Manufacturing & Production Engineering Magazine - November 2024
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Interview with Dave Grealis, Operations Director at SEA Weetabix opts for best of British with high-speed door installations by Union Industries Carter Manufactoring - helping to inspire the next generation of engineers How Emerging Technologies Are Transforming Safety and Operational Performance Laser beam characterisation using Optocraft SHSLab wavefront sensors
Editors Note
Welcome to the November issue of Manufacturing & Production Engineering Magazine.
In this issue we interview Dave Grealis, SEA operations director, providing insights into how the UK SME solved a manufacturing challenge for the Royal Navy. This focuses on an optimisation of hi-tech production, alongside operational efficiency within SEA strategic planning.
Moreover, with a focus on specialist equipment, IDTechEx comments on their latest reports on the production and supply of helium aligned with conservation methods.
As well as market insights, the polymeric repair composites and protective coatings developed and supplier, Belzona, highlights the importance of maintaining wind power assets to support transitions towards renewable energy.
We hope you enjoy this issue and like always, if you have any contributions you would like to feature, please email details to editorial@mpemagazine.co.uk.
Paul Attwood Editor
Labour shortages lead to revenue losses for four-in-ten
UK manufacturers
Delays
in projects (38%) also a consequence of the skills shortfall
Four-in-ten organisations (39%) have cited revenue losses as a key long-term consequence of the labour shortage. This is according to new research by Visual Components of manufacturing decision-makers in the UK.
In further findings from the research, increased labour costs are also identified as the main short-term consequence, alongside delays in projects, profit or
revenue declines and an inability to meet customer demand and production targets. With talent at a premium, organisations have had to spend more from their strained budgets on new hires. 95% of UK businesses have had to dig deeper into the company reserves to offer higher salaries to attract in-demand talent.
The need to offer higher salaries is only adding to the overall wage bill as overtime becomes a necessity to remain productive. Greater pressure is also being added to budgets as rising costs and inflation continue to take hold.
With talent at a premium, organisations have had to spend more from their strained budgets on new hires. 95% of UK businesses have had to dig deeper into the company reserves to offer higher salaries to attract in-demand talent.
S.M. Gauge Company Collaborates with British Rototherm to Unveil the DG75: A Revolutionary Digital Pressure Gauge
S.M. Gauge Company announces the launch of its latest innovation, the DG75 digital pressure gauge. In collaboration with the British Rototherm Group, global leaders in precision pressure measurement solutions, S.M. Gauge Company developed this state of the art gauge, incorporating the newest sensor technology, for unparalleled reliability and accuracy.
S.M. Gauge Company Ltd specialises in the supply, repair and certification of pressure, temperature, electrical and associated instrumentation.
The partnership has allowed S.M. Gauge to combine the team’s extensive expertise and knowledge
to create an advanced digital measurement tool that meets the highest industry standards.
The DG75’s high accuracy and 4-digit display make it easy to read. To optimise resolution across its measuring range, the DG75 automatically adjusts its display from two decimal places at higher readings to three decimal places at lower readings. For more information and to place an order for the DG75, please visit smgauge.co.uk or contact our sales team at sales@smgauge.co.uk
Water leaders talk environmental scrutiny and infrastructure needs
The Environment Agency’s director of water, Helen Wakeham, has discussed plans to increase scrutiny of water companies in England and Wales in a new water sector podcast.
Targeted recruitment campaigns, more site inspections and enhanced digital systems will drive better performance from the industry, Wakeham told the WiseOnWater Podcast: Conversations in Flow, from media specialist WiseOnWater and technology company Xylem UK & Ireland.
Site inspections will increase to more than 10,000, to be supported by new recruits, including “boots on the ground” and data analysts, Wakeham said. “It’s a really exciting time. There are a lot of people around with loads of experience. It’s brilliant for those people to be joined by a new cohort with new ideas.
The WiseOnWater podcast, which launched on 9 September 2024, is a monthly deep dive into the ever-changing landscape of the UK water sector.
Pollution reduction, nature-based solutions, smart metering, leakage, drought resilience and bill increases were among other conversation topics in the 30-minute podcast episode.
Episode two focuses on skills, recruitment and retention with guests Peter Simpson, chief executive of Anglian Water and Sarah McMath, chief executive of MOSL. Future episodes feature Wessex Water chief executive Colin Skellett and the managing director of Xylem UK & Ireland, Ian Thompson. Episode one of the WiseOnWater podcast is available now on Spotify.
Heat Pumps emit 95% fewer emissions than gas boilers a year, new study shows
A new study from STIEBEL ELTRON UK has found that heat pumps in a home setting emit almost 95% fewer carbon emissions than a traditional gas boiler annually.
The study, which took place over a 12-month period, found STIEBEL ELTRON’s WPL-A 07 Premium air-source heat pump produced 250kgCO2e, whereas a conventional gas boiler in the same dwelling would emit over 3,500kgCO2e.
The leading manufacturer of heat pumps and renewable energy technologies carried out the study to showcase the value of a heat pump in reducing carbon emissions, with the research focusing on its performance in a four-bedroom home.
As well as showing significant carbon savings, the heat pump maintained a comfortable indoor temperature above 20°C all year round, with a Coefficient of Performance (COP) consistently exceeding 4.2, highlighting its high energy efficiency.
Meanwhile, the heat pump cost £750 a year to run, some £250 less than a traditional boiler in the same setting, with the unit’s reduced energy consumption contributing to long-term savings on utility bills.
The heat pump cost £750 a year to run, some £250 less than a traditional boiler in the same setting...
STIEBEL ELTRON UK monitored the performance of the heat pump using real-time reporting and data analytics via the company’s monitoring software, providing valuable insights into its efficiency, cost-effectiveness, and environmental impact.
For more information visit: www.stiebel-eltron.co.uk
On The Move
Hanna Lye appointed Vice President Brand, Marketing and Communication at Seco
Hanna Lye has been appointed Vice President Brand, Marketing and Communication at Seco. She will report to Stefan Steenstrup, President Seco, and become a member of the Seco Management Group.
Hanna Lye holds a Master in Business Administration from the University of Stockholm. She brings a
wealth of experience and proven track record in strategic brand, marketing, and communication management. She has consistently demonstrated her ability to drive organizational success through impactful communication strategies.
In her most recent role as EVP Marketing and Communication at Epical, Hanna played a pivotal role in the creation and implementation of a new
Altus Enhances Customer Support in the North
Altus Group, a leading capital equipment distributor for the electronics industry in the UK and Ireland, is pleased to announce the addition of a Senior Sales Manager to its growing team. With this appointment, Altus strengthens its sales force, now comprising of a six-person strong Sales Team.
Matthew Fitzpatrick, who will cover the north of the UK, brings a wealth of experience in account management and new business development, having successfully managed large-scale, technical projects in adjacent sectors. His expertise will be instrumental in enhancing Altus’ account management capabilities and
expanding partnerships across the Northern region, where the electronics manufacturing sector is thriving.
The addition of Matthew reflects Altus’ commitment to providing the highest quality pre-sales and aftersales care. The company’s partner list has grown exponentially over the past five years, and with increased capacity in pre-sales and account management, Altus ensures that customers receive exceptional project support, which is a significant reason for the growth they have witnessed.
Matthew will undergo an extensive on-boarding process over the coming months, preparing him to support key accounts. Customers and suppliers
brand to improve competitive positioning and support business growth.
Before, Hanna has held various managing positions within Ericsson, Telenor and IBM. In Hanna’s new role, she will take an active part in strengthening the global brand position for Seco by developing and implementing strategic marketing initiatives, leading the global business marketing function into the digital era, and ensuring consistent execution of the brand identity across all internal and external communication.
She brings a wealth of experience and proven track record in strategic brand, marketing, and communication management.
will have the opportunity to meet him in person at Altus’ upcoming Factory of The Future taking place in September. www.altusgroup.co.uk
Hart’s Speedors meet requirements
Four Speedor high-speed doors have been installed by Hart Door Systems at a major frozen and cooked meat manufacturing in northern England. The doors, at just 1.5m wide and 1.95m high, are the second smallest Speedors ever manufactured by Hart.
“The contract demonstrates two things,” says Gordon Kipling, regional sales manager for Hart. “Not only is our Speedor range available in distinctly different types of doors but where applicable the doors can be available in reduced sizes for precise requirements.
“In this case there was a need to protect the production environment against drafts, humidity, dust and dirt by installing our Speedor Cleanroom with its fast opening and closing speed. Our pharmaceutical standard Cleanroom Speedors control airflow thus reducing contaminants.”
Designed specifically for manufacturing and research facilities, Speedor Cleanroom works in strictly controlled environments where hygiene standards are high, such as pharmaceuticals, food processing, electronics and micro-mechanics industries.
The main features of Speedor Cleanroom include maintaining strict air leakage requirements over specified pressure differentials. Complete with an intelligent control panel with digital display each Cleanroom has a reliable and clean in-line drive system complete with an integral safety brake and a non-touch safety light curtain ensures maximum protection to personnel. Seals minimise pressure drops and protect the manufacturing environment against drafts, humidity, dust and dirt.
www.hartdoors.com
Door Systems DOORS READY FOR
Interview with Dave Grealis, Operations Director at SEA
We asked Dave Grealis, Operations Director at SEA, how the UK SME solved a Royal Navy manufacturing challenge by leveraging process optimization, strategic planning, and cross-functional collaboration to deliver an innovative decoy launcher system.
Dave Grealis, who joined SEA in 2021 with over 25 years of senior management experience in manufacturing operations and international supply chains, is an expert in optimizing high-tech, lowvolume production environments, particularly in sectors like defence and intelligent transport. In this interview, Dave discusses how SEA aligns strategic planning with operational goals through Integrated Business Planning and market forecasting, while also improving operational efficiencies by reconfiguring production spaces and fostering a culture of innovation within his teams.
