Manufacturing & Engineering Magazine Issue 415

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ISSUE 415

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MANUFACTURING AND ENGINEERING MAGAZINE

M M MANUFACTURING AND ENGINEERING MAGAZINE

S H STRUCTURES

for solutions that require that extra edge S H Structures is there to help.

ISSUE 415

KARMELLE

JOHNSON MATTHEY

A complete solution

Independent provider of battery design, development and supply

P22

P36

ALSO INSIDE...

4Deersbrook Farm 4Plumis 4Colin Mear Engineering

...Plus much more

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Comment editor’s

ISSUE 415

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ife l f o e id s t h ig r b Look on the It is always better to be optimistic in the face of great uncertainty. However, having a sunny outlook is even more encouraging when every sign points up. Indeed, the UK’s manufacturing sector, according to the latest research from the manufacturing purchasing managers index (PMI), is expanding at a greater rate than at any time since May 2014.

The PMI’s latest data, which measures purchasing based on a score that fluctuates above and below 50, revealed that private sector firms had witnessed faster growth during the month of January than at any time in the last seven months. Any figure above 50 indicates expansion with February’s score reaching a high of 54.1.

While export growth did weaken for the fourth straight month, manufacturers were encouraged by stronger inflows of new orders from domestic based clients.

Andrew Goodwin, a senior economic advisor to economic forecast group EY Item Club, was, however, wary of getting ahead of ourselves. He said: “Even though the headline manufacturing PMI picked up to a seven-month high, beneath the impressive headline trends we continue to see a story of a two-speed sector, with domestic demand strong but the external sector struggling,” Certainly, falling oil prices have helped, maintaining output growth thanks to inputs being cheap.

“The domestic economy is clearly showing the benefits of cheaper oil, which is not only helping to boost demand but is also allowing firms to both reduce prices and build margins,” Goodwin said.

The pessimists would highlight the fact manufacturing output remains below levels reached before the 2008 crisis but that ignores the fact the sector took on more workers again in January – for the 22nd consecutive month. Manufacturers now employ 8% of the UK’s workforce and account for 10% of the UK’s total output.

Magazine Manager Daniel Beardsley Feature Managers Tom Waite Elliott Jenkinson Kyle Joyce Group Editor Daniel Stephens Editor Ciaran Jarosz Contributors Jeff Senior Amy Marsden Art Editor Stacey Brewer Designers Carla Taylor Sam Dickinson Production Vicki Lindsay Lisa Pollinger Lisa Barrans Accounts Nick Charalambous Manufacturing and Engineering Magazine is published by: Trafalgar Publishing Ltd, 6th Floor, Crown House, Southgate, Huddersfield, HD1 1DE Tel: 01484 437300

Manufacturing and Engineering magazine is published by Trafalgar Publishing Ltd. Company registered in England & Wales. All material is the copyright of Trafalgar Publishing Ltd. All rights reserved. Manufacturing and Engineering magazine is the property of Trafalgar Publishing Ltd. This publication may not be reproduced or transmitted in any form whole or part without the written permission of a director of Trafalgar Publishing Ltd. Liability: while every care is taken in the preparation of this magazine, the publishers cannot be held responsible for the accuracy of information herein, or any consequence arising from it. In the case of company or product reviews or comments, these have been based upon the true and honest opinion of the Editor at the time of going to press.

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Contents ISSUE 415

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SECTIONS

10 MANUFACTURING AND ENGINEERING 18 AUTOMATION 26 FOOD AND DRINK 30 POWER GENERATION 34 AUTOMOTIVE 38 CIVIL ENGINEERING ASSOCIATIONS 6 ADS GROUP

The premier trade organisation advancing the UK Aerospace, Defence, Security and Space industries.

18 PPMA

Providing a range of quality and cost effective services and publication

30 AMPS

The trade association and industry voice for the UK’s world-leading diesel and gas-engine power generating sector

40 S H STRUCTURES

34 SMMT

How to analyse and transform your manufacturing and supply chain operations

38 STEEL CONSTRUCTION INSITUTE (SCI) Best practice to the steel construction sector

52 STEEL CONSTRUCTION CERTIFICATION SCHEME The SCCS was established in the early 1980s to provide a Quality Management Systems certification service for steelwork contracting organisations

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6 ADS GROUP

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10 PRYOR MARKING TECHNOLOGY

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REGULARS 4 UPDATE

The latest news from the industry.

56 THE LAST WORD

Alan Turing - the father of theoretical computer science and artificial intelligence

FEATURES 10 PRYOR MARKING TECHNOLOGY

36 JOHNSON MATTHEY

Through innovation and pure drive pryor marking are the only UK manufacturer of marking machines

14 GROWING BUSINESS AWARDS Revolutionising digital intelligence gathering

16 PLUMIS

Plumis is proudly responsible for one of the top 15 British inventions of the last decade

20 COLIN MEAR ENGINEERING

Flexibility and a high customer focus is the key to CME’s success

22 KARMELLE

16 PLUMIS

26 DEERSBROOK FARM

Karmelle is a UK-based company specialising in the design, manufacture and installation of liquid packaging equipment

26 DEERSBROOK FARM

Family run deersbrook farm produce the highest quality british meat and put a keen emphasis on the importance of animal welfare

32 AVK

Design, planning, implementation, and on-going maintenance of critical power systems

36 JOHNSON MATTHEY

Leading independent provider of battery design, development and supply

40 S H STRUCTURES Rising above the rest...

50 TEMPLE MILL TECHNICAL STEELWORK Tailor made solutions from Temple Mill Technical Steelwork

54 ADVANCED METALCRAFT Impressive growth for metalwork specialist

54 ADVANCED METALCRAFT MANUFACTURING AND ENGINEERING MAGAZINE

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update BAE SYSTEMS SECURES £859M DEAL TO BUILD NAVY FRIGATES An £859 million investment in the next generation of Royal Navy frigates, which will sustain 1,700 jobs across the country, has been announced by the government.

Prime minister David Cameron said the money will be spent on developing the Type 26 warship, which will be built on the Clyde in Scotland.

The ship will replace Type 23s, with around 13 expected to be built by BAE Systems for service in the early 2020s.

About 600 jobs will be safeguarded in Scotland, with other BAE Systems sites and 30 supply chain firms also benefiting in areas including Derbyshire, West Yorkshire, Manchester, Cheshire, Warwickshire, Leicestershire and Hampshire.

Defence secretary Michael Fallon said: "This announcement is a clear vote of confidence in British industry and forms part of our commitment to invest over £160 billion in equipment and equipment support over the

next 10 years.

"As a result, our military will have some of the most impressive and technologically-advanced capabilities in the world, from the aircraft carriers and the F-35 Lightning II fighter jets to the Type 45 destroyers, Scout armoured vehicles, the A400M and the Astute Class submarines."

BAE Systems chief executive Ian King added: "Through the Type 26 programme, we are transforming the way we design and manufacture naval ships with innovative new technologies, leading-edge processes and modern infrastructure. New ways of working ensure we can continue to deliver the highest quality equipment at the lowest possible cost and compete effectively for future UK and international orders."

The first Type 26 is due to enter service as soon as possible after 2020 and will remain in service until 2060.

Lockheed unveils longer-endurance Fury UAV Lockheed Martin has tweaked the design of the flying wing-shaped Fury unmanned air vehicle (UAV) as it pursues contracts from US special operations forces and the international market.

The Block 10 update of the five-year-old Fury design adds a wider-chord and longer-span airfoil to increase endurance, especially when flying at low speeds, says Jay McConville, a Lockheed business development director.

The centre wingbox of the 136kg (300lb)-class UAS also is tweaked to make it easier integrate new and heavier sensors, he says, along with more reliable components.

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The Fury was originally launched in 2010 by a start-up company called AeroMech, which had designed the Desert Hawk UAS on behalf of Lockheed. AeroMech was later acquired by Chandler/May, which, in turn, was acquired by Lockheed.

In the specrum of UAS capabilities, the Fury falls between the tactical Insitu RQ-21 Blackjack and the brigade-level AAI RQ-7 Shadow. It is initially proposed as a surveillance asset for special operations, which is preparing to release a draft solicitation for the mid-endurance UAS programme.

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“We think Fury would bring a great capability to that customer set,” McConville says.

Since the acquisition, Lockheed has unveiled two major performance upgrade. The first design added a beyond line of sight communications antenna, allowing the aircraft to communicate with a ground control station to take advantage of its claimed 15h endurance.

So far, the Fury has not been sold to foreign customers, but Lockheed believes the design is exportable.

“We have export marketing licenses for a variety of customers around the world,” McConville says.

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update BOMBARDIER OPENS WINDOW FOR CS300 FIRST FLIGHT Bombardier has set a three-day window to achieve first flight of the 135-160seat CS300, the largest and most popular version of the CSeries family.

The first flight window was set after Bombardier received an experimental flight permit from Transport Canada.

Long-term weather forecasts predict temperatures well below freezing and a slight chance of snow in the morning on 26 February, but little chance of precipitation the following two days.

“The CS300 aircraft will perform its maiden flight in the coming days,” says Rob Dewar, Bombarcier’s vice president leading the CSeries programme.

The flight test milestone for the CS300 is scheduled at a critical time in the life of the seven-year-old CSeries programme. Last week, Bombardier named Alain Bellemare as the new chief executive. The former United Technologies executive replaces Pierre Beaudoin, who replaces his father, Laurent, as chairman of the company.

