ACE - Issue 33 2023

Altra

The nuclear option for power transmission

ABB

World’s leading robotics programming software expands into the cloud with powerful new functionalities

A

Shining a spotlight on ‘skills’ for the next generation this National Apprenticeship Week

Bauer

Bauer rolls out plug and play motor retrofit project for Aperam Châtelet steel mill

Fanuc

Global robot report highlights UK’s urgent need to increase automation

Midtherm Laser

Midtherm lasers in on growth after £1.2m machine investment

Portescap

Ensuring the lifetime of a DC gearmotor with systematic reliability testing Sulzer

Quick response maintenance service beats OEM support

The nuclear option for power transmission

With the global shift to low carbon sources, nuclear power is very much back on the energy agenda. These complex, high value installations require equipment that attains the utmost quality standards to ensure reliable operation. This equipment often needs innovative power transmission solutions – a specialty of Altra Industrial Motion Corp.

Back on the agenda

As of 2021, 439 nuclear reactors were operational worldwide1, providing around 10% of the world’s electricity2. Until recently it was a sector in slow decline, but the global drive to reduce carbon emissions and ensure a diverse energy mix has spurred a multitude of new nuclear projects utilising the latest reactor technologies.

Furthermore, governments and operators are extending the design life of existing sites in response to increasingly volatile energy markets. Obsolete equipment at these facilities is now being replaced by new. Another factor is decommissioning. Once a plant reaches the end of its useful life, the recovery and storage of radioactive materials is labour intensive over the long-term.

This rejuvenation of the sector means demand for cranes, pumps and drives for nuclear applications is increasing. From construction to operation to decommissioning, nuclear projects require the very best power transmission products.

Pressures on suppliers

Nuclear power generation is one of the most demanding industrial sectors to provide equipment for. Supplier accreditation, rigorous quality control, total traceability and extensive documentation are the minimum standards. Reliability and security of operations are paramount in all areas of the facility, especially in the handling of radioactive materials. Operators and contractors are looking for suppliers who can provide the ultimate in quality, redundancy and custom engineering capability.

The high upfront costs, long lead times, great complexity and tight schedules of nuclear projects put pressure on suppliers too. Consequently, contractors prefer suppliers who can provide turnkey

solutions, local support from experienced personnel and excellent product availability. Failing to deliver equipment on time can delay the schedule and risk the project going over budget, so local responsiveness and capacity is key.

A nuclear family

Leading brands of Altra Industrial Motion Corp. including Ameridrives, Bibby Turboflex, Formsprag Clutch, Nuttall Gear and Stromag are all proven suppliers of innovative power transmission solutions for the nuclear industry. Providing brakes, gearing, couplings, drives, power units and monitoring systems to new power stations, lifetime extension and decommissioning projects worldwide –these brands are experts in demanding nuclear applications. Altra products are utilised in reactor buildings, fuel storage and waste handling cranes, all types of pumps, cooling fans, generators and other rotating equipment. These brands are experienced in working closely with operators, contractors and OEMs to deliver specialised solutions.

For example, Nuttall provides speed increasers for Westinghouse pressurized water reactors, while Stromag installs EDF C3 approved

crane braking systems for use in advanced pressurised water reactor buildings. Formsprag was instrumental in the development of long-life Anti-Rotation Devices (ARDs) for reactor coolant pumps in pressure water reactors, while Ameridrives and Bibby regularly provide high performance couplings for cranes, generator sets and boiler feed pumps.

Familiar with the industry

As established power transmission OEMs,

each brand has the production capacity and stock availability to meet the supply demands of large-scale projects. Furthermore, each has the custom engineering capability to deliver assemblies and components to the required quality and redundancy standard.

This is evidenced by the familiarity of each brand with the requirements of the industry. Experience providing the correct quality documentation, traceability and product testing assures customers that power transmission equipment will perform as reliably in even the most demanding applications.

The nuclear option

The global reach of Altra also ensures that brands offer localised support to nuclear facilities worldwide. This includes new power stations in Europe, lifetime plant extensions in the U.S.A and beyond. Altra’s single-supplier, localised approach helps to simplify procurement and expedite project schedules. Additionally, expert personnel are ready to respond to any on-site requirement.

With Altra’s engineering capability, industry experience and high service level throughout the product lifecycle, new power station, lifetime facility extension and decommissioning projects have comprehensive, turnkey power transmission support. This helps to ensure reliability across all

operations, improving return on investment (ROI) for these high value undertakings that represent the pinnacle of engineering.

www.altramotion.com

ABB RobotStudio® takes to the Cloud enabling real-time collaboration

World’s leading robotics programming software expands into the cloud with powerful new functionalities

ABB has enhanced its industryleading RobotStudio® robot programming and simulation software with cloud-enabled functionality. The new RobotStudio Cloud enables individuals and teams to collaborate in real-time on robot cell designs from anywhere in the world, on any device. New features such as automatic version control increase transparency and productivity across teams. The software’s simplified interfaces and intuitive navigation allow users of all skill levels to work on robotic projects.

“At ABB Robotics, we continue to develop innovative and flexible solutions to help businesses overcome challenges, respond to changing customer needs and thrive in an age of increasing digitalization,” said Marc Segura, President of ABB Robotics division.

“New web-based tools like RobotStudio Cloud bring a new level of agility and flexibility to manufacturers in how they plan and design their robotic automation solutions. Offering a simplified user experience, RobotStudio Cloud helps to increase collaboration and reduce complexity, enabling both novices and experts to push the boundaries of robotics programming.”

Already the world’s leading robotic programming software, the new and enhanced cloud based RobotStudio software can help companies program robots more collaboratively while cutting the time, cost and disruption associated with physical testing and commissioning. Now system integrators and engineering teams can collaborate in real-time to design, develop and enhance robotic automation solutions.

New features in RobotStudio Cloud include version control, which allows users to keep track of changes and have full transparency of any amendments. With complete knowledge of who edited the program and when, developers can

cut the time needed to resolve errors and performance issues.

Incorporating RobotStudio’s cloud-based virtual controllers, developers have a rapid and powerful robot simulation tool to tune and test programs. By producing an exact digital twin, the virtual controllers give developers complete confidence that – once installed in the real world – the robot will move as precisely as in the simulation. This allows for the fine-tuning and optimization that can help minimize waste or problems when production begins.