In your role at SEA, how do you ensure that strategic planning aligns with both operational goals and the larger market demands, particularly in high-tech, low-volume environments?
At SEA we operate two levels of planning, and operations utilises both to ensure we are able to execute against short- and long-term strategic goals.
Our monthly Integrated Business Planning (IBP) cycle is our interpretation of the classic Sales & Operation Planning (S&OP), it looks out two years and drives our medium-term labour, materials, and equipment resources. Our two-toeight-year market forecast, total and addressable, is used to shape capital investments, PV Investments (R&D), physical capacity (facilities) and skills requirements. These complimentary processes have served us well to support the growth we have experienced in the last three years.
Can you share examples of how you have successfully developed and implemented strategies that improved operational efficiencies in a complex production setting?
Our space constraint has driven us to simplify and identify innovative solutions beyond which we would have normally sought, improving our efficiency as a result.
Once we had created the space, we worked on agility, in a low volume / high variety production environment rapid reconfiguration of cells is key. Developing the minimal viable production process utilising portable/mobile equipment, cross skilled technicians, and the deployment of standard work, ensured we could achieve consistency in even in ‘stranger’ processes.
Our space constraint has driven us to simplify and identify innovative solutions beyond which we would have normally sought, improving our efficiency as a result.
Process optimisation is a key focus in modern manufacturing. What are the most common bottlenecks you’ve encountered in manufacturing processes, and how do you address them?
Our Barnstaple facility is a good example of how an apparent strategic constraint can be turned to an advantage.
It was clear the facilities, in the form that they were, could not support the planned growth and the increased output required to support that growth. We had a siloed approach to production with many barriers to flow.
To overcome this, we set about physically opening areas up to facilitate agility and flow, with the strategic aim of increasing revenue output per SqMtr. We put a lot of effort into the execution of the sort phase of 6S process (Sort, Set, Shine, Standardise, Sustain, Safety) to sustain a high level of productivity and safety throughout our workplace, especially our production floorplate.
We have a few ‘monuments’ in some of our processes, primarily relating to pressure vessels required for in process and final product verification and test. These vessels are quite old, definitely not mobile, and do not lend themselves to Single-Minute Exchange of Die (SMED) techniques. They are utilised at differing stages in multiple processes, so the classic solution of moving the bottleneck to the start of the process was not an option. Therefore, work must travel to vessel from the assembly cell, which makes planning more important.
Our solution was to co-locate this equipment in one area so that we could staff that area with the relevant suitably qualified and experienced person (SQEP) and maintain acceptable utilisation of that SQEP across varied test cycle times.
With a wealth of experience in industries like Defence and intelligent transport, what are some of the unique challenges in process optimisation in these sectors, and how do you overcome them?
Whilst some of our products could be considered Repeaters, the majority are Strangers or even Aliens. This limits the level of investment we can justify in fully optimising production processes.
However, this does not mean we compromise efficiency. Our approach is to deploy appropriate tools proportionately. We use a Kanban system to manage our Control of substances hazardous to health (COSHH) items, not because we have high volume flow, but to visually manage shelf life and ensure control. Two-bin systems are used in our maintenance, repair and operations (MRO) cell to facilitate rapid repair of some products with pull system replenishment and light touch planning overhead. Low, nonrepeating volumes dictate that most of our materials are purchased lot for lot, so yield is very important. As a result, most of our process investment is aimed at improving repeatability and eliminating opportunities for error.
Given your extensive experience in managing large-scale projects, how do you ensure that production timelines are met without compromising on quality in industries with stringent requirements, like Defence?
We take a holistic approach to ensuring good quality is maintained. It starts with design for manufacture and the involvement of production engineering in the new product information (NPI) integrated project team, we also engage with key suppliers at this stage as required.
Then, as part of our manufacturing readiness, we design production cells
We take a holistic approach to ensuring good quality is maintained.
The problem then is we have to operate in the real world, where even the best laid plans can hit unforeseen challenges and pressures.
and assembly/test standard operating procedures to ensure (as much as possible) that we have a repeatable, error proofed, process. This lays the foundations for manufacturing products of a consistent quality. The problem then is we have to operate in the real world, where even the best laid plans can hit unforeseen challenges and pressures. However, having that solid foundation in place allows us to identify when we are deviating from process and take actions to pull ourselves back in line.
In industries with critical production, how do you handle unforeseen challenges that could delay project timelines or affect deliverables?
Like all manufacturing companies, SEA experienced supply disruption with the global electronic component shortage followed by the COVID pandemic. As an established defence supplier, we already had access to specialist electronic component suppliers who had the capabilities to assure the integrity and provenance of components. Our use of these services increased significantly during this period and we retain that capability today. Our supply chain is predominantly UK based by design and we dual source where we can. Our live Business Continuity Planning process also affords us some resilience to external disruption. Beyond that, it’s being alert and agile in response to the everyday challenges that, unless addressed early, can lead to delays to customer deliverables.
Cross-functional collaboration is essential for operational excellence. How do you foster collaboration
across departments like engineering, production, and supply chain to ensure a cohesive approach to project delivery?
We use an integrated project team (IPT) approach to NPI and large delivery projects. At project mobilisation the Project Manager (PM) identifies the stakeholders required for the project and forms a team. Each stakeholder attends the weekly IPT meeting and represents their function at those meetings. Often, stakeholders belong to multiple IPTs.
The mobilisation phase involves stakeholders collaborating to identify sub-deliverables and supporting the PM in establishing the baseline plan. Thereafter it is all about execution, strong communication, and clear/ co-ordinated re-scheduling if required with the involvement of all stakeholders led by the PM. This approach fosters a supportive culture and a strong sense of purpose for those involved.
Can you describe how you’ve built a culture of innovation within your teams while maintaining the high standards required in sectors like Maritime Defence?
A big part of our development has been in production engineering, where we have increased headcount 5-fold in two years. In that time, we have also introduced daily GEMBA meetings in all the cells.
The GEMBA meeting is the opportunity for production technicians to suggest improvements which are captured and put in the production engineering work funnel. Suggestions with the greatest potential are then worked on jointly - this is a source of much of our incremental improvement. Step change improvement comes from funded projects led by production engineering. To ensure product quality is not impacted when improvements to the production process are made, the product Design Authority is engaged with early on.
With over 25 years of senior management experience in manufacturing operations and international supply chains, Dave is an expert in optimizing high-tech, low-volume production environments, particularly within the Defence and intelligent transport sectors, driving operational efficiency and agility.
MAGNET
Magnetic switches are used for positioning and control in electric monorail systems and in lift construction, they are characterised by wide-ranging wear resistance and tolerance in the event of misalignment.
A connected control unit uses the signals to determine the position and section of the sensor box and controls the speed and holding positions of the drive motor. In addition, two angle sensors enable fine positioning.
Electric monorail conveyors are used to transport workpieces, tools and other purchased parts in almost every industry. The SSB-R magnet sensor box is used to define route sections for speed regulation for electric monorail conveyors in a manner that is cost efficient and maintenance free. It also allows park positions to be approached with careful accuracy.
SCHMERSAL | Enigma Business Park Malvern, Worcestershire, WR14 1GL
www.schmersal.co.uk
uksupport@schmersal.com
Measurement, Sensors & Monitoring
How leveraging smart factories optimises products and operations for manufacturers
By Mei Dent, Chief Product and Technology Officer, TeamViewer
Manufacturing processes and supply chains have become more complex, making traditional methods insufficient to meet demands for greater customisation and shorter production cycles. As global competition intensifies, manufacturers must find ways to stay agile and respond quickly to market changes.
Smart factories address these challenges by integrating advanced technologies to create a more efficient and sustainable production environment.
By leveraging technologies like artificial intelligence (AI), machine learning (ML), and the Internet of Things (IoT) to deliver predictive analytics and big data, manufacturers can optimise processes and improve factory management.
However, a significant challenge in smart factory implementation is the disconnect between IT professionals and plant managers. IT professionals’ preference for leveraging cloud solutions can clash with plant managers’ concerns about security and the usability of hyper-scale offerings. Bridging this disconnect is crucial for achieving successful IT and operational technology (OT) convergence in smart factories.
By aligning objectives and addressing the concerns of both IT professionals and plant managers, manufacturers can leverage the following benefits:
By seamlessly merging IT and OT, companies can break down barriers and adopt practical, datadriven solutions that optimise operations and build resilience.
• Enhanced productivity and efficiency
This provides optimised processes and just-in-time inventory management, reducing downtime and improving operational flow. Remote connectivity solutions provide detailed views of all IT and OT hardware assets, helping manufacturers manage warranties, patch information, and potential security risks while troubleshooting issues remotely.
• Improved workplace safety
Advanced robotics and automated systems can handle dangerous jobs, ensuring worker safety. Additionally, industrial augmented reality (AR) solutions enhance frontline workers’ skills by providing step-by-step instructions and remote assistance, empowering them to perform complex tasks more efficiently.
• Optimised sustainability efforts
Real-time data helps manufacturers adopt sustainable practices by optimising energy consumption and reducing waste. Implementing a central industrial IoT platform facilitates seamless communication between machines and IT systems across multiple factory sites, creating a strong foundation for sustainable operations.
• Upgraded product quality Trends and customer demands
can be responded to quickly by integrating cloud connectivity and real-time insights into the manufacturing process. This leads to higher product quality and a better customer experience as companies can deliver customised and up-todate products.
• Streamlined logistics and material flow
Automated material handling systems streamline logistics and material flow within the factory, minimising manual handling and reducing cycle times. Leading manufacturers’ smart factories interconnect humans, robots, and logistics using digital twin technology—a virtual representation of a physical object, process, or service—and AI-driven systems to optimise production plans and inventory management. This ensures high efficiency and responsiveness to customer demands.
