MEPCA September 2023

Discover our new large robots, now available in 22 modular variants

Discover our new large robots, now available in 22 modular variants

We have expanded our large robot family with four new models. With 22 variants for payloads ranging from 150kg to 310kg, and reaches from 2.5m to 3.2m, our IRB 6710, IRB 6720, IRB 6730 and IRB 6740 industrial robots offer more choice and greater flexibility for more sustainable production models.

We have expanded our large robot family with four new models. With 22 variants for payloads ranging from 150kg to 310kg, and reaches from 2.5m to 3.2m, our IRB 6710, IRB 6720, IRB 6730 and IRB 6740 industrial robots offer more choice and greater flexibility for more sustainable production models.

See how you can grow your productivity and competitiveness with robots: https://new.abb.com/products/robotics/

See how you can grow your productivity and competitiveness with robots: https://new.abb.com/products/robotics/

Discover our new large robots, now available in 22 modular variants

We have expanded our large robot family with four new models. With 22 variants for payloads ranging from 150kg to 310kg, and reaches from 2.5m to 3.2m, our IRB 6710, IRB 6720, IRB 6730 and IRB 6740 industrial robots offer more choice and greater flexibility for more sustainable production models.

See how you can grow your productivity and competitiveness with robots: https://new.abb.com/products/robotics/

Editor

Chris Callander chrisc@cimltd.co.uk

Publication Manager

James Davies jamesd@cimltd.co.uk 01795 509105

Account Manager

Hannah Moody hannah@cimltd.co.uk 01795 509115

James Burke jb@cimltd.co.uk 01795 509115

Design & Production

Grant Waters grant@cimltd.co.uk

James Taylor james@cimltd.co.uk

Administration Manager

Natalie Murray admin@cimltd.co.uk 01795 509103

Marketing Manager

Lucas Payne lucas@cimltd.co.uk

Head of Social Media

Beth Kellock beth@cimltd.co.uk

Sales Director

Tom Woollin tom@cimltd.co.uk

Chief Executive

John Denning

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The concept of a ‘lights out factory’, where a fully automated manufacturing facility operates without human intervention, to the point where the lights can be turned off, aims to maximise efficiency, reduce staffing costs, and increase production throughput using advanced automation technologies such as robotics, AI, and the IIoT.

While some examples of lights out factories are in operation, such as a facility manufacturing FANUC robots in Japan, widespread adoption is still a long way off.

Many manufacturing processes still require human oversight, intervention, and maintenance. However, significant advancements have been made in automation, and some factories do operate with minimal human presence during certain periods, especially in industries like automotive manufacturing and semiconductor production.

There are several advantages offered by the approach; alongside cost efficiencies, the quality and consistency, and safety benefits of a human-free automated manufacturing facility can be significant. However, factors such as high set-up costs, complex maintenance requirements and security concerns mean it is far from a no-brainer.

So, while examples of lights out factories will continue to emerge, not all production processes or industries will be suitable for complete automation. Hybrid models, where humans and machines collaborate, will, I believe, be more prevalent in many sectors for many years to come.

Chris Callander, Editor

Pump sector welcomes announcement on CE Marking

The British Pump Manufacturers Association (BPMA), on behalf of the £1.9 billion UK pump sector, has welcomed the recent announcement from the Department of Business and Trade regarding the indefinite extension to the use of CE marking for UK businesses.

The CE (Conformité Européenne) mark is used across Europe to certify that a wide range of items – including pumps and related equipment - meet stringent product safety standards. As a member of the European Union, the UK had for decades adopted the use of this safety marking for products being sold both within the UK and throughout the European continent.

However, as part of a wide range of proposed post-Brexit legislative changes, the Government had planned for this safety marking to be replaced by a new UKCA (UK Conformity Assessed) mark for all goods sold in Great Britain from the end of 2024, a deadline which had already endured several postponements and extensions.

UK businesses and their respective trade organisations have for many years been calling on the authorities to extend the use of the long-established CE mark, explaining that forcing them to meet the new UK

rules, which simply duplicates EU product standards, would add a significant and unnecessary cost burden to UK industry. With the UKCA mark not being recognised in the EU and only required for goods being sold in Great Britain, manufacturers would have needed to adopt both conformity protocols for products destined for both marketplaces. Notably, this would have also been the case for all overseas manufacturers wishing to sell products into the UK.

The BPMA has been key among this growing voice of objection, having pushed for the retention of the CE Mark from the moment a UK replacement had been suggested. Wayne Rose, Director and CEO at the BPMA, said of this latest announcement: “Our pump manufacturing members have always been at the forefront of technology adoption, whilst seeking improvement gains for both sustainability and energy efficiency. They have also led the way in developing the current European safety standards, and so we welcome this decision by the Department of Business & Trade, as a common sense and pragmatic approach to assisting UK Industry.”

Wayne continued: “Some of our larger members have already endured the unwelcomed expense and bureaucracy

of dual safety mark adoption, simply to continue selling the same products to the same markets, so although they too will welcome this announcement, a good deal of wasted time, effort and cost has already been spent. For our smaller members, they will be relieved that the cliff-edge deadline of UKCA mark adoption has been removed and that they can now redirect their efforts into product innovation and business growth.

Eleven more companies join Digital Catapult’s Digital Supply Chain Hub

Digital Catapult, the UK authority on advanced digital technology, has partnered with five leading technology companies and six pioneering SMEs to solve critical supply chain challenges facing small-to-mediumsized manufacturers across the country. As part of the Made Smarter Innovation | Digital Supply Chain Hub, the initiative will fund and facilitate the development of pioneering solutions to remedy significant industrial challenges, with a view to driving economic growth and advancing the UK’s manufacturing sector.

The competition will fund the development of advanced digital solutions with up to £100,000 for each tech company to deploy their solutions into the supporting manufacturer’s businesses, who will receive £25,000 to bolster this activity.

To maintain the UK’s position as number nine in the world in terms of manufacturing output, the challenges identified in this programme will be key to ensuring that manufacturers can look to innovation as a means of improving efficiency and achieving sustainable growth. These challenges include improving compliance and reducing the administrative burden on SMEs in the

FMCG industry through the use of digital and paperless systems, supporting export growth through improved compliance with export regulations; reducing waste in the textile industry through the use of digital infrastructure to explore the diversion of waste to secondary markets; providing visibility of inventory levels and/or delays in supply to enable better planning and prioritising by the SME manufacturer in the automotive industry; and understanding the true costs of purchasing materials so the SME manufacturers can make better decisions around sourcing and reduce their overall input costs.

Export support must reflect companies’ efforts to grow into new markets

The majority of English regions and Wales are seeing a downward trend in their share of manufacturing exports to the EU, suggesting a potential structural shift in the UK’s trade patterns, according to analysis published by Make UK and accountancy and business advisory firm BDO.

The analysis of official data as part of the Make UK/BDO Regional Manufacturing Outlook Report 2023 shows that the UK’s overall share of manufacturing exports to the EU increased in 2022 to 52% from 50% in 2019. However, this was a result of sharp increases in the share of exports to the EU from Northern Ireland and Scotland over the same period, without which the overall UK share of goods exports would also be on a downward trend.

Northern Ireland enjoys a unique Dual Access position retaining access to the Single Market for goods and being able to trade goods freely into the rest of Great Britain, while in Scotland, the oil and gas sector and its supply chains boosted exports to the EU during the ongoing Ukraine crisis.

Furthermore, given the share of goods exports to both Asia & Oceania and North America has remained relatively stable at around 16% since 2019, this would indicate that UK manufacturers are looking at opportunities outside their traditional big three markets.

According to Make UK, this has significant implications for Government policy on export support if the share of trade with the UK’s nearest and most important market is falling and businesses are looking for opportunities elsewhere. In response, Make UK is calling for a boost to export support for companies, especially SMEs, as well as changes to existing structures, to provide more support for companies exporting to countries outside the EU.

In order to help boost exports, especially by SMEs, Make UK has made the following recommendations:

1. Extend the geographical reach of the Export Support Service (ESS). The ESS should be extended to include all key UK export markets, not limited to the EU. In addition, a ‘continuous improvement’ approach to the advice available should be embedded as early evidence suggests in its current form it is a ‘signposting’ service and not for bespoke advisory work.

2. Ensure the package of grants and practical support to assist exporters in attending trade shows and similar events overseas remains in step with export market priorities and demands of exporters: Government should consider re-instating the Trade Access Programme (TAP), which was valued by manufacturing SMEs. This would help ensure current programmes meet the demands and priorities of existing and potential exporters.

3. The Export Academy (or similar channel) should create a

bespoke financial package to boost the skills base for exporters to improve their knowledge in exporting. Company-level exporting strategies should be as important as a marketing or business development strategy; however, businesses do not have easy access to provisions to help build that expertise domestically. Too often, business export strategies are underutilised; therefore, there is a need to identify partners to build up UK expertise on trade through schools, universities and within business.

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From waste to packaging material

Why buy new packaging material when used cardboard boxes are available? With the HSM ProfiPack packaging machines, used cardboard is converted into high-quality packaging and filling material – in an economical and ecologically friendly way. These devices are a perfect solution for all dispatch and storage areas as their steel-plate housing was designed especially for robust operation in outgoing goods departments.

The HSM ProfiPack C400 and P425 packaging machines form used cardboard to padding, creating packaging material for universal use. Besides reducing costs, this is a sensible and practical contribution to environmental protection.

Cutting and padding are done in a single step – no time-consuming precutting of the cardboard is required. The measurement scale on the device allows easy, infinitely variable adjustment of the working width. The HSM ProfiPack C400

is a compact tabletop device with a nonslip base; the HSM ProfiPack P425 is a floor-mounted device with castors and a parking brake. Both models can be used flexibly thanks to the 230V connection. The cushioning volume can be adjusted as required. The finished packaging padding can be used for the perfect

Colour sensor portfolio sees significant upgrade

SICK has announced a major advance in its colour sensor portfolio, with the launch of its CSS and CSX high resolution and high-speed devices. SICK’s newly developed flagship CSS colour sensor leads the way with best-in-class colour resolution and the ability to distinguish even the slightest nuances in shade. Its capability to identify subtle differences in surface structures and textures opens up wide-ranging applications.

The CSS Colour Sensor detects colours precisely, regardless of the distance from the object, at lengths of up to 500mm. Its unique distance regulation capability dispenses with the need for strict guidance of the target. It therefore accommodates changing sensing distances automatically on a production line, e.g. to account for differing orientations of a product on a conveyor, and to handle varying object sizes with ease.

Live L*A*B* or RGB colour values are displayed directly on the CSS’s on-sensor full-colour display. An innovative teach-in method enables the sensor to assess the similarity between the detected colour and expected colour in real time. Up to 15 colours can be output directly via the sensor’s four switching outputs. The IOLink enabled colour sensor also offers the unmatched capability to output up to 24 colours to a machine controller.

With a switching frequency of 13.8kHz, the SICK CSX High Speed sensor masters

protection of the most diverse objects: as a padding mat, a padding wrap or for filling hollows.

Users benefit in two respects from the cardboard perforators: they no longer need to purchase packaging material, and disposal costs are reduced.

www.hsm.eu

typical applications such as the detection of colour marks, labels and splices as well as high-speed production tasks such as rapid sorting of objects according to colour.

The CSS and CSX colour sensors help to achieve higher process speeds and higher throughputs with outstanding detection repeatability in wide-ranging applications, for example to distinguish metal parts by their temper colours, or to differentiate manufactured components or glued areas by colour.

www.sick.co.uk

Calibration and tooling asset management covered

IndySoft has been transforming the way both enterprise manufacturing and commercial calibration labs have managed their systems for over two decades. As perpetual innovators, IndySoft has introduced multiple technologies, which are now staple requests by any organisation seeking a professional asset management solution, and the company continues looking towards the future to add new technologies that will save time and money. Its focus is on calibration, tooling, automation, maintenance, and repair.

