Engineering Update - February 2023

At the forefront of digital marketing, Engineering Update strives to bring the latest in industrial engineering in a format that provides the best usability and ease of use for its readers.

Publication Director

Jodie Little

01843 595818

jodie@jetdigitalmedia.co.uk

Editorial Assistant

Laura Sharpe

01843 448 443

laura@engineering-update.co.uk

Editorial Assistant

Leigh Little

01843 448 443

leigh@engineering-update.co.uk

Publishing House

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

DK Holdings celebrates National Apprenticeship Week

ODU-MAC PUSH-LOCK Modular connectors with top packing density

diaphragm pumps

There has never been a more important time for our sector to pull together and to work together, to create a shared agenda and Manufacturing and Engineering Week will do exactly that. I am delighted to be part of the Advisory Board and that MAKE UK are a partner of this groundbreaking event.”

Stephen Phipson CBE, Chief Executive, MAKE UK and M&E Advisory Council Chairman

GSME and HOTSPOT detectors

Early detection of explosions and fires

With the GSME and HOTSPOT detectors from REMBE, an artificial intelligence has been created that detects fire and explosion events at an early stage. The GSME detector is an artificial nose, "trained" for pyrolysis - popularly known as smoldering gases, while the HOTSPOT detector represents an artificial eye that already detects surface temperature changes of 1 °C.

REMBE´s HOTSPOT X20 measures surface temperatures using an intelligent evaluation system, which divides the field of view into detection zones. A separate temperature threshold value can be set for each individual zone in order to tailor the detection to the process as far as possible. The HOTSPOT X20 can even identify small temperature increases (1 °C) and enables to warn the operator of a fire or glowing embers at extremely early stages. The HOTSPOT X20 can also be used in explosion atmosphere up to zone 20 and under high dust loads and monitors a temperature range in the standard version of 0-200 °C (higher temperatures possible, but typically not required).

Mainly hydrocarbon compounds are released when many substances thermally decompose. If there is incomplete burning without a flame and a low oxygen supply, carbon monoxide is created as well. The GSME X20 pyrolysis gas detector, for instance, has been designed for detecting these gases, even as they develop. Alongside carbon monoxide and hydrocarbon compounds, nitrogen oxide and hydrogen compounds (CO, HC, H2 and NOx) are also monitored. With the aid of an intelligent evaluation algorithm, a process behaviour can be ideally mapped and normal off-gasing be adopted. If a concentration increases above the usual level, the GSME X20 immediately triggers an alarm. The detector, is also suitable for explosion atmospheres up to zone 20, monitors concentration ranges from 0-100ppm.

When the location and mounting position are ideally designed in an explosion protection concept, HOTSPOT X20 and GSME X20 allow explosions and fires to be prevented through early detection.

GSME und HOTSPOT detectors

StocExpo 2023 Exhibitors Announced

Over 120 leading companies in the global tank storage and future fuels industry have already signed up for StocExpo 2023, which takes place on the 14th – 16th March 2023.

The world-leading tank storage and future fuels event will return to the Rotterdam Ahoy for another unmissable exhibition.

TThose exhibiting include Ivens Group, which are world-leading in total liquid storage solutions for the petrochemical sector. Emerson, which is a major provider of process automation systems, instrumentation, valves and services for storage and bulk liquid terminal facilities globally, has also signed up to exhibit.

Honeywell Process Solutions will also be in attendance, which pioneered process automation control and thermal process solutions, and today, plays a critical role across the entire lifecycle of an industrial facility.

Rikki Bhachu, Head of Marketing for StocExpo says: “Unarguably the tank storage and future fuel industry’s event of the year, StocExpo 2023,

is designed for those looking to get amongst key industry innovators and their cutting-edge services and products. Visitors will be surrounded by industry professionals who are able to offer expert information and advice, and anticipate what the future looks like globally for tank storage.”

“Returning to the Rotterdam Ahoy, the event provides an unmissable opportunity for exhibitors to showcase their new innovations, launches and developments to like-minded professionals and potential business leads.”

To view the full list of exhibitors, visit https://www.stocexpo.com/exhibitor/

For more information about StocExpo, register to attend or register to exhibit at the event, visit www.stocexpo.com

PRELUBE SYSTEMS IMPROVE EFFICIENCY AND PROLONG EQUIPMENT LIFE

Studies have shown, the majority of engine mechanical wear, almost 90%, occurs at start-up. At first crank of the engine, all the oil is in the sump and at the first rotation of the crankshaft the bearings, turbo bearings, rods, pistons, heads and all galleys are dry causing metal-to-metal contact to occur damaging the engine over it’s lifetime.

Common arguments are that warming up your vehicle before driving, frequent oil changes, oil preheating, etc work to prevent this problem. While all these practices are positive, none of them

actually move oil to where it needs to be at start up; only prelube does that.

Other arguments that, “diesel engines run for millions of hours anyway” or, “if prelube made a difference OEM’s (original equipment manufacturers) would put them on”, have been made to negate the value of prelube. In today’s world of environmental regulations and impact as well as rising fuel costs, industrial engine operation is changing. With no idling laws there are more frequent starts and getting enough hours is no longer enough –

consumers want to get the most out of their high-dollar equipment. Some OEMs are utilising prelube in certain applications like power generation and marine because they know the value in demanding applications and the benefit it adds. Although, typical factor-installed systems employ standard hydraulic gear pumps that are inefficient for this application.

Another benefit of a prelube system is when used for engine shut down & turbo wind-down to lubricate the hot bearings for substantial reduction in wear and increase in turbo life. Prelube is also helpful in cold climates for cold starting to help circulate the cold oil, if there is no oil heater, until it is viscous enough to move through the engine.  VARNA PRODUCTS OFFERS A RANGE OF PUMPS AND PRELUBE

In today’s economy and with industrial equipment prices on the rise, owners and operators are looking for practical ways to extend equipment life and increase time between top end and in-frame overhauls to maximise investment.