The leadership shake-up came after

MANUFACTURING GROWTH SPEEDS UP Activity in the manufacturing sector picked up pace in February, and output is expected to grow faster still in the next three months, according to the latest CBI Industrial Trends Survey.

The survey of 522 manufacturers found that 40% of firms said the volume of output over the past three months was up and 23% said it was down, giving a balance of +17%. This brought the pace of growth to levels last seen in mid-2014. The CBI found 16 of the 18 sectors anticipate growth in the coming quarter.

A majority of businesses expect output to grow in the coming quarter, with 36% predicting growth, and 12% a decline, giving a rounded balance of +25%.

The survey found that 26% of manufacturers reported total order books to be above normal and 16% said they were below normal, giving a balance of +10% - a six month high.

investors have grown increasingly impatient with the pace of the development programme and Bombardier’s ability to sign up new customers.

Although CSeries sales pale in comparison to the bulging backlogs for Airbus and Boeing narrowbodies, Bombardier executives have always insisted their goal is to sign 300 firm orders by entry into service of the CS100, which is currently scheduled two years late in the second half of 2015.

Four CS100 flight test vehicles have amassed more than 1,000 flight hours and “test results are looking great”.

Bombardier has said before that the flight test programme includes 2,400 flight test hours.

Although the CS100 will be the first to enter service, the programme’s future in large part rides on the success of the CS300 model. It competes directly against the two smallest Airbus and Boeing narrowbodies still in production as commercial airliners – the A319 and 737-700.

REXAM BACKS £4.4BN TAKEOVER OFFER FROM BALL Drinks can maker Rexam said it is backing a £4.4 billion sweetened takeover offer from Colorado-based rival Ball.

Rexam, whose customers include Coca-Cola and PepsiCo, is the leading drinks can maker in Europe and employs about 8,000 people in 55 plants across 20 countries. In the UK it employs around 700 workers and has plants in Luton, Milton Keynes and Wakefield.

It revealed earlier this month that it was in talks with Ball in a cash and shares deal valuing it at £4.3 billion.

Both companies said a combination of the two firms would boost their global footprint, as well as aid product innovation.

The deal is expected to complete in the second half of next year, subject to regulatory approval.

Ball said it will be able to make around $300 million (£194 million) of annual operational savings from the third year after the deal has been sealed. It said it has made no plans on plant closures or job losses, although the Rexam board will leave the enlarged company on completion of the takeover.

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ASSOCIATION ADS GROUP

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ASSOCIATION ADS GROUP

PROFITS RISE FOR COMMERCIAL AIRCRAFT DELIVERY Data from the ADS Group reveals a record January for deliveries, amounting to a total of 86 commercial aircraft delivered worldwide

The ADS Group was pleased to announce that the UK’s aerospace industry was boosted by around £1.3bn in the first month of 2015.

Data shows that this has been a record January for deliveries, amounting to a total of 86 commercial aircraft delivered worldwide. With the UK aerospace sector comprising 17% of the global market share, this has a significant impact on UK business.

The new figures also show that the aircraft backlog continues to grow, having increased by 14% over the last 12 months. The total backlog, which now stands at 12,848 and has been driven by increasing

demand for new, fuel efficient Single Aisle Aircraft, is worth up to £180bn to the UK alone.

Annual figures released by ADS Group last month showed that the backlog represents more than nine years work in hand to the UK aerospace industry.

Paul Everitt, chief executive of aerospace trade organisation, ADS Group, commented: “The UK aerospace sector continues to go from strength to strength. These latest figures are indicative of the commitment of airlines to invest in new, more environmentally efficient aircraft.

“The Aerospace Growth Partnership continues to play a vital role in strengthening the sector. As outlined in our manifesto launched by ADS Group last month, we hope that the next government continues to invest in growth by focusing on innovation, skills and supply chains.

This will allow the UK to have the technology, people and growth that will continue to strengthen its competitive advantage in fastgrowing global markets.”

Everitt also discussed Labour’s plans for business this month admitting that while the

next government would face many challenges ADS was encouraged by Labour’s proposals.

“The next government will face some tough decisions on public finances and sustaining growth. ADS believe that working with industry to build on successful Industrial Strategies, invest in industrial innovation and support growing SMEs offers the next government the best route to balancing the nations books and ensuring economic prosperity.

“Labour’s commitment to build on the successful industry partnerships in aerospace, defence, security and space is extremely important and will support continued investment in high-skilled jobs, high-tech exports and sustainable growth.”

Following the Chancellor's Autumn Statement in December, Everitt spoke of the importance of the government’s support for the UK’s high value, high tech manufacturing businesses. “The Chancellor’s statement delivered some important new support for the UK’s high value, high tech manufacturing businesses. The government’s Industrial Strategies prioritise innovation, skills and exports and the measures

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ASSOCIATION ADS GROUP outlined will help boost UK businesses and their long-term growth ambitions. High value manufacturing delivers well-paid jobs that can support the aspirations of families and communities across the country.”

ADS plays an instrumental role in bringing industry and government together, working closely and collaboratively to maintain and grow the UK’s world leading position in these industries. In doing so, these sectors will support and facilitate a sustainable UK economic recovery, securing future sector prosperity through a strong strategy and united approach.

Everitt was eager to emphasise other positives from the Chancellor’s statement such as its encouraging approach to innovation.

“Supporting innovation to remain ahead of growing global competition lies at the heart of the Industrial Strategies. Raising the rates of

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R&D tax credits, establishing the materials research centre and the additional funding for the successful High Value Manufacturing Catapult centres will help our sectors invest in the technologies of tomorrow,” he said.

On apprentices, he said: “Around 60% of UK aerospace, defence, security and space companies employ apprentices, providing high value and highly skilled employment. The measures announced to make it less costly for employers to take on an apprentice will encourage more businesses, especially small businesses, to consider their skills to ensure they have the right people to continue to innovate and compete in the long-term.”

Elsewhere on space, he said: “The recent Rosetta Mission provided an opportunity to shine a light on the exciting work underway in the UK Space sector here. Recognising this, the

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Chancellor has committed £55m towards European Space Agency programmes in which the UK will play a pivotal role in developing the technologies that make these programmes possible.”

The outcome is the UK aerospace industry is growing ten times faster than the UK overall, employs 109,100 people directly and supports many thousands in other sectors. The sector has grown 14% annually since 2011, with improved business confidence, investment and a focus on driving growth through exports.

Everitt says: “The Aerospace Growth Partnership has worked hard to put the right support in place to help UK industry make the most of significant increases in demand for new aircraft. The positive impact of this work is being felt, with almost three quarters of companies planning to increase investment next year and one in four looking at reshoring activ-

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ASSOCIATION ADS GROUP ity back to the UK.” ADS has around 900 members in the UK, ranging from small start-ups to large corporations and global operations. They include manufacturers, equipment suppliers, service companies and operators and, for them, the organisation provides support in many ways. “ADS offers a packed programme of more than 170 events per year in addition to organising UK groups at international exhibitions, offering a valuable opportunity for networking and forging new connections,” outlines Everitt.

“We facilitate access to the latest tender and business opportunities and provide assistance for SMEs with government funding and business development or building links with prime contractors. ADS has an important role to play in influencing UK and EU governments, representing the interests of industry.

Members can participate in more than sixty boards, committees and special interest groups which offer a valuable mechanism to discuss and debate particular issues or challenges faced by businesses.”

The biggest and best known event is the Farnborough International Airshow, organised by wholly-owned subsidiary Farnborough International Limited. This year’s event attracted more than 100,000 trade visitors and 1,500 exhibitors from 75 countries, affording ADS members the opportunity to showcase the country’s world-leading capabilities to a global audience. A record breaking $201 billion of orders and commitments were made at the show.

www.adsgroup.org.uk Telephone: 020 70914500

ADS plays an instrumental role in bringing industry and government together, working closely and collaboratively to maintain and grow the UK’s world leading position in these industries.

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MANUFACTURING AND ENGINEERING PRYOR MARKING TECHNOLOGY

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MANUFACTURING AND ENGINEERING PRYOR MARKING TECHNOLOGY

MAKING A

MARK

through innovation and pure drive pryor marking technology are the only UK manufacturer of marking machines

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We’ve survived and grown by innovating and we’re now the only UK manufacturer of marking machines,” proclaims Pryor Marking Technology’s Sales Director Alastair Morris. “We’ve taken a clear strategy to be innovative, pushing the boundaries of what we do. That’s driven our product range, our standard products coming from the latest innovations. We pride ourselves on solving problems so, whatever a company needs marking, we’ll have a way of doing it or we’ll find one.”

Whilst many competitors have focused on

stamping machinery, a commodity market with reducing prices, Pryor Marking Technology has been much more ambitious.

Having started 165 years ago making engraved dies for marking cutlery, a service it still provides for various products, it added a range of manual marking products to indent leather, metal and other materials.

The big change came in the 1980s with the development of computer controlled marking machines that now comprise the major part of the business. Further innovation followed

when putting 2D barcodes onto metal, the company acquiring expertise in vision technology through developing readers for those barcodes. After that came laser marking technology while the past few years have seen a further step-up with software development capability.