IndySoft believes that the purchase of a calibration or tooling asset management system is one of the most important decisions a company can make in relation to the efficient administration of its quality program. IndySoft’s feature-packed yet easy-to-use software is designed to complement and augment users’

processes, not dictate how they run their business. IndySoft personnel take the time to understand the requirements of all potential users, then by harnessing the company’s collective experience, suggest the exact mix of cost-effective products and services to meet long-term efficiency goals.

IndySoft’s global customer base covers the smallest manufacturing facility to the largest international enterprise organisations in a wide range of industry types, including aerospace, automotive, marine, rail, space, pharmaceutical, medical device, defence, test facilities, calibration laboratories, National Standards Bureaus and research and development facilities to name just a few.

A license of IndySoft gives users the ability to manage their assets, track them throughout the business, and assign schedules to them like calibration, preventative maintenance,

service and repair, plus much more. In addition, IndySoft has the ability to manage tooling, consumables, unique tools, gigs and fixtures and any asset with an identification number. Barcoding within IndySoft and RFID tracking are both options that can speed up your asset compliance and tracking.

www.indysoft.com

SEEPEX wins condition-based monitoring framework agreement

SEEPEX, a leading worldwide specialist in progressive cavity pump technology and digital solutions, has secured a framework agreement with Anglian Water. This agreement solidifies SEEPEX’s expertise and positions the company as a key player in the field of Condition-Based Monitoring (CBM).

The framework agreement involves the supply, installation, and management of CBM systems for Anglian Water. SEEPEX’s cutting-edge technology will enable Anglian Water to move towards a more proactive approach to maintenance and monitoring the condition of rotating and pumping assets. This condition-based approach will optimise asset performance, minimise costly repairs, and maximise the lifespan of their critical infrastructure.

SEEPEX and Anglian Water have enjoyed a long-standing collaboration since the Eighties. SEEPEX’s expertise in providing progressive cavity (PC) pumps has made them one of the nominated framework suppliers for PC

pump technology. Some 700 SEEPEX pumps are installed across Anglian Water’s sites in environmental applications, including thermal hydrolysis, sludge cake pumping and back mixing, pumping stations and chemical/ flocculent dosing.

SEEPEX’s success in winning the framework agreement highlights its achievements in the digital field. The comprehensive tender process involved navigating new horizons, incorporating IIoT capabilities and cybersecurity. SEEPEX’s dedicated team, including digital experts and cybersecurity specialists, demonstrated SEEPEX’s forward-thinking approach to digital innovation.

Being awarded the framework agreement places SEEPEX in an elite league of companies, shows that SEEPEX can compete with the specialists in the digital space and re-affirms SEEPEX’s superior digital ecosystem and portfolio within the CBM domain.

SEEPEX’s digital ecosystem – integrating digital monitoring and cloud-based services –will provide information to Anglian Water on its equipment’s condition, with reports showing

the actual status quo of the equipment and processes, enabling predictive and forwardplanned maintenance.

With the framework agreement in place, SEEPEX is positioned to revolutionise Anglian Water’s asset management strategies. By leveraging advanced CBM systems and comprehensive analytics, SEEPEX will empower Anglian Water to proactively monitor asset health, achieve greater operational efficiency, and deliver an exceptional level of service to millions of customers across the region.

Giving sight to robots

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The UR+ plugin ensures smooth and quick integration of the sensor. It detects any object, even moving ones, and transmits its exact position and dimensions to the robot control. Never before was gripper navigation so easy! ifm – close to you!

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Never underestimate the value of a good systems integrator

George Thompson, Chairman of BARA, the British Automation & Robot Association, explains why he sees system integrators as the most important facet of an automated manufacturing solution.

Iwas recently asked what I thought the most important part of an automated solution was. My reply could have been the robot, which I consider to be the beating heart of the automated solution, or perhaps the control architecture, which I would describe as the system’s brain and central nervous system. If we add in vision, then the system can see. The list goes on. However, the most important part for me would be the system integrators, and the core knowledge they have about a particular process or application should never be underestimated or assumed.

I often describe system integrators as being like the conductors of a worldclass orchestra. Even if you have the best musicians and instruments, the conductor is the key to it all. Just as the conductor understands how to get all the different component parts of the orchestra to work together and squeeze the very best out of each piece to create beautiful music, so do the system integrators. They understand how each component works and how to incorporate each part to create a highly efficient automation solution.

One of the first things that most integrators would like to understand is how their potential customers’ current process works. Personally, I want to have a discussion with the line operatives to learn what improvements they have made to the official process. Once this information is obtained and the detailed models of the parts to be handled or assembled have been studied, this is when we need to start the process of developing the initial concepts for the automated process.

There are times when perhaps an integrator is chosen from an area outside of its core expertise because of either how it approaches challenges, or because its expertise is close enough to

the manufacturing challenge that it would be deemed advantageous for them to at least look through the project. An example of this could be a company known for its work in the pharmaceutical or aerospace industries being asked to look at a project in the food and drink sector, because of its experience in traceability control procedures. Another may be for an integrator known for automotive tier 1 experience being asked to look at a project in general industry to give insights on how to rework the end product with automated assembly in mind.

As another example, I was recently looking at a project where the product needed a specific process that was unusual for the raw product. The inspiration for the solution came from a machine tending application I sold several years ago. The only similarity between the projects is they use robots to achieve the end result. They are entirely different industries, and the materials could not be more different. It was only as a direct result of looking at the information gathered from my site visit and one of those operator improvements to the manufacturing process that made me even think, ‘I wonder if this would work’.

So, if you are an end customer and you have a manufacturing challenge, when you

are researching system integrators, make sure that you carry out your due diligence and make sure that the integrator that you are thinking about engaging with has a wide range of experience within their pool of employees. You never know where the inspiration for the solution you have been looking for may come from.

If you want to start your automation journey, but don’t know where to start, I highly recommend visiting the BARA website (www.ppma.co.uk/bara.html), where we have outlined several topics under the expert advice section to give some initial information.

Have passwords had their day in factory operations?

David Dearden, UK&I Country Manager of safety specialist Euchner, offers a compelling argument for considering alternatives to passwords in factory operations. He presents a secure alternative - the Electronic Key System, capable of protecting people, processes, and increasing product safety in manufacturing and process industries.

In the age of industrialised digitalisation, the significance of managing processes and ensuring the safety of equipment and operators in modern manufacturing and process industries cannot be understated. For years, passwords have been the go-to method for access control and security in factories, with HMIs, touchscreens, industrial PCs, and robot controllers relying on login options and access levels based on passwords. However, as technology evolves and the demand for total traceability and transparency grows, questions arise around the efficacy of passwords in meeting these stringent requirements.

The pitfalls of passwords

Passwords, if used and managed effectively, can be a robust security tool. The key lies in ensuring they are not revealed, shared, or hacked. Unfortunately, human errors are common, leading to insecure practices like writing passwords on control panels, compromising product safety. Furthermore, poor password security can lead to the replication of passwords throughout the production lines, creating potential hazards where shared passwords can jeopardise individual traceability.

Moreover, many systems fail to automatically log users off after inactivity, enabling unauthorised access. For instance, incorrect recipe management due to open sessions can have severe safety implications in the food and beverage or pharmaceutical industries. As industries move towards more demanding traceability requirements, accurate identification of operators at specific times becomes paramount. Traditional password systems may not provide the necessary level of security and traceability in this environment.

The rise of electronic key systems

To address these challenges and enhance security and traceability in manufacturing processes, Euchner proposes the use of RFID-based Electronic Key Systems (EKS). Unlike passwords, electronic keys offer a secure solution for access control and data management while maintaining traceability within the existing plant control system.

EKS provides uniquely colour-coded inductive key tags that enable or control multiple processes, ranging from operations to maintenance, and even hazardous mode selection. The flexibility and versatility of an EKS makes it an ideal choice for manufacturing facilities seeking an enhanced level of safety for employees and customers alike.

The main advantage of Euchner’s EKS lies in its programmability, offering adaptability to various tasks within a manufacturing or processing facility. Some key features and benefits of EKS includes:

• Individual authorisations: The EKS allow for the precise assignment of individual authorisations to specific personnel,

enhancing security and accountability.

• Traceability: The system facilitates tracking of actions and events, allowing manufacturers to identify who performed specific tasks and when.

• Recipe and batch management: EKS enable the saving and recall of recipes, batches, and other process parameters, ensuring consistent and high-quality product output.

• Electronic signatures: The system supports electronic signatures, streamlining authentication processes and increasing data integrity.

• Fast user profile switching: The EKS enables quick and secure switching between user profiles, minimising the risk of errors during equipment setup and operation.

• Customisable ergonomic/language data: Electronic keys can carry ergonomic and language data, allowing operators to set up their workplaces individually, reducing the likelihood of mistakes.

• Data acquisition for enterprise resource planning: The EKS facilitates data acquisition for efficient enterprise resource planning, enhancing overall productivity.

Enhanced safety and efficiency

The EKS significantly improve safety and efficiency in factory operations. With fast and secure switching between recipes, user profiles, and data, operators save time when moving between equipment or changing parameters. Additionally, the system’s colourcoded keys simplify identification, with different keys assigned to operators, access levels, or specific products.

By assigning process parameters to individual keys, EKS ensures product quality, preventing the use of incorrect settings and potential hazards. The systems are also invaluable in multi-language settings, allowing operators to easily select their preferred language, reducing errors and improving communication.

Robust design for challenging environments

The tag readers in the EKS are housed in compact, robust, and hygienic units, making them suitable for harsh industrial environments. These units offer a high ingress protection rating, including IP69, ensuring compatibility with cleaning-in-place (CIP) applications and high-pressure jet spray cleaning in food processing plants. The EKS can be configured to ensure correct CIP and maintenance procedures, saving costs and energy and enabling individual traceability of cleaning activities.

All crucial information, including batch codes and process parameters, can be stored in a central database. This ensures reliable data tracking and traceability. Unlike magnetic-coded swipe cards that can lose data, EKS tags are immune to such vulnerabilities. Moreover, in case of a lost or stolen tag, it can be blocked without the need for reprogramming the entire system.

While biometric and machine vision technologies are gaining traction as password replacements, they may not be suitable for

all factory settings. For instance, fingerprint readers may face challenges in environments where operators wear gloves or have dirty fingers. Electronic keys, on the other hand, provide a flexible and effective alternative, eliminating human error and increasing safety across various systems and processes.

Electronic Key Systems in action

For one of the leading chocolate manufacturers in Europe, precise and safe delivery of the raw ingredients is essential, but unloading them is a complex operation and errors are costly. A total of 32 key-operated rotary switches would normally be necessary to direct the raw ingredients to the right station in the manufacturing plant. However, thanks to Euchner’s Electronic Key System, this number has been reduced to just four read stations, making the process of receiving the new raw ingredients into the warehouse much more effective. The confectionery industry is yet another food and beverage sub-sector where the EKS wins a (chocolate) gold medal.

Euchner’s innovative EKS not only makes the process of transferring the raw ingredients considerably safer but also significantly more efficient. All tasks are now carried out by one system with just four read stations, rather than a complex system requiring multiple keyoperated rotary switches and the potential for errors the original control system created.