Facilitating IT and OT convergence
A successful smart factory relies on the seamless convergence of IT and OT. Although they have different focuses, both domains must work together to realise smart factory innovation’s benefits. Four critical steps to facilitate this convergence includes finding common ground, practical solutions, leveraging private cloud and edge architectures, and establishing joint KPIs.
While the scope of smart factory applications is broad, it is important to note that most vendors focus on specific areas and the industry is still learning to find the best ways forward. Current use cases in smart factories might be limited; however, there are significant strengths in areas such as warehouse picking and after-sales services, like remote support and training, where innovation and value delivery are well-positioned to drive progress.
Embracing smart factory innovation puts manufacturers at the cutting-edge of industrial progress. By seamlessly merging IT and OT, companies can break down barriers and adopt practical, data-driven solutions that optimise operations and build resilience.
Ultrasonic Flowmeters
Turbine Flowmeters
Oval Gear Flowmeters
Instrumentation
Innovative Liquid Flow Measurement Solutions
Titan is a leading design and manufacturer of innovative end user and OEM high-performance flow meters, used within a wide range of environments and applications.
Tinytag Data Loggers: Robust Environmental Monitoring Solutions
Data loggers for indoor, outdoor and industrial/process application
• Rugged and compact
• Easy to use
• Dust, splash or waterproof
• Data downloaded to PC
• Cost-effective
Accompanying probes are available for monitoring extremes of temperature, and for awkward to reach areas such as pipework.
For sites requiring remote data access, Tinytag Radio and LAN loggers gather data automatically for viewing on a PC, across a LAN, or remotely across the inter net.
Gemini Data Loggers (UK) Ltd Scientific House, Terminus Road, Chichester, West Sussex, PO19 8UJ, England
Rotech End of Shaf t or belt driven units are used for monitoring:
- Stop/slip
- Underspeed/overspeed
- Interlocking/sequencing
- Distance/direction
- Rotation control
- Belt weighers
Tinytag Plus 2
Rugged outdoor/industrial temperature/RH logger From £110 +VAT
Telephone: +44 (0)1243 813000 email: info@tinytag.info www geminidataloggers.com www.tinytag info Manufactured in the UK
Radio and LAN
Automatic data collection Bundles – 3 loggers/receiver/ software from £1,100 +VAT
Energy Logger
Non-invasive single & three phase power monitoring Full kit £995 +VAT
Tinytag Ultra 2
Indoor temperature & RH From £80 +VAT
Warwickshire
firms urged to tap into dedicated £500,000 manufacturing support programme
Small to medium-sized manufacturers in Warwickshire are being urged to take advantage of a dedicated £500,000 business support initiative that will help them boost sales, create jobs and improve productivity.
Omron expands compact power relay range with improved high inrush variant
The Warwickshire Manufacturing Growth Programme, which is delivered by experts Oxford Innovation Advice, has already supported over 80 local companies to unlock barriers to growth through one-on-one coaching, consultancy, free workshops and signposting to other schemes.
Backed by funding from the UK Shared Prosperity Fund (UKSPF), the specialist support is available until March 2025 and, encouragingly, there is still scope to assist more manufacturing firms across North Warwickshire, Nuneaton & Bedworth, Rugby, Stratfordupon-Avon and Warwick.
The Warwickshire Manufacturing Growth Programme is open to SMEs in the area with fewer than 250 employees and a turnover less or equal to €50m euros.
Eligible companies start the journey with a Manufacturing Growth Manager meeting, they will discuss growth ambitions and challenges, before engaging them on GROWTHmapper, an
Omron Electronic Components Europe has launched the G5QHR, the latest addition to the G5Q family of 10A PCB power relays. The new relays can achieve reduced power consumption and heat, and are 45 percent smaller than equivalent 16A relays. For applications which require high inrush current such as lighting controllers, smart plugs, home
If required, a £500 grant is available towards supporting specialist coaching and consultancy...
industry-leading suite of diagnostic tools that identify opportunities for expansion.
If required, a £500 grant is available towards supporting specialist coaching and consultancy, whilst every participant can access free workshops on Digital Awareness, Lean Manufacturing and Supply Chain Resilience and Optimisation.
The Warwickshire Manufacturing Growth Programme is delivered on behalf of Warwickshire County Council, North Warwickshire Borough Council, Nuneaton and Bedworth Borough Council, Rugby Borough Council, Stratford-on-Avon District Council and Warwick District Council
For further information, please visit www.warwickshire-mgp.co.uk or contact Michelle Connor on 07790 358674.
appliances and power supplies, this can contribute to downsized equipment design, while opening up new printed circuit board configurations.
First launched in 2001, the G5Q series has sold more than 500 million units worldwide. Considered one of the industry’s leading compact power relay products, the G5Q portfolio now boasts a wide range of variants covering many diverse applications, from home appliances to industrial motor loads.
In response to customer demand for compact design and improved energy performance for 10A applications, Omron has now expanded its high inrush offering with the addition of the G5Q-HR, which is available in both single stable and latching variants.
As the only device in the G5Q portfolio that meets the TV-8 standard at 10A class, the G5QHR compliments the existing high inrush offering, while offering new possibilities for more powerful and compact end product applications.
Weetabix opts for best of British with high-speed door installations by Union Industries
Union Industries, the UK’s leading manufacturer of bespoke high-speed doors, is helping one of Britain’s most iconic cereal brands maintain its high standard of hygiene with the installation of more Bulldoors and Matadoors.
Weetabix initially approached Union Industries in 2023 to maintain and elevate hygiene standards at its site at Burton Latimer near Kettering. Recognising the superior quality and reliability of Union’s Bulldoors, it expanded its partnership by installing a further six doors around its facilities, including Burton Latimer and Corby, making eleven Union doors across the two sites in total to date.
The bespoke doors, tailored to fit each individual opening, address specific challenges such as tight spaces and sloping floors, ensuring a perfect seal and optimal functionality.
In addition to maintaining hygiene standards, some entries and exits in
Weetabix’s production and warehouse areas utilise a two-door solution of airlocks. This system interlinks the doors electronically to allow only one door at a time to be open, effectively prevents the ingress of insects, dust, and other foreign bodies, further safeguarding product integrity.
Union’s Bulldoors are regarded as the ‘reliable workhorse’ of rapid roll doors and arew known to perform more than 1.4 million cycles per year, making it a popular choice across multiple sectors. They feature specialist ‘Crash-Out’ and ‘Auto-Reset’ damage protection facilities, and offer control outputs for options such as airlocks, traffic control systems and remote monitoring, whilst aiding temperature control for ambient and chilled environments.
The market-leading, bespoke, highspeed roller doors help to prevent the severe drop of ambient temperature in buildings, especially evident in the winter months, eliminating any potential impact on production environments.
Tailored to fit each individual opening, address specific challenges such as tight spaces and sloping floors.
Alan Hirst, Sales Director at Union Industries, said: “We are delighted to continue our partnership with Weetabix in enhancing their operational efficiency and hygiene control. Our rapid roll doors are renowned for their reliability and performance, making them the ideal choice for Weetabix’s production environments.”
Anthony Brawn, Facilities Contracts Manager at Weetabix, said: “We are proud to partner with Union Industries in maintaining the highest standards of hygiene and operational efficiency across our facilities. The installation of Union’s high-speed doors ensures a seamless flow of operations,
“With Union Industries, we are confident in achieving our long-term goals of reduced downtime, enhanced productivity, and minimised costs.”
Alan Hirst, Sales Director at Union Industries.
Union Industries helps Crown Lift Trucks overcome operational challenges with installation of high-speed Ramdoor
Union Industries, the UK’s leading manufacturer of bespoke industrial doors, has assisted Crown Lift Trucks in addressing multiple operational challenges with the installation of its cutting-edge high-speed Ramdoor.
Crown Lift Trucks, based in Warrington, faced several issues at its facility, including the need to segregate two adjoining units with different temperature requirements while allowing the movement of high-mast forklift trucks through a large opening.
To tackle these challenges, Union Industries produced a bespoke solution to accommodate the building configuration, ensuring the required opening height could be achieved without compromising functionality. Additionally, the limited space at highlevel, between structural steel frames, posed a significant obstacle.
Since launching their UK operations in 1960, Crown Lift Trucks have become one of the world’s leading manufacturers of forklift and material handling equipment. Designing and manufacturing up to 85% of its forklift components, Crown provide their wide customer base with forklift rentals, servicing and maintenance, used equipment and a variety of support services.
The installation of the Ramdoor not only addressed the temperature control and safety concerns but also enhanced operational efficiency. Union Industries designed the door to accommodate Crown Lift Trucks’ requirements while incorporating a pedestrian access door to segregate traffic flow, ensuring a safer working environment.
The Ramdoor features a dual height opening facility, allowing for optimal heat retention while accommodating different forklift sizes. Furthermore, the engineered seals and infills achieve a seamless finish, enhancing both functionality and aesthetics.
It has also been designed to achieve a Class 5 wind resistance rating, making it able to withstand strong winds and to remain operational even during severe weather conditions.
Achieving this rating is supported by a number of the Ramdoor’s features, including its thick Ramhide door curtain material, which is high frequency welded to give the strongest fabric joins available.
In addition, it features heavy-duty windbrace and wind-bar systems for added strength, plus extra-deep side-guides, which all contribute to the Ramdoor’s ability to cope with high wind loads and
The engineered seals and infills achieve a seamless finish, enhancing both functionality and aesthetics.
pressures. Like other doors in the Union range, it also benefits from a ‘Crash Out’ facility, in case of vehicle or personnel impact to the bottom beam, thus ensuring minimal downtime and repair costs.
Alan Hirst, Sales Director at Union Industries, said: “We are delighted to have assisted Crown Lift Trucks in overcoming their operational challenges with our high-speed Ramdoor. This project highlights our ability to provide innovative solutions tailored to our customers’ specific needs.”