“It began as a tool for driving the marking machine but, with vision technology and the ability to read barcodes, the software developed into a traceability product,” recalls Alastair. “It can log all marked data and other manufacturing data, storing in a database for

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MANUFACTURING AND ENGINEERING PRYOR MARKING TECHNOLOGY full traceability of manufacturing data. For example, for a complete jet engine, you can trace back any components from the barcode, know everything about its manufacture and trace all other components in the same batch, picking up faults and improving the manufacturing process. The software is a product in its own right you wouldn’t need to buy marking equipment from us.”

Last year saw a further expansion of business due to customers requiring complex robotic solutions. Robotic control is now integrated into software for a robotic marking system that’s used in the automotive industry for marking vehicle identification numbers and, states Alastair, in the aerospace industry: “We’ve used robotic solutions to eliminate operator error. The vision system really comes into its own because it can identify the component automatically, the robot marks in the correct place and the vision system checks and stores what’s been done.”

All those developments have seen Pryor Marking Technology transformed from its cutlery marking origins and it now has a range of 30-40 standard products covering various marking technologies. Around 25% of turnover comes through bespoke prod-

ucts designed specifically for particular production lines, turnkey solutions being a company specialisation. It’s all mainly delivered from the Sheffield base, but Pryor also has an Indian joint venture providing additional manufacturing capacity for the local market there.

Alastair says: “We have in-house software, electrical and mechanical design capability, we manufacture here in Sheffield and we have a team of support engineers in the UK constantly installing, commissioning, training and providing service contracts over the life of the equipment. We have a huge network of distributors supporting us internationally. We’re about 50% export and have been exporting for 60-70 years so we’ve built up a really strong network to support our equipment globally.”

The distributors have to understand the technology to be able to support the equipment for a worldwide and complex customer base covering various manufacturing industries where marking and traceability of products are needed. A recent project, recalls Alastair, has been particularly notable: “We’ve won some innovations awards, including the Manufacturer Magazine National Awards and some

“We have in-house software, electrical and mechanical design capability, we manufacture here in Sheffield and we have a team of support engineers in the UK” Technology’s Sales Director Alastair Morris.

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Sheffield business awards, for a laser marking system for a vehicle VIN. Creating that mark is nothing new but we developed a vision guided robot laser marking system, the first in the world, and that presented quite a few challenges. It has been hugely successful and we’ve now installed three systems, two in the UK and one in China.”

The emphasis for all systems is on quality, reliability and standard of service because they’re necessary to keep production lines running. For robotic systems in particular, of which fourteen have been installed so far, that’s meant a big learning curve, especially to get vision systems working in real situations. That’s continuing through an association with the National Skills Academy that’s readying the business for the requirements of working with the nuclear industry.

Alastair says: “Innovations in robotics and elsewhere are likely to become our standard products so we’ll be delivering those much more easily. We’re already looking at what’s next, including expansion into the nuclear and the oil and gas industries and global developments. We’ve undertaken some incredibly successful projects in the UK for advanced manufacturing but there’s still a lot of development to bring others elsewhere in the world up to the latest levels of technology.” www.pryormarking.com Telephone: 0114 2766044

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MANUFACTURING AND ENGINEERING GROWING BUSINESS AWARDS

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MANUFACTURING AND ENGINEERING GROWING BUSINESS AWARDS

CELEBRATING EXCELLENCE & INNOVATION

The Growing Business Awards celebrate entrepreneurship innovation & business development

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Created by Real Business, held in association with Lloyds Bank and supported by the CBI, The Growing Business Awards are the most established and respected national recognition of SME and entrepreneurial success.

In 2014 the event had an unprecedented number of entries that demonstrated a wealth of business excellence and innovation in sectors ranging from manufacturing to lifestyle and beyond.

Plumis, the home sprinkler manufacturer, was one of the winners, taking home the prize for Innovator of the Year. Co-founder Yusuf Muhammad said, “Initially, I was taking part in a group research project and we set a remit to save lives. We went to a local fire brigade in South Kensington to brainstorm and hear novel things that could lead to a new device.

“One firefighter mentioned that rookies usually burn ears in the field, but more experienced guys would turn the hose nozzle to a mist

setting to control the fire and we thought it was quite interesting and thought about how it could be used in the home. It turns out the technology was being used frequently offshore, so we looked to bring it onshore.”

The Plumis team was created in a small business incubator with the Royal College of Arts and Imperial Business College, which allowed engineer and designer Muhammad to find partners possessing business knowledge to combine their skills over the 18-month development period.

“It helped us go from a design to business proposition. We then looked for angel investment as we continued more testing to validate that the product worked, testing it out on furniture fires to ensure the system was robust,” he said.

“Nobody has tried to push the envelope.

Innovation for us means trying to solve old problems in new and more lasting ways, and we've come at it from a different perspective that we feel is unique and different.”

The company’s lead product Automist has

also been recognised by the British Library as one of the top ten inventions of the last decade, in addition to receiving a Dyson Award.

The Plumis customer base is a mixed one, targeting homeowners that want open plan layouts, architects and builders – but also care homes, student accommodation and other high risk fire groups among clients.

“The main reason people buy is to satisfy building regulations. For example, a threestorey house can't have an open plan ground floor because if there's a fire, someone in the loft won't be able to escape from top floor to bottom,” Muhammad revealed.

“Our systems are relatively easy to install, enables more open plan opportunities and are aesthetically pleasing for architects and builders to create more desirable homes.”

www.gba.realbusiness.co.uk Tel: 020 7045 7600

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MANUFACTURING AND ENGINEERING PLUMIS

GIANT LEAP FORWARD Plumis is proudly responsible for one of the top 15 British inventions of the last decade

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London based Plumis took a giant leap forward within the fire protection sector by winning Innovator of the Year at the Growing Business Awards 2014. The business, which was founded in 2008, offers affordable alternatives to domestic fire sprinklers, having developed a series of innovative fire suppression systems including Automist, which the British Library counts as one of the top 15 British inventions of the last decade.

“The existence of the company has been, until 2014, to prove that there is a place for a product like Automist,” says co-founder and managing director William Makant. “We have managed to do that and the award was the cherry on the top in that respect, to close off another year in which we grew more than 100%.

“2015 is the year to up-shift gears and focus on sustainable long term growth as opposed to survival. We have big plans for 2015 in terms of product launches, marketing campaigns, presence in local and international fairs and growth of the Plumis team as a whole. We also plan to make our first significant international steps as a result of our product development towards international certifications.

“On the other hand, we also want to increase our presence in the UK in the social, sheltered and assisted living arenas where Automist could and should make the most significant impact. It is in these segments where fire statistics indicate domestic fire causes the most fatalities, not in newly refurbished family homes.

This will certainly be an exciting year for us.”

Following the conception of Plumis, the business has continued to develop, test, and

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MANUFACTURING AND ENGINEERING PLUMIS manufacture innovative fire protection devices based on watermist technology. The challenge initially was to draw attention to this form of fire protection and the advantages it can bring to safety in the home.

“Our aim is to be able to fill the massive gap of domestic active fire protection. Sprinklers rarely exist in domestic settings, especially for retrofits, because they have been historically considered to cause a lot of water damage, if activated, of uncertain cost while being bulky and disruptive. Automist avoids all of these issues which is why it has been increasingly used to meet building regulations on refurbishment projects where enclosed spaces and fire doors are removed in modern open plan layouts.”

Automist uses less than 10% of the water of a traditional sprinkler system, running at approximately 5.5 lpm, and therefore minimises consequential water damage and run-off.

“We enable this by not only using watermist but by maintaining the mist density at the fire base level (not the ceiling) maximising its efficiency. The use of embedded electronics also makes it smarter and more customisable than a mechanical traditional sprinkler system. We are now taking this to a next level where we will use electronics to make monitoring, diagnosis and suppression effectiveness much better than it is already.

Automist uses less than 10% of the water of a traditional sprinkler system, running at approximately 5.5 lpm, and therefore minimises consequential water damage and run-off “Following the trend of the "internet of things" we see the value in having our system communicating with the customer/homeowner/installer to indicate faults or activations.

This is because it both offers the ability to remote monitor the correct operation of the system as well as improve customer awareness and engagement with an equipment which may one day save their lives.”

Winning the Innovator of the Year was a very important third party validation for Plumis, adds William. “It’s an important sign that we are in the right direction. By definition, an invention is only an innovation when it has been proven in the market and this award is a very nice "formalisation" of this market validation.”

www.plumis.co.uk Tel: 020 7871 3899

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AUTOMATION PPMA

e h t

e c i o v

OF PROCESSING & PACKAGING SUPPLIERS

The PPMA’s mission is to provide a range of quality, cost effective services and publications to help members develop their businesses

T

he PPMA is the UK's trade association for suppliers of processing and packaging machinery to the UK market and represents over 400 member and associate companies. Its principle objective is to promote sales of machinery, both at home and abroad, through various projects and services of mutual benefit to both members and their

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customers by providing free technical and machinery information and advice.

Started in 1987 with just eight founder companies, the association grew rapidly over the following two years, and in 1989 enjoyed a substantial increase in numbers when it merged with the UK manufacturers association, PEMA. The years that followed saw further growth in membership and expansion in the number and type

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of services offered to members.

Currently the PPMA has over 365 member and associate companies who are responsible for the majority of machines sold in the UK each year.

