at Acciaierie Bertoli Safau SpA, explained the benefits of using both active thermography and acoustic imaging to increase productivity

and reduce cost: “I’ve been working with ABS for five years, and I immediately noticed that the company was very responsible with research and predictive analysis. Quality predictive research has always been closely correlated to the thermographic field and ultrasound analysis, which is why we chose to buy a FLIR T865 and Si124.

“The Si124, in particular, is very easy to use and doesn’t require much experience; it’s all very intuitive. As a thermographic and sonic camera, its usefulness in the energy field and the consequent cost reductions cannot be overstated – especially now when suppliers are paying drastically more per kWh. Specific tools like this one really do help underline key savings to our bottom line”.

To securely back up and share files and findings about their energy performance and quality control, ABS uses FLIR IGNITE cloud-based file transfer system. What’s more, to easily quantify energy saved in clear terms, ABS uses FLIR Thermal Studio reporting software for trend analysis and maintenance requirements.

“Using Thermal Studio is inevitable, really, because it gives us the opportunity to edit the files as needed and to file reports quickly and incredibly easily. It’s really useful,” concluded Daniele.

www.flir.co.uk

Series D is the new valve island from Camozzi Automation, able to ensure optimum productivity and flexibility for use in many industrial automation systems.

MULTIPOLE

DIAGNOSTICS AND VALVE COMMUNICATION LED

MANUAL OVERRIDES

MODULARITY 1 SUB-BASES WITH INTERCHANGEABLE CARTRIDGES

BENEFITS

Compact design

Individual, modular sub-bases in technopolymer

Flexibility in connecting different I/O modules

Integrated diagnostics and predictivity

Available protocols: PROFIBUS-DP, CANopen, EtherNet/IP, PROFINET, EtherCAT, IO-Link

FIELDBUS

HIGH NUMBER OF MODULES

CAN BE CONNECTED WITH THE MAIN FIELDBUS PROTOCOLS

FLEXIBILITY IN CONNECTING DIFFERENT I/O MODULES

PREDICTIVE MAINTENANCE

The Series D valve island is equipped with CoilVision® technology which can monitor and predict the wear and efficiency of parts of the solenoid valves.

Camozzi Automation Ltd 024 7637 4114

askus@camozzi.co.uk www.camozzi.co.uk store.camozzi.co.uk

4.0 READY

SERIES D VALVE ISLAND INCREASE EFFICIENCY, REDUCE DOWNTIME MAKE YOUR OPERATIONS SEAMLESS WITH SERIES D

DIGITAL MONITORING AND ANALYSIS

ON/OFF status of each valve

Health status

Power consumption

DIGITAL MONITORING AND ANALYSIS

24HR EMERGENCY VALVE ISLAND BUILDS

Within 24 hours, we can assemble and test Series D Valve Islands, creating an unbeatable turn around for valve islands in the UK. If you need valve islands fast, get in touch with our team today.

LEARN MORE ABOUT SERIES D

https://qrco.de/seriesd

Total handling solution for plastic packaging testing station

Torus Technology Group has partnered with Festo to create a purpose-designed integrated handling solution for its new TQ-Lab modular plastics packaging testing station.

Torus offers a range of custom-designed automated inspection and testing systems that enable customers to control high-speed processes, reduce costs and maintain quality in demanding environments. TQ-Lab is a unique, total quality testing station for plastic packaging, such as bottles and jars, typically used for soft drinks, health supplements, cosmetics, and domestic cleaning products.

Festo’s in-house design expertise and online software tools played a critical role in helping Torus to develop the optimum solution for the complex handling requirements involved.

Expanding horizons

Plastic packaging requires precision measurement of aspects such as material thickness, outer body and neck physical dimensions, neck diameter and volume, as well as load testing for crushing and pressure.