The EKS works using an electronic key and a corresponding key adapter. The electronic key contains a transponder with data memory that allows it to transmit data without using any contacts to the read head. In contrast to conventional installations with key-operated rotary switches, it is not necessary to replace the entire system if one key is lost. This isn’t a problem with the EKS, which allows the customer to generate a new electronic key with just a few clicks.

The flexibility and features of the EKS system were taken advantage of during the integration of the system in the company’s new raw ingredients warehouse. The process is simple, when the raw ingredients arrive by truck, an EKS chip is issued, allowing the employees to unload the delivery at the right receiving station and into the right container. Each receiving station, path and target container has its own corresponding programmed and numerically marked chip, whose code is read by the RFID readers, which are connected via PROFINET for easy integration into the original control system.

The information is then stored in a central database, ready to be processed by the ERP and recipe systems.

Euchner’s EKS is currently responsible for managing the entire raw ingredients warehouse and all of the elements and PCs associated with it. “We hope to soon use the system for our production computers as well,” said the company’s head of electrical engineering, who was responsible for the implementation of the new technology. He added: “The EKS is user-friendly, reliable, forward-thinking, safe, easy to configure and manage, and good value.” Plans have already been drawn up to expand the application of the EKS into the production areas because the solution has proven so successful in the ingredients warehouse.

A secure alternative

Passwords have served as a common access control mechanism in modern manufacturing facilities. However, with the rise of industrialised digitalisation and increased traceability demands, it’s becoming clear that alternative solutions are needed. Euchner’s EKS presents a secure and versatile option for managing processes, protecting people, and enhancing product safety in manufacturing and process industries.

The EKS provides individual authorisations, traceability, fast user profile switching, and a range of other features to streamline operations and improve efficiency. A robust design, combined with a centralised database and colour-coded keys, ensures enhanced safety and security while minimising the risk of errors. As the industry continues to evolve, the EKS solution emerges as a reliable solution to meet the ever-growing demands for safety and traceability in factory operations. www.euchner.co.uk

Sustainability through supply chain management

As part of the company’s focus on sustainability, Turck Banner outlines three applications in the supply chain management category which demonstrate that sustainability doesn’t have to come at a cost and can, in fact, save money.

At a distribution centre, maintaining the control of Returnable Transport Items (RTIs) can be extremely challenging as different suppliers use different RTIs. Once the RTI has been emptied, it has to be stored before being returned to the supplier. One distribution centre was upgrading its inventory control by utilising Turck Banner’s RFID system, which can read hundreds of tags almost simultaneously as they pass through a gate. In addition to the products having an RFID tag, a tag was added to the RTI. The task of checking-in product inventory was greatly sped up, and product traceability was enhanced, which were the primary objectives of the upgrade. However, the simple addition of tags to the RTI enabled the emptied RTI to be identified and directed to the allocated storage area, based on the type of RTI and the supplier. Damaged RTIs were also recorded by their tag, enabling the supplier to easily identify, repair or remove them. Although RTIs are designed to protect the product that they contain during transport, a damaged RTI can often be the cause of a product being damaged.

The distribution centre achieved its primary objectives of making itself more efficient and saving costs. Whilst using RTIs is, in the majority of cases, far more sustainable than using single-use packaging, the centre was able to enhance its sustainability by greatly reducing product damage and waste from damaged RTIs.

Streamlining product supply

While supply chain management is often thought of as only involving external companies, improvements can often be made in the movement of products around a premises.

Turck Banner was recently approached by a prestigious motor manufacturer to supply a simple light and a switch. When the company asked about the application and business objectives driving the request, it became obvious that by working in partnership with each other huge improvements could be made in the process of moving product from the main warehouse all the way to the assembly station. As a result of implementing the changes, the takt time (time to produce a finished product) was reduced, allowing the manufacturer to increase production, which in turn paid for the changes. The customer also reduced its internal transport and maintenance costs, improving its sustainability.

Invisible traceability

Even in industries where traceability is not a legal requirement, it is often becoming a business requirement in order to generate the data required for improving processes and driving efficiency.

Barcoding is often a cheap and reliable

method of marking a product for tracking and traceability. The barcode can be made in a number of ways ranging from Direct Product Marks (DPM) that are etched or stamped into the product, to adhesive labels attached to the product. The majority of these barcodes are visible to the naked eye and consume space on the product. Ultraviolet ink, however, is only visible when illuminated with a black light. By using a filter that blocks visible light but allows UV light to pass, it is possible to print a UV barcode on top of a product that already contains printing or decoration. This facilitates tracking and traceability with all the associated sustainability advantages, without spoiling the aesthetics of a product or requiring a larger product and packaging to accommodate the barcode.

These are just three examples where careful investment in the right products can have a significant impact on both short- and long-term savings, at the same time making the product or process more sustainable.

www.turckbanner.co.uk

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Tackling challenges in the production and use of hydrogen

With hydrogen’s potential to support the decarbonisation of sectors where emissions are hard to reduce, it’s no surprise that demand for the gas is growing. However, its production and use are not without their challenges. Thankfully, with the right solutions, these challenges can be overcome, as MEPCA found out when it spoke to Danny Nicholas, Business Development Manager - Chemical, Process & Industrial - Hydrogen Equipment, at flow control and instrumentation specialist Rotork.

MEPCA: Why are we seeing a growing demand for hydrogen in industry?

DANNY NICHOLAS: There are a number of reasons why we are seeing a growing demand for hydrogen in industry. These include:

Decarbonisation - Hydrogen is a cleanburning fuel that can help to reduce greenhouse gas emissions. When hydrogen is burned, it produces only water vapour, which does not contribute to climate change. As governments and businesses around the world work to meet their climate goals, hydrogen is becoming an increasingly popular option for decarbonising industrial processes.

For example, hydrogen can be used to replace fossil fuels in the production of steel, ammonia, and other chemicals. This would help to reduce the emissions of these industries, which are major carbon emitters. New applications - In addition to decarbonisation, hydrogen is also being used in a growing number of new applications. For example, hydrogen fuel cells are being used to power cars, buses, and other vehicles.

Declining costs - Despite the relative cost of hydrogen production remaining high, they are declining over time. This is due to technological improvements and economies of scale. For example, the cost of producing hydrogen from solar and wind power has declined recently.

As the cost of hydrogen continues to decline, it will become more economically competitive with other fuels. This will help to accelerate the adoption of hydrogen as a clean and sustainable energy source. Energy security - Energy security is a critical area for hydrogen energy, as it provides a clear avenue for the internal production of energy. Hydrogen can be produced from a number of sources, including renewable energy, natural gas, and biomass. This makes it a

more secure energy source than fossil fuels, which are subject to price volatility and supply disruptions.

Hydrogen can also be stored and transported more easily than other energy carriers, such as electricity. This makes it a good option for storing energy from renewable sources, which are intermittent in nature.

M: What are the challenges faced in the production, transport, storage and use of hydrogen?

DN: Hydrogen is a promising clean energy source, but there are still some challenges to overcome before it can be widely adopted. These challenges include: Production - The cost of producing hydrogen is currently high due to the cost of the raw materials and the energy required. Some methods of hydrogen production also have a significant environmental impact by producing greenhouse gases. There is also a lack of investment in equipment manufacture and the with which products are coming through.

Fine process controls are also required in production, and control systems, in particular, require a high-level safety rating due to the potentially dangerous nature of hydrogen. Transport - Hydrogen has a number of challenges when it comes to transport. First, hydrogen has a low energy density compared to other fuels, so it takes up a lot of space to transport. This means that hydrogen vehicles would need to be larger than vehicles that use other fuels, which could be a major drawback for consumers.

Second, hydrogen is a flammable gas, so it must be transported carefully to avoid accidents. This could make it difficult to develop a safe and efficient transportation infrastructure for hydrogen.

Finally, hydrogen is often produced in smaller spaces, such as in factories. This means that more compact actuators are required to transport hydrogen safely. Storage - Hydrogen can be stored in either its gaseous or liquid state. However, both of these states present challenges. In its gaseous state, hydrogen must be stored at high pressure. This can be dangerous, and it also requires special infrastructure to maintain the high pressure. In its liquid state, hydrogen must be stored at extremely low temperatures. This can be costly, and it also requires special infrastructure to maintain the low temperature. Use - There are also challenges associated with using hydrogen. First, the infrastructure for using hydrogen, such as fuel cells and refuelling stations, is not yet widely available. This means that hydrogen vehicles would not be able to travel as far as vehicles that use other fuels.

Second, the cost of using hydrogen is currently higher than the cost of using other fuels. This is due to the high cost of producing and transporting hydrogen.

M: How are these challenges overcome?

DN: Across the key areas already highlighted, solutions from Rotork can contribute to reducing and eliminating the effects of many of the challenges that are present.

- Rotork’s solenoid valves and actuators can be used in hydrogen production plants to control the flow of hydrogen and other gases. These products are designed to withstand the high pressures and temperatures involved in hydrogen production, and they can help to improve the efficiency and safety of hydrogen production plants.

Rotork-manufactured actuators are able to accurately control the flow of hydrogen, which is essential for ensuring that the production process is efficient and safe.

A number of Rotork products are ATEX IIC rated, which is essential for environments where hydrogen is present because of its volatility. This rating means that the products have been tested and certified to be safe for use in explosive atmospheres.

Transport - Hydrogen refuelling stations require high-quality flow control equipment to control the flow of hydrogen to fuel cell vehicles.

These products are designed to be sealed and to withstand the high pressures involved in hydrogen refuelling, and they can help to ensure that hydrogen is safely transported to fuel cell vehicles.

The valves and actuators are designed to be leak-tight, which prevents hydrogen from escaping during refuelling. They are also designed to withstand the high pressures involved in hydrogen refuelling, which helps to ensure that the refuelling process is safe.

- The safe storage of hydrogen is of critical importance. Actuators need to be designed to be leak-tight and to withstand the high pressures involved in hydrogen storage, and they can help to ensure that hydrogen is safely stored.

Use - Actuators need to be leak-tight and to withstand the high pressures involved in fuel cell operation, and they can help to ensure that hydrogen is safely used in fuel cell vehicles.

In addition to their technical capabilities, Rotork products are also designed to be easy to install and maintain. This is important for hydrogen applications, as the infrastructure for using hydrogen is still in its early stages of development.

M: How do these products work in practice?

DN: In a recent application, CVL process control electric actuators were installed on green hydrogen electrolysis skids for the French equipment manufacturer AREVA H2Gen (now Elogen). The actuators were chosen for their accuracy, fail-safe action, and high-duty cycle.

All Rotork actuators offer the accuracy required for electrolysis, and process control actuators (like the CVL) offer precise modulating control and the repeatability necessary for this application.

Each electrolysis skid has three CVL actuators mounted on globe valves to regulate the pressure and level of the water used for electrolysis. Many of Rotork’s electric actuators offer essential safety certifications, such as ATEX IIC certification, which is critical for environments and sites that use hydrogen.

Of course, safety must always be the paramount concern within hydrogen applications, and Rotork actuators meet this challenge.

www.rotork.com

Digital pressure measurement for hydrogen applications

Pressure measurement specialists, ESI Technology, has launched a range of pressure transmitters designed for use in a wide range of hydrogen applications. MEPCA found out more.

ESI Technology has created solutions across a multitude of applications, including aerospace, defence, oil and gas, subsea, and renewable energies.

Recent TUV testing has also allowed ESI to release a range of hydrogen-compatible pressure transmitters. Test passed to ISO 1114-2:2017, the new range meets European Regulations EC 79/2009 and EU 406/2010, and is available with DNV-GL, ATEX, or combination certification.

This new range offers a general industrial, high pressure and high accuracy variant (available with a combination of ATEX and DNV-GL certification) plus a digital pressure transducer in the form of the GD4200-H-USB.