The PPMA’s mission is to provide a range of quality, cost effective services and publications to help members develop their business. It also aims to provide a single voice for the machinery sector on relevant issues, while promoting standards of technical

service, training and know-how, making membership a mark of quality and service. It is also committed to providing channels of contact between members, members and customers, members and government and other organisations, and endeavours to provide cost effective access to professional and focused exhibitions.

The PPMA is a members' owned organisation and each member owns the same amount of

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AUTOMATION PPMA

“The PPMA is a members' owned organisation and each member owns the same amount of shares in the organisation”

shares in the organisation irrespective of their size or annual expenditure with the association.

Each member company can put forward an employee to be a director of the PPMA. The Board of Directors meets approximately every quarter to work with the executive to develop products and services that benefit the members. Each PPMA director has a functional role for which they are responsible. PPMA directors are not paid and give their time

voluntarily in the service of the association.

The current chairman is Richard Little. He became a director in 2007 and is a long standing director of Jenton International, a manufacturer and distributor of equipment to the packaging, printing and converting industry.

He is supported by vice chairman Grant Jamieson. Grant became a board member in November 2010 and is managing

director of Winkworth Group, a UK manufacturer and worldwide exporter of mixing equipment across all industry sectors.

Recently, the PPMA held its annual industry awards ceremony at the National Motorcycle Museum in Birmingham. The who’s who of the processing and packaging industry descended on the venue for the event hosted by Rory Bremner.

Companies demonstrating innovation, strength and success

were declared the best in their field across 14 closely fought categories by an independent panel of industry leading judges.

The top award went to Loma Systems which was named Processing & Packaging Manufacturer of the Year. The company was praised by the judges as “a great example of how the drive for excellence in the individual elements of any operation leads to a sound and successful business.”

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AUTOMATION COLIN MEAR ENGINEERING

flexibility and a high customer focus is the key to CME’s success.

CREATIVE

PACKAGING 4 Packaging any product can be a challenge, but not many come close to cigarettes. Constant changes in product requirement mean flexibility and a high customer focus is the key to CME’s success. It is this customer focus that has also pushed CME into the pharmaceutical and food sectors.

The company began 32 years ago, manufacturing spare parts for cigarette making and packing machines. It quickly moved onto rebuilding machines, and then manufacturing its own bespoke packaging machines.

“Customers come to us when they have a new product or one where they’re currently hand packing or using old equipment,” explains Engineering Director Paul Simmons. “Often it’s a completely new product they need to manufacture but firstly we’ll look to see if it’s possible to use existing equipment. If so, we’ll modify that, but sometimes the product is so different from anything which is currently on the market we need to design machinery that is completely new.”

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AUTOMATION COLIN MEAR ENGINEERING Most customers are cigarette producers although the nature of CME’s business means its machines are suitable for other products.

Consequently, it has now extended into the pharmaceutical and food sectors, successfully meeting the challenges of the different regulations and processes presented there. Recent projects, recalls Paul, have been varied: “There’s the Ploom pods, which are small Nespresso style capsules that are inserted into a heating device, which releases a tobacco vapour for the user to inhale. Each pod contains a small amount of tobacco. As well as tobacco related products we have also branched out into pharmaceutical products, for example nicotine delivery systems. This has given us the added challenge of validating our machines to the required pharmaceutical standards. There is also another smokeless tobacco product called Snus. It’s used in Sweden a lot and traditionally is packaged in cans, however this is another market where they want a different pack style completely. There wasn’t anything on the market to do that. Currently packing is by hand, which is quite expensive, so they’ve asked for a machine to do it.”

Around 95% of our products are for export, so we have a global network of agents who are

contracted to CME to provide product support and services. An in-house team in the UK handles all design and, depending on the workload, between 50% and 75% of manufacturing is inhouse. “We don’t manufacture everything in house,” remarks Paul. “The key purpose of the manufacturing facility is so we can provide a quick turnaround if we need to supply a spare part for a machine that is not working. Also, for development work, it’s not until we get the product on the machine that we can see how it behaves. So sometimes we need to modify things slightly and we can turn that around quickly in house rather than having to wait for someone else.”

Partner companies provide certain system components, such as transport, product feeding and ancillary systems, which saves on the design and manufacturing of elements that already exist. Support on many projects has been available through companies such as Baumer HHS (which provides gluing systems), and other companies for systems such as vision systems for verification and product quality checks. A recent tie-up with ThePackHub consultancy has led to the formation of CME Innovation for the design of creative packaging.

Those arrangements enable CME to provide

a complete service from design through manufacturing, installation, commissioning and training to ongoing support. They also, as Paul confirms, help it to build environmental and energy saving features into its machines: “One of the main things we get involved in is reducing compressed air consumption. We also fit servos instead of conventional motors, which can save energy. When they’re braked, you can get some power back and there’s a saving of energy when they’re accelerating/decelerating during the cycle.”

It’s something, he adds, that fits in well with the way the company operates and will continue to do so in the future: “The company really enjoys difficult technical challenges, especially for things that haven’t been done before. This is achieved by our total engagement with the customer, from the initial concept right through to production which is ably assisted by our project managers.

“The company’s infrastructure and size is well suited to accommodate multiple projects and customers, and our track record proves this.”

www.cme-ltd.com Telephone: 01460 269500

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AUTOMATION KARMELLE

A COMPLETE SOLUTION With over 30 years of experience Karmelle is a UK-based company specialising in the design, manufacture and installation of liquid packaging equipment.

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When Peter Krawczuk and Brian Dickinson took over filling machine manufacturer Karmelle in 2002, they aimed to offer something different.

Combining their technical and creative skills, they added to the product range to deliver a unique turnkey service — British made liquid filling, capping and labelling lines backed by full servicing and spares.

“We design, manufacture, install, and commission filling, capping and labelling machines,” explains Peter. “We also provide training and offer maintenance contracts tailored to suit customer requirements.

Manufacturing in the UK allows for quick response times for breakdowns and spares requirements as we know customer downtime can be costly.”

To extend the product range further and offer a more complete service, there’s been a recent tie-up

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with a Spanish manufacturer of robotic equipment for depalletising and palletising equipment, enabling a full automation with use of robots at the start and end of Karmelle’s packaging lines. This enables Karmelle to deliver turnkey projects.

Peter says: “We can supply a complete solution: we manufacture the majority of machines in house without relying on third parties apart from odd components and we team up with quality suppliers for complementary machinery. On the whole, we source everything and customers like that because it avoids them going separately to filling, capping and labelling companies; they come to us for the whole package including project management.”

The products are used by a cross section of industries including food and drink, chemical and pharmaceutical, ranging from start-ups to multi national manufacturers. Karmelle, as Peter outlines, is involved at the infancy stage of projects: “We work closely with the customer and the level of our input depends on the

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AUTOMATION KARMELLE stage they are at. Sometimes they’re building a factory but have no idea how to lay it out and we’ll help with the design of the line. Other companies, however, will provide detailed drawings for the production line and we’ll quote on that basis. It’s almost like consultancy and we’ll project manage jobs for companies and see them right through from start to finish, sourcing all the equipment. On the other hand, some customers just want us to deal with the filling line and they handle all the rest of it, so we’re flexible in what we do.”

That flexibility led to one customer requesting the development of a monoblock filler, capper and labeller capable of handling a large number of bottles in a limited space. The outcome was a machine with a footprint of only two square metres that was designed to fill 30 millilitre miniature whisky bottles at twenty per minute, although adjustable to different volumes and speeds, therefore suitable for various industries.

Karmelle was also chosen by biocidal raw materials and disinfectant manufacturer QuatChem to design, manufacture and install a filling, capping and labelling line. This comprises a fully automatic in-line four head volumetric filling machine, an EK40 in-line pick and place screw/push on capper and a servo-driven label applicator.

The product range has recently been extended with the addition of a new capper, the Karmelle 4CT that can tighten screw caps on virtually any shape of glass, plastic or metal container. An adjustable speed control means it can precisely match conveyor speeds up to fif-

teen per minute.

Many of Karmelle’s machines are exhibited at the PPMA show, Karmelle having been a member of the PPMA for ten years, which helps promote its products. “We’re pushing the fact they’re made in Great Britain because we’re proud of what we do and we’re trying to fly the flag for the UK,” remarks Peter.

A remarkable year of growth in 2014 included many new projects and the recruitment of

specialist staff to cope with the demand. Peter says: “We are prepared to wait for the right people, even if they haven’t worked in this industry before. If they have the core knowledge and have potential, we work with them to further develop their skills which, at the end of day, benefits the company.”

The plan for the future is to expand into overseas markets and generally grow further.

The process is already underway and, according to Peter, there’s a clear strategy behind it: “With the rapid growth, Karmelle has moved into purpose built premises with state of the art equipment to complement the new look. Over the years, we have focused on what we’re good at and just kept improving the product range to keep up with our customer demands. With the added infrastructure, we are now in a better position to accommodate bigger projects than ever before.” www.karmelle.com Telephone: 01484 533356

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FOOD & DRINK DEERSBROOK FARM

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FOOD & DRINK DEERSBROOK FARM

DEDICATED TO QUALITY family run deersbrook farm produce the highest quality british meat and put a keen emphasis on the importance of animal welfare

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Producing fantastic, authentic and top-grade British beef and rare breed pork, Deersbrook Farm is a rising star in the provision of only the highest quality and deeply cared for meats to an ever-expanding portfolio of customers and clients. Showing dedication not only in providing high quality but also in ensuring the welfare of all animals cared for, Deersbrook serves as an example of exactly how similar farms could, should and hopefully will operate onto and into the future.