The TQ-Lab is a unique concept that can undertake all the necessary tests on both empty and filled containers or preforms in a single system. Once batches of containers are placed onto the turnaround conveyor, the operator simply selects the relevant program and walks away. A bespoke vision system locates the position of the neck, and an intelligence force feedback gripper and multi-axis pick and place system transfers the product from the conveyor between measurement modules. The system is fully customisable, so customers can select the Torus test modules that suit their particular test requirements or budgets. Controlled via a single interface, TQ-Lab delivers reliable data to the network with no operator influence.

Its development is a major diversification for Torus. Traditionally, the company has focused on developing test stations for

metal packaging, but TQ-Lab extends its expertise to the plastics packaging sector.

“We knew that our in-house expertise would enable us to transfer our testing technology from metals to plastics packaging,” explained Brian Wilson, Engineering Director at Torus. “However, the handling complexities involved in offering a total testing solution in a single system was a real challenge.”

Accurate handling and repeatability were key to delivering the customer benefits Torus envisaged for TQ-Lab: such as reduced time and labour costs, the potential to collect a large amount of measurement data, and a reduced footprint to save valuable floor space.

Torus investigated the option of sourcing components to build the handling system themselves, but there were issues with compatibility and reliability using multiple suppliers. It also considered the option of

using an ‘off-the-shelf’ robot solution and modifying it to suit. However, this involved considerable design modifications and specialist automation skills that lay outside their core expertise. They recognised the need for an automation expert to work alongside them to optimise the system design.

“Festo had been a valued supplier of automation components such as electric drives, handling components and valve terminals to Torus for many years, but this was the first time we decided to tap into their design support services,” said Brian. “It was the best decision we could have made. Festo engineers enabled Torus to focus on their area of expertise, so the whole system benefited.”

Handling with care

The final TQ-Lab was developed over twelve months, and Festo was involved

from an early stage. Chandra Patel, Business Development Manager at Festo, explained: “We were able to speed up design lead-in times quite significantly: for example, by using our extensive software tools and experience to identify the best components for the handling system specification. The final design helped to simplify the handling system into a single integrated solution instead of multiple bespoke parts from separate suppliers. Using the recently introduced Festo ELCC cantilever axis, we were able to replace the original custom-built vertical module with a technically neat and commercially attractive single part.”

“The highly technical specification and complexities of movement also made it crucial to test that the design would work in principle before building out the handling system. Our dedicated sizing and simulation software enabled us to test different configurations and proved to Torus that the final design would deliver the desired performance in terms of accuracy and repeatability.”

The automation expertise available from

Festo enabled Torus to reach a final design more quickly and delivered a fully optimised solution. Festo then built and delivered the complete handling solution for installation in the TQ-Lab.

“Even though I was already familiar with Festo’s capabilities, I was really impressed with the finished handling solution,” continued Brian. “It was such a neat design, and all the details had been considered, right down to the mounting points and what fixings should be used. The whole handling system fits seamlessly into TQ-Lab, and it gives us real confidence that we are supplying a fully integrated, reliable, and high-quality testing solution to our customers.”

Festo support does not stop at the point of delivery. They have also made it easier for Torus to order the handling system in future by assigning it a single order number, which automatically generates a comprehensive list of all the necessary components. This streamlines purchasing and stores, while still supporting any repair or replacement needs. Festo also has a global network of service centres

that enables Torus to offer its customers local support with commissioning and any troubleshooting.

Total package

The versatile and modular integrated Festo handling solution delivers the accuracy of handling and adaptability to customer requirements that Torus wanted to achieve. It is also future-proofed, allowing reprogramming to suit changes in packaging design.

Festo’s complementary automation expertise and online software tools further improved the design and development of the TQ-Lab, significantly reducing the component selection and prototyping phase.