Investing today in future engineers of tomorrow

–DK Holdings celebrates National Apprenticeship Week

“DK Holdings is renowned for the design, manufacture and supply of off-the-shelf and bespoke Diamond Tooling solutions for a variety of applications and industries including the aerospace, automotive and defence industries as well as the emerging renewable energy sectors globally” , Darren tells us. “Supplying tooling solutions within these ever changing industries means that we invest continuously to evolve alongside them, in both, machinery and our people”

“The company was established over 60 years ago and from the get-go, it was vital to our founders to allow local youngsters to forge a career in Engineering”, Darren informs us. “We firmly believe that apprenticeships are a vital part of a company’s success as you combine the skillset of your experienced workforce and couple it with new ideas. Subsequently, this will lead to increased productivity as well as continuous development of new products which is very much the secret of our success”

“The company’s production facilities now span 4.000sqm and include manual, semi-automatic and CNC lathes, milling and grinding machines, with our apprentices being trained on all of the machines by our experienced

workforce. Our machining capabilities and a team of skilled engineers enable us to produce precision engineered components in a variety of materials such as aluminium, steel or tungsten carbide. Whilst cutting-edge machinery is vital, we know that our success

is also down to our production staff which enabled us in 2022 to expand our portfolio by offering the design, manufacture and supply of precision engineered components and a subcontract manufacturing service” , Darren explains.

“We are committed to supporting initiatives such as National Apprenticeship Week as it makes such a positive impact on not just the individual but also us as a company. Learning a practical skill in an engineering company such as ours helps to develop skills for life, a rewarding career path and futureready skills”, Darren concludes.

Darren Mills, Finance Director at DK Holdings, a market leader in Diamond Tooling solutions and Precision Component Manufacturing, based in the United Kingdom, is proud to celebrate National Apprenticeship Week which is held from 6th to 12th February.

Reducing energy costs and increase sustainability with next generation cleaning solutions

As we begin 2023, Businesses are stepping up on meeting ESG (Environmental Social Governance) targets and looking for ways to be more sustainable and cut carbon emissions.

They’re also looking at where efficiencies can be made and costs can be cut as energy prices continue to soar. In both cases, changing the chemicals and equipment used in the cleaning process can have a significant impact.

Significant advancements have been made in new innovative industrial solvent cleaning chemicals, making them a viable, safe, cost-effective and more sustainable option. One such product is Opteon™ SF80 from Chemours. SF80 has an ultralow GWP of less than 2.5, unlike common F-gas solvents that can have a GWP of up to 11,000. It is just as effective as damaging competitor products, and is often more efficient, so changing can have a huge impact on lowering carbon emissions.

It can also save huge amounts of money in the process. SF80 reduces weekly CO2 usage by 75%, reduces weekly fluid consumption by 50% and reduces the cost of average daily consumables by eliminating water treatment.

In addition to products, Fraser Technologies also offers equipment to support cleaning solutions, many of which increase efficiency and reduce cleaning time, saving costs and emissions.

Fraser Technologies Brand New SlimLine PLW 6011 & PLW 6111

aqueous cleaning systems from Miele Professional, for example, are single chamber aqueous cleaning machines offering time, energy and cost-saving efficiencies, which can meet the stringent cleaning requirements for high-reliability industrial sectors.

At only 65cm wide, the footprint is very compact, whilst still providing a large and flexible internal chamber space. This size, flexibility and smart

load system allows a variety of components to be cleaned highly efficiently all at once, whilst utilising much less space compared with a standard sized machine.

Fraser Technologies’ solvent and aqueous cleaning systems offer an environmentally friendly and cost-effective solution for your sustainability and precision cleaning needs. Find out more today!

Click here for further information or email sales@frasertech.co.uk

Fuel Depots

Ensuring the highest safety for

The Cygnus 1 Ex Ultrasonic Thickness Gauge is a rugged, handheld, intrinsically safe instrument designed for taking thickness measurements in Zone 0 explosive atmospheres.

• Certified Intrinsically Safe to ATEX, IECEx, UKEX for Zone 0 and NRTL for Class 1, Division 1

• 3 measuring modes for corrosion, various materials and through-coat measurements

• Manual Measurement Mode allows gates and gain to be configured to suit your application

• Live A-Scans and B-scan for visual verification

• 4 quick function keys for easy control

cygnus-instruments.com • sales@cygnus-instruments.com

Oil and Gas

LNG/LPG Tankers

Mines

Storage Tanks

Railtex 2023

Renewed public interest in rail travel and the need for more digitalised and greener solutions are driving the attention of many key players towards more innovative and sustainable mobility. The upcoming Railtex edition is an unmissable opportunity for railway professionals to discover the latest innovations and technologies in person, learn more about topics that move the industry from decarbonisation to digitalisation and meet business partners and new suppliers from around the world.

Attendees can expect an excellent cross-section of technologies and solutions to facilitate the safe, efficient, and sustainable operation of rail transport. Exhibits cover rolling stock technology, track, and infrastructure, signalling and communications, vehicle maintenance, fare collection systems, cable technology and many other rail-related sectors.

• Discover the latest technology in person and experience products and services from numerous exhibitors in more than 180 different categories.

• Connect with industry experts and make impactful business relationships

• Gain valuable insider knowledge and find out about the current trends and topics

On-Track Display: an established and successful feature

Placed in the hall, one length of track will be used by exhibitors to display and demonstrate tools and equipment in an authentic rail setting. There is no better way to experience a product than to see how it sits and operates on track as it would in the field.

