Manufacturing Update December 2021 by Jet Digital Media Ltd

MANUFACTURING PDATE www.manufacturing-update.co.uk

December 2021

Weidmiiller More productivity in your workplace with our THM MultiMark printer Let’s Connect

MultiMark: the smart all-in-one solution In Weidmüller, you have a trusted and reliable partner with years of experience in cable preparation, processing and systemised marking. Our THM thermal transfer printer integrates cutting and perforation tasks into the printing process; it can divide endless materials into arbitrary lengths. The result is a noticeably simpler production of custom cuts with a respective inscription assignment. Using the Mulitmark printer, you reduce the potential sources of error with complete data consistency. You will streamline timeconsuming work processes and increase your productivity.

£995 RRP*

Order 1 THM MultiMark Printer (2599430000) for £995 and you will receive £1400 worth of list price marking materials FREE!

Click here to order your THM MultiMark printer! Weidmüller UK Klippon House, Centurion Court Office Park Meridian Business Park, Leicester, LE19 1TP Tel: +44 1162 823470 Fax:+44 1162 893582 www.weidmuller.co.uk

* This action is limited to 1 printer per customer and valid until 30th September 2021 Terms and Conditions apply

MANUFACTURING UPDATE At the forefront of digital marketing, Manufactuing Update strives to bring its readers the latest in industrial manufacturing, in a format that provides the best usability and ease of use for it’s readers.

December 2021

Publishing Director

Editorial Assistant

Publishing House

Jodie Little 01843 448 443 jodie@jetdigitalmedia.co.uk

Taylor Owens 01843 448 443 taylor@manufacturing-update.co.uk

Publication Manager

Production

Tim Johnston 01843 448 443 tim@manufacturing-update.co.uk

Chris Sims 01843 448 443 chris@manufacturing-update.co.uk

Jet Digital Media Ltd, Suite 1 & 2 Spratling Court Offices, Spratling Street, Manston, Kent CT12 5AN

www.jetdigitalmedia.co.uk

Manufacturing PDATE

www.manufacturing-update.co.uk

Automated Parcel Consolidation Saves 80% Storage Space The automation of the process from good to person picking and buffer storage consolidation is making it easier to meet customer demand. Kardex customer Hella is a logistics service provider with long-standing experience in the automotive industry. They ship more than 2,000 orders to global customers every day and found that storing these orders until it was time to ship the stock out took up a lot of space. Traditionally they used a manual processes of loading cartons onto pallets and storing them until needed, but optimisation for leaner processes was required so they investigated ways to increase ergonomics, reduce sort and search times, and minimise walking distances.

Manufacturing PDATE

They made the decision to purchase a six-meter high Kardex Vertical Buffer Module LR 35 as it was the most efficient and economical solution to meet all their requirements now, whilst enabling future growth. The LR35 is utilised as a consolidation buffer for customer orders awaiting shipment and uses conveyor technology, so they are now able to transport various sized cartons automatically. Once a truck has arrived, a complete retrieval list for the relevant cartons starts. The cartons are pre-sorted by size and weight and ordered and are delivered via two access openings. Employees scan the cartons and move them onto a pallet. “With the LR 35, we were able to save 80% of storage space and no longer face any capacity restrictions,“ says Raphael Heimann, Project Manager Intralogistics, Hella Distribution GmbH.

December 2021

To learn more about how the LR35 can manage your order picking and consolidation requirements click here. Or contact Kardex on 01992 557237, email: info.remstar.uk@kardex.com

Leaders in temperature measurement

Hand Held Instrumentation Heading 3

A selection of hand held instruments for many applications including a large range of digital thermometers, light level meter and a range of great value handheld sensors.