As a family-run farm, Deersbrook has seen great change from generation to generation.

Originally founded with a dedicated milking herd which served as the foundations for later success, the company since developed into primarily caring for a beef herd as a result for the demand for high quality meats within the food sector. Yet again, however with the coming of the current generation the focus of the company has shifted to provide the same high quality

meats, but direct to the public and customerfacing venues such as restaurants, farmer’s markets and local shops where going that extra mile is both required and most appreciated.

Explaining how the new focus for the business will affect the already-established trade with current clients, Anna Blumfield, Director of Deersbrook Farm says: “We'll always have that element to the business – it'll be a business of two halves which will compliment each other.

Growing up on the farm we've always had our own produce back, if you then go and buy some eleswhere you'll quickly notice the difference.

Because my parents have always had their own meat, they thought it was normal, they didn't realise that it's actually much better in taste, texture and nutritionally too. It's really about giving local people the opportunity to enjoy great beef and pork in the way we do. We achieve this by selling meat boxes locally and nationally through our website and farmer’s markets ” With over 700 head of cattle on the farm,

Deersbrook has greatly diversified its stock over the years to cater to the more demanding nature of the consumer market, whilst still serving supermarkets and similar corporate establishments. As such, while the company has grown significantly in recent times, much of the growth lies in diversification and offering a more comprehensive and targeted portfolio of meats than in the simple expansion of operations.

Anna explains how Deersbrook has diversified in further detail: “For the direct to public sales we're focusing on the native breeds of cattle – last year we brought a new bull which is a pedigree Native Sussex, this is the new breed we're really concentrating on now. It's very challenging balancing the two sides of the business – in starting the new leg of the business there are always going to be challenges and it's about finding out what actually works. So far it's working out very well. ” Cattle raised by Deersbrook are reared on mature grassland which, combined with the

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FOOD AND DRINK DEERSBROOK FARM specialist cattle allows for guaranteed flavour and only the finest, tastiest and highest quality beef. Through raising them in such a natural and carefully monitored environment, Deersbrook is also able to ensure the highest level of care for all cattle, meeting the highest welfare standards as well as being farm assured by the Red Tractor scheme. Through operating in such a responsible manner, Deersbrook cannot be faulted for the high standards for care offered to all cattle and the results have seemingly paid off for the end-customer too, resulting in happy faces all round.

Detailing what it is that truly makes Deersbrook's meat so special in the highly competitive meats market, Anna comments: “Our animals are 100% traceable – the cattle are born and bred on the farm. They're out grazing most of the year, and when they come in for the winter we feed them with food we've grown on the farm so that we know exactly what's going to in them and that they're cared for. We do not use antibiotics routinely. When the time comes for them to go we continue our high standards, we hang the meat for at least 28 days.

Maturing naturally on the bone allowing the flavours to develop, producing truly succulent beef. We end up with a fantastic, highly nutritious product at the end of the day. The flavour really comes through with the tenderness of the meat.”

The future looks very bright for Deersbrook, with the new business angle starting to take off and Anna bringing a number of new ideas to the table. Anna explains: “We want to carry on and grow the new side to the business. We've started to supply local restaurants which is going very well, as well as doing the farmers market. We're increasing the sales with those which we're already supplying and we've even started a scheme where you can grow your own pork or steak.

As soon as the calf or piglets are born you can actually sponsor them, see how and what they've eaten, how they've grown and at the end of the day choose how to butcher them, then you get this high quality meat home into your freezer.

“We, as a family feel that farming is a real privilege and that we are responsible for the management of the land and the food production. We will always endeavour to do that in the most responsible way, caring for the animals and ensuring the best of products. We always look forward to new partnerships and new ventures as well as being very flexible in what we can supply, so if you need some high quality meats the contact us!”

www.deersbrookfarm.com

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POWER GENERATION AMPS

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POWER GENERATION AMPS

POWERING INDUSTRY

The Association of Manufacturers and Suppliers of Power Generating Systems (AMPS), is the trade association and industry voice for the UK’s world-leading diesel and gas-engine power generating sector

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MPS members vary in scale from global FTSE 100-listed companies to sole-trader manufacturers, but what all have in common is a commitment to the generating set industry and an understanding that raising and best-practice ensuring standards, safeguarding the future of the sector is best realised through a professional trade body promoting a culture of co-operation and teamwork.

AMPS was formed above a pub in 1986 and has been providing technical guidance, lobbying support, networking opportunities and bestpractice assistance for members, the industry and all those who need input - including National Grid, DECC and Europgen - ever since.

AMPS represents a number of sectors within the industry including suppliers and distributors, service providers and rental companies. One of its key sectors, however, is manufacturing. The UK has lost a lot of its manufacturing over recent decades but when it comes to buying the best generating sets and components customers around the world still value the unrivalled quality, reliability and attention to detail that comes from knowing their equipment was manufactured in the UK by passionate and experienced engineers.

Elsewhere, AMPS’ power generation suppliers provide the components the manufacturers need and/or the assembled sets the end-user requires, along with an invaluable wealth of expertise and industry know-how.

The AMPS also has a large number of members who provide advice, consultancy, installation and maintenance, because even the best generating set in the world will fail if it isn’t properly specified and serviced.

The organisation also represents a number of rental companies. Not everyone needs generating set power all of the time. From World Cup finals to music festivals, from building sites to hurricane relief, the rental providers are there to supply customers with whatever temporary power solution they may need.

Indeed, the membership goes even further.

Whether the need is for a solution for cleaning stored fuel, a fire suppression system or a generating set to work as part of a CHP system, AMPS members specialise in all these related products and services.

Joining AMPS means a company becomes part of an organisation containing some of the UK’s most successful exporters of diesel and gas-engine driven electrical systems in the world. Indeed, the AMPS Director General is the chair of EUROPGEN - the European Generating Set Association; and AMPS are associate members of EGSA - the Electrical Generating Systems Association of America; and BEAMA – the British Electrotechnical and Allied Manufacturers Association.

Members will have unlimited opportunity to network with over 80 respected companies at a range of events throughout the year including at the Annual Conference and Awards Dinner.

Furthermore, its monthly bulletins and quarterly magazines provide a unique opportunity to build partnerships with like minded businesses, while AMPS’ technical meetings provide input to Standards and Regulation bodies and the latest information on EC Directives, BSI, ISO, and IEC regulations. www.amps.org.uk Tel: 01787 221025

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POWER GENERATION AVK

ALWAYS ON POWER Design, planning, implementation, and on-going maintenance of critical power systems

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For some people, power outages can literally be a case of life or death. This is where AVK steps in. The UK's leading provider of critical power systems and maintenance, AVK provides reliable, high quality products, and are available 24/7, 365 days a year. The company specialises in all aspects of critical power systems, including the design, planning, implementation, and on-going maintenance crucial for a smooth and hassle-free operation.

“The world has, and continues to change: the way in which we work and live now means we require 'always on' power,” said a

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spokesperson from the company. “Continuous power is essential to most operations, whether it be a factory, financial institution, data centre or hospitals – revenue and lives are at risk.”

AVK isn’t exaggerating – if a hospital loses power for even a moment, for example, the results can be disastrous.

Founded in 1989, AVK has established a strong reputation for unbeatable quality over its 25 years of operation, working with 85 reputable companies like O2, RBS, and the NHS, on over 120 projects including the installation of a huge 5000KV of power.

Its Uninterrupted Power Supply (UPS) systems provide the

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“Continuous power is essential to most operations, whether it be a factory, financial institution, data centre or hospitals – revenue and lives are at risk.” first line of defence against loss of power, reacting instantly to outages and providing a much-needed bridge over the gap in power left by the short but critical few seconds of start up time of a backup generator. AVK UPS systems are designed to run for years, providing constant low-maintenance protection at the lowest operating cost in the industry, while it provides regular preventative, essential engineer services and maintenance visits in order to identify faults or problems before they can become an issue.

“For mission-critical systems and facilities where 100% power is vital for 100% of the time, a backup generator power system is essential to the continuous power delivery during times of mains power failure or outages,” explained an AVK spokesperson. “Where a UPS system will protect power to your critical system for a short period dependant on battery autonomy, a standby generator will, when longer outages occur, protect your equipment for much longer periods of time from hours to days or even weeks dependent on fuel storage.”

AVK is at the forefront of innovation in its field, becoming Europe's leading manufacturer of specialist G59/2 technology products for grid panelling applications in recent years. It is also currently in the process of launching the world's most advanced touch-screen generator controller, debuting at the Data Center World convention in London this year.

“We take pride in each and every critical generator power system and turnkey project solution we deliver – from Data Centres, Banking & Finance and Telecommunications providers, to Hospitals, Airports and Public Transport – anywhere where constant power is required to maintain normal business operations without risk to data, machinery, financial loss or even lives, AVK generator solutions keep the lights on for business.”

www.avk-seg.co.uk Tel: 01604 601188

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AUTOMOTIVE: SMMT INDUSTRY FORUM

BUSINESS IMPROVEMENT SOLUTIONS Dr Chris Owen, Chief Executive Officer, SMMT Industry Forum explains how to analyse and transform your manufacturing and supply chain operations.