Mark Eccleston, Branch Manager, at Crown Lift Trucks, said: “Union Industries’ Ramdoor has revolutionised our operational efficiency and safety standards. Their dedication to understanding our unique requirements and delivering a bespoke solution underscores their commitment to customer satisfaction. The Ramdoor not only enhances temperature control and traffic segregation but also contributes to our sustainability goals. We are grateful for their expertise and partnership in achieving our objectives.”
(L-R) Bradley Whipday, Crown Warrington Workshop Manager and Mark Eccleston, Crown Warrington Branch Manager, with Alan Hirst, Sales Director at Union Industries.
Training & Education News
New partnership to help professionals return to manufacturing after a career break
Domino Printing Sciences (Domino) has partnered with STEM Returners on a new programme to help STEM professionals return to work in manufacturing following a career break.
As part of the programme, Domino will work with STEM Returners to help four people return to STEM work as part of a structured 12-week placement at their site in Cambridge. The programme is open to anyone on a career break.
Heading Toyota Community Fund helping UK charities and schools make a difference
The Toyota Community Fund has been actively helping charities and schools across the UK, making financial donations to support a wide range of community initiatives, from riding for the disabled, to accessible parks for children with severe learning difficulties.
The fund is designed to improve the quality of life and the environment, with local causes nominated by Toyota and Lexus centres receiving grants of up to £2,000. Since the fund was launched in 2011, more than £1.42 million has been distributed.
Research from STEM Returners (STEM Returners Index) has found that many people face challenges when returning to work following a career break, with recruitment bias against gender, age and race, shown to be the main barrier to entry.
For example, nearly a quarter (24%) of women feel they have personally experienced bias in recruitment processes due to their gender compared to nine percent of men.
STEM Returners’ programmes aim to eliminate these barriers by giving candidates real work experience and mentoring during their placement, as well as supporting them to adjust to life back in work.
STEM Returners, based in Hampshire, will source the candidates for the Domino programme and provide career coaching and mentoring
So far this year, more than a third of the Community Fund donations (38 per cent) have been made to civic initiatives, 28 per cent to health and medical-related services,16 per cent to environmental initiatives and the remaining 16 per cent has gone to education, arts and culture, mobility and road safety initiatives.
Causes to have benefited so far this year include: -
Queen Elizabeth’s Foundation, Leatherhead
It provides driver and passenger assessments and theory test assistance.
The Change Foundation, Croydon
Funding from the Toyota Community Fund has helped The Change Foundation to set up a slow-paced football team for people with physical or mental disabilities.
Rowan Park School, Liverpool
A Toyota Community Fund donation has helped the school re-open its accessible park for disabled children and the local community, a space for inclusive play and the development of motor and social skills.
Little Miracles, Peterborough
It has used its Toyota funding to run training programmes for volunteer assistants.
throughout the paid placement. At the end of the programme, returners may be offered the opportunity to become permanent employees.
Since STEM Returners first launched in 2017, more than 500 candidates have joined programmes across the UK.
To view STEM Returners’ opportunities, visit https://www. stemreturners.com/placements/.
Nearly a quarter (24%) of women feel they have personally experienced bias in recruitment processes due to their gender compared to nine percent of men.
Vale Primary School, Epsom
The Community Fund donation was used for local safety signage and safety programmes for pupils.
Chigwell Riding School, Essex
The Toyota Community Fund donation is being used to provide lessons for children with disabilities and special needs, helping them build confidence and communication and problem-solving skills.
Lancashire Wildlife Trust, Preston
The Toyota Community Fund donation was used to create a hedgerow habitat for the endangered willow tit. It has also supported biodiversity and protection for other wildlife species.
Training & Education News
Electrification community set for ‘single source of truth’ boost with launch of new skills Framework
A vitally important £800,000 initiative - designed to provide a ‘single source of truth’ for electrification skills and capabilities - is nearing its first big milestone.
The Electrification Skills Network (ESN), which is funded by UK Research and Innovation (UKRI) and delivered by Coventry University, is weeks away from launching the UK’s first-ever Framework for a sector that has the potential to create more than 100,000 jobs by 2025.
Extensive research, interactive workshop sessions and the creation of a dedicated forum have all been completed, involving more than 100 academic partners, training providers, accrediting bodies and employers, including Aston Martin and Bentley.
All this knowledge and real-world experience has been channelled into the ongoing development of an interactive website, which
Extensive research, interactive workshop sessions and the creation of a dedicated forum...
will house the Framework and layout a common set of skills to support the development of job roles and specifications for high quality electrification training and qualifications.
The ESN Framework, which is also backed by the Warwick Manufacturing Group (WMG), the UK Battery Industrialisation Centre and Enginuity, will feature multiple listings, placed in relation to roles/ operation levels within industry and, where appropriate, grouped by sector or specialism.
Each listing represents one ‘Common Set of Skills’, which has been collated, reviewed and ratified for inclusion by key stakeholders within the electrification community and will reflect current and future skills.
Importantly, where no existing training and/or qualifications are linked to a listing, the Framework provides a nationally available standardised starting point for the development of specific training modules or qualification units. For further information, please visit www. electrificationskillsnetwork.co.uk
Siemens Mobility welcomes bumper intake of young talent to rail village
Siemens Mobility has taken on 24 young people in apprenticeships and graduate roles at its new UK rail village.
The centrepiece of the Rail Village in Goole, East Yorkshire, is a train manufacturing facility, from where Siemens Mobility is assembling new Piccadilly line trains and which could deliver the UK’s next generation of main line trains.
The recruitment includes 22 apprentices – the highest number of apprentices recruited by Siemens Mobility in the UK for a single site in a year – and comes as the pioneering development gears up to becoming fully operational.
The trainees are aged between 16 and 26 and all started on the same day, across a variety of roles in the Manufacturing, Logistics and Warehousing, Quality, Commissioning,
The first trains built at the new factory will be new tube trains for Transport for London.
Components, Materials Control and Operations at Goole.
Taking on so many young people in a single phase demonstrates Siemens Mobility’s commitment to developing a new generation of talent while establishing Goole as a centre of excellence for the rail industry in the UK.
Global rail technology leader Siemens Mobility is investing £200m to develop a train manufacturing facility and associated operations in Goole, creating up to 700 jobs directly as well as around 1,700 opportunities in the wider supply chain.
The first trains built at the new factory will be new tube trains for
Siemens Mobility’s commitment to developing a new generation of talent while establishing Goole...
Transport for London. 80% of new trains for the Piccadilly line on the London Underground will be assembled at Goole.
Siemens Mobility plans to build all future main line trains for the UK at Goole, including new battery bi-mode trains that it has calculated could save Britain’s railways £3.5bn and 12 million tonnes of CO2 over 35 years.
The factory is the centrepiece of the wider Rail Village, featuring a Components Facility, a Materials and Logistics Warehouse, and a research, development and innovation cluster, establishing Goole as a centre of excellence for rail technology in the UK.
The new starters will develop their skills through a wide range of training programmes, relevant to their specific roles. Many of these programmes are overseen by the National Training Academy for Rail (NTAR), working with regional training providers, including York College.
Science and Technology
Nuclear Science and Technology
MSc - 1 year full time
MSc - 1 year full time
MSc - 2 or 3 year part time
MSc - 2 or 3 year part time (Taught and Distance Learning)
PG Diploma • PG Certificate
Short Courses for CPD
PG Diploma • PG Certificate
Short Courses for CPD
Designed to create a generation of nuclear engineers and scientists with the skills to secure a sustainable and safe future for nuclear energy.
info.ntec@manchester.ac.uk
Training & Education Case Study
Carter Manufactoringhelping to inspire the next generation of engineers
The current demand for skilled engineers across all sectors of UK industry is well documented and something constantly mentioned in the general, specific engineering and manufacturing media. It was one of the key topics discussed at the recent Farnborough International Airshow (FIA) showcasing an industry which generates income to the UK economy estimated to be £13bn per annum and predicted to grow exponentially. It was also an ideal platform for the new UK government to announce ‘Skills England’, a body that aims to provide valuable opportunities for ambitious young individuals, particularly those interested in apprenticeships. With the world of work evolving faster than ever, it’s never been more important to secure and nurture the best new talent in engineering, so the availability of apprenticeship opportunities is crucial.
A good example of where apprenticeship opportunities can be effective is at precision bearing and tooling specialists CARTER MANUFACTURING who are delighted to share the experience and
With the world of work evolving faster than ever, it’s never been more important to secure and nurture the best new talent in engineering...
success of one of their Apprentice Engineers, 19 year old Jake Hopgood.
Jake attended Abingdon and Witney College studying for a ‘Level 2 Engineering Diploma’ one day a week, along with his hands-on, practical experience 4 days a week at Carter.
He recently completed his 2 year apprenticeship at Carter and we caught up with Jake to talk about his role and experience at Carter, perhaps helping to inspire others hoping for a career in engineering.
What was the main inspiration for Jake to pursue a career in Engineering?
From a young age I actually wanted to be a builder following in the footsteps of my father, although he always used to tell me, it’s not a great job and I think you could be doing something better! Another family influencer was Jake’s grandfather who told Jake about engineering and told him to look it up and find out more about what engineers actually do. “Ever since then engineering is all I wanted to do.”
No other family members are involved in engineering although Jake added that a few of his friends are engineer apprentices at other companies.
What specific industry sectors was Jake interested in?
“The sectors I’m most interested in are machining, assembly and inspection, mainly because I really enjoy using the CMM machine”.
What role, job function did Jake fulfil?