IR Industrial IR Medical Infrared Thermometers Thermometers

Pressure Manometers

Digital Light Meters

Anemometers

Temperature & Wood Moisture Meter Humidity Meter

Grain Moisture Meter

www.labfacility.com Bognor Regis tel: +44 (0)1243 871280

sales@labfacility.com Shefﬁeld tel: +44 (0)1909 569446

Bringing flexibility to additive manufacturing

Manufacturing PDATE

To provide engineers with more flexibility when using additive manufacturing systems, global engineering technologies company Renishaw has launched a new range of 3D printing machinery, which can be seen at Formnext on 16th to 19th November 2021. The RenAM 500S Flex, a single laser additive manufacturing (AM) machine and the RenAM 500Q Flex, a four laser AM machine, are variants of the RenAM 500 range. Both systems feature a simplified powder handling system, which is suited to manufacturers who must regularly swap build materials during production, such as research and development (R&D), pre-production or bureau environments. The range features the same industry leading optical, chamber and gas-flow designs as the RenAM 500 series and produces the same high-quality parts, but also provides additional flexibility when changing powders. The simplified, non-recirculating powder system enables manufacturers in R&D, pre-production or bureau environments to easily change between materials,

December 2021

without compromising on part quality or build capacity. To avoid cross contamination, engineers can easily clean the system between powders by changing out hard to clean parts, rather than manufacturers having to invest in a new machine for each material test. Parts can also be swapped in again if the operator wants to retest the same material again, further reducing costs. “Manufacturers can quickly change powders in the RenAM 500S Flex and RenAM 500Q Flex in-house, giving them the flexibility they need to meet customer demand,” explained Lily Dixon, AM Project Manager at Renishaw. “Once the pre-production stage is complete, the common build environment allows any parameters to be directly transferred to a

RenAM 500Q with powder recirculation, without the need to retest the gas flow, chamber and optics. Manufacturers can also build full size parts on a small scale before mass production.” Dixon continued, “If the manufacturer no longer requires a flexible AM system, the Flex can even be converted into a recirculating machine — a feature that is unique to this system. Converting the system provides manufacturers with the highest productivity AM option for serial production.” To find out more about the benefits of RenAM 500S Flex and RenAM 500Q Flex, as well as other additive manufacturing equipment from Renishaw, visit the Renishaw website www.renishaw.com

sales@lamonde.com

     

4 Comm ports, inc Ethernet Built-in data logging to microSD Free no-limit programming Slim stackable design Multiple i/o wiring options Starter kit available

www.lamonde.com +44 (0)20 3026 2670

Lamonde Automation Limited Quality Products: Expert Advice

Power loss protection can you afford not to have it?

Why power protection is a must for industrial SSDs

Manufacturing PDATE

When power is terminated before a shutdown notification is completed, an “unsafe shutdown occurs,” preventing data in the temporary buffers from being safely flushed onto the nonvolatile NAND. This causes data to be corrupted or lost, and may render the storage device unusable. Examples of unsafe shutdowns include unexpected power outages, accidental removal of the SSD from the computer, unplugging the storage device while power is still on, or battery power loss. Such occurrences can potentially damage a storage device and corrupt data unless there is an effective power loss protection (PLP) mechanism. SSDs are particularly vulnerable to

December 2021

power-loss events. Unlike HDDs, SSDs do not have mechanical parts, so every component is electronic. The internal data management of an SSD involves many operations that occur in the background, and every power failure can mean undue interruption of those operations, which could affect drive performance. That’s not forgetting system downtime, engineering resource and associated costs for loss of revenue which all could be considerable. So what solutions are on offer in the market? ATP Introduces MCU-based PLP in Latest NVMe/SATA SSDs Taiwanese manufacturer ATP electronics has introduced the N600 Series M.2 2280 NVMe and A600 Series Serial ATA (SATA) SSDs, which feature a completely new design of the power loss protection (PLP) array.

The PLP utilizes a new power management IC (PMIC) and new firmware-programmable MCU (microcontroller unit). The new MCU design is integrated into ATP’s latest PLP technology, which allows the PLP array to perform intelligently in various temperatures, power glitches and charge states. In addition to the MCU-based PLP array, the M.2 2280 NVMe N600 Series modules combine the speed and performance of PCIe NVMe with the reliability and endurance features of 3D NAND flash, the high capacity of triple level flash (TLC), high-performance 8-channel controllers, and end-to-end data protection. So how does the MCU enhance the Power loss protection mechanism? The MCU intelligently monitors de-glitch power failure conditions

The following table illustrates the advantages of SSDs with MCU-based control compared with SSDs that do not: SSDs without MCU

SSDs with MCU

PLP capacitors need to discharge/reset before power-on

Immediate power-on initiated regardless of residual voltage on PLP capacitors

If power-off state is extremely short: • PLP might discharge incompletely • Controller reset might fail • SSD might not be recognized and will not be able to reboot

If the power-off state is extremely short: • No need for the PLP to discharge completely • MCU resets the controller • SSD can be recognized and will reboot correctly

SSD power on-off with/without MCU

•

In addition the microcontroller unit can keep detecting power failure conditions; for example, for a 2.5” SSD, if input voltage drops down to less than 4.0V for several consecutive milliseconds (de-glitch), the MCU will notify the controller to start cache flushing and at the same time, the capacitors will be activated to provide the sustaining power for cache flushing.