The software’s simplified interface makes it easier than ever to produce and change programs, enabling users with little engineering expertise to program robot applications rapidly and with minimum effort. Meanwhile, enterprise-grade protection ensures high security and productivity.

RobotStudio Cloud is the latest chapter in the ongoing development of ABB’s RobotStudio software, which already offers over 500 integrated productivity-enhancing functions. Automatic path planning, for example, can reduce the time needed to program robots by 80 percent. In addition, AR (augmented reality) and VR-enabled (virtual reality) options allow users to optimize the design of their robotic installations by enabling them to visualize and interact with them in a virtual 3D

environment. RobotStudio® Suite including the RobotStudio Cloud are available in the Premium license package.

The company’s solutions connect engineering know-how and software to optimize how things are manufactured, moved, powered and operated. Building on more than 130 years of excellence, ABB’s ~105,000 employees are committed to driving innovations that accelerate industrial transformation.

ABB Robotics & Discrete Automation as one of the world’s leading robotics and machine automation suppliers, is the only company with a comprehensive and integrated portfolio covering robots, Autonomous Mobile Robots and machine automation solutions, designed and orchestrated by our value-creating software. We help companies of all sizes and sectors - from automotive to electronics and logistics – become more resilient, flexible and efficient. ABB Robotics & Discrete Automation supports customers in the transition towards the connected and collaborative factory of the future. The business area employs approximately 11,000 people at over 100 locations in approximately 53 countries. go.abb/ robotics

https://global.abb/group/en

FOAMplus® perfect protective packaging solution from Storopack

As a leading global protective packaging supplier Storopack recognizes the importance of ensuring goods are protected during transit and arrive in perfect condition.

Damaged goods not only incur costs for replacement orders but also affect businesses’ reputations. So while costs need to be kept to a minimum it is vital to choose the correct protective packaging type.

Usually a void fill packaging medium will suffice. However when the product is more sensitive to shock and vibration, such as engineering, electronics, aeronautical, and many other expensive products then more consideration has to be given to using the right type of in-the-box protective packaging.

Storopack’s FOAMplus® range is a perfect solution for companies that manufacture or ship products that require this highest degree of protection eliminating transit and handling damage.

The success of FOAMplus® polyurethane foam is based upon its huge versatility as a packaging medium. The foam can either be dispensed directly into the carton where the expanding foam will mould itself to the contours of the product shape or can be made into pre-moulded cushions to enhance presentation. The product will satisfy the most rigorous cushioning demands for high value, fragile and awkward shaped products. The light weight foam packaging also ensures that shipping costs are kept to a minimum whilst providing customers with total product protection.

As a space saving solution FOAMplus®, polyurethane foam packaging is ‘on demand’ and mixes two components together which then expands up to 200 times its liquid volume negating the necessity for large storage areas required for pre-fabricated packaging.

The benefits for customers are numerous. As well as an ideal solution for protecting awkward and valuable products, customers with product design changes and new product line additions are able to quickly adapt the packaging without the need to carry a large range of bespoke cartons or fabricated packaging.

There are two dispensing methods available for the insitu protective packaging solution. Either FOAMplus® Hand Packer, a manually operated system, with a fully electronic microprocessor control to maintain consistent quality that delivers the foam direct into polythene lined carton via a foam dispensing gun.

Alternatively the Bag Packer² Foam-in-Bag dispensing system is fast, easy to use, efficient and economical. The machine can produce up to 23 foam-filled bags per minute at the touch of a button. Polyol B 5504R, foam B component is made from 30 percent recycled polyurethane

www.storopack.co.uk

SUPERIOR INDUSTRIAL PACKAGING PROTECTION

PAPERplus® - Paper pads provide maximum performance, high density, and strength. Ideal in-the-box protection for heavy products.

100% recycled content and 100% recyclable

Petrochem and Bürkert bring value for process control projects in Ireland

The success of large projects in the process sector relies on the collaboration of its stakeholders. Within this relationship, the role of the distributor is essential. The Petrochem Group, a major distributor in Ireland, has built a relationship with Bürkert to deliver valves and instrumentation components with optimum performance and value. This relationship also provides an excellent trade-counter service, ensuring knowledgeable staff with a firm connection to the equipment manufacturer.

Across various sectors within the process industry, the key to building value is partnership. In markets from pharmaceutical manufacturing through to wastewater treatment, each stakeholder provides a unique contribution. As engineers responsible for project specification select from process equipment manufacturers, the role of the distributor is often integral to assembling the best solution.

The distributor is central to communication between the specifier on one side, which could be the engineering services provider and their chosen contractor, or an OEM with in-house expertise, and on the other side, the equipment vendor. An experienced distributor with the right engineering knowledge ensures that the specification is met as quickly as possible within time-constrained projects. Assuming the distributor is equipped with a broad stock, they also typically facilitate rapid product supply.

sive solution, this is combined with valves and instrumentation, the point where Bürkert integrates within the portfolio.

“Among our biggest customers are contractors for large engineering firms who design and specify projects for the dairy and pharmaceutical industries. We also work on projects for some of the large multinational corporates based in Ireland, taking care of their process control requirements for office space and data centres,” says Petrochem’s James O’Driscoll, responsible for service to the company’s existing accounts.

“When it comes to valves, valve actuation, instrumentation as well as the control and measurement of pressure, flow and temperature, many projects have specialised requirements. This is where we rely on Bürkert’s knowledge to help guide the detailed specification,” adds James.

Petrochem has a wide network of contractor relationships in Ireland as a result of the company’s broad ranging experience. When the distributor is approached for a new project, they typically engage with Bürkert’s engineering experts, dedicated to specific segments such as hygienic or pharmaceutical applications. This enhances advice provided by Petrochem in meeting a specification with specific expertise gained from working on applications around the world.

network and experience enabled us to initially source the opportunity, but Bürkert’s engineering expertise dedicated to this sector helped increase the value we could provide to the project,” says James.

Notwithstanding the partnership that enables Petrochem to involve Bürkert’s expertise, the company has extensive specification knowledge in its own right. From Petrochem’s 70-strong team across Ireland, the company has an in-depth understanding of valve and instrumentation integration.

“The importance of Petrochem, in terms of their sector knowledge and experience, is crucial,” says Bürkert’s Ireland Account Manager, Des McCarthy. “The close contact they have with contractors and OEMs, from dairies to chemical plants, and the understanding of the engineering challenges that this brings, is very important. With their technical know-how of valves and instrumentation, they can arrive at a very close specification that, if required, our engineers can fine-tune.”