The GD4200HUSB digital pressure transducer has been designed to plug and play. It connects instantly to a PC, tablet, or laptop via the ESI-USB software and enables users to measure, analyse and record pressure directly to a PC without the need for costly I/O interface boards.

Nine pressure ranges have been carefully selected to enable the user to cover any pressure that the application requires, from vacuum up to 5,000 bar.

Features of the new range include:

• Pressure ranges from vacuum to 5,000 bar

• Silicon-on-Sapphire sensor technology

• A titanium diaphragm and pressure port

• Sample rate software selection up to 1,000Hz

• Accuracy (NLHR) +0.15% of span BFSL

• Free ESI-USB Software with auto-updates

• Support for easy integration with applications created by C#, VB, Labview and Excel VBA (api dll library)

The pressure diaphragm and threaded pressure port are machined from a specialist titanium alloy specifically designed to withstand harsh and demanding environments. This, along with the non-oilfilled sensor and high-integrity stainless steel

housing, results in a robust and versatile unit that offers excellent media compatibility across a range of environments.

The GD4200-H-USB also benefits from the same Silicon on Sapphire (SOS) sensor technology used throughout the ESI brand, providing outstanding performance, stability and highly accurate pressure measurement.

The ESI-USB software is compatible with Windows 8, 8.1 and 10 and is presented onscreen in real-time without loss of accuracy or bandwidth. The sample rate enables dynamic pressures to be measured with up to 21-bit resolution at user-selectable speeds up to 1,000Hz. Data can be displayed in graphical or tabular form, with a choice of pressure units and fully adjustable scales and saved to a file or exported to Excel, PDF and .csv.

Other useful features include certificate generation, customisable certificate templates, leak testing, the ability to measure, record and view up to 16 sensors at the same time, virtual differential pressure measurement, options to set automatic test start and stop times, alarm levels for each individual sensor and autoupdates for new software versions.

Ideal for hydrogen applications

Hydrogen offers a cleaner, more secure, and more affordable source of energy with the potential to drastically reduce and tackle CO2 emission levels and is already used in a growing variety of industries. Although the oil and gas sector remains the predominant source of energy supply and usage, there are significant efforts being made to find an alternative.

With that in mind, ESI is committed to offering a product range that is not only versatile and environmentally friendly, but also offers the same outstanding performance and stability that they are known for.

You can find ESI’s hydrogen products available to use in a range of applications, including hydrogen storage and production, hydrogen re-fuelling, hydrogen engines, marine propulsion, hydrogen fuel cells, laboratory environments and industrial applications. www.esi-tec.com

The value in modular robotic automation

With robotic automation called on to help companies

boost productivity and navigate a tight labour market, modular solutions address many of the practical challenges faced by manufacturers looking to optimise their operations. Julian Ware, UK & Ireland Sales Manager for ABB Robotics, explains.

Agrowing shortage of workers and an increase in the number of companies looking to near or re-shore their operations are two major drivers that are leading to a rising interest in modular robotic solutions.

Available for a wide variety of industrial applications, pre-configured, packaged robotic solutions enable easier integration, speed up installation times and minimise the effort and potential for error associated with sourcing equipment from multiple suppliers. With all the components of the production cell being serviceable by one supplier, users can access the right support more easily in the event of a problem. A fully integrated cell means that the layout can also be optimised to save space, and all the components should be able to work together at full capacity to enhance productivity.

For manufacturing companies, these benefits are typically delivered by applicationspecific packages for unit operations such as machining, welding, machine tending or quality inspection.

Scalability is a key advantage of modular systems. Modules can be changed or added as needed, while a standardised design makes it easier to re-configure existing cells to make different products to meet changing market demands.

All this enables modular robotic solutions to turn some of industry’s key challenges into opportunities.

Labour

Companies across multiple industrial sectors are being impacted by labour shortages, especially in skilled roles.

A specialised production cell such as ABB’s OmniVance FlexArc Compact incorporates robots, controllers, software, and peripherals into a single welding cell. Up to four robots can be added without changing the structure of the cell, providing improved flexibility to tackle a wide variety of welding tasks.

Quality

Eliminating quality-related issues is another key challenge because manual inspection is time consuming and error-prone. An automated solution can slash the time and effort involved at the same time as it improves accuracy.

For instance, ABB’s OmniVance 3D Quality Inspection cell uses a 3D optical sensor to inspect components ten times faster than conventional techniques and is accurate to below 100μm, enabling fast and precise identification of any product defects.

Flexibility

Maximising production line flexibility is high on every company’s wish list, so they can respond quickly to changing customer demands. In contrast to fixed-purpose machines that are designed to perform specific roles, robotic solutions can adapt quickly to new requirements.

For example, with its pre-tested combination of robot, controller, and turntable, plus pressure and level sensors and other equipment, ABB’s OmniVance Machining Cell is the first standardised machining solution able to perform up to eight different applications in a single cell. Simply by changing the end effector, the same cell can be adapted for multiple duties, including

sanding, deburring, polishing and dry ice cleaning.

Fast delivery

For logistics companies, customer expectations for fast delivery, the rise of e-commerce and the emergence of omnichannel distribution models create the biggest challenges. Compact, automated storage and retrieval systems make the best use of available warehousing space and are scalable to meet changing needs.

For instance, the OmniVance FlexBuffer combines an ABB robot, a suite of grippers, configurable storage management software, storage racking, an infeed conveyor, and an outfeed conveyor in a single cell. One version is designed to handle standard boxes such as totes, while another features an adjustable gripper for handling parcels, trays, and crates. Both versions handle a payload of up to 50kg and conduct sequencing operations at up to 500 cycles per hour.

With many businesses lacking the in-house expertise to specify, operate and manage robots, modular solutions offer a fast, flexible and cost-effective way of introducing robotic automation to a production or distribution process.

www.abb.com/robotics.

ABB’s OmniVance machining cell brings flexibility and simplicity to a range of applications including sanding, polishing, cutting, and surface finishing.

Disrupting the automated palletising market

With the company launching just months before the first lockdown, Endoline Robotics Managing Director Andrew Yates reflects on how the automated palletising operation has secured multimillion-pound orders in such a short timeframe and increased turnover tenfold in under two years.

The decision to launch Endoline Robotics (ERL) was underpinned by its parent company’s strong 40-year history in automated case erecting and sealing systems installed by global manufacturers. Backed by robust market intelligence that the demand for end-of-line automated palletising systems was on the cusp of a huge growth trajectory, it rapidly became apparent to Endoline’s leadership team that customers were seeking more than just a well-supported robot palletiser. To corroborate this, enquiries for a complete premium package connecting upstream packing operations with automated downstream palletising began to roll in.

Leveraging Endoline’s in-house technical design and engineering expertise and strong OEM partnerships, ERL realigned its strategy. As soon as the lockdown restrictions lifted, the business secured several credible leads to engineer complex, high-value full turnkey automation projects.

Andrew Yates recalled: “For almost two years, automation enquires virtually dried up, and investments were put on pause. Meetings and demonstrations switched to virtual platforms. Visits to essential manufacturers were minimised.”

However, as a supplier of equipment to essential businesses, the palletising start-up was well-placed to react to leads and design connected, automated systems that would strengthen UK manufacturing and increase productivity.

Responding to retail demands

Carr’s Flour Mills was the first ERL project to go live. Responding to the home baking boom, Carr’s needed to process and palletise 167,000 bags of flour weekly. Running 24/7, Carr’s doubled its production for one major supermarket chain from 120 to 250 tonnes per week.

“We had always planned to automate the line. Constrained by the manual process, Endoline’s robotic solution has enabled us to redeploy eight workers to other, more skilled areas of the business. Quality and efficiency have improved, and we now have greater flexibility to increase productivity for our customers,” commented Carr’s Operations Director, Ben Clark.

Making history

Valued at over £2.5 million, an installation in May 2023 at Life Health Foods (LFH) marked a pivotal turning point for automated palletising in the UK. It was also the biggest and most complex order in Endoline’s history.

In 12 months, the team designed and installed a fully-operational start-to pallet cell comprising three Fanuc M410 palletising robots, over 250 metres of straight, spiral and overhead conveyor, integrated with a centralised ERP system. Notably, palletising was relocated from the clean production space to the Peterborough plants’ adjacent warehouse located over 90m away.

All of this was done without increasing the physical footprint. What’s more, the switch from manual palletising to fully automating the handling of 100 different SKUs and

product cases was delivered without shutting production down.

Now fully operational, LHF has the increased capacity to palletise 86,000 individual product cases every 24 hours.

Peterborough Production Manager, Jon, enthused: “This fully automated palletising turnkey line has increased the versatility of our busy plant. We have already observed that staff morale is higher, labour costs are down, line speeds have improved and palletising errors have been eliminated.

There are also significant workforce health and safety and stock control benefits.”

Testament to the accelerated drive towards smart, fully-automated production facilities in the UK, Andrew reported: “Endoline Robotics has delivered five highvalue systems in a short timeframe, each of which meets a very specific customer need. For an SME, this is quite unprecedented. Yet, this validates the appetite among UK manufacturers for customised, modular automation systems that can be integrated into existing manufacturing lines and serviced and supported locally – without disrupting production.”

www.endoline-robotics.com

The palletising line installed at Carr’s during the first lockdown enabled the company to respond to increased retailer demand for flour during the pandemic.

Twenty years without a day off I

n the late 1990s, Kawasaki Motors Manufacturing Corporation (KMM) implemented a Kawasaki J series robot to weld the frame sides of Kawasaki Vulcan 800 motorcycles. More than 20 years later, this reliable robot was still running in KMM’s facility, welding different parts for a more in-demand product.

During its lifetime, this robot has run for more than 39,000 hours, the equivalent of 20 years’ worth of eight-hour shifts. It only logged 57 maintenance entries and showed flexibility by working on two different welding lines.

“The robot paid for itself in less than two years back in the ‘90s, so we’ve basically been using it for free for more than 20 years,” said KMM Chief Engineer Scott Gordon. “It really helps with the capital expense budget when you don’t have to replace something frequently.”

When KMM stopped making the Vulcan 800 motorcycle in 2004, it was able to reprogram the robot to weld steering shafts

in a product that was steeply growing in popularity: ATVs.

“We were making up to 60,000 (ATVs) per year, and they all had a steering shaft,” Scott added. “So, it was a very busy robot when it was first implemented.”

Manufacturers need to be agile enough to react to the ever-changing needs of their market. Kawasaki’s reliable robots can be reprogrammed using AS Language to tackle different applications, giving them the versatility they need to keep up with demand.

Kawasaki’s state-of-the-art BA and R series welding robots match the quality of an expert welder on their best day – every day. Each robot is equipped as standard with welding-specific software for quick and easy programming of the process path. Adaptive welding functionality is available to modify robot position, weave pattern and speed

during welding to fill variable joints, which yields high-quality welds every cycle.

Utilizing the J series robot helped KMM cut costs, improve product quality, increase efficiency, and adapt to market needs. “The robot just ran and ran and ran,” said Gordon. “The squeaky wheel gets the grease, but it never squeaked.”

kawasakirobotics.com/uk

Buy or lease? Financing your new cobot

Peter Lange, Business Business Development Manager Robotics at OMRON, looks at the options for financing an investment in robotic automation.

Skills shortages, digitisation, sustainability, and energysaving plans are accelerating automation projects in many companies. Once manual processes that lend themselves to automation have been identified, the next question that usually follows is: What does it all cost?