•

Getting under the cover of the SSDs we can see how this works in the diagram below;

Precise Control of Reset Signal Generation and Power Up/Down Sequences

•

Suppression of power-up inrush current according to customer request.

•

Input over-voltage protection to prevent damage to the SSD circuitry.

Fast Power On/Off Control

Prevents potential issues in the power up/down of the SSD.

Customization Options •

The new MCU-based design allows PLP capabilities to be tailor-fitted according to unique customer requirements, application-specific needs, or use cases.

ECC Engine / RAID Support •

Features and Benefits Enhanced Device Protection

Cuts the time required from power-off to re-power on the SSD.

Error detection and correction with redundant backup algorithm to eliminate the possibility of uncorrectable errors.

Better Data Integrity •

Input power noise de-glitch to prevent incorrect cache flushing caused by false triggers such as noisy or unstable host input voltage.

•

Under-charge/over-charge protection for hold-up power capacitors.

End-to-End Data Path Protection •

Prevents unauthorized access to data while it is being transferred from one storage device to another.

To sum up The new MCU-based design combines hardware and firmware solutions that safeguard data as well as the storage device for higher levels of integrity and reliability. ATP SSDs with MCU -based PLP include mSATA, 2.5” SSDs, M.2 2242/2280 and NVMe modules with both I-Temp and C-Temp support. ATP’s industrial memory and storage solutions undergo stringent testing and validation to meet the highreliability, high-performance and high-endurance requirements of mission-critical applications to deliver the best total cost of ownership (TCO) value. For more information on ATP’s MCU-based industrial flash storage products, contact Simms International.

www.simms.co.uk December 2021

Manufacturing PDATE

and checks the health status of capacitors through the I2C interface, with the Polymer tantalum capacitors providing sufficient sustaining power for data cache flushing, if a surprise powerloss condition occurs.

December 2021 ENGINEERING

ABB’s Robot Podcast returns for Season Two, exploring the world of robotics and automation Weekly panel of experts from industry, media and academia look at the cutting edge of robotics, analysing how advances in automation are benefitting society and businesses, and what the future holds

Manufacturing PDATE

Following a well-received first season, The Robot Podcast from ABB returns for Season Two with a wide-ranging exploration of the world of robotics and their benefits to society and industry. The new season kicks off with Episode One on November 17th and looks at how everyday technologies have evolved over the last ten years; how robotics and automation will revolutionize the decade to come; and how AI and robotics can be an accelerator for industries worldwide. Across six entertaining episodes, a wide variety of societally relevant topics will

December 2021

PDATE

The ABB Robot Podcast Release Schedule

Episode

Theme

Release Date

2021 – The Dawning of a Transformative Decade

17.11.21

Sustainable Construction

24.11.21

Robotics in Education

01.12.21

Digital Twinning

08.12.21

The Retail Revolution

15.12.21

Megamix (Season Highlights)

22.12.21

be discussed by the panel of assembled experts and commentators. Robotics in construction and education; the game-changer that is digital twinning; and the current retail revolution lead by automation – The Robot Podcast shines a light on all these hot topics. Fran Scott, a regular contributor to the BBC and Channel 4 in the UK, returns as host. Fran said: “It’s great to be back presenting another season of The Robot Podcast. Over the next six weeks, myself and a team of experts will investigate the cutting edge of robotics and automation, as well as what it means for us and the way we live our lives. From major changes in the way we shop, to our search for sustainable solutions;

a shifting workforce to the increase in digital simulations – we’ll explore it all in a way that makes sense to our growing gang of listeners.” Subscribe now to The Robot Podcast wherever you get your podcasts, or via smarturl.it/therobotpodcast and global.abb/group/en/media/ podcasts/the-robot-podcast, so you never miss an episode. If you missed Season One, you can catch up on all previous episodes at the same link. The Robot Podcast is part of the ABB Decoded series of podcasts.