With two large facilities in Ireland, in Cork and Meath, Petrochem is also able to carry a wide-ranging stock, enabling rapid availability for large projects. This also means that Petrochem can provide trade-counter sales to contractors.

“As well as the technical support they provide, Bürkert is at the forefront of design and innovation, meaning that their products continually improve on accuracy and efficiency. Their designs are built to last, so this gives us confidence and helps create the trust we share with our customers,” says James. “Together, this creates a strong partnership to serve engineers at all levels across process sector projects.”

In Ireland’s process control sector, this is exemplified by the partnership between flow control specialist Bürkert, and distributor Petrochem Group, which has provided value to end users and OEMs, as well as contractors, for over 15 years. Originally founded to supply the petrochemical market, today the vision includes all sectors within the process industry including pharmaceutical, food & beverage, water treatment and biotech. Supplying tubing and hardware is a mainstay of Petrochem’s expertise, but to provide a comprehenwww.burkert.com/en

“A good example is a recent project working with a big engineering services provider that was specifying a water supply and wastewater control system to a tech corporate. Measurement of organic impurities was crucial. Our

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BIRMINGHAM

SHINING A SPOTLIGHT ON ‘SKILLS’ FOR THE NEXT GENERATION THIS NATIONAL APPRENTICESHIP WEEK

In celebration of National Apprenticeship Week 2023, Automechanika Birmingham is officially welcoming the next generation of aftermarket professionals with open arms to its summer show on 6th – 8th June, as the event organisers look to take a proactive approach in helping to bridge the ongoing skills gap and train the future specialists of the industry.

National Apprenticeship Week 2023, which runs from 6th – 12th February, is the 16th annual celebration of apprenticeships and aims to bring

together businesses and apprentices throughout the country to highlight the positive impact that apprenticeships make to individuals, businesses and the wider economy.

In line with attracting future talent into the industry, along with aftermarket apprentices, Automechanika Birmingham is also encouraging first-year, secondyear and third-year students to attend its informative event in June, and embrace the many opportunities available to them.

Alex Jones, marketing director of Messe Frankfurt UK, organisers of Automechanika Birmingham, said: “The statistics don’t lie, and unfortunately the number of dropouts in the first year of college is frighteningly high for automotive courses. Not only is it important to capture the interest of fresh talent by offering attractive apprenticeship schemes and college courses, once we have these individuals on board, we need to ensure we can keep hold of them.

“A key way to achieve this is by shining a light on the vast scale of technical innovations that our exhibitors offer, as well as the myriad of training opportunities available at the show. There are a multitude of options to explore for people wishing to kickstart their aftermarket career, from getting hands on in workshops, right through to product development at manufacturer level. And with a future based around an alternative fuelled vehicle parc and autonomous driving, apprentices and students can expect a long and fruitful career in the automotive aftermarket.”

The theme for National Apprenticeship Week 2023 is ‘Skills for Life’. The week will reflect on how apprenticeships can help individuals to develop the skills

and knowledge required for a rewarding career and help businesses to develop a talented workforce that is equipped with skills for the future.

As a keen supporter of ensuring nextgenerational aftermarket professionals are equipped with the skills to succeed in the industry, apprentices visiting Automechanika Birmingham can benefit from a comprehensive programme of more than 192 hours of free skills training, technical talks and topical discussions on current industry issues and inspiring new technology, as well as live demonstrations all presented from industry experts.

Automechanika Birmingham has also partnered with School of Thought, who will be exhibiting at June’s show, which was created specifically to address the skills and generation gap and promote all the career opportunities the industry has to offer.

Recognising very early on that there was a disconnect with education, School of Thought focused on addressing this by creating a portal with its partner in education, which is available to every student, allowing them to easily find out information about automotive careers.

School of Thought also believes in the importance of going out to meet young people face to face and its ambassadors have attended over 200 careers events to date meeting thousands of young people.

Dave Reece, founder of School of Thought,

said: “This year we are planning to push on with these events and also be part of many of the national career fairs to promote all the ways young people can get into the industry, including highlighting the topic at Automechanika Birmingham. This could be through our work experience programme, apprenticeships, internships or just getting that first step on their career paths.”

Jones continued: “It’s clear that, as a sector, we need to pull together and showcase the many exciting career avenues our industry can offer, and Automechanika Birmingham offers the perfect platform to do this.”

For the first time Automechanika Birmingham will host an Automotive Talent & Skills Conference, which will take place on Thursday June 8th. Committed to addressing the issues pertaining to attracting and retaining talent in the industry, while identifying and promoting the opportunities available within the sector, the one-day conference will be a platform for everyone committed to finding solutions for the challenges the sector faces.

The National Apprenticeship Week website has more information and a toolkit to help you plan and promote your activities, which you can find more information about here.

To register to attend Automechanika Birmingham, please do so here

Danfoss Power Solutions to showcase products “Powering the future of machine performance” at IFPE 2023

Danfoss Power Solutions will showcase its range of hydraulic, fluid conveyance, and electrification products and services at the 2023 International Fluid Power Exposition, March 14-18, in Las Vegas, Nevada. At its booth, S80515, Danfoss will demonstrate how the company is “Powering the future of machine performance.”

“Autonomy, electrification, connectivity, and digitalization aren’t just buzzwords. They’re enabling original equipment manufacturers to develop machines with better productivity, safety, efficiency, precision, and operator experience,” said Mike Hill, senior vice president, OEM sales, Danfoss Power Solutions. “At Danfoss, we’re helping OEMs harness these trends and working with them to design, iterate, and validate their machines faster. It’s how we’re powering the future of machine performance.”

With dedicated booth areas for autonomy, connectivity, and digital tools, plus the company’s Editron electric powertrain systems, Danfoss will highlight how it’s paving the way to autonomous machines and zero-emission construction sites as well as delivering next-generation performance through smart, connected solutions. Stations showcasing system solutions for excavators, telehandlers, skid steer loaders, and wheel loaders will demonstrate Danfoss’ application expertise and how it helps OEMs increase speed to market. A variety of the company’s key products will be on display in these areas, including two of its newest releases: Thorx™ cam lobe motors and the Dextreme™ system for excavators.