Meet the experts and learn about rail industry trends

Railtex provides an excellent opportunity to rekindle contacts and will bring prominent industry experts, stakeholders, and decision-makers in attendance, along with the exhibitor presentations and an extensive conference programme. The programme will accentuate not only the opportunities but also the challenges that the industry has been going through, and it creates a chance to expand in-depth discussions about the latest developments in the rail industry.

Interested in attending Railtex 2023? Tickets are now available and can be ordered online free-of-charge before the show or purchased online and on-site during the exhibition.

Register now!

https://www.railtex.co.uk/en-gb/visit.html

Railtex 2023 will gather the UK’s railway industry from 9 - 11 May 2023 at the NEC in Birmingham.

Snap-on’s Level 5™ asset management system is network

ready

As engineering managers come under pressure to meet demanding schedules, often with fewer skilled hands and tighter budgets, the benefits of professional tool storage and management become stronger than ever.

Snap-on Industrial’s Level 5™ automated total asset management system brings order to any workplace, enabling engineers and technicians to know exactly where to find every tool they need, when they need it, saving time and easing stress.

How useful would it be if all valuable tools could be tracked from one central point? Snap-on’s Level 5™ system makes that possible. It provides complete reports on everything

managers or supervisors need to keep an eye on.

And then there’s FOD. The threat of foreign object damage is a real and present danger in many engineering workplaces. Using Snap-on Level 5™ minimises the risk of human error, as automated tool control constantly tracks every tool and detects which tools have been removed or returned, ensuring greater protection against FOD.

Engineered to track individual tools by user, without bar codes, scanners, RFID tags or other add-ons, the system works at the speed its users demand. Other systems require additional steps to scan or log activity. The Snapon system does this automatically so users save time and don’t have to depend on other steps to ensure accurate results.

Snap-on’s Level 5™ ATC boxes are network ready, using either Ethernet or wireless connection. That enables users to review activity at all Level 5 boxes in their location from one central computer, avoiding the time consuming need to inspect each box.

Major benefits of the system include:

• No individual tool scanning required;

• No RFID tags to install or replace;

• No limitations on tool size: from ¼” screwdriver bit upwards;

• Intuitive interface, with an easy to use touchscreen

• Audible voice announcement of tool removal and replacement

• Automatic locking for maximum security

• Errors announced and displayed to indicate incorrect tool position or advise when a drawer is not closed.

Says Richard Packham, Director UK & Europe for Snap-on Industrial: “Snapon’s automated system takes asset management to an entirely new level. The ability to monitor several boxes from one central computer offers a huge advantage to engineering managers.”

For technical information visit: www.snapon-industrial.co.uk; call (01536) 413904 or e-mail:

ukindustrialmarketing@snapon.com

Safe for use in hazardous areas, ATEX certified installed LED lighting is now available from Wolf Safety

Wolf Safety have introduced a powerful new range of ATEX certified LED installed lighting, designed for permanent use in potentially explosive atmospheres.

The world’s leading manufacturer of portable and temporary ATEX and IECEx certified hazardous area safety lighting, Wolf have been keeping people safe for more than 110 years.

The company’s designers and production engineers have now brought their vast knowledge and expertise to bear on a new range of highly effective LED installed lighting, which is safe to use in Zones 1 and 21 hazardous areas.

The range includes:

• Linear luminaires featuring the new, revolutionary Directional Linear Optics (DLO) or standard Forward Facing Array LED configurations (with battery back-up emergency versions also available);

• Floodlights with a market leading maximum light output of up to 25,932 lumens;

• Bulkhead lighting, also featuring DLO (with battery back-up emergency versions also available);

• High bay lighting.

DLO directs light exactly where it’s needed and is ideal for use in specific, close-up workspaces, reducing glare to avoid people being ‘blinded’ by the emitted light, while its excellent colour definition facilitates safety critical hazardous area tasks.

Forward Facing Array (FFA) technology can be preferable for safely illuminating large hazardous areas which need wide, even and bright light coverage, where lights are mounted away from people or at heights where glare and intensity can’t have an adverse effect on the working environment.

Says Miles Jackson, Wolf Safety’s Sales and Marketing Director:

“We know that users of Wolf products trust us to keep them safe, especially when they need to work in highly volatile atmospheres and other hazardous workplaces.

“All the values people expect from Wolf - and are seen in our portable and temporary lighting ranges - can now be found in this new installed lighting range, which we are proud to introduce.”

For detailed technical information visit: www.wolfsafety.com

IntraLogisteX 2023

The Biggest Warehousing Logistics Event of 2023

The most comprehensive intralogistics show of this year is almost here.

Now in its ninth year, IntraLogisteX is not only UK’s biggest and best factory and warehouse logistics event, but it also features the most advanced industry innovations and solutions – everything you need to create the factory or warehouse of tomorrow, today.

IntraLogisteX offers visitors the chance to discover how the latest automation and robotics technologies can improve their business efficiency, reduce costs, enable them to improve sustainability, and give them a competitive advantage. By attending IntraLogisteX, engineering and manufacturing professionals can condense weeks of online research into just a few hours, all while networking and sharing ideas with their peers.

Manufacturing companies make up a significant portion of the event’s visitors. As well as most of the major car producers, such as Hyundai, Toyota, Aston Martin, Bentley, Ford, Arrival, and BMW, a vast range of manufacturing giants like Sony, Airbus, Perkins Engines, Caterpillar, Bosch, Lego Group, and Tata Steel are all sending delegations to the event.

Visitors can meet industry-leading exhibitors who will be showcasing solutions in factory and warehouse automation, robotics, materials handling, storage, racking, sortation, picking, barcode scanning, labelling, packaging, software, facilities management, and more!