Tebis 4.1 Intelligent Manufacturing Offers Automation, User-Friendliness and Practical Implementation Tebis 4.1 is a complete CAD/CAM system that’s designed for intelligent manufacturing. It enables CAD/CAM users to perform tasks in design, manufacturing preparation and NC programming in a single system with a high degree of automation. Tebis presented the most important new developments in CAD and CAM at the EMO in Milan (4th – 9th of October). Tebis is consistently moving forward with greater automation, userfriendliness and practical implementation. It has clearly demonstrated the many advantages of rule-based procedures by drawing on its proven internal expertise with both CAD and CAM applications. Major innovations Faster preparation for manufacturing: Highly automated, flexible preparation of CAM programming with parametric CAD templates Every imported data set has to go through a design process to be prepared for CAM programming. This usually takes many individual work steps: Bores for clamping systems must be placed, tilt axis systems defined, fill surfaces designed, blanks created, connection points for setups generated, clamping devices positioned and retract planes defined. These many individual steps can be automated in Tebis using parametric CAD templates. These templates can be extended as needed and modified to meet customer-specific requirements. Users can remain flexible: changes like the selection of a different clamping system can now be controlled directly and conveniently with the user parameters in the object tree.

As always in Tebis, all system components are fully accounted for in collision checking and simulation. Programming is incredibly easy. Tebis automatically generates NC code for any machine and supports all control-specific program structures. Easily machine surfaces with 5-axis barrel cutters Tebis also introduced a function that simplifies programming of multi-axis toolpaths for pre-finishing and finishing with circle-segment cutters, also known as “barrel cutters.” It automatically determines the best setting for manufacturing the machining area totally free of collisions. The function simultaneously calculates the optimal contact point at the surface boundary to ensure material removal over the largest possible area. Machining is indexed or 5-axis simultaneous: the user can independently specify the preferred variant or can leave the decision up to the system.

Optimal cutting conditions for roughing rotationally symmetrical parts A real plus for combined turning/milling operations: In addition to cylindrical parts, now tapered parts like screw conveyors can also be machined with high efficiency. The tool first roughs the part to the maximum possible depth with a low stepover and large downfeed in a single pass, then it machines the residual stock from bottom to top with a smaller cutting depth – precisely to the stock allowance. This procedure reduces tool wear and ensures a high material removal rate on the machine.

Manufacturing PDATE

Improved support for multi-channel machine tools This innovation is beneficial for manufacturing companies that rely on combined turning/milling operations, especially if the components to be machined have a high milling fraction: Tebis can now be used to program toolpaths for sequential processing on machines with multiple tool and component holders. The individual steps – like milling with a milling head or turret, stabilizing with a centering tip or clamping with a sub spindle – can be combined in any way. All tool and component holders are stored in the virtual Tebis process libraries, which can be interchanged quickly and flexibly during programming.

December 2021

Tebis (UK) Ltd Tel: 02476 158178 Email: info@tebis.co.uk www.tebis.com

Precise process monitoring

Hygienic pressure transmitter with IO-Link Interface

RANTY AR

years if m pr od

Whether food or beverage industry, milk production or meat processing: The ifm pressure transmitter, PM, reliably monitors your process, with a high accuracy of 0.2 percent! The excellent temperature compensation allows for rapid temperature changes in the process, eg. In CIP / SIP up to 150° C. This makes the pressure transmitter ideal for demanding applications in the food industry. A free factory calibration certiﬁcate for each sensor is available as a download. Interested? ifm - close to you!

Go ifmonline ifm.com/ uk/pm

ENGINEERING PDATE December 2021

Process precision demonstrating repeatability that is unmatched by human workers. For instance, when properly calibrated, it’s possible for a six-axis industrial robot to achieve a position repeatability of 0.1 millimetres (mm) or better.

Another assessment where automation is beneficial is tensile testing, where the product is pulled and then monitored when it deforms or snaps to measure its resistance to breaking under tension. This is often used on metal alloys to discover how they perform under different loads. Tensile testing devices may be used as part of a quality control system or during material research when developing new alloys.