Danfoss Thorx cam lobe motors reduce shock at speed changeover by 70%, improving machine handling and operator comfort. With an integral parking brake, the motor is 33% shorter in length than other cam lobe motors,

reducing space requirements. In addition, the motor’s optimized brake technology lasts 20 to 25 times longer than competitive products, extending the motor’s service life.

Based on Digital Displacement® technology, the Dextreme system provides a pathway to 50% energy

savings by tackling losses in the whole excavator hydraulic system. With the most efficient and controllable hydraulic pump at its heart, the Dextreme system provides unique digital flow control, resulting in vastly improved system efficiency and faster operator response times. Through the fast response and digital control of the hydraulic pump, engine loading can be controlled, providing significantly reduced fuel consumption without compromising on productivity.

Visitors can also see Danfoss’ fluid conveyance and industrial hydraulics portfolios. The company’s comprehensive offering of hose, tubing, fittings, and connectors will be highlighted. In the industrial zone, the Vickers by Danfoss line of pumps, motors, valves, cylinders, and brakes will be on display.

To learn how Danfoss can improve machine performance and decrease time to market, visit the company at IFPE in the South Hall, booth S80515, or https://Danfoss.com/IFPE23.

Danfoss Thorx cam lobe motors reduce shock at speed changeover by 70%, improving machine handling and operator comfort.

Bauer rolls out plug and play motor retrofit project for Aperam Châtelet steel mill

Carrying out a large scale retrofit at any facility can be daunting, but at a steel mill, where extreme conditions and high productivity demands combine, particularly so. As equipment such as motors require replacement, plant operators need to install new units quickly to safeguard uptime. That’s why Aperam, a leading producer of steel and alloy, selected Bauer Gear Motor to carry out a three-year retrofit project for the roller table conveyor drives at its Châtelet facility.

While the operating life of a motor can exceed 10 years, eventually plant managers will need to upgrade to a new efficiency standard or replace faulty units. However, the footprint and interfaces of new equipment will almost never match up to the original, which can make retrofitting a modern motor problematic. Complex mechanical adaptations to fit the new unit can be very time consuming. With demand and prices for steel and alloy through the roof, any extended downtime for a retrofit project at a steel

mill must be avoided.

The Aperam Châtelet facility in Belgium consists of a melt shop and a rolling mill, which produces durable steel and alloy. During routine inspections, maintenance engineers at the plant identified that the motors powering the roller table conveyors required replacement. Due to the weight of the slab, each roller was powered by its own dedicated motor. Therefore, carrying out a motor retrofit project – which would

Bauer Gear Motor has completed a three-year retrofit project for the roller table conveyor drives at Aperam’s Châtelet facility in Belgium.

require extensive mechanical adaptation for each unit - was unacceptable. Consequently, Aperam approached Bauer Gear Motor, a leading brand of Altra Industrial Motion Corp., to provide a plug and play motor retrofit solution.

Bauer Gear Motor is a world leader in geared motor technologies, with a proven track record in providing highly robust and reliable drives for use in challenging metal industry applications. Focused on delivering motors that attain the highest efficiency standards, Bauer also offers operators in the metal industry a plug and play retrofit solution for drives operating on roller table conveyors. The Bauer retrofit solution features two key elements. A standardised shaft connection using either a flange or coupling ensures increased ease and speed of installation. This is matched by a foot adaptor plate, which allows a one-to-one changeover between the old and new motor. A plug and play design eliminates the need for any costly, time

consuming mechanical adaptations. Consequently, retrofitting new motors can be done with minimal downtime.

“What was key for the Aperam project was that we could offer a plug and play solution as a complete package, which was particularly important to engineers at the facility,” explains André, Regional Sales Manager, North Europe. “Our extensive engineering knowledge in the metals industry and the OEM support we could provide were also deciding factors. One of the primary challenges was to deliver the volume of motors required within the timeframes of the plant’s scheduled downtime, but our production capacity ensured we could achieve this. Over three years, we have updated all the motors on the roller table conveyors, bringing the system up to a new efficiency standard while also streamlining future maintenance and retrofit work.”

Bauer offers specialised motors specifically for roller table conveyors. With heavy duty fan or non-ventilated designs, the motors feature windings

for delivering high torque, heavy duty gearbox housings and gear wheels, seals to withstand high temperatures and IP65 enclosures as standard.

By standardising the shaft connections and footplates for Aperam, Bauer was able to not only streamline the initial retrofit project, but all subsequent motor upgrades or replacements required for the roller table conveyors in future. This ensures that as the Châtelet facility moves to improve energy efficiency and boost reliability, these dual aims can be achieved while safeguarding production uptime.

www.bauergears.com

Bauer offers specialised motors specifically for roller table conveyors.

Bauer Gear Motor has been a provider of solutions within geared motors for more than three quarters of a century.

About Bauer Gear Motor GmbH

Above, the motor retrofit solution features a standardised shaft connection and foot adaptor plate, unlocking plug and play motor replacement. Below, Roller table conveyors are used to move hot, heavy slabs of metal, with each roller powered by a dedicated motor.

One-stop shop for compressor services

As of January 2023, Arkos Field Services, acquired by Burckhardt Compression in 2019, is integrated with Burckhardt Compression (US) Inc. Customers benefit from combined knowledge, expertise and unrivalled solutions for reciprocating compressors and other equipment from one provider. The integration of the two brands streamlines business processes to provide easy access and a solutionsdriven customer experience.

With 10 service centers across the

USA and a dedicated workforce Burckhardt Compression US is qualified and equipped to deliver a comprehensive range of services to customers. From emergency call-outs to parts manufacturing and planned maintenance, the company offers the best from both sides of the integration process from one platform. The fast response to get equipment back up and running as well as the knowledge and expertise to keep all makes and models of reciprocating compressors in perfect working condition.

At Burckhardt Compression, the mission is to establish working partnerships that promote trust, communication and a paramount commitment to safety, health, and excellent stewardship of the environment.

Safety ethos

Working in gas gathering and processing means safety is of paramount importance and Burckhardt Compression sets the benchmark by ensuring that all staff and operators are properly trained and certified for working in such a challenging environment.

About Burckhardt Compression

efficient solutions are offered, by taking account of all the stakeholders’ considerations.

Driving sustainability

Reciprocating compressors face many challenges operating in a difficult environment where reliability is crucial. Maintaining optimum performance requires expert support that offers operators long-term solutions as well as rapid responses to any emerging challenges.