Manufacturing plants are short of skilled workers. A BCG survey conducted in seven countries in 2022 found that employers are at risk of losing up to 37%of their employees who do not have a typical desk job but work in production, maintenance, or service in the next months. Nearly one-third of these workers are already planning to leave the company where they are currently employed. Companies that cannot find a replacement must rethink production processes and implement technologies that reduce manual processes. But how can such investments be financed? Is buying or leasing the better option?

One technology that companies might consider first is collaborative robotics. Cobots do not require a high investment and often offer a fast ROI, which makes this technology more attractive than traditional industrial robots if used in the right applications. Cobots can be used in a broad range of applications. They are easy to deploy for different activities, and the design and implementation of the application can be done quickly. Key applications include material and product handling, assembly, and disassembly, welding and soldering, dispensing, and others.

It is easier to weigh an investment against the costs per product. For example, the price of purchasing a cobot application is 100,000 euros, and you calculate over three years. During this time, you produce 8,640,000 products, corresponding to a cycle time of five seconds per product if

production runs for 20 hours per day and 200 days per year. In this particular example case, the investment per product is one cent. Therefore, the investment in a cobot is much lower than many people assume.

The total investment cost is usually approximately equal to the average annual salary of a production employee. Based on this calculation, the investment can pay for itself after just one year or even faster.

SMEs, in particular, are often still reluctant to purchase a cobot because they are concerned about budget, cash flow, CAPEX, or lengthy project approvals. Leasing can be a good alternative here, as cash flow or seasonal fluctuations are not an issue. Leasing offers added flexibility, allowing smaller companies to reap the benefits of automation through cobots. Leasing also falls under operating expenses (OPEX): the expense is paid monthly, and investments can thus be better monitored and planned.

If the leasing contract also includes maintenance and service, it is easier and clearer to keep the cobot fleet up to date and running without having to budget for

additional costs. Plus, the cobot is always available – eliminating downtime. Automation costs the most when it breaks down. That’s why continuity must be guaranteed.

When it comes to leasing offers, it is important to ensure that financing options can be customised, as no two companies are the same. It is also ideal if the rates can be adjusted to cushion any cash flow bottlenecks. In addition, there should be the option of working with a financial service provider or even the company’s bank to be more flexible.

The complete solution should be covered. A robot needs tools, peripherals, bases, and more. Therefore, the system integrator and cobot manufacturer should offer a complete solution that can be financed holistically. Patchwork solutions are not very effective.

Many SMEs wonder how to finance a new investment. OMRON’s ROI calculator shows two options: the traditional CAPEX option with full payment at the beginning and an OPEX option with leasing, where payments are split over three to five years. bit.ly/44rTIO5

Connecting with our digital future

The recently launched Rotork App provides intelligent control and communication capabilities for the new IQ3 Pro actuators.

Rotork’s Intelligent Asset Management (iAM) cloud-based system helps reduce unplanned downtime by using analytics based on data taken from intelligent actuators to create a maintenance plan.

Smart features include:

Secure Connection - Security assured with ‘PIN pairing’ on smartphones

Valve Configuration Wizard - Guided configuration streamlines setup

Manual Configuration - Commissioning settings all in one convenient place

Setting Tool - A setting tool is always to hand

Data Logs - Flexible download, export, and upload simplifies the process

Unlock your automation with D:PLOY

Collaborative robot specialist, OnRobot, explains how its D:PLOY solution enables users to tackle labour shortages, improve flexibility, and increase production efficiency.

The scarcity of skilled robotics employees has long been a roadblock for companies seeking to integrate automation seamlessly. As labour shortages persist, demands for flexibility continue to rise, and the quest for heightened production efficiency becomes more pressing than ever. That’s where D:PLOY steps in as an innovative technology that helps users build, run and monitor your collaborative application easily and quickly. D:PLOY is now available for packaging, palletising, CNC machine tending and transferring applications.

With D:PLOY, OnRobot offers a way forward that democratises the automation landscape. By streamlining the automation process, D:PLOY enables your team to confidently adopt and implement robotic applications without needing specialised robotic expertise. Now, automation becomes accessible to all, levelling the playing field and allowing businesses to thrive regardless of their size or resources.

Flexibility on the factory floor

Industries are constantly in motion, responding to changing demands, market shifts, and unforeseen challenges. The modern business landscape is defined by those who can adapt quickly. D:PLOY’s commitment to flexibility extends beyond operational efficiency, understanding the importance of agility in the production processes. Its intuitive platform empowers you to deploy and re-deploy complete applications directly onto your manufacturing floor in a matter of hours, not days. This unmatched flexibility ensures that you can swiftly adjust your automation strategy to match the dynamic nature of your industry, giving you a competitive edge that sets you apart from the rest.

Elevating production efficiency

The value of time cannot be underestimated. Every moment saved in the deployment and re-deployment

of automation applications translates to enhanced productivity and increased efficiency. With D:PLOY, you’re not just embracing automation; you’re embracing efficiency. Say goodbye to lengthy setup and configuration processes that drain your resources and time. D:PLOY reduces deployment times dramatically, allowing you to allocate your time and resources where they matter most – refining your core business operations and driving innovation.

As you stand at the crossroads of automation advancement, D:PLOY beckons you towards a future where labour shortages, flexibility demands, and efficiency challenges are not barriers but stepping stones. Embrace the power of automation excellence with D:PLOY, and watch as your business rises above the challenges and emerges as an industry leader. Your journey towards automation success starts here with D:PLOY.

bit.ly/ORDPloy

The future of laser marking technology

A complete system of hardware, software and accessories, the Murrplastik LM-3 laser printing system available from Murrelektronik, provides a cost-effective solution for producing quality, durable labels for a variety of applications, including identification and security marking of wires, cables, components, control panels or signalling equipment.

As technology has developed, laser marking has become faster, more accurate and thus more popular.

Subsequently, this technology is now the preferred method for the permanent marking of metal and plastic labels in a diverse range of industry sectors.

Tim Bradbury, UK Sales and Technical Engineer for Murrplastik Labelling Systems, explained: “I’m very confident that laser marking technology will continue to get more precise and more cost-effective in the future. The LM-3 is already at the forefront of this technology and offers a complete laser marking solution for companies and organisations looking for a faster, more accurate process for producing in-house labels and ID tags.”

Highly flexible

The LM-3 is so flexible and automated that it can label onto polycarbonate, polypropylene, adonised aluminium, stainless steel or laser foils, producing durable labels that are UV, acid, oil and chemical resistant. The LM-3 is able to function under extreme environmental influences and mechanical stress.

The LM-3 does not require any additional consumables such as printer cartridges, ink, thermal transfer ribbons or even toners. The whole inscription process is done by laser inside the unit.

Automated batch processing and marking software integration enables the LM-3 to perform at a high output. The magazine filling aid enables a smooth and time-optimised labelling process due to the parallel preparation of the magazine loading. The additional carrier plates are used to hold the variety of labelling materials.

Labelling material can be stacked directly in the labelling magazine. However, separator plates can also be inserted into the magazine. These allow mixed loading in one batch – various materials in different thicknesses, shapes and colours for different applications can be labelled. With the help of the mp-LM single-line adapter plates, part-used label frames can continue to be used. The Universal Marking software used with the mp-LM 3 can also operate other labelling technologies or devices: deviceindependent and processoptimised, time- and cost-saving, as well as intuitive and interactive.

With a dedicated UK Sales and Technical

Team devoted to helping customers get the very best out of their Murrplastik hardware, it’s clear to see why Murrplastik is the number one choice for a flexible, costeffective solution for the in-house production of industrial labels.

www.murrelektronik.uk

by Murrelektronik

End-to-end solutions for the FMCG industry

While demand for FMCG continues to rise, challenges necessitate innovative solutions. From supply chain disruptions to sustainability concerns, the players must adapt swiftly to maintain a competitive edge. Amid these challenges, Bosch Rexroth emerges as a strategic partner with the ability to revolutionise the industry with end-to-end solutions that redefine the entire value chain.

The fast-moving consumer goods (FMCG) sector has always been marked by its dynamism. However, recent times have brought forth a host of unprecedented challenges. Supply chain disruptions caused by the global pandemic have underscored the vulnerability of traditional models. Fluctuating consumer preferences, volatile commodity prices, and changing regulations further complicate matters. In this landscape, it’s imperative for companies in this industry to reimagine their operations to ensure resilience and efficiency.

End-to-end solutions

This is where Bosch Rexroth steps in with its unique ability to serve as a partner for the entire value chain. Unlike isolated solutions that address specific pain points, Bosch Rexroth offers a comprehensive suite of technologies and expertise that span the entire production and distribution process. From engineering to automation, from hydraulics to digital solutions, Rexroth’s integrated approach streamlines operations and enhances overall productivity.

The FMCG industry thrives on interconnectedness. Every link in the value chain, from raw material sourcing to distribution, plays a vital role. Harmonising various processes through cutting-edge automation and digitalisation enables companies to achieve higher levels of efficiency and visibility. Real-time data analytics and predictive maintenance tools empower decision-makers with insights that drive informed choices, minimising downtime and optimising resource allocation.

Sustainability and adaptability

As the global focus on sustainability intensifies, the consumer goods industry is under increasing pressure to reduce its ecological footprint. Bosch Rexroth’s commitment to sustainability is reflected in its solutions that

prioritise energy efficiency and environmental responsibility. By optimising energy consumption through intelligent drive systems and leveraging renewable energy sources, as well as the remanufacturing of electric motors and drives, Rexroth contributes to both operational cost savings and carbon footprint reduction. This resonates profoundly with the sector’s aspirations for sustainable practices.

Adaptability is the hallmark of success in this industry. Consumer preferences shift rapidly, and companies must respond swiftly to stay relevant. Bosch Rexroth’s modular and flexible automation solutions provide companies with the agility needed to reconfigure their production lines with minimal disruption. Whether it’s introducing new product variants or adjusting batch sizes, Rexroth’s technology ensures that changes can be implemented seamlessly, empowering companies to stay ahead in a dynamic market.

Quality and safety

Quality and safety are non-negotiable in this sector. Product integrity and consumer trust are cornerstones of success. Rexroth’s stateof-the-art automation and control systems play a pivotal role in ensuring consistency and precision in production processes. From stringent quality control mechanisms to realtime monitoring, Rexroth’s solutions reduce the

likelihood of errors and deviations, ultimately leading to enhanced product quality and safety.

The challenges facing the FMCG industry are multifaceted, demanding solutions that are equally versatile. By offering end-toend solutions that encompass automation, digitalisation, sustainability, and flexibility, Rexroth empowers FMCG companies to overcome obstacles and embrace opportunities with confidence.

As the industry evolves, collaboration is key. By working closely with companies, understanding their unique challenges, and tailoring solutions to meet their specific needs, Rexroth fosters an environment of shared growth and mutual advancement.

The industry stands at a critical juncture where challenges can either stifle growth or serve as catalysts for transformation. Working with a company that has the ability to be a comprehensive partner for the entire value chain offers a beacon of hope for companies striving for operational excellence, sustainability, and resilience. Through seamless integration, innovative technologies, and a profound commitment to a sustainable future, Bosch Rexroth paves the way for a reimagined FMCG industry that embraces change and emerges stronger than ever before.

www.boschrexroth.co.uk

A quarter century at the forefront of forklift truck innovation

As handling solutions specialist Combilift celebrates its 25th anniversary, MEPCA spoke to the company’s Managing Director, Martin McVicar, about how its customers’ needs have evolved over that time and how its solutions have developed to meet those needs.

MEPCA: When you founded Combilift in 1998, what were the key challenges facing the users of load-handling solutions and, in particular, forklifts?