There are a number of production stages that can benefit from the precision of automated equipment. For example, a torque controlled power screwdriver ensures each screw in the workpiece is turned to the exact same level of tightness, avoiding loose or overtightened screws.

Not only would these testing tasks be highly monotonous for human workers, but they would also take much longer to perform than an automated system. High performance motors can power an automated system to perform these mechanical tests repeatedly at a fast rate with no human intervention.

In addition, an automated dosing pump can supply the exact amount of materials, such as adhesives, lubricants or sealants, required to the target product area. As well as preventing waste and avoiding contamination of other product parts, being able to supply precise amounts helps meet the miniaturisation trend, aiding the assembly of products with ever decreasing sizes.

Superb motor systems

How motorised equipment aids testing and control in manufacturing PWC’s UK Manufacturing Operations Pulse Survey 2021 found almost half of UK manufacturers are prioritising robotic process automation over the next two years. Automated equipment can perform to exact requirements, making it inherently advantageous in testing and control. Here Dave Walsha, sales manager at drive system supplier EMS, looks at how reliable, high performance micromotors are achieving process precision. Developments in robotics have allowed automated equipment to become increasingly sophisticated, performing tasks with superior speed and accuracy. For instance, a hospital in Oxford found a surgical robot could perform an eye surgery with ten times more precision than a human surgeon alone. However, it’s not just the medical sector that can capitalise on the high accuracy of automated machines - manufacturers can reap the benefits too. Keeping control

Manufacturing PDATE

Meticulous testing Manufacturers who adopt automated production lines gain a high level of control over the assembly process, which minimises waste from defected goods and ensures customers consistently receive a high quality product. These benefits have contributed to the record high of 2.7 million industrial robots operating in factories around the world in 2020. Automated equipment can be digitally programmed to perform tasks to exact measurements,

December 2021

along a motorised conveyor belt to a vision system.

However, the benefits of precise automated equipment aren’t restricted to product manufacturing, they’re also advantageous in testing. For example, an automated testing rig with a motorised locking mechanism can hold a product in place while it’s subjected to different tests. One of these tests could be scanning the product for defects, such as missing screws, damage or incorrect dimensions, by moving the rig

It’s important that automated industrial equipment are matched with advanced motor systems that deliver reliable power. The FAULHABER brushless motors are ideal for automated systems, as they provide a long life with a wide speed range. They also have a range of compatible motion controllers that create an advanced, programmable drive system with easy and accurate control that is simple to integrate into an automated system. Many manufacturers are focusing on automation in their future development plans. Motorised equipment bring high levels of accuracy and precision to production lines and testing facilities, ensuring only consistently high quality products reach customers.

Tel: 01296 611660 Email: rk@pmgb.co.uk www.phoenix-mecano.co.uk 26 Faraday Road, Aylesbury Buckinghamshire HP19 8RU

We are delighted to announce that INSPHERE have been awarded the contract to deliver our new IONA system for Robot Monitoring and Control to AMRC Cymru The University of Sheffield Advanced Manufacturing Research Centre (AMRC) Cymru is a £20m state-ofthe-art research centre in North Wales. The team behind AMRC Cymru is a powerful partnership between the Welsh Government, local authorities, growth and enterprise agencies and a world-leading R&D centre in advanced manufacturing. Its goal is to help the region’s manufacturing community access advanced technologies that will drive improvements in productivity, performance and quality.

“We are excited to be installing the new IONA system to monitor our robot AM cell and we look forward to working closely with INSPHERE to get maximum value from the system for the benefit of our members and the wider manufacturing community. We intend to use IONA on a range of robot cells in the centre to demonstrate its value for enhancing automation in aerospace, the food and drink sector, and other applications too.” AMRC Cymru Research Director, Andy Silcox

Manufacturing PDATE

• AMRC Cymru is installing a cutting-edge robot cell for additive manufacturing (AM). This new technology has many applications and enables rapid manufacture of large and complex parts which often cannot be made by any other means. For the cell to operate effectively, the robot needs to perform accurately, and its performance needs to be closely monitored at all times. INSPHERE has developed the IONA system to provide accurate real-time monitoring of robotics and so it is ideally suited to this setting. It has the added advantage that monitoring data can be used to control the robot directly through closed-loop feedback, enabling sophisticated control of the robot AM process.