Concluding, Brian said: “Festo were there all the way, from early concept discussions, through component selection and system design, testing to commissioning, to finetuning and completion. With their support, we have delivered a unique automated testing solution at least six months earlier than predicted – giving us and our customers a real competitive advantage.”

www.festo.com/gb

The not to be missed event for lifting equipment users

If you use lifting equipment in your job, LiftEx 2023 is the ideal event for you to visit. The free-toattend flagship show of the Lifting Equipment Engineers Association (LEEA) will be held on 21-22 November 2023 at the state-of-the-art Exhibition Centre in Liverpool, which is located on the banks of the city’s world heritage waterfront – gateway to one of the world’s most famous ports.

The leading annual networking event for the lifting industry is set to be the best yet in 2023, with sponsors including Rope and Sling Specialists (RSS), Green Pin and Delta Hoisting. The organisers would also like to welcome CoreRFID as Headline Sponsor for LiftEx 2023.

Lifting is an essential function in many supply chains, including manufacturing and production, engineering, automotive, oil & gas, construction, ports & maritime, logistics, offshore, utilities and entertainment. In common with all of these sectors, manufacturing and production environments rely on a broad variety of cranes, hoists, platforms, cradles and their associated chains, ropes, slings and other lifting equipment. In plants and factories, manufacturing companies may be surprised to discover how much lifting equipment they actually own. In addition to production equipment, there is likely to be materials handling kit that is used to make work not only easier and more efficient but also to reduce musculoskeletal and repetitive strain injuries.

The Lifting Equipment industry is constantly evolving with the onset of new materials, innovative ideas, better ways of doing things and the inclusion of modern technologies. There are also vital services such as inspection, maintenance and training. A comprehensive portfolio of solutions to improve productivity and efficiency, as well as providing safety for end users, will be on show on an exhibition floor packed with major suppliers from the lifting industry.

Safety continues to be a major focus at LiftEx because it underpins everything the

Lifting Equipment Engineers Association (LEEA) has been doing throughout its history and will continue to do going forward, with zero accidents and injuries from working at height being the Association’s prime goal. Leaders responsible for procuring lifting equipment and services in any of these markets must fully understand the risks, consequences and legal obligations, as well as being able to filter good practice from the bad.

A series of informative speaker sessions at LiftEx, delivered by the LEEA team and industry experts, will discuss not only safety issues but also lifting-relevant topics of recent interest, issues, trends, and recruitment strategies. There will also be learning and development opportunities as well as hands-on training sessions to give visitors a chance to top up their knowledge.

With almost 100 exhibitors and over 1,500 industry professionals attending across two days of knowledge sharing and training, there will, of course, be many chances to network with your peers and colleagues, not least on the evening of 21 November 2023

– day one of LiftEx – when the fifth annual LEEA Awards ceremony will be held at the Rum Warehouse in Liverpool. This promises to be the Lifting Industry’s party of the year, particularly with the recent announcement of comedian, presenter, actor and singer Jason Manford as the evening’s host.

All of this means a visit to LiftEx 2023 offers the perfect chance for anybody using lifting equipment in manufacturing and production to gain vital lifting-related knowledge and insights, as well as an opportunity to meet LEEA members and discuss ways they can help achieve best lifting practices. Delegates can register now for free at bit.ly/LiftEx23.

See the many exhibitors already confirmed at the exhibition website, which also features a film of highlights from the 2022 show, and there are news bulletins on what’s coming up in 2023. For those interested in exhibiting, a few stands remain available. Sponsorship packages are also available for the exhibition and Awards Dinner.

liftex.org

The networking exhibition for the lifting equipment industry

Sponsors and Partners: Hosted by:

Packed show floor of lifting equipment and services

FREE TO ATTEND FOR USERS AND BUYERS OF LIFTING EQUIPMENT ACROSS MULTIPLE MARKETS

Exhibitors signed, new hall sealed, Subcon delivered

The eagerly anticipated Subcon Show returned to Birmingham’s NEC for two exceptional days of industry celebration and innovation.

The 46th edition of Subcon truly lived up to its reputation as the industry’s leading subcontract manufacturing supply chain show and continued to bring together an abundance of high-quality visitors, with over 4,500 in attendance. This represented a 15% increase on 2022, 70% of whom had joint/sole responsibility in purchasing.