As an OEM with over 175 years’ experience in engineering excellence, the company offers unrivalled knowledge and expertise in compressor operation and maintenance. Central to the continued success of the company is a program of continuous training for both staff and customers. Only by improving the knowledge of people working with compressors can they be expected to deliver more reliable and efficient service.

Burckhardt Compression believes in delivering the optimal solutions for every individual situation. Listening and understanding the needs of customers is essential to establishing the best course of action. The exceptional knowledge base within the company ensures that the most effective and

In today’s market, customers expect suppliers to have very high standards and sustainability is of great importance. Burckhardt Compression enables customers to optimize their efficiency and extend the service life of their equipment. By minimizing energy consumption and reducing emissions, operators can benefit from reduced operating costs as well as reducing their impact on the environment.

The partnership between operator and maintenance provider is crucial to the long-term, reliable service of any gas compressor. As new markets, such as hydrogen fuel, emerge from their infancy, Burckhardt Compression will lead the field in driving sustainable solutions and outstanding customer support.

www.burckhardtcompression.com

Burckhardt Compression is the worldwide market leader for reciprocating compressor systems and the only manufacturer and service provider that covers a full range of reciprocating compressor technologies and services.

New WSCAD search function ensures efficient electrical engineering

Anewly launched quick search function for WSCAD ELECTRIX is helpings users to speed up the delivery of electrical engineering projects. Electrical designers can now simply enter a keyword and all associated functions, components and information will be instantly displayed, ready for use in design documents.

Being competitive in electrical engineering relies on creating and transmitting information quickly. From the initial schematic diagram to control cabinet design, planning and engineering data needs to be available to the whole project team as fast as possible.

There are two essential features for professional electrical designers using CAD software: the right technical design toolset to enable flexible working, and the ability to search for the right function or component for the task quickly and easily.

To support this, WSCAD has launched a new Search & Click function that can be accessed in any area of the CAD environment. By using the menu bar or the keyboard shortcut Ctrl+Q, users can now source functions or components faster, making it easier to meet electrical and cabinet layout design targets.

For example, if the user wants to insert a new symbol or part into a schematic design for a control cabinet, rather than opening an additional Symbol Browser or Part

Management window, all they have to do is enter the relevant term in the search bar. This displays a categorybased results list. When searching for a part, the user can simply double-click on their selection to insert it in the document they are working on.

In WSCAD ELECTRIX, the search bar can be used for all major software function areas. It includes both menu commands and basic settings, as well as symbols, parts, macros and reference names. Consequently, delays during

the planning and engineering process caused by lengthy searches in different programs become a thing of the past. To execute the corresponding command, all users have to do is double-click on the results list when reusing predefined assemblies and subcircuits.

To find out more about Search & Click, visit the WSCAD blog at https://blog.wscad.com/.

To limit the results to a specific category, users can enter the letter shown in brackets, followed by a space in front of the search term in the search field.

About WSCAD

WSCAD is part of the Buhl group with more than 700 employees. WSCAD has been developing electrical CAD solutions for three decades.

Quick and easy: in WSCAD ELECTRIX, electrical designers can search for components using the new quick search function Search & Click and insert them directly into design documents – without the need for selection via the menu bar.

The search results are ordered by category: double-click on your chosen part and it will be inserted in the place provided in the document you are working on.

ARE YOU READY?

MAJOR CHANGES TO R&D RULES FROM APRIL 2023

As you will know, in the Autumn Statement 2022 Chancellor Jeremy Hunt announced changes to R&D Tax Credits for UK businesses, affecting both SMEs and large organisations from April 2023. The changes to R&D Tax Credits reflect a shift in strategy from the Treasury for investment in UK innovation.

The coming changes will only affect expenditure from 1st April 2023. This means that SME’s undertaking innovative R&D can still take advantage of the government’s more generous relief rates for expenditure up to 31st March 2023.

Do you do any of the following? If so, it’s important to ensure that your business doesn’t miss out on the tax relief available.

• Review design and manufacturing services to improve a product

• Develop new manufacturing methods which create efficiencies

• Modify or improve existing equipment and tools

• Create bespoke products to client needs

Visit pricepearson.com to find out more.

As the leading Chartered Accountancy practice based in the West Midlands, Price Pearson offers a tailored R&D service to help support your business journey.

Our team of experts have an abundance of knowledge and experience to provide suitable guidance on how the coming changes will affect your R&D Tax Credits claim. Call us today for a free initial discussion to assess your eligibility.

Global robot report highlights UK’s urgent need to increase automation

By Tom Bouchier, Managing Director, FANUC UK

The UK has a strong and proud manufacturing history and, for a small nation, has long punched above its weight on the global stage. Today, the UK remains the ninth largest manufacturing nation in the world, with a £183bn output . But our seat at the top table is looking precarious as a result of our slow adoption of industrial automation. No longer the preserve of Asian powerhouses like China, Japan or the Republic of Korea, the recently published IFR World Robotics Industrial Robots 2022 report reveals that countries far closer to home such as Slovenia, Slovakia, Finland and Hungary are now outpacing the UK when it comes the adoption of robotics. If we are to continue competing on the global stage, it is imperative that the UK’s automation community comes together to support British firms to embrace robotics and

ensure our reputation as a nation of manufacturers continues to thrive.

A record-breaking year

As acknowledged in its foreword, the statistics contained in the 2022 IFR report are a strong indication of the

vital contribution that robotics is making towards supporting businesses to protect their core production processes against the effects of the numerous global crises that we have experienced over the past few years. A record 517,385 new robots were installed in 2021 – an impressive 31% uplift from 2020. As well as traditional automation adopters such as the automotive, electronics, and metal & machinery industries, advances in robotic capability through digitalisation and AI have seen sectors such as warehousing and logistics also begin deploying automated solutions.

UK bucks the global trend

Robotics has a key role to play in enabling manufacturers from all countries to remain agile, cost efficient and globally competitive, and the fact that 2021 saw the highest number of

FANUC UK’s Managing Director, Tom Bouchier highlights that the UK is currently languishing at 24th in the world robot density rankings, making us the only G7 country to sit outside the top 20.