The event organisers, Akabo Media, are introducing a number of important changes for this year’s event. Following on from last year’s sold-out event, the organisers have announced that the 2023 edition will take place on 28th–29th March 2023 at the UK’s leading live events venue – the NEC Birmingham.

This exciting move not only offers a wider range of services and transport links to exhibitors and visitors, but also allows IntraLogisteX to grow after its 2022 event sold out the Coventry Building Society Arena. IntraLogisteX can now offer its guests an unrivalled selection of 250+ exhibitors.

The move isn’t the only good news for automation and manufacturing professionals. This year, IntraLogisteX will be co-locating with Robotics & Automation Exhibition – the UK’s largest dedicated robotics and automation

exhibition. This follows the huge success of Robotics & Automation’s 2022 event, held at the Coventry Building Society Arena last November. This co-location gives visitors access to a wide range of leading robotics and automation organisations such as Autostore, Brillopak, Dexory, KNAPP, Locus Robotics, OnRobot, and many more!

IntraLogisteX 2023 is a totally free exhibition, visit their site to learn more and register now: www.intralogistex.co.uk

Series 35X

HIGH ACCURACY IS THE OPTION

Pressure Ranges 0…0,3 to 0…1000 bar

Accuracy ±0,05 %FS

Total Error Band ±0,1 %FS @ -10…80 °C

Interfaces RS485, 4…20 mA, 0…10 V

Operational Temperature Range -40…120 °C

keller-druck.com

Dixon

Petrochemical

Products

Fluid transfer products for upstream, downstream and refining

• Global inventory and locations

• Sales and technical support worldwide

• In-house engineering & design

• ISO 9001 accredited

• Pressure Equipment Directive

Products:

• Hoses and hose assemblies

• Hose & pipe fittings

• No-spill couplings

• Safety breakaway fittings

• Blow-Out prevention couplings

• Hydraulic Fracturing: Low Pressure Systems

• Loading arms

• Liquid level sensing

• Zero emission valves

•

Visit the UK’s largest robotics & automation exhibition this March!

It will take place on March 28th & 29th at the NEC Birmingham. This step up in venue will produce a similar step up in scale – the larger venue provides room to grow. Also, the event will be co-located with IntraLogisteX, a show focused on technologies for warehouses and distribution centres.

As this year, there will be a wide range of factory and warehouse automation on

show, and it will be an ideal opportunity to make sure your business can survive and thrive.

Visitors to Robotics & Automation 2023 will discover how the latest technology can be applied to their operations to provide massive improvements in productivity and accuracy. Products include Robots & Robotic Systems, Automated Assembly Machines &

Systems, Parts Handling Equipment, Conveyors and materials, Industrial Automation Control and more. There are also live demonstrations of the latest solutions taking place throughout the exhibition, so visitors can get first-hand insight into how they work in practice.

Once again, a comprehensive conference programme which will allow attendees to hear directly from people implementing projects using the latest technology. Experts from manufacturing businesses and more will share their insights and give real world examples of how they have automated their own, and their customers’, operations.

Invest a day or two in your future, and visit the show, which is free to attend for qualifying professionals. To register, visit www.roboticsandautomation.co.uk.

Robotics & Automation 2023 is moving, both in terms of the venue and the time of year.

The

Sponsors and Partners: Hosted by:

networking exhibition for the lifting equipment industry

Packed show floor of lifting equipment and services

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

Prima Tooling designs and manufactures tooling for CNC machining, alongside the supply of milling and drilling tools from Sutton tools.

With more than four decades’ of experience in the tooling industry, Prima Tooling’s expert team are fully equipped with all of the knowledge and equipment to assist with any tooling enquiry. Our fantastic ranges of drilling tools, end mills, threading taps, and compression routers are capable of tackling a huge range of cutting, drilling, and profiling tasks.

Our new online shop

Prima tooling are excited to announce the launch of our new webshop for Carbide End mills, Carbide Drills, Threading Taps & Reamers to name a few. Giving our customers a quick and easy way to restock their CNC tools. We will soon be adding our composite tooling to the shop to ensure our tools continue to be readily available.

Whilst our woodworking tools are available through a network of distributers across the UK, Ireland, Europe, Canada and USA. Our in house developed tools for Composite, Foam and those from Sutton Tools are easily purchased from Prima Tooling direct.

If your design requires more detailing or finer shaping than simple stock tools will allow, our bespoke manufacturing and servicing of all tooling; engineering, wood, foam and composite tools includes everything you need to take on any CNC project.

Prima Tooling have also introduced the brand-new ToolTray aimed at giving customers somewhere to safely store and transport their CNC tooling.

Our new ToolTray offers the ultimate modular system for organising, storing, and transporting your cutting and drilling tools. But that’s not all!

The ToolTray is also suitable for use in cleaning and coating your tools. Let’s take a look at some of the ToolTray’s incredible features in more detail:

Sturdy and Safe Storage

The ToolTray offers the perfect tool storage solution. Crafted from impact resistant Polyamide (PA6), the ToolTray offers complete protection from potential damage to your tools due to bumps or scrapes. PA6 is one of the most popular thermoplastics used in engineering across many

due to its high strength, heat resistance, and electrical insulation properties. The ToolTray is heat resistant up to 120oC, solvent resistant, and designed to ensure complete protection against impact damage.

Fully Modular for 100% Customisation

The ToolTray is a fully customisable, completely modular system, allowing you to personalise your ToolTray to match your exact needs! Our ToolTray frame and inserts are sold separately, so you don’t have to pay for inserts you won’t use. Our colour coded, interchangeable inserts range in diameters from 6mm to 25mm, and inserts are reversible to swap between a 25mm and 40mm depth.