Martin McVicar: The mainstream forklifts on the market at the time - reach trucks, counterbalance forklifts and sideloaders, could each carry out a specific task, such as offloading from delivery trucks, putting goods into racking and carrying loads across large distances, but did not lend themselves well to other truck’s tasks. Added to these limitations was the fact that they could only travel either forwards or in reverse. This made the handling of long and bulky loads problematic, particularly in tight spaces. Getting a 6m long load through a 3m wide doorway, for example, involved a lot of risky and tricky juggling and manoeuvering, if it was at all possible.

M: How did Combilift’s solutions overcome those challenges?

MV: Feedback from contacts and potential customers in the materials handling sector indicated the opportunity for us to develop a niche versatile one-truck solution to replace multiple types of forklifts and enable the safer, space-saving and, therefore, more productive handling of long and bulky loads.

So the Combilift C4000 3-wheel, all-wheel drive multidirectional forklift was born. As its name implies, as well as forward and reverse, sideways travel was also possible thanks to push button change of wheel direction. The lateral transportation of oversized products suddenly became much more straightforward, and companies could reduce the number of forklifts needed, which led to reductions in capital expenditure, insurance premiums, fuel consumption and maintenance costs. Our aim was to help companies do more with less, so to speak, and this has proved to be the case. A further major benefit our solution offered was the much better use of available space as aisle widths in storage areas, and production facilities could be narrowed down to pretty much the depth of the truck, whatever length of load was being carried. Space has become an ever more valuable commodity, and optimum use of it can avoid costly and disruptive expansion and relocation of premises in times of growth. Customers in many industry sectors have also been able to buy and store raw materials in bulk quantities for more costeffective purchasing, which enabled them to be competitive on price for their customers. The ability to rest potentially dangerous loads on the integrated platform of the multidirectional

models for stable low-level transportation also contributed to enhanced occupational health and safety practices.

M: In the 25 years since those first machines were launched, how have the market’s needs evolved, and how has Combilift adapted its offer in response?

MV: We have closely followed the needs of the market since we launched our original model, and nearly every product we have developed in the past 25 years – and there have been dozens of them – has been the result of direct feedback or requests from customers. Our portfolio now encompasses trucks with lift capacities from just 1t to over 100t, which can handle almost any product that you can think of. Over the years, we have seen an increase in the size of products that companies want to manufacture and move, the offshore and green energy sectors being good examples. We have not only followed the market but have led it too, as we have been instrumental in enabling evolving market needs to be realised due to the development of new models such as the straddle carrier (Combi-SC) and mobile gantry (Combi-MG) ranges. These have solved the challenges of moving the most extreme loads, such as 100m+ long wind turbine blades or

Combilift is celebrating 25 years at the forefront of forklift truck innovation.

machinery for subsea operation that weighs in at over 100t.

M: So, what are the key load-handling needs that the Combilift portfolio meets today?

MV: Across every industry, safety is higher on the agenda than it ever was, and our main focus for any new product is to ensure the safest possible working practices. Over the past decade there has been a move towards replacing ride-on forklifts with pedestrian-operated stacker trucks as these are considered to be safer, particularly in busy manufacturing plants. Combilift’s pedestrian models, first introduced around 12 years ago, all feature its patented offset tiller arm, which means that operators are no longer required to be in the dangerous crush zone behind the truck but can now safely operate the truck from the side, where they also have excellent visibility of the load. Our pedestrian range is also not just for lighter capacities; we designed the high capacity Combi-PPT powered pallet truck for Cummins UK, who wanted to enhance operational safety and product flow at its Daventry site when moving 16t assembled

engine units from production to the testing and despatch areas.

M: Finally, what does the future hold? What emerging requirements do you see for load-handling solutions in the coming years, and how will Combilift support its customers’ needs?

MV: There is a lot of buzz around automation at the moment, but the reality is that there will always be a need for forklifts with operators, and we are committed to continual development in this sector to ensure that safety is maximised not only for operators but also for surrounding personnel.

Sustainability is a big issue, and forklift truck users increasingly want to ensure that their carbon footprint is reduced whilst benefitting from powerful and productive performance. The advances in battery technology mean that forklifts will be able to lift ever heavier capacities using electric power. Already this year, Combilift has launched two new electric trucks, with the high-capacity CBE70 opening up an entirely new market segment, while enabling our

existing customers to take advantage of electric power in these higher-capacity trucks. More and more customers are looking for emission-free and quiet operation and are therefore switching to electric fleets. Ground engineering specialist Roger Bullivant for instance, has replaced its fleet of dieselpowered trucks with five Combi-XLE 5t capacity electric models, chosen for their ability to efficiently cope with the vast yearly output of around one million metres of precast concrete piles. Currently, 70% of Combilift’s output is electric, and this is set to rise in future.

combilift.com

The high-capacity COMBi-CB 70E has opened up a new market segment for Combilift.

Deep learning overcomes OCR challenges

Zebra Technologies Corporation, a leading digital solution provider enabling businesses to intelligently connect data, assets, and people, gives manufacturers the ability to leverage optical character recognition everywhere with its new deep learning software deployed on a range of devices to meet the needs of automotive, pharmaceutical, electronics, and food and beverage manufacturers, as MEPCA found out.

Zebra’s flexible, deep learning optical character recognition (OCR) solution can handle complex use cases, eliminate training time, and ensure stability and ease of use, even for a nonexpert. It’s the solution for overcoming the familiar time, cost, training and stability issues of conventional OCR technology.

“Conventional OCR needs a lot of training time, can be unstable when faced with a change in environment, and doesn’t handle complex use cases well,” said Donato Montanari, General Manager and Vice President, Machine Vision at Zebra Technologies. “Many OCR tools require manufacturers to invest a lot of time for something that works in perfect conditions, but too often struggles to read obscure and damaged characters, engraved and embossed formats, characters on reflective and curved surfaces, or perform in changing or harsh lighting conditions.”

Zebra’s deep learning OCR solution is flexible. It can be deployed on desktop PCs, whether Windows, Linux or Linux ARM embedded (ideal for compact devices like Raspberry Pi or Nvidia Jetson), Android handheld devices, and Zebra smart cameras. Reading identification, compliance, safety and other markings on vehicle tires, test tube label and cap analysis, blood pack labels, and waybill documents for logistics are just some of the use cases that Zebra’s deep learning OCR solution can handle with a level of ease beyond older OCR options.

“This powerful tool delivers very high accuracy straight out-of-the-box and works on both graphics and central processing units,” added Donato. “Manufacturers can also take full control over development and

integration with other applications in C++ or .NET using Zebra’s Aurora Vision Library.”

Zebra’s OCR software, powered by deep learning, uses a convolutional neural network that mimics the human brain. It comes pretrained using thousands of different image samples. This enables the user to create a robust OCR application in just a few simple steps, even if they don’t have machine vision or deep learning expertise.

The simple yet powerful deep learning OCR is easy to use even in complex scenarios. It’s as easy as drawing a box around the characters and letting the tool do the rest. There’s no need to train fonts or maintain libraries. End-users just set the characters’ height, minimum confidence score and match string and are up and running very quickly. Inspections can be rapidly amended on the fly to account for new printing methods or font changes without any of the time-consuming setup

required with older OCR technology.

“Workflows are optimised, and the role of the engineer is elevated, as they are taking more and bigger steps toward thinking and acting like data and AI specialists to shape the future of work,” concluded Donato.

Traditional OCR technology has not addressed longstanding challenges faced by manufacturers, and is ill-equipped for the complexity, compliance, speed and volume of today’s manufacturing environments. Zebra’s pioneering the next generation of OCR uses deep learning to deliver a tool that is ready out-of-the-box and can handle complex use cases. As part of Zebra’s deep learning-powered machine vision portfolio, this enables engineers to think and act like data and AI specialists, while also giving programmers and data scientists the tools needed to develop bespoke solutions.

www.zebra.com

ERP systems: Streamlining success

Herbst Software explains how ERP systems are revolutionising engineering and manufacturing and how a modular approach to a system’s adoption can realise benefits that aren’t immediately apparent.

The primary objective in any company is to achieve lean business operations, and a growing number of ERP (Enterprise Resource Planning) systems promise to provide the silver bullet. At its core, an ERP has a single comprehensive database. When new information is entered in one place, related information is automatically updated. For manufacturing and engineering companies dealing with complex processes involving production planning and scheduling, inventory management, procurement, cost tracking, quality assurance etc., the allure of a system that can seamlessly integrate various departments and functions to ensure smooth operations and accurate data flow is undeniably appealing.

Many companies depend on a set of 12 to 15 spreadsheets that form the backbone of their operations (often carrying more importance than their accounting software as they aid in managing various aspects of the business). But if a company’s sales and order processing systems can’t communicate seamlessly with its production scheduling setup, it leads to a decline in manufacturing efficiency and customer service. Similarly, if the sales and marketing systems do not align with the financial reporting infrastructure, decision-makers are left relying on intuition rather than a comprehensive grasp of product and customer profitability. To put it simply: when a company’s systems are disjointed, its business also becomes disjointed. While an ERP system might not completely eradicate the use of all spreadsheets, it will significantly reduce their number while providing realtime information accessibility that surpasses previous capabilities.

Meeting expectations

When implementing an ERP, a lot of people expect to have the perfect system from day one. However, this isn’t very practical. While

it would be great, even if you have the budget, the smarter way is to introduce the ERP solution in stages. This makes the integration process more manageable and efficient without stifling production.

The initial step starts with the finance department, streamlining operations and reducing paperbased tasks. The procurement team follows, optimising purchase orders and pricing control. Next up, the sales team which will incorporate the system for creating and managing quotations. The manufacturing or operations department can then utilise the system to set up jobs and manufacturing processes, creating cohesion between departments. Having an integrated business management solution offers another compelling advantage: automated tracking of stock movement across all business processes. This seamless integration ensures a high level of accuracy in various critical aspects, such as job costing, cost of materials, cost of manufacturing, and sales margins. Precise stock tracking offers better resource management and responsiveness to market shifts. Consolidating functionalities enables informed decisions with real-time data.

What’s particularly exciting for small and medium-sized organisations is the advent of modular systems. These systems cater precisely to companies that are mindful of budget constraints, avoiding hefty investments in comprehensive ERP setups or the overhead of maintaining dedicated IT departments. The brilliance of these systems lies in their inherent flexibility.

Orson Herbst, CEO of Herbst Software, explained: “It’s common for people to acquire a system to tackle a specific challenge and then discover opportunities for enhancing various facets of their business in stages. Take,

for instance, an engineering client of ours who initially adopted the system to address stock control issues. Subsequently, they seamlessly integrated an additional module – the Herbst Jobber app – empowering their engineers with a handheld tool that automatically incorporated time and parts into job records. A seemingly minor enhancement that not only simplified life for the engineers but also saved time for the accounts department. Most importantly, it provided management with real-time insights into the variances between actuals and estimates.”

This exemplifies how the incremental approach of adding modules can provide an opportunity to take a fresh look at a company’s strategy and foster continuous improvement.

In the dynamic landscape of engineering and manufacturing, choosing the right ERP system is a pivotal decision. The journey might seem daunting, but armed with a clear understanding of your unique needs, careful evaluation of options, and a strategic implementation plan, you’re poised to harness newfound efficiencies, enhance collaboration, and drive your company toward a future of innovation and growth. www.herbstsoftware.com

Transform your maintenance management

In today’s business world, the integration of technology is becoming more and more essential for success. Digital transformation has become the new norm and is a buzzword that we hear everywhere. One of the key components of digital transformation is the integration of Computerised Maintenance Management Systems (CMMS) and the Industrial Internet of Things (IIoT). These technologies are revolutionising the way businesses operate and manage their maintenance programs.