Robotics has a key role to play in enabling manufacturers from all countries to remain agile, cost efficient and globally competitive.

new robot installations on record is particularly encouraging. But, from a UK perspective, the IFR results were more sobering. At 2,054, the number of new robot installations was down 7% year-on-year, giving the UK an average manufacturing robot density of 111 robots for every 10,000 employees, which the report notes is ‘very low for a Western European country’. This figure is well below the global average of 141 and considerably under the top performing nation of the Republic of Korea (1,000) and the European frontrunner, Germany (397). In fact, the UK is currently languishing at 24th in the world robot density rankings, making us the only G7 country to sit outside the top 20.

Boosting productivity

The UK’s position as a leading manufacturing nation is unquestionable; but we could increase our productivity levels significantly if we used more

automation. To put it into context, many countries have a manufacturing industry that accounts for a similar 10% GDP as the UK (the USA, the Netherlands, Denmark and Sweden, for example); but their productivity rates are higher than ours as a result of their greater investment in automation. Astonishingly, a German worker is around 30% an hour more productive than a UK worker – put simply, we cannot expect to continue competing on the international stage unless we automate.

Labour crisis

The need to automate has become even more imperative in the last few years in the face of a series of unprecedented global and national crises, which have impacted UK manufacturers’ ability to recruit staff. Already facing a labour shortfall, a perfect storm of Brexit and the Covid pandemic prompted an exodus of European labour from our shores, contributing to the 97,000 vacancies in

the manufacturing sector reported in January 2022 (a year-on-year increase of 113%) . As well as this ‘cost of leaving’ crisis, the country is also facing a cost of living crisis, which has seen manufacturers grapple with rising bills for energy, transport and raw materials. Recruiting hard-to-find manual labour while managing increasing costs is a difficult balancing act, but it can be alleviated through automation. By using robots to do the dull, dirty and dangerous tasks, automation enables manufacturers to make better use of their human employees, upskilling them to boost recruitment and retention rates while increasing productivity.

A bright future

The outlook, therefore, is brighter than it may currently appear. In 2015, robot density in the UK was just 71 robots per 10,000 employees – the current figure of 111 demonstrates a 56% increase, and this is reflected here at FANUC UK in our healthy order book going into 2023.

The UK already boasts world class engineers, world class machine tool builders, world class integrators and a world class workforce. To retain our reputation as a nation of world class manufacturers, we now need to support firms to implement world class automation technology..

The FANUC Corporation is one of the worldwide leaders in factory automation for CNC control systems, robots and production machinery (ROBODRILL, ROBOCUT and ROBOSHOT).

IFR World Robotics Industrial Robots 2022 report reveals that countries far closer to home such as Slovenia, Slovakia, Finland and Hungary are now outpacing the UK when it comes the adoption of robotics.

Making productivity sustainable with Pharma 4.0

David Bean, Solutions Group Manager at Mitsubishi Electric looks at how industrial automation can improve the environmental footprint of pharmaceutical manufacturing activities.

Smart pharmaceutical manufacturing can do more than drive up productivity. It can transform the lives of patients by providing access to high-quality medicines while also improving the sustainability of operations and contributing to net zero policies. As a result, pharmaceutical companies can help to protect both people and the environment.

The future of pharmaceutical manufacturing, also known as Pharma 4.0, is based on data-driven technologies. These can generate in-depth knowledge on processes and activities, share this information with key equipment and automatically act upon this intelligence in real-time to optimise entire production lines.

This digital transformation of pharmaceutical operations can make businesses more lean and agile, delivering key opportunities in a number of areas beyond the shopfloor. In particular, smart manufacturing can help companies improve their environmental footprint.

The pharmaceutical industry is considered a major emitter, producing 55% more greenhouse gases than the automotive sector(1). As a result, businesses in this market will need to invest in key actions to help facilitate their journey to net zero. Digital transformation technologies offer a unique opportunity to support net zero policies with quick ROIs. In addition to forming a gateway to green manufacturing, they can also enhance the competitiveness of pharmaceutical manufacturers in a demanding marketplace, making digitalisation a particularly appealing strategy.

Pharma 4.0 is green

Well-designed automation solutions can optimise resource utilisation, reducing both waste and rework.

Mitsubishi Electric’s specialist teams

have supported a multitude of projects in the pharmaceutical and life sciences sectors, delivering improvements using customised automated systems. For example, smart process control solutions and robotics can improve yield and process performance whilst reducing energy consumption and thus improve manufacturing sustainability metrics.

These technologies can also reduce emissions, production time and costs, which in turn benefits both businesses and patients. In effect, it is estimated that Pharma 4.0 will save 30 minutes per year for each clinical trial patient and cost savings for customers of £1 billion are expected(2).

As the manufacture of increasingly advanced treatments and medical equipment becomes more expensive

and resource intensive, the utilisation of automation offers pharmaceutical companies an opportunity to thrive. By leveraging state-of-the-art components, such as Mitsubishi Electric’s range of robots, controllers, drives, HMIs and MaisartTM based AI technologies, businesses can meet ambitious environmental goals while creating highly responsive production facilities.

To learn more about how industrial automation can help pharmaceutical manufacturers improve their environmental footprint and operations, download Mitsubishi Electric’s latest white paper ‘Advancing pharmaceutical manufacturing now – Key automation technologies, applications and realworld benefits’:

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Midtherm lasers in on growth after £1.2m machine investment

Aspecialist sub-contract laser cutting and forming specialist is reaping the operational and environmental benefits of a £1.2m machine investment.

Midtherm Laser, which employs 45 people at its factory on Peartree Lane in Dudley, has increased its capacity and speed of processing thanks to the installation of a new Bystronic Bystar Fiber 12kW laser with part automation.

One of the largest purchases in its 23-year history introduces the next level of power in fiber laser cutting and will help the company deliver high cutting dynamics and thin to thick cutting capabilities to a customer base that spans aerospace, automotive and decorative work to food processing, agricultural and conveyors.

It has also made a massive difference to the firm’s environmental performance, with the Bystronic model replacing

two older CO2 machines and is already delivering a 50% energy saving – the equivalent of powering 2100 average homes every month.

“Our expertise in laser cutting and metal forming is respected throughout our sector and has led to us increasing

sales by a further 6% last year, a great achievement considering the volatility of the market,” explained Mark Hannon, Director of Midtherm Laser.

“The knowledge of our experienced people is one of our greatest strengths and we like to complement this with a sustained investment programme that incorporates the latest technology into our production processes.”