Exhibitors mirrored feelings of success at Subcon. Simon Bluff, Managing Director at Taylor Forgings, commented, “It’s been a really good day so far, the footfall has been amazing, and we’ve had orders well in excess of £300,000 today alone”. Simon’s comments were echoed by an impressive onsite rebook rate of 60% and the average stand size increasing by 28%.

Event Director, Jason Dante, commented: “It was great to be back in Birmingham to see Subcon doing what it does best, bringing together the full manufacturing ecosystem for two jam-packed days. Thank you to our show sponsors, Omnidex and Turkish Machinery, as well as our exhibitors. We can’t wait to deliver another fantastic show next year”.

World-class providers

More than 200 solution providers were in attendance, representing the best of British manufacturing alongside a wealth of marketleading international suppliers.

Thousands of new products and innovations were displayed across the full range of advanced engineering technology, systems and services – from additive manufacturing and metrology solutions to frictionless bearings, cables and controls, and everything in between.

Curated by The Engineer, Manufacturing Management and Machinery, Subcon brought together a variety of quality conference content.

The conference delivered high-quality, case study-led discussions on a range of topics, including automation, cybersecurity, energy storage, net zero, recruitment and retention, supply chain resilience and much more, featuring speakers such as Professor Paul Monks, Chief Scientific Advisor for the Department of Energy Security & Net Zero, and Mike Wilson, Chief Automation Officer at the MTC.

For the first time, the Subcon badge also gave visitors access to a number of other shows taking place in adjacent halls on the same dates. Visitors had free access and seamless entry into Subcon, Med-Tech Innovation Expo, TCT 3Sixty, Automechanika Birmingham, Automotive Supply Chain Forum, Smart Factory Expo, Design Engineering Expo, Maintec and Drives and Controls Zone.

Event Director Jason Dante commented on the co-location, saying: “We were thrilled

to be a part of this collaboration that brought together a wide range of manufacturing and engineering events. Subcon has been at the forefront of the UK’s subcontract manufacturing supply chain for almost 50 years, and we were proud to have the opportunity to showcase our exhibitors’ capabilities and innovations alongside other industry-leading events.”

Bigger and better in 2024

Subcon returns to the NEC, Birmingham, on June 5-6, 2024, this time in Hall 3A, making accessing the events taking place across the same dates even easier. Additionally, the Subcon floorplan has an incredible 33% expansion on 2023; this, along with the high rebook rate and the continued growth in visitors, makes for a brilliant couple of days next year.

Automation UK dazzles audiences on its debut

The inaugural Automation UK event, hosted by BARA and co-located with the established Machine Vision Conference, proved to be a major hit with visitors, justifying the decision to launch the new exhibition.

During the two-day Automation UK event at the CBS Arena, Coventry, hundreds of visitors packed the venue’s aisles, eager to take in the exhibitor displays, gather the latest market intelligence at the event’s seminar programme and network with likeminded professionals.

The new event featured the finest in UK automation and robotics. Special guest and double keynote speaker Jeff Burnstein, president of the US-based A3 (Association for Advancing Automation), said: “I am very impressed by the focus on robotics as well as the customers who are walking the show and seem to be finding solutions they are interested in.”

For some visitors, Automation UK was their entry point into the world of automation and its implications for future working practices. The event’s organisers, BARA (British Automation & Robot Association), said all of the exhibitors had been keen to assist the attendees and prospective customers with any questions or queries they might have had.

Over the course of the two-day exhibition, visitors filled the halls repeatedly and were treated to an array of seminars, with live working demonstrations of robots of all shapes and sizes, including the very housetrained ‘Spot the Dog,’ an agile, mobile robot which came to the show with his Manufacturing Technology Centre handlers.