Suitable for Use in Cleaning and Coating

The ToolTray is able to make cleaning and coating of tools much quicker, easier, and more convenient! The ToolTray is suitable for use in

immersion baths, meaning you can keep your tools conveniently organised while you conduct your cleaning or coating. Due to the electrical insulation properties of PA6, the ToolTray won’t interfere with your coating process. The ToolTray is the ultimate customisable modular tool storage and transportation system, giving you a convenient case to store, transport, clean, and coat your tools while keeping them neatly organised and sorted. The ToolTray is even stackable when not in use, so multiple ToolTray’s won’t clutter up your workspace!

LiftEx 2023 is the unmissable global event for the lifting industry taking place at the Exhibition Centre, Liverpool on 21-22 November 2023.

Go to liftex.org now for the latest updates.

LiftEx 2023 is coming to Liverpool

The annual event hosted by LEEA (Lifting Equipment Engineers Association), the leading global representative body for all those involved in the lifting industry worldwide, offers the ideal chance for exhibitors to connect with customers, meet new clients and do business.

Almost 100 exhibitors and over 1,500 industry professionals will be attending across two days of knowledge sharing and training, as well as the celebrated LEEA Awards.

The show attracts end users from a wide range of vertical markets, including manufacturing, oil & gas, energy, offshore, road & maritime transport, construction, utilities, rail, renewable energy, civil engineering, entertainment, and more.

The LiftEx 2023 website is now live at www.liftex.org, where you can find useful features including a film of highlights from the 2022 show, news bulletins on what’s coming up in 2023, as well as the lifting suppliers who will be demoing their products on the show floor. Requests to exhibit will be dealt with on a first-come, first-served basis, so please contact Leah Phelps on +44 20 3488 2865 or at enquiries@L2Events.com to secure a sponsorship package or a prime position at the exhibition.

Ross Moloney, CEO of LEEA, said: “LiftEx will be celebrating its 18th year in 2023 and we are very excited that it should be doing so in the world famous city of Liverpool. It will be 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. Our thanks go to Rope and Sling Specialists Ltd, confirmed as Sponsor of LiftEx 2023, and to DELTA Hoisting Equipment, confirmed as Silver Sponsor.”

Sign up to register your interest here: https://liftex.org/liftex-liverpool-2023/contact

Flow Sensing Challenges in Food & Beverage Production

Titan Enterprises offers a range of highperformance flowmeters in food grade materials where both food hygiene and precision flow measurement are required.

Flow measurement is a critical tool for food and beverage manufacturers, the industry having a diverse range of processes that require the precise control of liquid flow rates. Production processes including filling of vessels or bottles, measuring liquid ingredients, and controlling cleaning processes, require varying degrees of complexity and accuracy to ensure consistent product yield and minimise wastage. Although there are a wide variety of general flowmeters on the market, only a few high-performance measuring devices will ensure the high levels of hygiene and precision are maintained for applications in the food and drinks sector.

“The physical properties of the liquids themselves lend additional complexities to the choice of flow measuring equipment,” says Neil Hannay, Senior Development Engineer at Titan Enterprises. “Consideration of whether the liquid is viscous, volatile, corrosive, flammable, or contaminated with

particles, for example, or needs to be maintained at a high temperature, are key factors in deciding a suitable flow meter.”

Monitoring Flow of High and Low Viscosity Fluids

Flow monitoring of high viscosity liquids, such as cooking oils, sauces and syrups (e.g. syrup injections in beverage lines) require devices such as Titan’s oval gear flowmeters, which provide highly accurate flow measurement. Unlike other flowmeters, measurement accuracy of oval gear flowmeters improves as the liquid viscosity increases, from a nominal 1% to around 0.1% of flow rate at higher viscosities.

Whereas for low viscosity liquids such as water, beer, wine and spirits, Titan’s NSF-approved 800-series and beverage flowmeters provide a lowcost drink dispensing solution. Designed to give high performance over 6 flow ranges from 0.05 to 15 l/min, these devices have totally non-metallic NSFapproved wetted components making them ideally suited for applications where both food hygiene and precision flow measurement are required.

Flow Monitoring at High Temperatures

In processes where ingredients need to be maintained at high temperatures – chocolate for example – a flowmeter designed for applications requiring precise flow measurement at elevated temperatures would be needed. Capable of operating up to 110°C, Titan’s inline non-invasive Atrato® ultrasonic flowmeter is largely immune from viscosity and offers excellent turndown and repeatability.

Titan Enterprises offers a range of oval gear flowmeters in food grade materials for viscous products such as sauces, oils and syrups, as well as NSFapproved mini-turbine flowmeters for drink dispensing. As an experienced OEM supplier, Titan develop customised flow meters for specific customer applications within the food and beverage industry.

To discuss an optimised flow measurement device for your OEM application please contact Titan Enterprises on +44 (0)1935 812790 or email sales@flowmeters.co.uk. Or visit our website for further information.

Innovative brushless DC motor technology for KNF diaphragm pumps

With the new DCB-I drive, KNF is introducing an in-house developed BLDC motor generation for the first time in its history.

This new generation of brushless motors further increases the advantages of KNF diaphragm pumps to the next level in terms of performance, robustness, and durability in combination with the ability to digitally customise the motor parameters. By integrating the motor directly into the pump housing, it was thus possible to implement these features in a more compact size.

The development of this BLDC motor allowed KNF to specify the individual components required to perfectly match the drive needs of a diaphragm pump.

Compared to what is usual for other motors, the DCB-I features much larger ball bearings. This significantly improves the robustness and durability, which is reflected in a life expectancy of >20’000h. Furthermore, the unique design creates not only a visually appealing look, but also technical advantages. The cooling fins on the aluminium motor cover also improves heat management, especially when the motor is permanently under heavy load.