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very business has its own way of operating, organically developing its strengths based on its workforce, processes, management and market place over a period of time to create opportunities for improved efficiency, productivity and profitability.

Because every organisation is different, there is no one-size-fits all approach to business improvement. A strategy that works for one organisation simply won’t work for another.

Since 1996, SMMT Industry Forum has worked across an array of sectors, including automotive, aerospace, electrical, food and 34

drink, and industrial manufacturing. Our clients include Boeing, Carlsberg, Phillips and Toyota. Such variety means that we are adept at tailoring our services to each client.

SMMT Industry Forum ensures that your business gets the help it needs to gain a competitive advantage. Our engineers will engage your business at every level to deliver sustainable results in four practical ways.

Firstly, they will diagnose the issues and opportunities your organisation should address. Then, we will deliver prioritised, rapid response actions to get production on track. Following this, the engineers will work to build capacity or efficiency through precision intervention and

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“SMMT Industry Forum ensures that your business gets the help it needs to gain a competitive advantage” monitoring. Finally, we will introduce step change initiatives to grow processes, people or capacity.

These initiatives can come in a number of forms, including Lean

Manufacturing processes and Total Production Maintenance, while every step is backed up by expert training packages.

Nowadays, most UK manufacturers are aware of the

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concept of Lean Manufacturing, even if they are not properly practising it. SMMT Industry Forum was among the first organisations to bring Lean processes from Japan nearly 20 years ago. Today, our Lean Manufacturing course is among one of the most visited in the world.

SMMT Industry Forum is the only UK practitioner for Total Productive Maintenance (TPM) in the UK to be accredited by the Japanese Institute of Plant

Maintenance (JIPM), which is the holder of the world-renowned TPM Excellence awards. Originally practised in Japan, TPM makes production more economical by increasing efficiency and eliminating accidents, quality defects and breakdowns. Typically, our clients can cut production costs by around 30% by properly implementing TPM. To ensure that these principles are properly adhered to, SMMT Industry Forum offers a range of implementation and training

support. Each year, we also run the Japan Best Practice Programme, in which delegates travel to Japan with our Lean Manufacturing and TPM specialists, to see how the principles are put into action.

This year’s programme runs in November, and those interested in attending should visit our website for further information on the programme content and to see the benefits that participating in the programme can bring to businesses.

All of SMMT Industry Forum’s trainers are expert practitioners with hands-on experience in their field. Our range of training packages improve skills in all areas of your business to make sure it works more effectively, assessing its work processes, efficiencies and analysis. SMMT Industry Forum also offers ISO/TS16949 accreditation training.

For more information: www.industryforum.co.uk.

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AUTOMOTIVE JOHNSON MATTHEY

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Although Johnson Matthey Battery Systems operates in an industry in its infancy, it’s part of a group with over 200 years of history, credibility and financial resources. The original company started as a battery business in 1999 and is now part of Johnson Matthey’s Battery Technologies group.

Part of the company is based in Poland, manufacturing batteries for e-bikes and power tools, while the UK operation has a different focus. “We are mainly developing automotive and high voltage battery systems,” states Business Development and Marketing Manager George Paterson. “We mostly look at bespoke applications for general energy storage projects and across a range of automotive

systems, which could be heavy duty truck and bus, performance cars, delivery vans and a variety of systems architectures including EV (electric vehicle), PHEV (plug-in hybrid vehicle) and HEV (hybrid electric vehicle).”

Customers, typically car manufacturers or tier one component suppliers, often have a specification for a new product for which Johnson Matthey develops a battery based on the best available cell technology. George says: “We’re very strong on electrochemistry so, although we don’t manufacture cells, we have a team that extensively tests and evaluates them.

We deliver solutions without being constrained by one particular type of electrochemistry; we

can offer a wide selection.

“Usually we come up with various solutions that are differentiated on performance and price — a high-end solution that lasts a longer time and delivers extra performance or a lower cost solution compromising performance but maximising short term cost-effectiveness. This is purely dependant on the application and customer expectation. We can start this process from a clean sheet or in some cases we might have a detailed specification supplied from the customer.”

The focus is on very demanding applications in terms of power requirements, performance, thermal and battery management systems. That tends not to translate into mass volume production but currently suits their

BESPOKE SOLUTIONS

Johnson Matthey Battery Systems is a leading independent provider of battery design, development and supply

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“car manufacturers or tier one component suppliers, often have a specification for a new product for which Johnson Matthey develops a battery based on the best available cell technology” business model. This is influenced to some degree by the infrastructure availability and legislation increasingly concentrated on environmental matters which means flexibility is key at this point in the industry.

“We’re driven frequently by cost because everybody wants cheaper cars and hence cheaper batteries,” explains George. “They want batteries with longer range, smaller and more lightweight, so we employ techniques from other industries. We have batteries using F1 grade, carbon fibre materials and we’re using composite metal bus bars to reduce weight as well as other process. The cell materials are constantly evolving which will lead to long range and cheaper batteries. Reuse or recycling of batteries will be a big issue in the future if not considered during the design phase now. We have to make batteries that can be easily disassembled, marking materials in them and understanding their history through the battery management system so we know if they’ve been stressed or damaged. If all is good we may be able to use the battery in a second life application.”

Coping with the changing landscape is helped by a close relationship with suppliers that results in technology exchanges.

The company has also benefitted from its membership of the SMMT. The company has been actively involved in its electric vehicles group and has received help on establishing its automotive supply chain that is innovating new technologies.

That, as George says, will help the next stage of development: “We have a long-term strategy to work on high performance automotive projects and others such as marine, a big target for reducing emissions. Battery technology can lend itself to different applications and the only limiting factor is the number of resources available. At the moment, we’re focused on automotive because Johnson Matthey has a proven track record there.”

www.jmbatterysystems.com Telephone: 01382 618000

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CIVIL ENGINEERING STEEL CONSTRUCTION INSTITUTE

TRUSTED EXPERTISE sci are the leading, independent provider of technical expertise and disseminator of best practice to the steel construction sector.

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As the leading independent provider of technical advice and disseminator of best practice within the steel construction sector, the Steel Construction Institute (SCI) serves as the most knowledgeable and experienced independent organisation in support of the steel construction sector and those operating within it.

Formed in 1985 to assist with growing the market for steel in construction, the SCI initially served as an independent, objective and unbiased body to promote the efficient and effective use of steel in construction. Since then, the institute has been able to create a great foundation for the support of the steel construction industry through support and financing from an ever-increasing number of clients and members

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– initially having been almost entirely funded by a sole client, this has allowed the institute to diversify and solidify its position in the market through not being wholly dependent on the success of a sole funder. Of note is that while the SCI has a long established membership base, less than 20% of the institute’s income is actually sourced from the membership and the remaining 80% comes from clients who depend on the services of the SCI to carry out specific project work. This essentially serves to represent the fact that while the SCI, at its core operates in a way which is for the good of the sector, it also acts as an independent organisation which serves the commercial needs of industrywide clients.

Historically, the significance of the SCI's

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involvement and support for the steel construction sector cannot be ignored, for example having housed a number of internationally recognised composite construction expects who contributed to the boom of composite construction in the 1980s for the London commercial buildings market. Graham Couchman, Chief Executive of the SCI explains: “If you look at the proportion of the construction sector utilising steel and how it has grown since the 1980s then it's very significant – it must be around 65-70% of the multi-storey market now, which is much higher than it was. I'd like to feel that we did a lot to help convince designers that steel is a viable option.” In addition, the SCI runs the Light Steel Forum, having been involved in the development of light steel framing since its

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inception in the UK, providing how-to guides for steel framing as a valid alternative to timber framing.

Through both membership services and direct services for clients, the SCI is able to offer a wide range of technical advice to industry professionals, ranging from highly challenging design issues all the way through to how-to guides and basic advice. “One way to look at SCI Membership is that it is our way of packaging our consultancy services in a way that is appropriate for the design community. If a designer has a problem, then instead of paying for a specific bit of project work then they can contact us for some immediate technical advice. The service that our members most appreciate is our advisory desk, which they can phone in or

email and get technical advice, very much like the AA – worth every penny when you need it!

Technical information is alternatively offered on our Steelbiz technical information site, and through our internationally respected publications,” explains Graham.

Looking to support the modern-day industry professional, the SCI has also been working closely with members and clients on how best to adapt to Eurocodes, specifically covering areas of design where the codes greatly differ from the previous national standards. “The Eurocodes are becoming more and more requested by clients, and indeed are demanded for public sector work, so one way or another designers are having to come to terms with the Eurocodes. We've produced a number of design

guides, courses, and webinars to help designers, including in the key areas of portal frame design and composite construction. We have also produced Eurocode compliant load span tables for a number of product manufacturers,” adds Graham.

With a broad range of expertise which can be used to address an even broader range of issues, for technical advice and support there's no organisation better placed to assist than SCI: “We're in a unique position where we know the problems which designers are facing, and can bring high levels of specialist expertise to help find solutions,” adds Graham.

www.steel-sci.com

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ABOVE THE REST

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sidering the UK steel industry, the majority of the output is generally the production of the more conventional beam and column work; however when projects are a bit more complex and demanding in nature, that's where S H Structures comes into its own.