“As an Apprentice Engineer at a precision bearing specialist company I fulfilled quite a few things, for example; bearing and tooling assembly, machine operating, a little bit of SolidWorks/CAD, MD coating, programming and operating a riveting machine. Also, programming and operating the CMM machine, cryogenic testing bearings using Liquid Nitrogen and using the RIC rig to find out the radial internal clearance of bearings. In addition, fire warden and health & safety training”. Most importantly, Jake’s experience included
Training & Education
a first-hand insight into Carter’s acknowledged specialist expertise as a leading precision bearing and tooling supplier too many of the UK’s leading high-technology companies. This meant he needed to be involved in assembling hybrid bearings for cryogenic applications, light weight slewing bearings for the defence sector, titanium bearings for highly competitive yacht racing and aluminium thrust bearings for the medical sector.
Why has your time spent at Carter been a success story?
Jake comments, “I wanted to share my positive experience as an apprentice at Carter. I feel like it’s been a great success story because I joined a specialist bearing and tooling company knowing next to nothing and in the last 2 years I have learnt so much. I now know how to do things I never imagined I would know”.
What next for Jake?
Jake concluded, “Hopefully, I can go onto bigger and better things and keep building myself up, step-bystep and achieve great things in engineering”.
More information - What is an engineering and manufacturing apprenticeship?
An apprenticeship in engineering is a hands-on, work-based route into your chosen career. You will gain the qualifications and skills to become an engineer or manufacturer, while earning a salary and not paying tuition fees.
You could be building smart cities, working in robotics, or working with pyrotechnics on film sets.
More at: https://www.ucas. com/explore/industry-guides/ engineering-and-manufacturing
Training
initiative launched to
help manufacturers engage with young talent
Funded training courses are being offered to Chesterfield’s manufacturing and engineering sector to support recruitment and growth.
A new initiative, Manufacturing Futures, will teach mentoring skills to businesspeople from the sector to help firms engage with young talent. This programme will empower companies to offer more work experience opportunities, confidently take on apprentices and interns, and provide career advice to young people.
Manufacturing Futures was launched alongside the tenth edition of Made In Chesterfield, an annual festival supported by The Chesterfield College Group offering tours of local manufacturing, engineering, and construction businesses to school pupils, showcasing diverse career opportunities available.
The programme is funded through the UK Shared Prosperity Fund and is one of several skills programmes to receive funding which will help ensure residents can advance their career and that the local economy can grow.
Certified Pump System
Safetytech Accelerator Report Explores How Emerging Technologies Are Transforming Safety and Operational Performance
As organisations across safetycritical industries seek to enhance both workplace safety and operational efficiency, Safetytech Accelerator has released a new report, “Delivering Safety Innovation: Advancing OSH with Emerging Technologies”.
The report outlines how emerging technologies like artificial intelligence, wearable devices, robotics, and real-time monitoring offer solutions that address both evolving safety regulations and the need for greater operational efficiency.
At a time when UK businesses face increasing regulatory demands, including Health and Safety Executive (HSE) inspections prioritising musculoskeletal disorders (MSDs)which affected 473,000 workers in Great Britain in the year to March 2023 - alongside other workplace hazards and upcoming updates to RIDDOR (Reporting of Injuries, Diseases, and Dangerous Occurrences Regulations), the report offers guidance on how organisations can leverage cuttingedge technologies to ensure compliance and improve safety outcomes.
Central to this guidance is a 7-step framework that outlines
In this new report we outline the technologies with the highest OHS impact and provide a 7-step framework to help leaders in safety critical industries integrate these technologies in their organization effectively and efficiently.
a clear approach to successfully implementing these technologies.
Beyond compliance, the report highlights how these innovations also drive operational improvements and contribute to corporate responsibility and ESG performance.
Key Insights from the Report:
• Reducing Musculoskeletal Injuries: In the year to March 2023, 473,000 workers in Great Britain experienced work-related musculoskeletal disorders (MSDs), primarily due to manual handling, repetitive motions, and poor ergonomics. Trials show that robotics and exoskeletons have reduced the number of warehouse workers developing MSDs by 30%
• Improving Height Safety: With falls being the leading cause of work-related fatalities in the UK, drones and augmented reality (AR) can be used for inspections and training, enhancing safety by reducing the need to place workers in high-risk situations. • Predicting Equipment Failures: In mechanical lifting operations, AI-driven sensors can predict equipment failures and optimise load handling, reducing accidents.
• Enhancing Site Traffic Safety: In environments with moving plant equipment and site traffic—major causes of workplace injuries and fatalities—visual analytics can reduce the likelihood of being struck by a vehicle by over 60%.
• Monitoring Hazardous Substances: Wearable sensors that monitor air quality in realtime alert workers to dangerous conditions, such as asbestos or dust exposure, improving safety.
• Inspecting Confined Spaces: Confined spaces, which pose significant risks due to limited access points, can be assessed more safely with robotic inspections and remote monitoring, reducing the need for human entry by 75%.
Dr. Maurizio Pilu, Founder and Managing Director of Safetytech Accelerator, commented: “Emerging technologies are transforming workplace offering businesses powerful tools to improve safety, reduce operational risk while also enhancing efficiency and operational performance. In this new report we outline the technologies with the highest OHS impact and provide a 7-step framework to help leaders in safety critical industries integrate these technologies in their organization effectively and efficiently.”
For more information on how emerging technologies can help your organization improve both safety and efficiency, while navigating the evolving regulatory landscape, download the full report here.
EcoCooling Evaporative Cooling
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Thousands of EcoCoolers are installed in facilities across the UK, they are the go-to provider for evaporative cooling for industrial cooling applications. The installation network provides free site visits and quotes for supply and install. All spares and coolers are held in our Suffolk warehouse, ensuring rapid supply and maintenance.
Website: www.ecocooling.co.uk
Email: sales@ecocooling.co.uk
Phone +44 (0)1284 810586
L O W C O S T
Health & Safety
Back to the Basics of Safety
Laura Hedley, Head of Consultancy and Talent Services at the OPC, explores why some employees struggle with fundamental safety practices.
In many organisations, safety performance fluctuates, with periods of high accident frequency which can prompt renewed vigour or new safety initiatives. These efforts often lead to temporary improvements, but longterm safety gains can sometimes remain elusive, leading to cycles of fluctuating safety performance.
Laura Hedley from the OPC said, “While equipment or insufficient training can contribute to poor safety performance, human factors are often the primary cause. Even though most employees adhere to safety protocols, everyone makes mistakes. In many cases, incidents occur simply because we just don’t get the basics right.”
“When we talk about the basics, these can include ensuring the availability and proper condition of PPE; thorough equipment checks and maintenance; conducting safety briefings before any work; strict adherence to industry regulations; and prioritising safety over operational or commercial pressures.”
Laura also points out, “The NonTechnical Skills (NTS) of vigilance and conscientiousness also play a crucial role in the basics of safety, e.g., tools left on site or untidiness could lead to an incident. Risk and situational awareness are also vital in identifying and mitigating potential hazards.”
So, what prevents employees from mastering the basics of safety?
Through research and having undertaken hundreds of Post-Incident Assessments (PIA), OPC psychologists have found several common obstacles to mastering the basics of safety:
• Effort vs. Payback: Skipping the safety basics, preferring convenience over compliance.
• Balancing the job vs. the basics: Prioritising job completion over safety.
• Over-reliance on experience: In the absence of an incident or ‘near-miss’, we might believe there’s no need to focus on the safety fundamentals.
• Why Bother! A lack of positive senior leadership action to safety concerns can lead to employee disengagement.
• False sense of security: Overconfidence and a failure to recognise potential risks can hinder sticking to the basics.
• Not my responsibility! This pervasive attitude can mean a culture of disengagement and neglect, ultimately leading to failure in getting the basics right.
Laura emphasised, “Recognising human fallibility and promoting a culture where safety is everyone’s responsibility is essential. Employees must also feel empowered to report unsafe behaviours without fear. Regardless of role or seniority.”
The OPC identified some key factors why employees find challenging unsafe behaviour in others hard, such as:
• Fear of reprisal, rejection or ridicule.
• A lack of confidence in their own safety knowledge inhibits them challenging others.
• Social dynamics, such as not wanting to upset colleagues – ‘You don’t rat on your mates.’
• An organisational culture that may prioritise productivity over safety.
Doing things differently
To overcome these barriers, creating a supportive environment where safety issues can be openly discussed without fear or negative consequences is crucial. A recent OPC client survey of over 600 workers revealed that more than 90% prefer having their safety mistakes pointed out.
“Making the workplace safe isn’t just down to one person—it’s about all of us looking out for each other,” said a Maintenance Delivery Manager. “We need to speak up and hold each other accountable, even if it means having difficult conversations.”
How can the OPC help?
The OPC offers various training initiatives to improve safety performance, including:
• Non-Technical Skills training
• Back-to-Basics workshop
• Accelerate Your Safety Leadership (AYSL) workshop.
Contact the friendly OPC team if you think your operations need some help getting back to the basics of safety.
E: admin@theopc.co.uk
T: +44 (0)1923 234646
W: www.theopc.co.uk
Safety tailored solutions, designed with your employees and their wellbeing in mind
With over three decades of safety-critical expertise, the OPC delivers bespoke solutions that strive to improve people performance, identify talent and nurture a safer culture.
Our expert psychologists help to:
Discover top talent through specialised recruitment support and role profiling.
Improve performance using Non-Technical Skills and safety initiatives.
Develop best practices, stand-out safety leaders, and deliver post-incident support for a safer culture.
Partnering with the OPC means collaborating with a dedicated team focused on safety and people performance. Trust us for tailor-made solutions from pre-selection to employment. We prioritise safety and strive to enhance your processes to go beyond industry standards.
Machining & Machinery
Exploring how autoclavable brushless DC motors are powering advances in surgical power tools
The demand for hand-held surgical power tools is at an all-time high due to significant surgical procedure backlogs and rising calls for elective and cosmetic surgeries. Where hospital administrators are under pressure to manage their costs, manufacturers are being challenged to produce tools that can be re-used, typically requiring them to withstand autoclave cleaning processes. This is where Portescap’s autoclavable brushless DC motors can prove advantageous.