Sitting alongside the new Automation UK event, the 7th Machine Vision Conference (MVC), organised by the UKIVA (UK Industrial Vision Association) – also part of the PPMA group of associations – provided visitors with the opportunity to see the latest in machine vision technology, development and applications as well as its capabilities.

Visitors were given unique displays of

industrial vision, and imaging technology, alongside many active demonstrations involving high-speed cameras. In the event’s five seminar theatres, industry experts imparted unparalleled knowledge on subjects ranging from vision innovation and understanding vision to 3D vision.

MVC attendees were able to visit 50 presentations during the two-day show, as well as view demonstrations on almost 50 exhibition stands. Visitors ranged from engineers thorough to company founders, all looking to learn about new developments and innovations within vision systems.

Scott McKenna, Deputy Chief Operating Officer at PPMA Group of Associations, said: “It was important that we set a precedent of excellence with the inaugural Automation UK exhibition, which we certainly achieved. Exhibitors reported seeing buyers from a

wide range of industry sectors, people they wouldn’t meet at any other UK exhibition. Visitors also commented that the show felt like an already established event, despite this being the first edition. We are planning to capitalise on the momentum that has been generated, with double the floor space reserved for 2024.

“The established Machine Vision Conference, which evolved into a two-day event alongside Automation UK, was also a huge success; capitalising on the synergies that exist within these sectors, visitor numbers were at an all-time high. We very much look forward to growing the event next year with even more informative content and innovative technology on display.”

www.automation-uk.co.uk

www.machinevisionconference.co.uk

Smart camera for constrained spaces

OMRON has launched the MicroHAWK F440-F smart camera, a configurable device with a 35 frame-per-second 5-megapixel monochrome global shutter sensor. The camera’s C-mount lens compatibility and support for external lighting options allow users to optimise their imaging setup. Additionally, the F440-F’s compact size positions it as the smallest smart camera in its class, while the AutoVISION setup tool allows for quick and easy configuration enabling users to quickly achieve optimal imaging performance.

The camera supports Digital I/O, RS-232, Ethernet TCP/IP, EtherNet/IP, and PROFINET. industrial.omron.eu

Swift ERP upgrade achieved

Supply chain solutions provider

TouchPath has achieved a swift ERP upgrade to Microsoft Business Central for user VADO, a leading bathroom fittings company. The change has been enabled by TouchPath’s flexible ‘Touch WMS’ system, which now integrates with ten mainstream ERP systems market-wide. TouchPath technology uses smart, flexible modules that can be bolted together in almost any combination to deliver a customised solution at an off-the-shelf price, deploying systems technology.

www.touchpath.com

WorkfloPlus drives sales success

One of the world’s leading drivetrain component remanufacturers has surpassed its sales goals, exceeding its targets consistently since introducing Intoware’s WorkfloPlus platform.

Drivetrain manufacturer, Centranz, has exceeded sales targets consistently since introducing Intoware’s WorkfloPlus platform.

WorkfloPlus captures details of failures and communicates their findings to the company’s customers through a report, identifying problems and clarifying solutions.

The results of streamlining this process between Centranz and its customers have seen the company surpass its quarterly sales goals since implementing WorkfloPlus in December 2021. bit.ly/Workflo

Precision industrial automation and motion control

British Encoder Products has launched its newest catalogue, showcasing a collection of encoders tailored for various industries. From manufacturing and robotics to aerospace and medical devices, these encoders are purpose-built to excel in specific applications. With meticulous attention to detail, BECo ensures that each encoder seamlessly integrates into the unique environments and challenges of different industries, Whether for precise positioning, reliable feedback, or complex motion control. Find your ideal motion control solution.

www.encoder.co.uk

Multi-machine data connection package

At PPMA 2023, Fortress Technology is launching a centralised data collection package that can work across an unlimited number of inspection machines – including checkweighers, metal detectors, x-ray, and even label and coding machines. Featuring a simple front-end system, processors can connect as many or as few inspection devices on one software system, even different makes, models and non-Fortress machines. Once installed, the subscription-style package can be easily scaled up to incorporate more machines. Data captured ranges from an industry-standard weight and quality monitoring system, to monitoring and reporting COP checks. All data is date and time stamped, logged, and reports all non-conformities.