The development and manufacture of this new generation of motors is the outcome of a cooperation between KNF and a leading motor manufacturer.

As a result, not only is the motor more powerful (in relation to its size), but the development of its electronics makes it possible to use additional functionalities. As a result, this allows total control over the motor to fully exploit the potential of KNF pumps.

KNF offers the DCB-I for the following pump types:

Gas Pumps

• NMP830

• NMP830 HP

• NMP850

• NMP830 HP

Liquid Pumps

• NF30

• NF60

• FP70

KNF develops, produces and distributes high-quality diaphragm pumps and systems for neutral and aggressive gases and liquids.

MAKING STEAM WITH AN ELECTRIC BOILER

In this article, Carl Knight – managing director of process steam and heat transfer specialist Fulton – looks at the advantages of electric steam boilers versus their traditional fuel-fired counterparts.

Electric steam boilers work in a very similar way to fuel-fired boilers except in the way that the water is heated.

The process of creating steam with an electric boiler is a relatively straightforward one. Electricity is passed through a heating element that acts as a resistor to create heat through resistance. Water from the feedtank is then pumped into the pressure vessel, heating the water enough to boil and become saturated steam at (depending upon the pressure setting controller) typically between 6 and 10 Barg, at which point the saturated steam is available to the process.

Advantages

Some believe that electric steam boilers are superior to fuel-fired steam boilers in a few ways. They believe that using electric boilers may be less expensive than using a fuel-fired boiler in the long term, whilst also possibly being more environmentally friendly.

Using Fulton’s portfolio of electric steam boilers as an example, less ancillary equipment is required than a traditional steam boiler, therefore helping to reduce the installation costs that come with a fuel-fired boiler. Electric boilers also generally have a smaller footprint and can therefore fit into smaller areas thanks to the way they are constructed and the lack of ancillaries that a fuel-fired boiler needs to operate.

Possible Disadvantages

Electric boilers are sometimes overlooked as a potential solution to steam generation due in part to the higher cost of electricity versus the cost of traditional fuels. To help meet its climate change and air quality targets, in the 2020 budget the government announced that it would remove the entitlement to use red

diesel from most sectors, including for use in industrial boilers, from April 2022. The tax changes will ensure that most users of red diesel will use fuel taxed at the standard rate for diesel from April 2022. As a result, many companies are now turning to more sustainable methods of generating electricity, including solar or wind generation. These schemes offset, or at least partially offset, the higher fuel costs.

Safety of operation

Traditional fuel-fired steam boilers generally require multiple elements to operate successfully. In contrast, electric boilers are relatively simple devices. Additionally, because electric steam boilers do not use complicated forms of heat exchange, they do not contain many of the potential hazards that are commonly present in a fuelfired boiler and will simply trip out if elements are exposed due to low water conditions that can arise in the operation of steam boilers.

Electric boilers are also generally easier to maintain because they have no heat transfer tubes, nor require burner maintenance or statutory nondestructive testing (NDT), all of which fuel-fired boilers often require.

Electric boilers also have smaller carbon footprints than their counterparts and, again thanks to their small footprints, can often be used for point-of-use steam requirements, making them a good choice for many smaller operations needing steam.

Additional benefits

Another benefit that should be considered is sustainability, thanks to their low maintenance requirements; and marketability owing to their green attributes, in the same manner as electric vehicles are seen as “green” versus petrol or diesel counterparts.

Electric steam boilers are also more efficient than fuel-fired boilers

them for operation at capacity. This is because there is little energy lost when the transfer of heat from the heating element to the water occurs, unlike traditional fuel-fired boilers where there is a substantial amount of energy loss from the air flow required to supply oxygen to the flame.

Additionally, because electric steam boilers can be fitted, in some cases, with up to 15 electrical elements (dependent on model), they have a high turndown (up to 15:1 in the case of Fulton’s electric steam boiler range), so are able to modulate efficiently to varying steam loads.

Electric boilers are, as already stated, more efficient, but for large generating capacities are frequently not practical to install due to large supply cables and infrastructure requirements. However, the actual maintenance costs can be up to 50%* less than those of fuel-fired steam boilers. Generally, the only major parts that are periodically changed are the electric elements themselves, yet these are often replaced quickly and cost effectively. This balances lower life cycle costs against the high maintenance requirements of fuel-fired boilers, including refractory repairs, 5-year NDT requirements, burner maintenance, flue maintenance and the requirement for highly-skilled and often highly-paid plant operatives.

For additional information about Fulton, please visit www.fulton.co.uk

Integrating Legacy Systems with Industry 4.0

The automation world is moving swiftly towards Industry 4.0. Forward-thinking companies in every sector are merging physical systems, distributed control systems, and virtual digital data into new kinds of cyber-physical systems. Among the technologies enabling this transition is OPC UA, providing secure real-time data communications to pull the pieces together.

OPC UA meets the needs of Industry 4.0 in ways that its predecessor, OPC DA could not. It can run on any platform, not just Windows. It has robust network support, a more sophisticated security model, and it is being developed to integrate with many other specialized industrial protocols. Small wonder that OPC UA is the protocol of choice for many Industry 4.0 projects.

However, there is still a huge installed base of preIndustry 4.0 legacy equipment and systems out there. Many of these use the OPC DA protocol for data communication. A wide range of existing OPC client applications, like HMIs and DCSs, support OPC DA. On the other hand, many legacy devices connect using OPC DA servers. This OPC DA-enabled hardware and software will be in place for years to come.

The quickest and most cost-effective way to bring a legacy OPC DA-based system up to Industry 4.0 standard is simply by using a DA/UA software gateway. This kind of middleware tool can connect an OPC DA server to an OPC UA client. Or an OPC DA client to an OPC UA server. Effectively, it provides instant OPC UA connectivity for any OPC DA server or client.