He went on to add: “The 12kW Bystar Fiber is a class leading machine that can cut from 0.5mm to 30mm in mild steel, aluminium, and a host of other materials. It gives us more capacity to target new opportunities and, importantly, means three quarters of our machines are now fiber technology instead of gas.

“With this in mind, and when you consider we have also invested in LED lighting, sensor switches and electric vehicles and charging for our staff on

Our expertise in laser cutting and metal forming is respected throughout our sector and has led to us increasing sales by a further 6% last year, a great achievement considering the volatility of the market.

Caption for Midtherm (L): (l-r) Gavin Brettell, Linda Whitehouse and Mark Hannon (all Midtherm Laser)

the road, it’s not difficult to see how we have managed to cut our energy usage in half since 2018.”

Midtherm was originally established in 1968 by Ray Andrews and operated through sister companies offering powder coating, enamelling and UV flues.

There was a laser cutting machine that was occasionally being used at one

of the factories and the decision was taken in 2000 to put it to better use by creating a ‘laser’ business that initially employed just three people.

With orders starting to take off, Ray’s son Richard Andrews moved the business to its current 20,000 sq ft factory on Peartree Lane in Dudley in 2004, with the next big milestone taking place in 2018 when Mark Hannon replaced Dean Cockayne as

Director and took over the operation alongside Richard and Kate Birt.

Today, Midtherm Laser works with more than 500 companies across 20 different sectors, cutting or forming various sheet metal from 0.5mm to 30mm to a +/0.25mm tolerance.

It is also the only sub-contract laser provider that can offer the cutting of non-ferrous materials without the risk of cross contamination for industries, including food processing and chemical manufacture.

Richard Andrews, Director at Midtherm Laser, concluded: “There has been a lot of investment recently, with the new laser following the installation of automated warehousing and the rebrand to form the Midtherm Group.

“Embracing new technology is a must for our business, but the company still thrives on the same values my father started it on in 1968, which are quality, service and technical knowledge.”

For further information, please visit www.midthermlaser.co.uk

Tobermore invests in sustainable lighting

Responsible paving and walling manufacturer, Tobermore, has invested £34k into the installation of energy-efficient LED lighting across their sites.

Tobermore is committed to reducing their carbon footprint where possible. By switching from fluorescent/metal halide lighting to LED lighting in each of their 10 factories and quarry, Tobermore has implemented a quick way to reduce their overall CO2 emissions. Retrofitting the exterior and interior lighting at their facilities has also created a much brighter working environment for operatives.

LEDs can use approximately 50% less power when compared to traditional lighting sources. LED technology is a readily available and easily actionable solution to dramatically lower carbon.

With soaring energy prices and global emissions rising at unprecedented levels, companies and households alike are transitioning to energy-efficient LED lighting. Tobermore leads by example in taking immediate climate action.

According to The Climate Group, lighting accounts for nearly 5% of global CO2 emissions. It has been projected that a

global switch to LED lighting could save over 1,400 million tonnes of CO2 and avoid the construction of 1,250 power stations.

David Henderson, Managing Director of Tobermore, commented:

“Sustainability is of the utmost importance at Tobermore. We are constantly looking for ways to reduce our carbon footprint. Rolling out £34k of LED lighting within our production facilities was a no brainer. The energy-efficient lighting will reduce our CO2 emissions while saving money on our energy bills. LED lighting is a win-win for businesses and households alike, I would encourage more people to make the switch.”

“We continue to reduce our Carbon Footprint in the following ways:

• 100% of electricity produced from our 250kW wind turbine is used during our production process.

• We have over 1,250 solar panels installed producing 38,950.90 kWhr per annum.

• We have reduced our production waste to landfill to zero through a process of continual improvement in production efficiency and the 100% recycling of manufacturing residue.

• 100% of the water used in the production of our products comes from our rainwater harvesting system and our own bore hole.

• We have invested in more sustainable product packaging. The 100% recyclable polyethylene film contains 30% recycled material. By using recycled material, we have decreased waste and reduced our packagingrelated carbon footprint by 20%.”

Sustainability is of the utmost importance at Tobermore. We are constantly looking for ways to reduce our carbon footprint.

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Ensuring the lifetime of a DC gearmotor with systematic reliability testing

Utpal Rabha, Lead Engineer, Portescap, explains the RDT procedure

From industrial power tools to surgical robots, through to applications in aerospace and defence, a motion solution that delivers high power density in a small package is a common requirement. However, integrating a gearmotor means an assurance of reliability is crucial. When operational life exceeds the duration allowable for testing, a systematic approach to Reliability Demonstration Testing (RDT) can provide OEMs with 95% certainty that the gearmotors will meet or exceed their required run time.

DC gearmotors are designed to meet the torque requirements of specific tasks while ensuring compact dimensions. With an assembly of a brush or brushless DC motor, the device combines a gearbox that optimises torque, speed, and efficiency requirements. This enables a

gearmotor to reduce output speed while increasing torque to the required level, achieving this with a more compact diameter compared to using a higherrated individual motor alone.

With the additional gearbox mechanism, it’s imperative that the design of the gearmotor is sufficiently reliable for the duration of its required use. To ensure resilience for real-world conditions, Reliability Demonstration Testing (RDT) is required.

RDT stages

The first task of the planning stage is to establish the reliability objective, which is required to set the RDT parameters. Typical gearmotor characteristics subject to RDT include voltage, current, speed, temperature, noise, and physical integrity. The test models can then be selected

to calculate sample size, as well as the test time required. The preference depends on whether the test duration differs from the expected service life; it is needed for a device that operates long-term, compared to a device that might just require single-shot operation. An accepted test tolerance level must also be set.

Ideally, testing should take place under actual application conditions, and be continued for the full duration of the intended operational period. However, if time to market requirements don’t allow this, such as for long life expectancy gearmotors that might operate for 10 years, an accelerated test method can be used. In this case we would calculate the B10 life, the time at which devices have a 90% probability or more of survival.

Portescap

Throughout the pre-defined timescale of the test, observations are made at regular, defined intervals from which data analysis can take place. The typical goal is zero-failures at the testing conclusion. If failures are observed before this time is reached, the required test time will be recalculated. If a low number of samples fail during testing, the failure data can be analysed with the Weibull Method, a life data analysis that determines trends of a relatively small data sample, to calculate the achieved reliability.