Despite the obvious opportunity for OEM designers, there are pitfalls that must be considered when designing surgical hand tools. It is a market of swift innovation with a trend towards miniaturisation to improve convenience, ergonomics and overall performance. This trend requires advanced microelectronics performing to the tough regulatory standards that are demanded of medical tools.
OEMs are faced with two choices; reduce component quality with a view to producing ‘low cost’, disposable solutions; or develop solutions which can reliably be re-used, thus decreasing the ‘Total Cost of Ownership’. The second option is typically regarded as a more sustainable solution, both in terms of economic and environmental considerations.
Exceptional global demand for hand-held surgical power tools is forecast to continue into the next decade.
For the subset of surgical hand-tools that are designed to be re-usable, their components must be engineered to endure multiple autoclaving cycles. Autoclave (or steam sterilization) cycles are one of the most effective means of fast sterilisation of medical instruments. During autoclaving, equipment is exposed to up to 100% humidity, 121°C minimum and variations between positive and negative pressures for up to 30 minutes; the process is designed to kill bacteria, viruses, fungi and spores.
Various approaches were developed by manufacturers which protected the motor – or avoided the autoclave cycle completely – such as disposable tools, removable battery packs and ‘redundant seals’. However, none are compatible with the requirements for convenience. This is why more designers are looking to
brushless DC motors to answer the challenges of cost, performance and reliability.
By replacing brushes and a commutator for an electronic drive, brushless DC motors deliver performance improvements over other motor technologies. The brushless design can also deliver up to 30% more torque than traditional motors of the same size, while generating less heat and greater speed control for the operator.
Designers should also typically specify brushless slotted (rather than slotless) technology, which, by design, offers protection to the slotted motor winding when inserted into the slots of the lamination stack. From here additional coating or moulding protection can be added within impacting the motor performance.
It is crucial to partner with miniature motor manufacturers who have a proven track record of delivering high-quality autoclavable solutions, given that the reliability and performance of these motors are vital in ensuring the success and safety of the surgical power tools being designed.
Exceptional global demand for hand-held surgical power tools is forecast to continue into the next decade. As such, the outlook is positive for companies that are on the forefront of development. However, they are operating in a competitive environment, where pressure to reach the market must be balanced with ergonomic performance, product reliability and cost effectiveness.
OEMs must ensure the tools are engineered to endure autoclaving cycles. It stands to reason that designers must adopt the most suitable technology to maintain reliability without sacrificing overall performance.
In this case, autoclavable brushless DC motors currently offer the best opportunity to designers looking to push the boundaries of size, performance and reliability for these critical devices.
Read more Portescap articles on the DMA News Portal
MAPAL to exhibit high-volume milling products at Advanced Engineering
On stand M182 at Advanced Engineering Exhibition the tooling experts at MAPAL will be displaying a range of industry-focused products from their comprehensive portfolio. On focus will be the latest tooling solutions for Fluid Power and Aerospace industries.
Visitors to the MAPAL stand can expect to see a range of tooling innovations and technologies set to optimise production processes, enhance efficiency, and ensure
consistent MAPAL quality and performance.
Eugene Nugent, National Sales Manager comments “We look forward to connecting with industry professionals to demonstrate our full capabilities as a leading tool manufacturer and technology partner. MAPAL products are proven to excel overall manufacturing productivity and increase throughput. Our representatives can provide expert guidance for a wide range of tooling solutions.”
Aero Industry Prepares for Take-Off at Starrag Event
The Starrag-Tornos Group recently welcomed guests to its 25th annual ‘Aerospace and Turbine Technology Days’ event hosted by Starrag in Switzerland.
The much-revered event welcomed some of the most prominent OEMs and supply chain partners from the world of aerospace manufacturing, R&D and product development arenas.
Celebrating the success of the event on its second day, Martin Buyle, CEO of the Starrag-Tornos Group said: “The Aerospace Days event has become a tradition. It’s an environment where people want to learn about technology.
Enhance efficiency, and ensure consistent MAPAL quality and performance.
We position ourselves as technology leaders - and not just machine or equipment sellers. One of the means to demonstrate this expertise is to bring together specialists from all over the world to learn about what we can offer and also provide an environment where engineers can learn from their peers and what they do. This event really is like a family that we bring together - and we bring a lot of technologies together.”
The next Starrag TechDays Event will take place in Chemnitz, Germany on the 5th and 6th of November.
This event will bring together some of the new compact machines as well as a large new machine whilst also presenting solution integration with technology partners such as Blum Novotest, FANUC, Siemens, Fastems and Haimer.
If you would like to attend this exciting event, you can register your interest here: www.starrag.com/en-us/tdc
“This has been absolutely fantastic—far beyond our expectations! The turnout has been incredible, with more visitors than we ever anticipated. We’ve attended other shows across Europe in recent months, and this one is by far the largest. The energy has been amazing right from day one, with a constant flow of enthusiastic visitors. We’re thrilled with the outcome!
Agnieszka Radecka Regional sales manager, TME
Belzona Case Study: Polymeric Leading-Edge Protection Extends Lifespan of 42 Wind Turbine Blades
Contribution by Chloe Hirst
Given the important role wind power plays in the transition to net zero, it is absolutely critical that windfarms are maintained to an excellent standard. Otherwise, damaged wind power assets may needlessly be decommissioned and replaced; the process of which comes with a hefty carbon footprint as well as considerable financial expenditure.
As such, asset owners are investing in a simple yet extremely beneficial (both from a cost and environmental perspective) solution to extend the lifespan of wind turbines. This solution involves the use of polymeric repair composites and high-performance protective coatings to repair and protect key assets in the wind industry. This includes: turbine blades, nacelles and generating components, turbine bases, towers, transformers, amongst other assets.
The use of this technology is based on a circular economic business model: repairing damaged assets rather than replacing them. In turn, not only does this mitigate the carbon footprint incurred during the replacement process, but it is also enables the asset owner to make significant financial savings as well.
Case Study: 42 Wind Turbine Blades Repaired and Protected
At an onshore Windfarm in Denmark, 42 wind turbine blades were exhibiting signs of severe erosion on the leading edges. Previously, the Customer had used pre-formed shells that were bonded onto the substrate to provide leading edge protection. However, this process proved to be extremely time-consuming and expensive. Therefore, the Customer was seeking an alternative solution which would be financially viable and also ensure optimal operation for many years to come.
Specification of Polymeric Leading Edge Protection System
Based on test results, the ease of application as well as the highquality finish that can be achieved, the Customer decided to repair and protect the leading edges with a
Asset owners are investing in a simple yet extremely beneficial (both from a cost and environmental perspective) solution to extend the lifespan of wind turbines.
combination of Belzona 5711 and Belzona 5721.
The thixotropic paste, Belzona 5711, which is now supplied in a larger unit and more robust side-by-side cartridge, is specially designed to be applied in conjunction with the Belzona 5721 protective coating. This solvent-free LEP system is formulated for the in-situ repair and rebuilding of leading edge erosion and impact damage on wind turbine blades.
In-Situ Repair Ensured Minimum Downtime Was Incurred
As the polymeric systems were applied in situ without the need for specialist tools or equipment, this ensured that a fast and seamless application was carried out. Thus, this enabled the Customer to make considerable financial savings as it mitigated the profit loss that can be incurred through lengthy periods of downtime.
Safeguarding Key Wind Power Assets for the Long Term
The scaling up of the wind power industry is absolutely critical in order to support the transition to renewable energy, in keeping with the net zero by 2050 pathway. By safeguarding key assets within this industry through the use of polymeric technology, asset owners can successfully bypass the environmental and financial costs associated with asset replacement. Therefore, it could be argued that polymeric technology plays an intrinsic role in supporting this energy transition.
For more information: AESSEAL DANMARK A/S.
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Help minimise your impact on wildlife. Choose PYROSTAR™ Neo+ Endotoxin Testing alphalabs.co.uk/pyrostar-neo+
Babcock Wanson UK Expands
Environmental Solutions with DCT Regenerative Oxidisers & Solvent Recovery Systems
Following the acquisition of Donau Carbon Technologies (DCT) by the Babcock Wanson Group in 2022, industrial process heating equipment and solutions specialist Babcock Wanson UK has expanded its range of regenerative oxidisers and is now able to offer complete solvent recovery systems to help reduce customers’ carbon foot print and meet increasingly stringent emission limits for solvents and volatile organic compounds (VOC).
DCT solvent recovery systems feature activated carbon adsorption, using steam or inert gas for the regeneration. A distillation section (batch or multi-columns) allows for a very high level of purity – frequently exceeding international standards - for the recovered solvents to then be reused in production, making for a rapid return on investment. These solvent recovery systems are easy to use and, because they are modular, can be expanded and reconfigured to meet changing site requirements.
For more information, please contact Babcock Wanson on 020 8953 7111 or info@babcock-wanson.com or go to www.babcock-wanson.com
Totalkare’s ergonomic positioners are single or double column devices that enable the lifting and rotation of a product during welding and assembly operations.
With overall capacity from 2,000 - 90,000kg to suit, they are both compact and flexible.
Building a future that’s a few shades greener Sustainability
As customers, investors, and regulatory bodies mount pressure on businesses to become more sustainable, and with an increased focus on ESG responsibilities, technology can be a valuable partner in achieving these goals.
Did you know? The latest government data shows the UK generated an estimated 40.4 million tonnes of commercial and industrial (C&I) waste in 2020, of which 33.8 million tonnes (84%) was generated in England. The latest estimates for England only indicate that C&I waste generation was around 33.9 million tonnes in 2021.
By taking an insights-driven approach to their waste streams, businesses can create additional revenue streams, reduce waste management costs, and boost their green credentials.