Moving to Industry 4.0 is a huge undertaking, requiring shifts in attitudes, hardware, systems, and software. But at least one problem is solved—communicating between OPC DA and UA.

Find out about Skkynet’s DataHub

OPC Gateway solution.

THE FLOW MUST GO ON. WITH EFFICIENCY.

Green energy firm Exagen plans £350m battery energy compound in heart of the Midlands

Agreen energy company wants to build a £350 million battery energy storage compound in the heart of the Midlands.

Exagen has put in planning for a 19 acre site which it said could hold enough green energy to power 235,000 homes for two solid hours.

It said, pending approval, it would be 10 times bigger than typical battery storage sites, storing spare energy from wind and solar which it would release when the wind stops blowing and the sun stops shining.

It wants to build the site, which it is calling the Normanton Energy Reserve, on fields in countryside between Leicester and Hinckley.

The plans have been supported by a multi-million pound investment in Exagen from the Octopus Energy Development Partnership, which was announced last summer.

The new fund is managed by Octopus Energy Generation, one of Europe’s biggest investors in renewable energy. Octopus Energy has a major base in Leicester.

If Blaby District Council gives the go-ahead, construction could take place through 2027 and the site could be linked to the grid in 2028.

Exagen development director Mark Rowcroft said: “Over the next few months, we’ll be announcing a variety of opportunities for individuals and businesses to get involved.

“We look forward to hearing from those in Thurlaston, Earl Shilton and the surrounding area about how we can make this site best work for them long-term.”

Safeguards the availability of your plant: The newly developed Amarex submersible motor pump features non-clogging impellers, operates more energy-efficiently, is easy to service and environmentally friendly.

19 acre site could hold enough green energy to power 235,000 homes for two solid hours

Heat pumps could reduce biogas carbon footprint more than a third, claims research

Using air-source heat pumps for anaerobic digestion could slash the carbon footprint of the process by 36%, new research by the University of Glasgow and University College London asserts.

The scientists say their findings could help support efforts to decarbonise national electricity grids and enable remote communities to produce their own low-carbon power locally.

Anaerobic digestion uses microorganisms in oxygen-free conditions to break down biodegradable materials such as food waste and sewage sludge to release biogas that can be burned to turn turbines, generating low-carbon electricity.

Bioreactors are then employed to maintain optimal temperature during anaerobic digestion to maximise the amount of biogas generated.

The research, ‘Integration of Anaerobic Digestion with Heat Pump: Machine Learning-based Technical and Environmental Assessment’, published in Bioresource Technology, involved the creation of a computer model of the thermodynamics of heat pumps. This was coupled with machine learningbased anaerobic digestion modelling to train the new system using a database of existing research.

This was tested with actual data to check accuracy before comparing the carbon footprint of a heat pump-based system with a natural gas-based one over their life cycle. The results suggested that the heat pump would emit significantly less carbon when processing food waste and sewage sludge for biogas.

The modelled carbon reduction attained up to 28.1% in an anaerobic digestion process maintained at a temperature of 55°C. At a lower temperature of 37.5°C, the carbon footprint of the process was reduced even further to a maximum of 36.1%.

Co-author Dr Siming You, from Glasgow University’s James Watt School of Engineering, said harnessing gas from waste for power production instead of letting it decay naturally, would advance the circular, net-zero economy to reduce the impact of climate change.

“That could help inform future planning for municipal waste management facilities to help reduce their carbon footprints. It could also underpin the development of future bioreactors which could be used in remote communities to help people turn their waste into biogas,” said You.

“That kind of decentralised waste recycling could go a long way to helping people produce their own local source of electricity. The research is also part of a larger effort to decarbonise water and wastewater treatment in rural communities.”

The research was supported by funding from the Engineering and Physical Sciences Research Council (EPSRC), the Supergen Bioenergy Hub and the Royal Society.

A Recipe for Success: Titan Enterprises discusses the process and challenges of research and development

By investing in research and development and continually pushing the boundaries of technology – and running down a few rabbit holes along the way – Titan maintains its competitive edge in the flowmeter market.

Titans’ focus for R&D is achieving a solution for our OEM customers, driven by flow technology. This can take the form of:

1. Product portfolio development: such as identifying where products can be improved as Titan has recently achieved with the launch of the new Pulsite® Link pulse & analog converter.

2. Breakout R&D: Exploring a new market focus or application such as developing a low-cost ultrasonic flow measuring device utilising our technology.

Titan Enterprises is a leading international manufacturer and supplier of small-bore liquid flowmeters, building their reputation designing and producing cost-effective reliable flow sensor products. New product development is the lifeblood of any manufacturing company.

Customer / OEM bespoke product development to be incorporated into a customer’s specific application.

Where do ideas come from?

The R&D creative process is generally sparked by a customer who presents a problem that the development team can progress and investigate workable solutions. Development routes can also derive from a ‘Eureka’ moment, a mistake (3Ms post-it notes come to mind) or where we feel the market is going – driven by emerging technology.

Neil Hannay, Senior Development Engineer with Titan Enterprises, explains: “OEM customers come to us with a problem or need and we scope out a bespoke design concept that has the potential to solve this.”

Concept Designs

In forming the initial concept designs, close working with the customer to develop specific design parameters and

overcoming fundamental difficulties that may be encountered is key from the outset. Understanding what the priority is for the customer is also essential at this early stage as it will influence the development route and technology used within the concept design process. In the simplest terms, is the customer prioritising accuracy over product costs, or looking for a low-cost solution with reliable performance?