www.fortresstechnology.co.uk

CONNECTIONS

3D Print Manufacturing

Midlands 3D Printing

Units 6-7 Emerald Way, Stone Business Park, Stone, Staffordshire, ST15 0SR

T: 01785 594389

E: sales@midlands3d.com

W: www.midlands3d.com

Anti Vibration Products, Mounts & Bushes

Fibet Rubber Bonding (UK) Ltd

Unit 9 Dale Mill, Hallam Road, Nelson, Lancashire, BB9 8AN

T: 01282 878200

E: sales@fibet.co.uk

W: www.fibet.co.uk

Control Systems

Beckhoff Automation Ltd

The Boathouse, Station Road

Henley-on-Thames, Oxon RG9 1AZ

T:+ 44 (0)1491 410539

E: info@beckhoff.co.uk

W: www.beckhoff.co.uk

Dust & Fume Solutions

Impact Technical Services

3 Kingsley Street, Leicester, LE2 6DY

T: 0116 244 8855

E: enquiries@impactts.co.uk

W: www.impacttechnicalservices.co.uk

Flow Meters

Titan Enterprises Ltd Unit 2, 5A Cold Harbour Business Park, Sherborne, Dorset, DT9 4JW

T: +44 (0)1935 812790

E: sales@flowmeters.co.uk

W: www.flowmeters.co.uk

High Shear Mixing Equipment

Silverson Machines Ltd

Waterside, Chesham, Buckinghamshire, HP5 1PQ

T: +44 (0)1494 786331

E: sales@silverson.co.uk

W: www.silverson.co.uk

Industrial Communications

Brainboxes

T: + 44 (0) 151 220 2500

E: sales@brainboxes.com

W: www.brainboxes.com

Industrial Fans

Axair Fans UK Limited

Lowfield Drive, Wolstanton, Newcastle-under-Lyme, ST5 0UU

T: 01782 349 430

E: aj@axair-fans.co.uk

W: www.axair-fans.co.uk

Machine Safety

Schmersal UK Ltd

Sparrowhawk Close, Malvern, Worcestershire, WR14 1GL

T: 01684 571980

E: uksupport@schmersal.com

W: www.schmersal.co.uk

Pipework Systems

Jacob UK Ltd

Laundry Bank, Church Stretton, SY6 6PH

T: 01694 722841

E: sales@jacob-uk.com

W: www.jacob-group.com/uk

Robotics & Automation

KUKA Robotics UK Ltd

Great Western Street, Wednesbury, West Midlands, WS10 7LL

T: 0121 505 9970

E: sales.uk@kuka.com

W: www.kuka.com

Rotation Monitoring Equipment

Rotech Systems

Unit 57, Canal Bridge Centre, Ellesmere Port, Cheshire, England, CH65 4EH

T: +44 (0)151 356 2322

E: sales@rotechsystems.co.uk

W: www.rotechsystems.co.uk

Sensors

Carlo Gavazzi UK Ltd

4.4 Frimley Business Park, Frimley, GU16 7SG

T: 01276 854110

W: www.carlogavazzi.co.uk

IFM Electronic

Efector House, Kingsway Business Park, Oldfield Road, Hampton, Middlesex, TW12 2HD

T: 020 8213-0000

E: enquiry.gb@ifm.com

W: www.ifm.com

PLUS Automation Ltd

Lyth Farm, Lyth Lane, Ombersley, Droitwich, Worcestershire, WR9 0LG

T: 0121 58 222 58

E: Sales@PLUSAutomation.co.uk

W: www.PLUSAutomation.co.uk

Test & Inspection

Cupio Services Ltd

T: 01256 262800

E: info@cupioservices.co.uk

W: www.cupioservices.co.uk