Sadly, the amount of commercial and industrial waste generated by businesses is having a massive impact on the environment. Most of this waste ends up in landfills, generating greenhouse gas emissions 25 times more effective at trapping heat than carbon dioxide.
This is terrible news for our planet. And consumers are not ignoring the facts.
Deloitte’s 2023 Sustainable Consumer survey revealed that 30% of consumers had stopped buying products due to ethical or sustainability-related concerns. And almost 50% see circularity (explained in more detail later) as essential for buying a product.
If those aren’t reasons enough to reconsider waste management within your business, then how about this statistic: Every year, UK businesses can spend between 4–10% of their average annual turnover on waste disposal.
That’s a significant chunk of profit.
For actionable strategies check out our recent waste management blog.
Understanding sustainable waste management
Instead of collecting, transporting and disposing of waste, sustainable waste management looks for solutions that won’t harm the environment or human health and instead focus on reducing natural resource consumption.
Sustainable waste management revolves around a hierarchy:
“We already work with a range of major electricity network operators, offering them unique services for their transformer and switchgear recycling, ensuring that nasty elements like PCBs and F Gases are safely recycled. Additionally, we are developing some unique technologies in the WEEE waste sector, allowing us to extract precious metals from WEEE waste.”
Nicola Guest, Waste Mission’s Group Marketing Manager
• Reduce the initial amount of waste generated
• Reuse where possible
• Recycle what can’t be reused
• Sell what we can
• Only then, dispose of what’s left
From helping to reduce carbon emissions to improving air and water quality to commoditising waste streams that may be currently running at a financial loss – sustainable waste management has incredible environmental, economic and social benefits.
This type of model, where everything is reused, repaired or recycled, can also be understood as the circular economy.
Why
the UK
manufacturing industry needs to embrace sustainable waste management
From groaning landfill sites to ecosavvy consumers and wasted profit, there are multiple reasons to embrace a sustainable waste management strategy and reduce the amount of waste your company produces.
Plus, let’s not forget how there are growing concerns around securing supply chains in an ever more volatile world. But, the great news is that sustainable waste management practices can help manufacturers ride the fluctuation in raw material prices.
We believe that to achieve a more innovative and sustainable future, manufacturers in the UK need to prioritise long-term sustainable waste management goals.
And that’s where our team at Waste Mission can help.
Making Sustainable Waste Management Easy Through Insights
At the recent PPMA Show, Waste Mission unveiled our custom-built Waste Management Portal. This innovative platform is designed specifically for contracted customers, enabling them to manage their waste more effectively and sustainably than ever before, staying up to date with waste streams, compliance and ESG targets.
“These features are groundbreaking for our clients,” says Nicola Guest, “People have been blown away by the simplicity of use and the ease of understanding the data. Everything you need is at your fingertips and simplifies what has historically been a complex process - making sustainability simple.”
See the portal in action
At Waste Mission, we are driven by our unwavering commitment to doing what’s right – for our clients, staff, and the planet. No matter the complexity of the task, we want to simplify waste solutions for UK industries and manufacturers. We aim to educate, encourage and uncomplicate waste management by offering a bespoke, tailored service, all from a single point of contact.
Our responsive team of experts becomes an extension of your business, taking care of waste so you can stay focused on your core operations. We promise to:
1. Guide you to reduce waste and increase your profitability
2. Help turn your waste into solutions, reducing reliance on new materials
3. Navigate complex regulations for you, ensuring you meet environmental and legal requirements
4. Provide a waste portal so you can easily access data on your waste production, recycling levels, and carbon footprint.
If you care about your environmental impact and are looking for a reliable partner to help navigate the complexities of your waste management, then we’d love to talk.
“What separates Waste Mission from their competition is the level of professionalism and transparency they bring to the industry. They continue to question the status quo and propose initiatives to drive our business forward.”
To book a waste review or learn more, visit our website wastemission.com, call us at 01438 745307 or email control@wastemission.com
The Anker SOLIX X1 Modular Energy Storage Solution
The Anker SOLIX X1 is a modular energy storage system for solar power offering advantages over conventional storage systems. The capacity can be flexibly adapted to requirements, with the autonomy of the individual modules increasing reliability, and the design being attractive and minimalist.
The modularity enables simple assembly and uncomplicated maintenance, which provides stress free maintenance for installers. The hybrid single-phase system consists of a control unit and battery modules that can be connected individually.
In the event of a power failure, the Anker SOLIX X1 switches to emergency power mode in less than 10ms. The home energy storage system is 40 per cent slimmer than standard industry solutions and is ultra quiet at less than 30 dB.
The model can pull anywhere from 7,36-12kW from solar panels and output in the range of 3,68-6kW, ensuring that every user can get as much power as their individual situation demands in the case of a power outage.
Anker SOLIX offers a full 10-year warranty on its X1 devices and provides companies with an overview of the systems they have installed, any failures or upcoming maintenance at any time. www.anker.com/anker-solix
The design being attractive and minimalist...
Rotork enhances data collection with industrial ethernet
Rotork introduces its fully integrated ethernet actuator, which is compatible with EtherNet/IP Modbus TCP and PROFINET protocols. This marks a leap forward in industrial automation, offering unprecedented data connectivity, speed, and operational efficiency.
With Rotork’s integrated Ethernet solution, a data gateway is no longer required, reducing complexity and increases the volume and speed of data extraction, with transfer rates up to 100 Mbps.
This is housed within a robust weatherproof or explosionproof enclosure and supports RJ45 and M12 connection standards.
Compatibility extends to industrystandard protocols, with PI certification, GSDML files for PROFINET, and ODVA certification with supporting EDS files for EtherNet/IP.
The new Ethernet solution accelerates data transfer and enhances the capability for in-depth data analysis.
By leveraging the Rotork Intelligent Asset Management (iAM) cloud-based system, operators can unlock powerful insights from their operational data. This enables predictive maintenance, optimised performance, and informed decision-making, driving productivity and reducing downtime.
Artec 3D releases new ultrahigh resolution 3D scanner: Artec Spider II
Global 3D scanning leader Artec 3D has launched Artec Spider II, a new target-free handheld 3D scanner designed to capture complex objects.
Spider II scans quickly, in full colour and ultra-high resolution with significant improvements including greater depth and field of view and capture speed.
With blue-light technology, Spider II captures a unique mix of high-quality geometry and texture data for incredibly detailed models.
Features:
• Enhanced Capture Speed: Scans at a rate of 30 FPS, four times faster than previous models.
• Increased Volume Capture: A capture zone of 1,800 cm³, allowing for larger and more complex objects to be scanned efficiently.
• Versatile Design: The 950-gram, lightweight, target-free scanner is easy to use and setup, enabling quick start for 3D modeling.
The Spider II is suitable for various applications:
• Design and Art: High color capture accuracy supports the creation of detailed 3D models.
• Body Scanning: Captures fine anatomical details, beneficial for medical device customization and digital twin diagnostics.
• Reverse Engineering: Provides accurate scans for industries requiring fine tolerances, such as automotive and manufacturing.
Alongside Spider II, Artec 3D has unveiled Artec Point, a highly accurate new laser 3D scanner designed to address demand among industrial metrology customers.
Find out more about Artec Spider II here or Artec Point here.
Lightweight Angle Heads Enhance Versatility
Industrial Tooling Corporation (ITC) has now introduced two new lightweight angle heads from BIG KAISER. One is a small bore version suitable for tools with a diameter from 0.25 to 6mm, and the second head has been optimised for high torque tapping.
These heads facilitate vertical, horizontal and angular operations without the need to reposition the workpiece, thus increasing accuracy and productivity. This enhancement not only saves machining time but also accelerates production workflows.
Weighing less than 2kg, their reduced weight makes them compatible with the automatic tool changers (ATC) of small dynamic machines, such as those from FANUC and Brother. The lighter weight also
enables the ATC to operate more swiftly, reducing tool change times and shortening overall cycle times. Designed specifically for BBT30 machine spindles, the new angle heads include a high-precision BBT30 interface. The lineup includes three variants that are tailored for general machining, high torque tapping and small bore applications.
The angle heads feature a compact design that minimises overhang, enhancing both rigidity and strength. An advanced non-contact seal offers superior protection against coolant and particulate contamination compared to traditional sealing methods. Additionally, a unique coolant jacket effectively directs coolant to the cutting edge while cooling the angle head, which helps to reduce noise and vibration.
Moore Concrete Cements Foundations for Growth with Inforlogic and Infor CloudSuite Industrial
Northern-Ireland-based precast concrete manufacturer moves to cloud ERP for visibility, standardisation and scale.
Inforlogic announced that precast concrete leader, Moore Concrete, has deployed Infor CloudSuite Industrial. As part of a modernisation programme the platform will support greater visibility and control across manufacturing operations to optimise performance and profit margins. In parallel, access to integrated intelligence on the production lifecycle will enhance the customer experience as sales and service teams will be able to communicate status updates and delivery schedules with greater accuracy in a few clicks.
Having outgrown its previous Sage 1000 ERP system, Moore Concrete undertook a detailed review of the market before selecting Infor CloudSuite Industrial (SyteLine) and Inforlogic
With ambitions to grow its business and consolidate its position as a world class manufacturing facility, the concrete leader selected Infor SyteLine based on its comprehensive deep manufacturing capabilities, cloud architecture and ability to scale. Inforlogic’s experience, expertise and ethos meant that they were a natural choice as a partner.
Looking ahead, Moore Concrete will leverage Infor SyteLine’s integrated document management (IDM) capabilities to move towards a truly paperless operation, while Factory Track will facilitate greater transparency in the production facility.
With ambitions to grow its business and consolidate its position as a world class manufacturing facility...