December 2021

IONA is a network of sensors and software that can simultaneously capture alignment data from industrial robots and other points of interest, be that the work piece, fixture or cell datums.

•

Using IONA, engineers can monitor the performance of automated systems and ensure they are performing consistently in accordance with the simulated or programmed intent.

•

The data generated with IONA can be used to make corrections either as a one-off system calibration or as part of regular dynamic adjustments compensating for natural process variation.

The outputs of IONA are: •

Improved System Accuracy – Allowing more processes to be automated and improving process quality

•

Correction to robot programs – Enabling faster commissioning and validating a digital twin

•

Reduced automation downtime – Enabled by predictive maintenance using IONA SPC trend data.

Download the Brochure to find out more about IONA and the ways we can help your business www.insphereltd.com/iona-brochure/

The new Interroll Split-Tray Sorter Fast, flexible sortation for everyone Interroll introduces the new Split-Tray Sorter: the perfect solution for small and mid-sized items. Efficiency and low maintenance make this new sorter attractive for those looking for lower operating costs and quicker return on investment. It is an ideal solution for the 3PL , E-Commerce, Fashion and CEP industries. Easy to install and reliable with its proven mechanical components & integrated control solution Lightweight and energy-efficient - with a single motor every 40 meters Compact but dense footprint with plenty of destinations Extremely quiet with only <70 dB(A) noise levels

Interroll Limited Unit 1a Orion Way Kettering, Northants NN15 6NL Tel. +44 / 15 36 31 27 70 Email: gb.sales@interroll.com

interroll.com

ess space, more output is not surprisingly high on the ‘wish list’ for any forward thinking manufacturer and the ArcWorld standard systems available from YASKAWA are ideal for replacing, or supplementing manual welding required in metal manufacturing applications. These fully integrated systems offer the distinct advantage of being selfcontained, so it’s a bit like buying any machine tool, you choose the size of machine you need and a location to install it and away you go. The YASKAWA ArcWorld HS Micro and RS Mini systems are easy to install, operate and relocate in a small footprint of either 2.3 sq. metres for the Mini, or as little as 1.4 sq. metres for the Micro. Both systems offer the possibility for operators to double their output with up to half the preparation time, compared to manual welding. The Micro system is supplied complete with robot and controller and its hinged door opening provides lots of options even though it’s a very small, compact system. The Mini system has a revolving door and table, which again means maximum flexibility within a compact system. The systems are designed to allow quick changes of jigs, which is crucial in helping to reduce the all-important setup time and improving production output compared to conventional manual welding practices. Furthermore, improved operational consistency by never missing a weld and ensuring the same quality of weld at the end of the shift as at the start, also means reduced ‘spatter’ which improves the capacity for fettling.

Manufacturing PDATE

Both systems incorporate a MOTOMANAR900 robot with YRC1000 controller, a start / stop button panel and fume extraction hood. They also feature a platform and casing with dark green polycarbonate glare shield protection and CE-marking. The Yaskawa Motoman ArcWorld Micro and Mini robotic welding systems are pre-engineered, pre-assembled and shipped ready to weld and represent the latest generation of cost-effective automated solutions for welding applications. They can be configured with your choice of welding power source and are ready to mount your component tooling.

For more information click here.

December 2021

ULTRA COMPACT, SELF CONTAINED ROBOT WELDING SYSTEMS Exploring the benefits of using robotic systems across a wider range of manufacturing applications has accelerated recently where investment in the most up-to-date systems is making a significant contribution to maximising efficiency. Welding applications are a good example and the availability of new, highly flexible, space-saving systems is helping manufacturers to integrate robotics into their welding and fabrication processes.

Reduce unscheduled shut downs, reduce maintenance costs and improve plant safety with our Valvescan Diagnostic Monitoring System. Our revolutionary system is an end-to-end solution that captures data from every valve operation, analyses it and provides targeted alerts on the valve health without any requirement for involvement from plant personnel or any potential impact on the asset real-time control integrity. It is a true IIoT solution for automated valves. This system is not only a pioneering development in valve monitoring, it is also; ● Cost effective and easy to install ● Works with all existing valve systems ● Enables data retrieval and transmission to the cloud ● Provides a ‘real time health’ check on the valve and alerts when performance drop off is detected

08700 340 002 www.imtex-controls.com

Bunting Magnetic Separators for CRS Overseas Recycling Project Bunting-Redditch has completed the manufacture and supply of three (3) magnetic separators and one (1) eddy current separator to recover metals in an overseas recycling plant designed and installed by CRS NI Ltd.