Tim Burton, Sales & Marketing Manager for S H Structures explains: “While we are a steel fabricator, we don't really do what you might consider to be the 'traditional' steel projects. A typical S H Structures type project would generally have a more complex geometry which means we have to produce them in bespoke jigs to control the critical dimensional tolerances of large assemblies such as footbridges. It's also quite unusual for the steelwork we provide not to be visible in a project as, with the bulk of our work not

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Whilst it is in our very human nature to rise to the challenges with which we are faced, it is rare to see an organisation which not only rises to these challenges, but thrives on the opportunity to work on such technically demanding and increasingly complex projects as with S H Structures. Working with some of the UK's foremost architects and consultants, S H Structures is a company whose reputation for excellence in intricate steel fabrication and structural engineering projects is nothing short of awe-inspiring and as such a credit to the industry.

Having already built up a wealth of experience in the steel industry as a chartered structural engineer, Managing Director Simon Holden established S H Structures in 1992 with the aim to utilise this technical expertise and target many of the more demanding engineering projects. When con-

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“it is rare to see an organisation which not only rises to these challenges, but thrives on the opportunity”

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“S H Structures has won numerous awards, with individual awards rolling in almost year upon year to serve as testament to the company's reputation”

only acting structurally but also playing a major part of the overall aesthetics of a scheme.

Rising to the challenges of the market, S H Structures may indeed be a company which has found a niche, specialised sector of the market in which it can prosper on a commercial basis, however to the S H Structures team, work and pleasure could be seen as one and the same.

“While this is what we set out to do, we very much enjoy it and we're very lucky to work on such unusual, high profile projects with a lot of the UK's major consultants,” explains Tim. While S H Structures does indeed take its work incredibly seriously, it is equally inspiring to perceive a company which not only excels at what it does, but enjoys it so much that the S H Structures team are motivated to complete a job by the challenges of the job itself.

One such challenge which the company rose to over the course of 2014 was the addition of moving footbridges to the company's portfolio, as T i m

explains: “While we've always historically undertaken footbridge projects, last year was the first time in which we'd done any moving footbridge and we completed two, one with consultant Flint and Neil which was the Greenwich reach swing bridge in Depford which was with Moxon Architects and we also did a very unusual lifting bridge in Merchant Square with Knight Architects and AKT II – when the bridge lifts up, it actually lifts up in five separate pieces much like a fan and is therefore very much an architectural statement as well as a footbridge.”

Over the course of the last 10 years S H Structures has won numerous awards, with individual awards rolling in almost year upon year to serve as testament to the company's reputation. In addition, the company has earned great renown for offering a service which goes beyond all expectations and essentially “beyond the call of duty”, often providing ground-breaking alternatives to structural solutions which provide the client with improved structural performance, cost reductions, or both.

For example, Tim details further as to works undertaken for the regeneration of Helix Park where the company's technical expertise afforded new design concepts for the benefit of the client: “2014 saw the opening of the Kelpies project which form a central part of the 360 hectare Helix Park regeneration scheme outside of Falkirk. The Kelpies take the form of two 30 metre high horses heads standing majestically beside the newly extended Forth and Clyde Canal. It has been a very successful job for us – albeit very challenging. We were involved from as early as 2008 and finally went on to price the tender design, however we always felt with that project that there was an alternative way of creating the internal structure and we were able to offer a value engineering solution which effectively

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“S H Structures is dedicated to using only the most reputable and specialist suppliers.”

saved the client over £750,000.”

Remarking on the versatility and adaptability of the company, Tim also details: “While fundamentally, S H Structures is a steel fabricator, the nature in which the company's structures have had to to interface with other materials over the years has resulted in more and more clients coming to us and asking us for the supply of these other materials. So, if we're doing a footbridge for example, then we will not only provide the steel structure, but also the timber decking, lighting, glazing and balustrades effectively providing our clients with a 'one-stop shop'.“ Understanding that a company's own serv-

ice potential is reliant upon the performance of its suppliers and specialist partners, S H Structures is dedicated to using only the most reputable and specialist suppliers. Ensuring that all new suppliers are sufficiently qualified and performing well in areas of corporate responsibility, the company then looks to build up working relations with such companies to provide an ever-improving, reliable and fluid service from supply chain to project. “We've got a very good relationship with our supply chain and we've developed relationships with other specialists which allows us to tackle the more unusual projects and offer more to the client. This has, for example allowed us to

undertake a number of projects where there is a large steel, structural component but also a large timber one,” adds Tim. This flexibility is integral to how S H Structures operates, as Tim explains that every job the company walks into is one which it must do so with open eyes as it can never be predicted what will come in through the door.: “We get phone calls for all sorts of unusual structures and its something which we thrive on. It's a privilege to work on things such as this.” This approach has also, understandably earned much acclaim amongst the company's clients due to S H Structures effectively being able to rise to almost any challenge, in almost

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CIVIL ENGINEERING S H STRUCTURES any structural application and present a solution which is second to none in all respects. “Our versatility and our ability to effectively tackle anything which is put in front of us is what really sets us apart. We're also always working very closely with consultants and we're regularly looking at schemes where they're looking for early advice on budget and installation. At the end of the day, all of the jobs which we win are in competitive tender, however by being proactive, supporting and assisting consultants really makes a big difference.”

Further to the importance of supply chain partners, S H Structures also recognises the importance of having such a skilled team at its disposal. The construction industry in particular is one which has historically been losing favour amongst youths looking at their career options and this has become an increasing problem for organisations looking to take on increased workloads in the improving economic climate, yet lacking the workforce to support that. Crucial to this is improving the public image of the construction sector, encouraging youths to pursue a career within it and also providing opportunities for them to take advantage of – these are areas in which S H Structures has shown true dedication.

Tim explains further as to the importance of

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“S H structures will continue to offer a professional service whilst delivering innovative structural solutions across a broad -range of challenging projects.” promoting the image of the construction industry and bringing in more and more intelligent, qualified and motivated youths: “We're a great believer in getting new people involved in the construction industry. We've come out of the recession and if the predictions are correct then we're looking to enter something of a boom, yet we are facing skill shortages which needs to be resolved. We support a number of local schools in careers events and I personally work with the CITB as a construction ambassador. We also have a mentoring programme with students of Sheffield and with the International Association of Bridge Structural Engineers and provide advice for recent graduates looking to break into the construction industry.

“Internally we take looking after our staff very seriously. Without the people we employ we wouldn't even exist. We have a number of people who celebrated 20 years of service last year and there is a very positive vibe in the office.

Because we're not turning out the same stuff day in day out, every job is different. We run an apprenticeship scheme with the BCSA and a couple of those guys started work when we were

fabricating the Kelpies. For them to be able to work on something as iconic as that and take people to see the completed project and say 'I worked on that', they love it.”

For health and safety, S H Structures operates with a fully documented system to promote the safety and well-being of all team members.

With a recently appointed full-time health and safety manager, S H Structures displays the importance which is placed on health and safety which is backed up by the company's track record along with its invested interest into digital data capture and communication systems for health and safety purposes.

Looking to the future, S H structures will continue to offer a professional service whilst delivering innovative structural solutions across a broad -range of challenging projects. Building on over twenty years of experience S H Structures aim to be at the forefront of the specialist structural sector. S H Structures is a true pioneer of excellence and a champion in rising to the everincreasing challenges of the sector – for solutions which require that extra edge, S H Structures is there to help.

www.shstructures.com

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CIVIL ENGINEERING TEMPLE MILL TECHNICAL STEELWORK Being a preferred fabricator for Aldi and Lidl generates a steady flow of work for Temple Mill Engineering.

That currently amounts to around six new sites a year for which the firm provides the structural steelwork.

It’s something the company has been doing for fifteen years and it undertakes a variety of work nationwide, covering portal frames, schools, hospitals, fire stations and other projects in addition to the retail stores. Most work is for main contractors, featuring well known names such as Balfour Beatty and Bowmer & Kirkland as well as local firms like GF Tomlinson that provide plenty repeat business.

As Contracts Co-ordinator Daniel Tipple emphasises, it’s a complete service: “It varies with the contract but we undertake design and build projects where we’re working from the principal engineer’s drawings. The fabrication and manufacturing is all done in-house and then, depending on where the job is and what other work we have on at the time, we either use our own labour to install or we go to a third party.”

One of the latest and most prestigious projects

has been providing around 300 tonnes of steelwork for the £11.8 million Innovation Centre in Derby. Built in conjunction with main contractor GF Tomlinson, the Innovation Centre is an iconic building with a striking curved design that is intended to boost the region’s reputation as a centre of excellence on transport engineering. The 50,000 square feet facility has high quality metal cladding and is at the heart of Infinity Park Derby.

It is intended to be a catalyst for the development and growth of the business park, a manufacturing focused innovation and technology park.

Other notable contracts include a year long project for North Midlands Construction, just over £1 million worth of steel for a new furnace for Tata Steel at Stockbridge and further stores for Aldi and Lidl, one completed in November 2014 and another due to start in April.

Aside from regularly used third party companies for some installations, everything else is handled through Temple Mill’s own workforce and there’s a big emphasis on training, especially for health and safety needs. “We use a sub-contract health and safety representative and all workshop operatives are up-to-date with welding and

health and safety procedures, etc.,” remarks Daniel. “Some office staff have relevant cards and certificates to do more than just their role, so they can go onto sites for weld inspections and similar.”