Design Specification

Defining a more comprehensive design specification will enable concept models of designs to be composed that meet both Titan’s performance specifications and the customer’s process or system.

Working with a drinks dispenser OEM, the design brief needed to consider:

• Dimensions to fit within the limited physical space available

• Dual fluids – a single unit being able to measure both non-viscous and viscous liquids side by side

• Specific connections to fit existing equipment

• Use of approved (NSF/FDA) food grade materials

• Cost and production window

Prototypes and Testing

Once the concept designs are agreed, the next phase is to agree pricing of the tooling and final meter, based on expected production quantities. For Titan, typically our OEM customers invest in the injection moulded tooling which is bespoke for them and they ultimately own this; the design remains within Titan’s intellectual property.

Machined prototypes are put through a rigorous in-house testing process for design and performance before being issued to the OEM to test in-situ. “This allows us to uncover any unexpected issues - or indeed cause unexpected issues!” says Neil. “We often find ourselves doing lots of ‘head scratching’ in the testing phase and it’s where the team’s problem-solving skills come into their own,” Neil continues.

For example, a recent machined prototype unit in test was below its expected performance. Several rounds of rebuilding followed, from gears to

body parts, but the performance of the meter was still erratic. Two crucial aspects were discovered:

1. The surface finish of the machined body was not good enough for the oval gears to freely rotate so friction lowered performance.

2. The softer material of the unit was fractionally distorted when clamped in the calibration rig, causing a minor impedance of the gear rotation which constricted the flow.

The prototype here was reworked using a harder material and polishing the internal surface, resolving the performance issues identified.

In-Situ Testing and Final Design

The prototype is sent to the customer to test in situ and verify both the meter’s physical and mechanical performance meets their requirements in all operational situations. Any modifications to dimensions for example, or adjustments to fittings within the system are worked into the final design. This iterative process of finalising design requires close working with OEM customers, including reevaluating costings and agreeing production volumes.

Titan’s flow meters are typically incorporated into much larger industrial systems where accurate, reliable recording or control are required. Neil concludes: “Investing in R&D is paramount to us staying ahead of the game and taking advantage of the latest technologies, and our R&D spend is more than three times the industry average.” A team that combines suitable training and commercial experience, market awareness, problem solving skills and a creative spark enables Titan to deliver solutions for their customers or inventions for breakthrough markets.

For further information on Titan’s range of liquid flowmeters visit https://flowmeters.co.uk/. To discuss a flow measurement solution for your specific OEM application, contact Titan Enterprises on +44 (0)1935 812790 or sales@flowmeters.co.uk

ARC’s production begins

Production of Arc’s exclusive Vector electric motorcycle has begun in Coventry. “We shipped bike ‘number one’ a few weeks ago,” said ARC’s CEO and founder Mark Truman.

Instead of conventional front forks, the motorcycle features unique hub-centre steering. It is powered by the company’s own 399V battery and class leading electric motor which produces 850 newton-meters of torque, propelling the bike to 60mph in 3.1 seconds and on to a limited top speed of 125mph.

Mark formerly worked for Jaguar Land Rover (JLR) where he first began developing the bike as a prototype for their skunk works division. JLR considered producing the motorcycle themselves but instead invested a 15% seed share in the business, which has been selffunded since 2020.

“The Vector has had the very best people involved and has been designed in collaboration with a former MotoGP engineer and a designer of F1 carbon tubs for Ferrari,” explained Mark. The bike is made-to-measure with components including handlebars manufactured to fit each customer. Fifteen bikes have been sold with production now in full swing.

The Vector retails at £90K plus taxes. Arc are currently looking to raise £10m to scale the business, increase production and develop new models.

www.arcvehicle.com

ODUMAC® PUSHLOCK

Modular connectors with top packing density

Unique hybrid rectangular connectors with simple push-pull locking.

When panel space is at a premium, then the maximum possible connector density needs to be achieved. That’s what ODU offers with their push-lock option for rectangular connectors.

ODU have created a hybrid rectangular connector, incorporating expertise from its range of push-pull locking circular connectors into their ODU-MAC® Blue-Line product range.

The resultant PUSH-LOCK creates an even more compact ODU-MAC® modular connector with a design that makes these innovative hybrid connectors stand out from the crowd.

The goal was to offer a connector that was ergonomic, easy to use, and highly flexible –in a style as small as possible. The size was incredibly important to meet the growing trend for miniaturization. The result is a sleek hybrid IP67 connector capable of over 5,000 mating cycles, equipped with various module inserts and yet with a large M25 cable outlet.

The plastic housings come in white or black as standard, with the white version fitting perfectly into the design of medical devices.

Push-pull locking is incredibly simple and reliable. This locking style saves a huge amount of space, so several connectors can be mounted very close to each other – an advantage that is inextricably linked to its locking principal. This, combined with low mating and de-mating forces, means the connector can be used intuitively with just one hand.

ODU-MAC® PUSH-LOCK is just one of the locking options available in the ODUMAC® Blue-Line range, which is setting new standards with manual connector solutions that can be configured for the smallest installation spaces – giving an impressive, custom-fit end result.

Modules are assembled and removed without tools, while a special coding function ensures no mistakes can be made when clipping them in. Contacts are replaced from the mating side, so the crimp-clip contacts are easy to release even after connector assembly.

Summary

• Over 5,000 operations

• Easy handling - clip-in modules & contacts – no tools

• 6 Coding options on the clip modules to prevent incorrect mating

• IP 67 when mated [covers available for when unmated]

• With a maximum of 740 contacts, the most compact hybrid connector in the market.

• Separate PCB-termination module option

• Range of transmission types: signal, power, high current, coax, compressed air, fluid coupling, high-speed data transmission and fibre-optics.

Learn more about the ODU-MAC® PUSH-LOCK