CMMS is a software solution designed to streamline maintenance management activities. It allows businesses to schedule maintenance activities, manage work orders, track equipment history, and generate reports. It provides a centralised platform for managing maintenance records and reducing downtime, extending the lifespan of critical assets. A CMMS is particularly useful for asset-intensive industries such as manufacturing, energy, and utilities.

IIoT is a network of connected devices that transmit data to a central platform for analysis. It enables businesses to monitor and manage their operations in real time, providing valuable insights into equipment performance and overall efficiency. IIoT has transformed industries such as manufacturing, energy, and utilities by providing real-time data on equipment performance and enabling predictive maintenance.

When CMMS is combined with IIoT, businesses gain access to real-time data on equipment performance and maintenance needs. This combination enables predictive maintenance, which can reduce downtime and extend the lifespan of critical assets. Predictive maintenance involves analysing data from sensors and other equipment to predict when maintenance is needed. This approach enables businesses to address maintenance issues before they result in downtime or equipment failure.

The integration of CMMS and IIoT is

essential for businesses that are looking to undertake digital transformation. Digital transformation is more than just implementing new technology. It involves a fundamental shift in the way businesses approach operations, with a focus on using technology to improve efficiency and productivity. The combination of CMMS and IIoT is a perfect example of this approach, providing businesses with real-time data on equipment performance and maintenance needs.

However, implementing CMMS and IIoT is not without challenges. One of the significant challenges is integration. Businesses often have a complex network of legacy systems that need to be integrated with new technologies. This integration can be time-consuming and require significant IT resources and expertise. However, the benefits of digital transformation far outweigh the challenges.

Managing Data

Another challenge is data management. With the amount of data generated by IIoT devices, businesses need to have a robust data management strategy in place. This strategy should include data storage, analysis, and reporting. It should also include data security protocols to protect sensitive information.

Despite these challenges, the benefits of digital transformation are significant. In addition to improving efficiency and productivity, digital transformation can help businesses reduce costs, improve quality, and increase customer satisfaction. For example, a manufacturer that implements a CMMS and IIoT solution may see a reduction in maintenance costs, an increase in equipment uptime, and improved product quality.

The adoption of CMMS and IIoT solutions is witnessing significant growth as businesses increasingly seek to capitalise on the advantages of digital transformation. Organisations across various industries are recognising the value of these technologies in enhancing operational efficiency and productivity. The increasing implementation of predictive maintenance practices and the integration of CMMS and IIoT technologies further signifies the growing importance of these solutions in driving improved maintenance management. This upward trend is expected to continue as businesses continue to realise the benefits of CMMS and IIoT in their pursuit of operational excellence.

The integration of CMMS and IIoT is transforming the way businesses approach maintenance management and digital transformation. By providing real-time data on equipment performance and maintenance needs, these technologies enable predictive maintenance and reduce downtime, extending the lifespan of critical assets.

pemac.com

Donal Bourke, Director of Sales with maintenance and asset management software specialist PEMAC, explains the power that Computerised Maintenance Management Systems and the Industrial Internet of Things have in driving digital transformation.

Cutting edge processing and packaging technology on show

The PPMA Show is traditionally the largest processing and packaging machinery exhibition in the UK, showcasing the very latest in processing and packaging machinery, robotics and industrial vision systems.

The free-to-attend showpiece event on 26-28 September spans the full spectrum of the processing and packaging industry, with exhibitors displaying the latest innovations for sectors including food, beverages, pharmaceuticals, household products and toiletries, building materials and supplies, pet care, microbrewery and distilleries, FMCG, as well as contract packers and more.

When the show opens its doors at the NEC in Birmingham, visitors will have the opportunity to network face-to-face with over 300 exhibitors, together representing more than 2,600 brands. There will be a host of new product launches and a contentrich seminar programme that will appraise people of the latest technological innovations and products, helping to shape the various markets.

Virtually every aspect of the production line will be represented, from labelling, filling and packaging to processing, robotics, automation and industrial vision systems. As such, visitors will have the opportunity to source new ideas and solutions for innovating their processing and packaging solutions, added to the opportunity to meet new suppliers and influencers, and tapping into the knowledge of leading experts in their field, all under one roof.

Visitors to the 2023 staging of the PPMA Show can expect the following:

• Live demonstrations of new machinery in action.

• Video presentations by influential industry experts broadcast on screens across the exhibition and later on PPMA TV.

• Major networking opportunities.

• The ability to monitor the competition and benchmark best practice by gauging yourself against industry-leading performers.

• Building new relationships, developing a deeper understanding of the industry, sharing

information, and gaining valuable insights.

For those needing to source new solutions, visitors need look no further than the cuttingedge machinery on display. By integrating new machines into their own business, visitors can streamline processes, improve efficiency, and boost productivity. Whether they are looking for ways to reduce costs or improve output, all visitors can learn how new machinery will help them achieve their goals.

Where the PPMA Show really scores is the opportunity it gives visitors to experience the complete production line event in action from start to finish. This is a rare opportunity to see how everything all connects.

The show’s unique seminar programme will help visitors stay ahead of the trends so far as the latest processing and packaging solutions are concerned. Visitors can hear from a range of industry experts about the latest trends and innovations in their sector and how these can be applied to their own businesses.

Keynote speakers lined up so far include Ross Verrall, of Artificial Intelligence specialist Nvidia. Ross will be speaking about enabling the future with accelerated computing - from ChatGPT to robots.

Joining him will be Dimitrios Spiliopoulos, Industrial IoT Lead for Manufacturing at Amazon Web Services, and Philip Hooker,

VP Strategic Programmes at Cumulocity IoT, who will share their vision and expertise in empowering packaging and processing enterprises to tackle critical smart production and smart connected product challenges head-on.

Topics covered in other presentations will include food packaging innovation, the importance of sustainability, successful selling and how manufacturing is evolving to meet the needs of the processing and packaging sector.

Scott McKenna, Group Exhibitions and Membership Manager at the PPMA Group, said: “We know from experience and previous research that the PPMA Show attracts a lot of the upper tier purchasers and senior engineers who will report back with the knowledge they acquired at the PPMA Show. This all translates into potential sales and is what the exhibition is all about, an opportunity for our exhibitors to generate excitement within end users in relation to what they could be achieving for their businesses.”

Free tickets to the 2023 PPMA Show can be secured at bit.ly/PPMA23, while ahead of the show, visitors can browse through all the exhibitors on the event’s website.

www.ppmashow.co.uk

Han® F+B - Hygienic and robust.

Connectors for the food industry

■ Easy-to-clean design especially for the spray zone

■ Reliable connections ensured, even with daily cleaning

■ Protection against water jets and aggressive cleaning agents

■ IP69K rated, Ecolab approved and complies with EHEDG guidelines

One Range. No Limits: www.HARTING.com/UK/en-gb/connectors-food-industry

Mixing it up at PPMA

Silverson Machines has the largest capacity range of high-shear rotor/stator mixers from a single manufacturer and has been helping customers across a range of industries to improve their mixing processes. The extensive range that the company manufactures means that it can help with mixing as little as 1ml, or large volumes of up to 30,000l and everything in between. Here is an overview of some of the products in the Silverson range, which will be available to view on Silverson Machines’ stand, E20, at the 2023 PPMA show.

For mixing small batches from 1ml up to 12l, Silverson has a range of laboratory mixers suitable for a wide range of mixing processes. All Silverson rotor/stator mixers come with a range of easily interchangeable workheads, which allow one mixer to perform many mixing tasks that would otherwise need several pieces of mixing equipment. Silverson laboratory mixers can blend, emulsify, homogenise, disintegrate, dissolve and de-agglomerate, and mix in-line with flow rates up to 20 l/min using an inline mixing assembly. The most popular mixer in the Silverson product range, the L5M-A laboratory mixer, features touchpad controls and a tachometer, ammeter and programmable timer.

Scaling-up is a relatively simple process as all Silverson mixers are manufactured to the same precision-engineered tolerances. So anything you produce in the laboratory can be replicated in production, without the need for reformulating.

In-tank mixers

For in-tank mixing of volumes up to 30,000l, Silverson supplies in-tank batch mixer models. Capable of performing all of the same mixing processes as Silverson laboratory mixers, it is possible to reduce mixing times by up to 90% when using highshear batch mixers as opposed to traditional mixing methods such as stirrers or agitators. Small to medium range batch mixers can be used on mobile floor stands, further increasing their versatility.

The Silverson Ultramix in-tank mixer is designed for applications that are beyond the capabilities of a conventional agitator or stirrer but do not necessarily require the intense high shear of a Silverson rotor/stator mixer. Ideal for rapidly wetting out powders, including gums and thickeners, the Ultramix

is also ideal for use in vessels with narrow openings. The vigorous mixing action is capable of moving the entire contents of vessels, even in difficult shaped containers.

Laboratory-scale in-line mixing

Silverson will be displaying production-scale in-line mixers as well as demonstrating working benchtop models such as the Verso-UHS-HV.

The Verso-UHS-HV is a laboratory-scale in-line mixer designed for mixing highviscosity products. It incorporates the same unique and innovative pumping rotor design as the production scale HV in-line mixers. This substantially increases its self-pumping capacity, allowing it to process products such as gels, creams, sauces and gum solutions on a laboratory scale.

A conversion kit is available, allowing the Verso-UHS-HV to be configured as an FMX5 powder/liquid mixer. This kit increases the versatility of the machine, allowing one mixer to be used as a laboratory scale highviscosity in-line mixer or powder/liquid mixer.

Powder/liquid mixing

For mixing large quantities of powder, Silverson developed the Flashmix. Unlike many powder/liquid mixers, which use a vacuum to pull in powder, the Flashmix literally forces powder into the liquid stream. This not only allows it to disperse and hydrate large volumes of powders, but it also means it can be used at higher temperatures and with higher viscosity mixes.

The FMX5, the laboratoryscale version of the Flashmix, is suitable for small-scale manufacturing and R&D work with a typical batch size of up to 10l, depending on viscosity.

These are just a few of the mixer options available in the Silverson product range; you can find out more about additional models, such as bottom entry mixers and pilot scale batch mixers, on the Silverson website. Or visit stand E20 at the PPMA show and talk to Silverson about your mixing requirements.

Filling and mixing solutions on show

At the 2023 PPMA Show, packaging machinery manufacturer and supplier Adelphi will be showing products from its extensive range of automatic filling machines, benchtop fillers, monobloc fillers, IBC mixers and more.

Visitors to stand D92 at the 2023 PPMA Show will be able to talk to experts from the Adelphi Group and see a wide range of the company’s filling and mixing solutions.

Automatic filling machine

The company’s automatic filling machine incorporating a new quick change feature is a well-established and successful concept, with a track record of supplying over 1,000 units worldwide. Quick-release nozzles enable seamless and tool-less transitions between different containers and products. A range of cylinder choices are available, allowing users to select the ideal capacity for specific applications. Whether it’s 1, 3, 5 or 6l, users have the flexibility to match a product’s volume accurately.

The machine offers versatility with the ability to adjust fill speeds as needed during the filling cycle. This dynamic feature ensures optimal precision and efficiency, accommodating various product viscosities and container sizes seamlessly. The system includes ‘no container, no fill’ sensing technology, minimising wastage and streamlining production processes with effortless precision.

And for hassle-free maintenance, the system offers an optional flushing circuit. This feature allows for efficient in-place cleaning, optimising downtime and ensuring a hygienic production environment.