Keeping up-to-date is a big priority and extends to always tending to be ahead of main contractors when it comes to technology changes. That applies to the introduction of Building Information Modelling, where the company was involved very early, now generates all steelwork designs in 3D before sending to manufacturing and is introducing the process to all trades. It’s a continuation of a process that’s been ongoing since 2001 when, as Daniel confirms, the company rather re-invented itself to embrace the latest technological changes: “We moved to our current site around that time for expansion.

“We built the premises ourselves and it’s all tailor made for us. We’ve streamlined the workshop, segregated an area off to have in-house painting and there’s a specific loading bay for that now. It’s all been specifically designed and developed and there’s been a lot of money spent on advancing the building itself in terms of filters and things like that for paint fumes. We’ve put in new

TAILOR MADE Being a preferred fabricator for Aldi and Lidl generates a steady flow of work for Temple Mill Engineering

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CIVIL ENGINEERING TEMPLE MILL TECHNICAL STEELWORK walkways and a new access road down the back of the building for forklifts on our site to avoid having to drive on the public road. We’ve opened a second shop on the site as well and the aim of a lot of the changes was to make everything more efficient and effective, create bigger premises and streamline the process.”

That’s enabled a faster turnaround of jobs, helped by the company operating a two shift system.

The introduction of filters to deal with paint fumes was also part of a wider aim to operate in a safe and environmentally friendly manner, with all scrap metal and empty paint tins going for recycling.

The recent recession has caused a customer focus on prices and a general slow down of actual work compared to the company’s potential. That potential is, however, now becoming realised and there is, according to Daniel, scope for much more: “We’re working on the overall turnover of the business, increasing that year by year. There are plans for future expansion on this site although we still have spare capacity. We’ve moved everybody into one car park to free up more loading space, enabling us to store more fabricated steel in our yard before it goes to sites.

A lot of it’s made up front ready and we have some large projects on at the minute.”

Keeping up-to-date is a big priority and extends to always tending to be ahead of main contractors when it comes to technology changes.

www.templemill.co.uk Telephone: 01623 741720

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CIVIL ENGINEERING STEEL CONSTRUCTION CERTIFICATION SCHEME

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CIVIL ENGINEERING STEEL CONSTRUCTION CERTIFICATION SCHEME

ENCOURAGING QUALITY & PRODUCTIVITY

The SCCS was established in the early 1980s to provide a Quality Management Systems certification service for steelwork contracting organisations

There is a case for steel in all construction scenarios. There is a solution for all projects and the different engineering requirements that they bring, such as fire protection, thermal insulation, acoustics, vibration and BREEAM excellence. Whether it is hospitals, housing, schools, offices, mixed use, warehousing, bridges, power generation, there are abundant examples of where steel has been the preferred choice.

The Steel Construction Certification Scheme (SCCS) is a wholly owned subsidiary of the British Constructional Steelwork Association (BCSA). It was established in the early 1980s to provide a Quality Management Systems certification service for steelwork contracting organisations. SCCS has subsequently developed additional certification and monitoring services for the steelwork contractors with integrated or separate environmental and health and safety management systems and factory production control systems.

The directors are committed to the principles of impartiality in carrying out

management system certification activities, management of conflict of interest and ensuring objectivity of the management system certification activities.

Quality management systems operated by the certified contractors' are formally assessed to ensure compliance with the requirements of ISO 9001:2008. Each certificate issued is valid for three years during which period SCCS conducts regular surveillance audits to monitor continued compliance with the certified management system.

Meanwhile, environmental management systems operated by the certified contractors' are formally assessed to ensure compliance with the requirements of ISO 14001:2004, and occupational health and safety management systems operated by the certified contractors' are formally assessed to ensure compliance with the requirements of BS OHSAS 18001:2007.

The BCSA, of which SCCS is a wholly owned subsidiary, is a national organisation for the steel construction industry. Its member companies undertake the design, fabrication and erection of steelwork for all forms of construction in

building and civil engineering. Associate members are those principal companies involved in the direct supply to all or some members of components, materials or products.

Corporate members are clients, professional offices and educational establishments which support the development of national specifications, certification services, fabrication and erection techniques, overall industry efficiency and good practice.

The principal objectives of the association are to promote the use of structural steelwork; to assist specifiers and clients; to ensure that the capabilities and activities of the industry are widely understood and to provide members with professional services in technical, commercial, contractual, quality assurance and health and safety matters. The association's aim is to influence the trading environment in which member companies have to operate in order to improve their profitability.

www.steelconstruction.org Tel: 020 7839 8566

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CIVIL ENGINEERING ADVANCED METALCRAFT

IMPRESSIVE GROWTH FOR METALWORK SPECIALIST Strong relationships with high profile main contractors is a sign of Advanced Metalcraft’s specialist expertise

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CIVIL ENGINEERING ADVANCED METALCRAFT

With expertise across both metalwork and structural steel, Advanced Metalcraft has enjoyed impressive growth over its elevenyear history. Originally established by Kris and Victoria Barnes as KB Welding Services the business has remained true to its family roots by developing long-term relationships with an array of high profile clients. Indeed, the company has developed an enviable reputation for high standards, operational efficiency, and customer service. This has seen it become the preferred supplier to major contractors including ISG, Lovell, Tamdown, Hill Partnership, Foster, Morgan Sindall, Kiers, Persimmon, and St George.

From its roots as an architectural metalwork provider, specialising in staircases and gates, the business has grown to offer a full “one stop shop” approach for prospective developers and main contractors for all metalwork elements and structural steel.

The company has witnessed massive growth in the last couple of years with major projects such as the £1.5m ISG Stoke Quay development contributing to Advanced Metalcraft’s increasing turnover. It also completed a significant project for Tamdown Group on the Norwich NR1 Phase 1, 2 and 3, a new apartment scheme located in the centre of Norwich offering a great location close to shops, amenities and transport links. Here, Advanced Metalcraft provided design, fabrication and installation of structural and architectural steelwork consisting of architectural metalworks, automated gates, balconies, stair cores, linked steel walkways and balustrade.

Andrew Deal, quality assurance manager, says SCCS certification has greatly assisted the business as it looks to continue its growth.

“As a notified body SCCS have provided us and our customers the assurance that Advanced Metalcraft Ltd is fully compliant to both ISO 9001:2008 and CE marking to 1090-1.

“These systems are driving our

improvements throughout our company, pushing continuous improvement in our quality systems into all aspects of our business and driving customer focus.”

Increasingly, customers require proof before tender of a company’s CE marking compliance so it is vitally important that Advanced Metalcraft can satisfy these demands with the assurances required.

Through SCCS Certification, the company is able to do this.

Indeed, it has recently invested in new welding plant and an integrated management system to fully support its CE marking compliance. Advanced Metalcraft also sources its raw materials from suppliers that

are compliant with CE marking while maintaining material traceability that is essential to maintaining the mandatory certification.

As well as its commitment to enduring high standards, marked in 2014 with the company’s ISO 9001:2008 + ISO 1090-1:2009 + A1 2011 to execution class 2, Advanced Metalcraft continues to recognise the importance of its employees, particularly in creating a safe and secure working environment.

“We value our employees and are committed to providing them with a workplace which is safe and secure,” says Andrew. “We aim to create a culture where every employee is treated fairly and with respect. We recognise the value that a diverse workforce can bring and we do not accept any form of discrimination. We believe in creating an inspiring workplace, committing to developing our people, giving them the right skills to help deliver our business strategy.”

The company clearly has every reason to look forward to the future. Kris Barnes continues to head the organisation and is now supported by a dedicated team of professionals that are highly skilled, experienced and able to provide competitive solutions within a demanding market. www.advancedmetalcraft.co.uk Tel: 01603 741839

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THE CODE BREAKER

THE LAST WORD...

Alan Turing is widely considered to be the father of theoretical computer science and artificial intelligence With the Academy Awards having taken place recently, the world of film celebrated the best movies of the last year including the unsung hero of World War II Alan Turing. In the film The Imitation Game, Turing’s life and work during the early 1940s is brought to life by actor Benedict Cumberbatch, who displays this computer genius with a fitting assortment of oddball quirks that characterised the often lonely, underappreciated man at his most innovatively potent.

The reason why he’s an important figure as we “look back” at manufacturing achievement is, in addition to the contribution he made to military 56

intelligence during the Second World War, his creation of what would become the modern computer.

Turing was highly influential in the development of computer science, providing a formalisation of the concepts of "algorithm" and "computation" with the Turing machine, which can be considered a model of a general purpose computer. Thus, Turing is widely considered to be the father of theoretical computer science and artificial intelligence.

Perhaps his most important technological achievement was the one he made in the 1940s mixing computer science with cryptanalysis.

During the Second World War, Turing worked for the Government Code and Cypher School

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(GC&CS) at Bletchley Park, Britain's codebreaking centre. For a time he led Hut 8, the section responsible for German naval cryptanalysis.

It was here that he devised a number of techniques for breaking German ciphers, including improvements to the pre-war Polish bombe method, an electromechanical machine that could find settings for the Enigma machine.

Turing's pivotal role in cracking intercepted coded messages enabled the Allies to defeat the Nazis in many crucial engagements, including the Battle of the Atlantic. It has been estimated that the work at Bletchley Park shortened the war in Europe by as many as two to four years.

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for solutions that require that extra edge S H Structures is there to help.

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