Eku Energy announces commissioning of Maldon Battery Energy Storage System
Global energy storage specialist
Eku Energy has announced the completion of commissioning of the Maldon Battery Energy Storage System (BESS) located in Maldon in the county of Essex, England.The Maldon BESS is Eku’s first UK project to reach commercial operation.
Strategically located on the outskirts of London, the Maldon BESS will provide flexibility to enable more renewable generation to connect to and increase the resilience of the UK electricity network.
Constructed by Trina Storage and supported by leading independent connection provider (ICP), ESM Power Ltd, the Maldon BESS has a capacity of 40MW/40MWh capable of responding within 350ms, suited
to deliver ancillary and balancing services to support both the local and National Grid.
The project has secured a longterm Capacity Market contract.
Traded by renowned energy trader EDF, Maldon BESS delivers both commercial benefits and grid services supporting the UK network.
Eku Energy combines global expertise in financial and energy markets with specialist technical capabilities, working across the full project life cycle to develop, build, and manage battery storage assets, with a presence in the UK, Australia, Japan and Italy.
The Maldon BESS forms part of Eku Energy’s wider portfolio of battery projects in the UK, where the company aims to grow its footprint.
for Great British
Manufacturers
forge transparent partnerships as we simplify the complexities of marketing for all our customers. Since 2005, our mantra has been: success will look after itself.”
We look after your marketing from start to finish!
Future Care with Multiwavelength VCSELs
LASER COMPONENTS is pleased to offer multi-wavelength VCSELs which are now used in a multitude of applications. By incorporating multiple chips, each being designed to emit a specific wavelength means
a single device can emit light at multiple wavelengths simultaneously or sequentially.
By employing this technology, the multiwavelength VCSELs can be used for targeted treatment with minimal side
effects. For example, in skin rejuvenation these VCSELs can target specific chromophores in the skin or tissue, allowing precise treatment without damaging surrounding healthy tissue.
Due to their small size they are easily
Plug-in partner for cable connectors in demanding industrial applications binder adds flange components for the PBC15 connector system to its portfolio
Demanding industrial applications today require compact, robust connectors that can reliably transmit high currents and voltages.
Binder, a provider of circular connectors, now offers special flange components act as plug-in partners for the PBC15 cable connector.
The connector proves itself in the industry by supplying three-phase motors and asynchronous motors, as well as for frequency inverters. It can be used in drive technology, automation technology, intralogistics, and mechanical engineering, (in fans, pumps, and packaging machines).
The flange components create seamless connections for secure power and signal transmission, further supporting the advantages of the PBC15 system. Available as flange plugs and flange sockets (with locking
Due to their small size they are easily integrated into handheld devises which make them compact, and ideal for various applications, including minimally invasive procedures.
integrated into handheld devises which make them compact, and ideal for various applications, including minimally invasive procedures.
This means there is also a cost saving as multiple wavelengths can be used in a single device. Other applications include hair removal, hair growth, scar rejuvenation, and ACNE treatment.
Further information VCSEL (lasercomponents.com)
The flange components create seamless connections for secure power and signal transmission, further supporting the advantages of the PBC15 system.
Walter Tools Expands Grooving Range
With the new WSM13G, WSM23G, WSM33G and WSM43G grades, Walter is expanding its Tiger•tec® Gold range for grooving applications and also making it suitable for universal use. The diversity of the new grades makes them suitable for everything from grooving and parting off to groove-turning – in virtually every material.
Walter is offering the grades in four versions with different levels of hardness or toughness. If the level of wear is too high, users can choose from two harder grades for ISO M, S and P materials.
More information: www.walter-tools.com mechanism), each in unshielded plastic versions or shielded versions with metal components.
The standardized flange components are cross-manufacturer compatible according to DIN EN IEC 61076-2-116, offering maximum flexibility.
The multi-layer Tiger•tec® Gold PVD coating of the inserts was specially developed for the main types of wear that occur when grooving. What makes them so special is the combined TiAlN and TiSiN multi-layer coating. This makes the layers of the grades very hard and resistant against both flank face wear and plastic deformation.
This is complemented by a special post-treatment process which ensures smooth rake faces, less friction and improved toughness.
The diversity of the new grades makes them suitable for everything from grooving and parting off to groove-turning – in virtually every material.
Specialist Equipment & Tools
IDTechEx Looks at Why Sustainable Helium Use is Needed to FutureProof the Semiconductor Industry
By Dr Shababa Selim, Technology Analyst at IDTechEx
Semiconductor manufacturing processes require many chemicals and specialty gases. Owing to its cryogenic properties, exceptional thermal conductivity, chemical inertness, and high diffusivity, helium is used throughout the semiconductor manufacturing line, particularly for wafer cooling where there are no viable alternatives. Given the US Chips Act, EU Chips Act, and several other government initiatives worldwide to boost the semiconductor industry, IDTechEx predicts the helium demand for semiconductor manufacturing will increase by over five-fold by 2035 in their latest report, “Helium Market 2025-2035: Applications, Alternatives, and Reclamation”.
With helium being a finite resource, questions remain on how this will impact the sustainability of the semiconductor manufacturing industry.
Among gases, helium’s exceptionally high thermal conductivity combined with its chemically inert nature is second to none. It allows the fast cooling of chips during the manufacturing process. Furthermore, with semiconductor technologies advancing toward smaller nodes, the need for effective thermal management during manufacturing processes is
increasing the reliance on helium for semiconductor miniaturization. Demand from AI, quantum computing, telecoms, sensors, electric vehicles, and automation in the automotive industry are all projected to be significant drivers for growth in semiconductor manufacturing and, hence, helium use.
Over the last twenty years, the helium market has been subject to chronic supply challenges and price volatility resulting from geopolitical tensions, unexpected plant outages, and maintenance downtimes of helium production and processing plants. Furthermore, the difficulty in storing helium over prolonged periods means that semiconductor manufacturers have resorted to reducing their production rate to manage helium use during periods of helium shortage.
With helium being a finite resource and critical for several applications, including semiconductor and fiber optic manufacturing, leak testing of lithium-ion batteries and aerospace components, cryogenic applications, and many more, helium conservation and management will need to play an increasingly important role in manufacturing industries.
Although expansions of helium production capacity may help ease some of the supply challenges associated with the helium market, geopolitical tensions in regions where helium is largely produced still leave questions unanswered regarding the
With helium being a finite resource, questions remain on how this will impact the sustainability of the semiconductor manufacturing industry.
future of supply security. IDTechEx forecasts the helium demand for semiconductor manufacturing will increase by over five-fold by 2035. To meet the growing demand, the semiconductor industry will not only need a stable supply of helium but will also need to invest in helium recycling and reclamation technologies to conserve helium and future-proof the sustainable growth of the industry.
IDTechEx’s latest report, “Helium Market 2025-2035: Applications, Alternatives, and Reclamation”, provides key market insights into the production and supply of helium, major applications, outlooks, and trends in how industries are adapting to cope with chronic supply challenges with helium conservation methods (e.g., reclamation technologies), or adopting substitutes where possible.
To find out more about this IDTechEx report, including downloadable sample pages, please visit www.IDTechEx.com/ Helium.
For the full portfolio of advanced materials market research available from IDTechEx, please visit www.IDTechEx.com/ Research/AM.
Precision Engineering
Laser beam characterisation using Optocraft SHSLab wavefront sensors
The SHSLab is a powerful and comprehensive wavefront measurement solution from MicroEpsilon. Developed by Optocraft GmbH, a member of the MicroEpsilon group of companies since 2018, SHSLab Shack-Hartmann wavefront sensors are used for applications such as optics testing, optics alignment and laser beam characterisation. Wavefront sensors are used in production and R&D in optics manufacturing, laser industries, astronomy and space applications, as well as by contact- and intra ocular lens manufacturers, including mobile phone optics, microscope and photographic lenses.
For laser beam characterisation, the conventional camera-based method described in ISO 11146 requires several measurements at different locations along the beam path. When using a wavefront sensor, a single measurement is sufficient to characterise a laser beam with moderate or good beam quality.
The following application describes the characterisation of a diode laser using the Optocraft SHSLab
Distinguished by their high speed, singleshot measurements, excellent unreferenced accuracy, extreme dynamics and broad spectral ranges.
wavefront sensor. A diode laser with a wavelength of 635nm coupled to a single mode fibre is collimated by a lens with a small focal length and then focused by a second lens with a large focal length.
For comparison, first a standard industrial camera is used with a pixel size of 3.75µm to characterise the beam according to ISO 11146, taking several images of the beam crosssection at different positions along the beam. Next, the SHSLab wavefront
sensor (type AR-S-130) is used to measure the wavefront at position zm = 144mm in the divergent part of the beam.
In order to analyse the stability of the wavefront measurement, continuous measurements were taken with a frame rate of 3Hz for a period of 30 minutes. The resulting mean values and standard deviations (rms) of the respective beam parameters are shown below. For all parameters, the fluctuations are reasonably small.
Optocraft SHSInspect instruments are widely used in R&D and production when performance, reliability and efficiency counts most. Based on the state-of-the-art wavefront sensor SHSLab, Optocraft offers measurement modules, turnkey instruments and automated tools for a great variety of applications in the field of optics and optical systems, such as:
• objective lens testing
• testing of optical elements and windows
• surface shape measurement
• inline measurement and automation
Optocraft provides wavefront sensors and inspection systems that are distinguished by their high speed, single-shot measurements, excellent unreferenced accuracy, extreme dynamics and broad spectral ranges. They are also able to measure wavefronts with very strong higher order aberrations.
They can measure large tilt angles and strongly defocused beams. They offer high intrinsic stability and reliability, powerful, customisable evaluation software and are versatile and flexible in usage. Optocraft’s systems are in operation in many demanding customer applications.
For more information on the Optocraft product range, please visit www.micro-epsilon.co.uk or call the Micro-Epsilon sales department on +44 (0)151 355 6070 or email to: info@micro-epsilon.co.uk