Benchtop filler

Also on display will be the company’s Response benchtop filler. This device offers industry-leading accuracy of +/-0.25% (compared to the industry average of +/-1%), significantly reduces waste and enhances filling reliability.

A fast production rate of 20-40 bottles

per minute is achievable, equating to an impressive average of 15,000 containers within an 8-hour shift. With fill volumes ranging from 3ml to 1l, catering to a diverse range of product requirements.

In just three minutes, the filler can be stripped down for thorough cleaning, minimising production downtime when switching between products and containers.

The Response benchtop filler is designed to cater to complete product ranges, offering interchangeable nozzles to handle various viscosities such as essential oils, reed diffusers, candles, and more.

It is available in both single and twin-head configurations, providing versatility to cater to different production needs.

Monobloc filler

Visitors looking for a bespoke production line will be able to see an example of Adelphi’s Response monobloc filler, which is able to fill from 5ml up to 1000ml, fill and cap 1525 containers per minute and has a filling accuracy of up to +/-0.25%.

The Monobloc can incorporate various elements to give a complete turnkey packaging line, including an in-feed table, bottle blower, filler, automatic cap placement, capper, labeller and collection table.

IBC mixer

Also on the stand will be a new IBC mixer from Pharma Hygiene. Specifically crafted for use on Intermediate Bulk Containers (IBCs) with a 150mm screw cap and sturdy metal outer frame, this versatile mixing solution is ideal for liquid-to-liquid, oil-tooil, and powder-to-liquid mixing, as well as maintaining consistent product blending during storage. An exceptional average finish of 0.5 micrometres Ra is possible, ensuring a

flawless surface without any pits or crevices.

The mixer is equipped with a variable speed drive, offering speed adjustment from 420rpm to 1400rpm, enabling adaptability to various mixing needs.

It has been designed for products with a viscosity of up to 700 CPS (mPas), ensuring suitability for a wide range of applications and attaches to standard 1000l IBCs using ‘killswitched’ toggle clamps, enhancing safety.

The mixer is powered by a .37kw motor with a variable speed drive, ensuring reliable and controlled mixing performance and has been constructed from durable 304-grade stainless steel, incorporating 316L pharmaceutical-grade wetted parts to prevent any risk of product contamination.

www.adelphi.uk.com

Unveiling tomorrow’s silicone technology innovations

The stage is set, the countdown is on, and anticipation is reaching a crescendo. Get ready to immerse yourself in the heart of innovation at the upcoming Silicone Expo USA. From 4 to 5 October, at Huntington Place in Detroit MI, the spotlight will shine on the dynamic and versatile world of silicone technology, and you’re invited to be part of the excitement. As the excitement builds and the doors to innovation swing open, let’s take a sneak peek at what awaits you at this one-of-a-kind event.

The agenda for Silicone

Expo USA promises two days packed with insights, discussions, and revelations that can redefine the way you approach manufacturing. Day one kicks off with a market analysis keynote address, setting the tone for a conference that will empower you with the tools to revolutionize your processes. Subsequent sessions dive deep into topics such as ‘Reducing the CO2 footprint of silicone rubber, foams, and adhesives’ and ‘Advancements in the field of textile silicones’.

Day two keeps the momentum going with riveting discussions on ‘Silicone Based Adjuvants in Agrochemicals’ and ‘Engineered Silicone Solutions for Energy Storage Applications’. The expo culminates in a dynamic panel discussion where industry pioneers will share their experiences, challenges, and successes in harnessing the power of silicone for manufacturing advancement.

In a world that moves at lightning speed, where information zips across screens and connections are forged through virtual platforms, there’s unparalleled value in face-to-face interaction. Silicone Expo USA is more than an event; it’s an opportunity to step away from the virtual realm and engage in meaningful conversations, explore tangible innovations, and experience the energy of shared passions.

Networking becomes more than a buzzword here – it’s a chance to shake hands with visionaries, share ideas with industry pioneers, and establish connections that could redefine your professional trajectory. As attendees, you’ll be part of

a community that thrives on collaboration, innovation, and pushing the boundaries of what’s possible.

Secure your spot

The excitement is palpable, the agenda is captivating, and the clock is ticking. Don’t miss your chance to be part of this transformative experience. By registering early, you not only secure your place among the brightest minds in the industry but also gain access to exclusive benefits, including an immersive on-site experience, high-quality networking opportunities and full access to the tradeshow and technical conference.

Exhibiting companies

The heart of any expo lies in the exhibits, and Silicone Expo USA is no exception. Prepare to be dazzled by a lineup of industryleading companies showcasing their latest breakthroughs, innovations, and cuttingedge technologies. From gold sponsor Novagard to Momentive, Elkem, Shin-Etsu, Krauss Maffei, and Sumitomo, the floor will

be a playground of possibilities.

Engage in conversations with experts, get hands-on with the latest developments, and discover the trends that will shape the industries of tomorrow. Each booth is a portal into a world of opportunities, and you have the key to unlock them all.

Embrace the Future

As the curtain rises on Silicone Expo USA, you’re poised to be part of a groundbreaking experience that promises to shape the trajectory of industries and redefine what’s possible. Whether you’re a seasoned professional or a fresh enthusiast, this event transcends titles and roles. It’s an opportunity to engage, learn, and explore with an open mind, ready to be inspired and to inspire.

For more information, including the comprehensive agenda, speaker profiles, and hassle-free registration, visit Silicone Expo USA.

www.silicone-expo.com

Visit LiftEx 2023 for your lifting solutions

LiftEx 2023 is the unmissable global showcase for the lifting industry, taking place at the Exhibition Centre, Liverpool, on 21-22 November 2023. The annual flagship event of LEEA (Lifting Equipment Engineers Association) is free to attend, and registration is open now.

Plants, factories and manufacturers use a bewildering variety of cranes, hoists, platforms, cradles and their associated chains, ropes, slings and other tackle to lift goods during production and lineside support. People involved with, or responsible for, this equipment in this sector can join over 1,500 industry professionals in catching up with the latest innovations and lifting knowledge from over 100 exhibitors across two days.

LiftEx 2023 is proud to announce CoreRFID, the provider of lifting inspection software and RFID technology, as the headline sponsor of the event, which this year promises to be the best yet. Visitors can catch up with suppliers, view demonstrations and explore the latest solutions from the industry’s top vendors.

These will include a broad array of lifting equipment solutions from companies such as Atlas Winch & Hoist Services, Cromax, Delta Hoisting Equipment, George Taylor Lifting Gear, Green Pin (Royal Van Beest), Hird, Modulift, Nautilus Hooks, Pinpoint Manufacturing, Rope and Sling Specialists (RSS), TTC Lifting, Tusk Lifting and Worlifts. Visitors interested in hoists and materials handling equipment will find Davinder Technical Services, GGR Group, Lift Turn Move, Probst and Prolift Handling.

Chains, ropes and accessories will be featured by companies including Bridon Bekaert, Codipro, European Management & Marine (EMM Corp), Hendrik Veder Group, Latch and Batchelor, Lift Turn Move, RUD Chains, Sahm Splice, Talurit and William Hackett Chains. There will be slings and rigging from Aberdeen Web, Crosby, Dolezych, Hendrik Veder Group, Petersen Stainless Rigging, PMS Industrie and Suhbo Industrial Co.

Exhibitors displaying height safety

equipment include Guardian Fall, RidgeGear, SafetyLiftinGear, Safehold, SpanSet, Tiger Lifting, Trans-Web and YOKE Industrial Corp. There will be load monitoring equipment from DLM, Load Monitoring Systems (LMS) and Red Rooster Lifting. A range of IT solutions will be shown from companies, including CoreRFID, Onix Work, RiConnect and Tele Radio UK.

Stands featuring load moving and transport include Liftket UK. Test machinery can be seen from Structure-flex, and there will be administrative services exhibited by IBS Industrial.

There will be organisations such as Career Transition Partnership, the MoD’s official provider of Armed Forces Resettlement for over 13,000 skilled and experienced individuals who leave the military. MND Association, LEEA’s chosen charity for 2023, will have a stand, as will LEIA Assessment,

the sole endpoint assessment organisation for the Level 3 Lifting Equipment Technician apprenticeship in England. LEEA itself will, of course, have its usual prominent stand for visitors to meet and engage with the Association’s team.

LiftEx will be celebrating its 18th year in 2023 with a jam-packed event, so keep an eye out for the schedule of on-site activities and show features to be announced over the next few months.

There will also be the celebrated LEEA Awards on the evening of 21 November 2023 – day one of LiftEx. The fifth annual LEEA Awards ceremony will be held at the Rum Warehouse in Liverpool, and with special guest comedian, presenter, actor and singer Jason Manford, it promises to be the Lifting Industry’s party of the year.

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21-22 November

Exhibition Centre Liverpool

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Versatile plug-andwork solution for IIoT

Ideally suited for building IIoT functionality into new and existing machines and plant, the new AE3100 controller from ifm electronic combines convenience and exceptional versatility with outstanding performance and a wide range of communication options. Measuring just 120 x 125 x 36mm and suitable for DIN rail mounting in various orientations, the AE3100 is easily accommodated within almost any control panel and is capable of continuous operation at temperatures as high as +55 ºC.

At the heart of the AE3100 is a 1.3 GHz quad-core processor, which ensures smooth and reliable operation even in the most demanding applications. Designed for easy integration with IT systems and automation networks, full support is provided for industrial Ethernet protocols, including Profinet, EtherCAT, EtherNet/ IP and Modbus/TCP. The AE3100 can also exchange data with common cloud platforms such as AWS, Microsoft Azure and AnyViz, and it supports standard digitisation languages such as OPC UA and MQTT.

At the plant or machine level, the AE3100 controller offers plug-and-work connectivity for IO-Link devices, including IODD (I/O device description) interpretation, while the controller’s CODESYS 3.5 programmability provides complete flexibility. Remote management is also possible using the CODESYS Automation Server, which offers remote debugging and web visualisation. www.ifm.com

Packing in more innovation

The Colder Product Company’s Puncture Seal system, available from authorised UK distributors Tom Parker, offers a clean and secure way to dispense liquids from bag-inbox and other types of flexible packaging. With its polypropylene and polyethylene construction, it delivers increased chemical resistance and durability as well as simple and secure dispensing of liquids.

The system features a puncture seal closure cap with a screw cap or snap-in closure and a specially designed quick-connect coupling body which automatically breaks the membrane seal on closure. When it is empty, it is simple to disconnect and switch to a new container. www.tom-parker.co.uk

Securing a powerful connection

Tom Parker has announced its official appointment as Authorised UK Distributor for Oetiker. Oetiker has gained a reputation as one of the most reliable manufacturers of mission-critical connection solutions providing dependable products across many industries and applications, including automotive, aftermarket, industrial, plumbing, medical treatment lines, food and beverage, home appliances, irrigation and crop watering systems, and electric vehicle chargers. They are also commonly used with flexible and inflexible thin-walled, rubber and welding hose, plastic tubing, and electrical cables.

The company’s engineers ensure that their products are high quality, suit a wide variety of individual application needs and withstand the test of time. www.tom-parker.co.uk

Revolution in titanium machining

Starrag is set to revolutionise titanium machining performances with its new ultra-rigid and robust STC 1250 HD horizontal machining centre, the first machine in its large-capacity class with hydrostatic guideways for zero friction/non-stick/slip movements. The machine provides users with unmatched roughing times reduced by up to 50%, reduced energy consumption rates during machining of 33% and more dynamic finishing and, therefore, more precise parts courtesy of higher acceleration and jerk rates plus frictionless/no micro-vibration in the X axis. Hydrostatic guideways also mean reduced maintenance demands compared to conventional box guideways.

www.starrag.com

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