Manufacturing PDATE

Bunting is one of the world’s leading designers and manufacturers of magnetic separators for the recycling and waste industries. The Bunting European manufacturing facilities are in Redditch, just outside Birmingham, and Berkhamsted, both in the United Kingdom.

CRS NI (Complete Recycling Systems) is a leading player in the UK waste processing market, designing and manufacturing bespoke Material Recycling Facilities (MRF) to suit any size operation, from in-line trommel plants to full co-mingled waste plants as well as original plant extensions and “add-ons”.

Figure 1 - EMAX150 ElectroMax Overband Magnet

December 2021

After an extensive review of recycling equipment suppliers at the end of 2020, CRS selected Bunting-Redditch to supply the metal separators. The configuration of the waste processing plant led to the selection of three (3) ElectroMax Overband Magnets and one (1) Eddy Current Separator with vibratory feeder.

The Model EMAX150 ElectroMax Overband Magnets recover steel cans and other ferrous metals from the conveyed waste. One is suspended inline with a conveyor, over a non-magnetic head pulley, with the remaining two positioned across the conveyors. All the ElectroMax models feature compact, air-cooled, high-powered electromagnets with heavy-duty self-cleaning rubber belts. In operation, the waste passes under the electromagnet on a conveyor where any ferrous metal attracts up and out of the burden. The self-cleaning belt transfers captured ferrous metal out of the magnetic field, discarding into a collection area. Each EMAX150 weighs 2.8 tonnes and is 2750mm long, 460mm high and 1590mm wide.

Figure 2 - 1.5m wide Eddy Current Separator

The 1500mm wide Eddy Current Separator, with integrated vibratory feeder, is located later in the process and recovers non-ferrous metals such as aluminium cans. The HIC Model (high-intensity concentric) features a 300mm diameter magnetic rotor. The vibratory feeder regulates an even and controlled feed of waste material onto the faster running Eddy Current Separator conveyor belt, which then transports the waste into the alternating magnetic field of the rotor. An Eddy Current Separator is a dual pulley conveyor system, where the non-metallic rotor cover houses an independently rotating high-speed magnetic rotor. Separation occurs when a non-ferrous metal particle (e.g., aluminium, copper or zinc) is conveyed into the magnetic zone. The non-ferrous metal particle is exposed to rapidly changing magnetic polarity. This induces ‘eddy currents’ into the particle generating an electrical current (Fleming’s left-hand rule) that subsequently creates its own magnetic field. The two magnetic fields oppose each other (i.e., North vs North pole repulsion), causing the repulsion of the non-ferrous metal particle and change in trajectory. The measured positioning

of a splitter enables the separation of non-ferrous metals from nonmetallic material due to the altered and unaltered material trajectories. The 1500mm wide Eddy Current Separator and vibratory feeder combined system weighs 3.9 tonnes and is 5.8 metres long, 2.6 metres wide and 2.3 metres high. 15 tonnes per hour of mixed waste with a maximum particle size of 50mm feeds through the separator. The waste contains approximately 1% non-ferrous metals, which are dominantly aluminium beverage cans. The combination of the ElectroMax Overband Magnets and Eddy Current Separator ensures the maximum recovery of metal from the waste stream. “This is another manufacturing export success story for the United Kingdom,” said Adrian Coleman, the General Manager of Bunting-Redditch. “CRS is one of the leading designers and suppliers of recycling plants and we [Bunting-Redditch] were thrilled to be selected as the suppliers of the metal separators. Effectively managing waste is a global challenge and we are proud to see UK designed and built plant being used in overseas recycling projects.” For further information, please contact us on press@buntingmagnetics.com or visit our website: Bunting-Redditch – www.bunting-redditch.com

December 2021

Manufacturing PDATE

In this project, two of the conveyors are 1200mm wide for the crossbelt installation, with the third being 1500mm for the in-line position. There are three size fractions: <50mm, 50-150mm and 150-400mm with the burden depth on all three conveyors averaging around 300mm.