Testing in practice

As a real-world example of RDT testing, Portescap designed a DC gearmotor for an infusion system developed by a medical device manufacturer. To validate reliability, the specification required an operational life of 10,000 hours, tested to achieve 95% confidence. This required a B10 life calculation with RDT performed under an accelerated model.

As a gearmotor’s operational life is primarily dependent on the applied load and application conditions, the engineering team selected torque and speed as the stresses for accelerating the test time. The inverse power law, commonly used to test non-thermal accelerated stresses, would be used to calculate the acceleration factor.

As the specified torque requirement for the actual application was 10 mNm, for the acceleration factor calculation, the torque for the accelerated stress was set at 25 mNm, with a constant speed of 200 rpm. Then, the test duration was set using

a parametric binomial method, preferred when the real lifetime of the device will exceed the allowed test duration. This generated a test time of 1,081 hours considering zero failure cases. Using Weibull calculations, a sample size of 10 gearmotors was set.

To perform the RDT, the required torque level was applied to the gearmotors, maintained using a hysteresis brake, acting as a torque limiter. Performance parameters were recorded daily, including voltage, current, speed, and temperature. On conclusion of 1,081 hours, all gearmotors completed the test without failure or abnormalities, and the required B10 life of 10,000 hours with 95% confidence level or more was validated.

Systematic approach confirms reliability

A systematic approach to RDT achieves significant confidence in the operational lifetime of DC gearmotors. Even when actual life test duration isn’t a practical possibility, a robust RDT procedure creates high reliability in accelerated life testing.

Portescap’s engineers work alongside OEM teams to design and implement RDT whenever a project requires it. Systematic RDT doesn’t just assure confidence but creates actual reliability for real-world use.

For more information, visit www.portescap.com

offers the broadest miniature and specialty motor products in the industry, encompassing coreless brush DC, brushless DC, stepper can stack, gearheads, digital linear actuators, and disc magnet technologies.

Portescap’s engineers work alongside OEM teams to design and implement RDT whenever a project requires it.

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We take pride in overseeing the entire manufacturing process, from design, prototyping and manufacture to delivery, installation, full product certification and after-sales service

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We regularly produce complex assemblies that demand high levels of skill, precision, accuracy and consistency. The engineering and manufacturing teams at Drallim are highly skilled in this type of work, with awareness of critical engineering tolerances when producing assemblies of this complexity. Our skills-base extends to include testing of electrical, electronic, mechanical, hydraulic and pneumatic assemblies. Following rigorous approval processes Drallim’s supply chain partners for custom parts, such as plastics, machined and fabricated metalwork etc, are monitored closely for quality and delivery performance. Tight control of the material supply chain ensures the availability of high quality mechanical parts is maintained for timely production.

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Quick response maintenance service beats OEM support

Sulzer called in to overhaul storm pump after extended delays

Stormwater pumps will often be motionless for extended periods of time, but when water levels rise, they must be able to perform at a moment’s notice. Achieving the necessary reliability requires regular maintenance and periodic component refurbishment. However, when an original equipment manufacturer (OEM) was unable to supply parts for 12 months, a water supplier called in Sulzer to support an urgent maintenance project.

The storm pumps at a wastewater treatment plant had been in operation for around 25 years and had reached the point where a complete overhaul was required before a potentially serious failure was experienced. Regular vibration monitoring had highlighted the need for a refurbishment, but the situation had been exacerbated by the lack of support from the OEM.

Beating the OEM’s offer

The maintenance team at the plant had become frustrated by the delayed support from the OEM and started the process of removing the first pump. During a visit by Sulzer to the site to discuss the maintenance of a set of unrelated large pumps, it

transpired that the site team had been waiting for the OEM to provide spare parts and service visits for over 12 months.

Chris Weston, Area Sales Manager, for Sulzer comments: “Having detailed what Sulzer could offer in terms of support, we took the opportunity to look at the pumps during the visit. We explained how we would lift and transport both the pump and motors to our service center as well as the timeframes involved in completing the necessary work.”

A number of factors persuaded the utility to select Sulzer to complete the work, not least the competitive tender, which was 25% below the investment required by the OEM. Furthermore, being able to

provide a full turnkey solution to the full equipment and the proximity of a Sulzer service center to the site, as well as the speed in which the work could be completed, were also favorable.

Cutting lead times

Sulzer put together the complete lift plan documentation as part of the method statement and risk assessment, all of which are essential for projects such as this. The pump had to be partially disassembled and removed in three sections. The service center designed and manufactured a specialist

lifting tool that was tested and certified before being used by the field service team to remove the pump from the dry well.

The process was further complicated by the fact that the main shaft, which required replacement, would not come apart and had to be cut in one place to enable removal. Sulzer provided a solution to manufacture a new shaft section after the OEM provided a lead time for a replacement of several months

The project involved the complete overhaul of the pump and motor assemblies, all of which could be completed at the same location. As a turnkey solution, Sulzer provided field service engineers to arrange the lift and removal of the pump as well as the reinstallation of the full unit including motor, after the refurbishment had been completed.

One-stop-shop for maintenance

Once the pump had been disassembled, all the components were inspected and identified for replacement or reengineering. A considerable amount of corrosion was found on the impeller and the suction sleeves. Sulzer applied a specialist coating on all parts that required additional protection against corrosion to extend the operating life of these components.

During the project, some of the maintenance team from the wastewater treatment plant visited the service center to check on progress and see for

themselves the levels of corrosion inside the pump. Sulzer’s open-door policy means customers are always welcome to call in and see the ongoing work.

Having discovered the full extent of the wear and tear on the pumps after 25 years, the site maintenance team is putting together a plan with Sulzer to refurbish the remaining pumps. This can be achieved without affecting the capacity of the site, with Sulzer providing the engineering and logistics support for a turnkey project.

Chris Weston concludes: “Our network of service centers means we always have a local presence that can provide a fast and responsive solution for any rotating equipment. Our one-stop-shop enables us to keep all mechanical and electrical repairs in-house, optimizing repair times and minimizing any downtime for our customers.”

Sulzer is a global leader in fluid engineering. We specialize in pumping, agitation, mixing, separation and purification technologies for fluids of all types

Above, The project involved the complete overhaul of the pump and motor assemblies, all of which could be completed at the same location. Below, The storm pumps had been in operation for around 25 years and were in need of a serious overhaul. (Image source: shutterstock)

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Discover your component sourcing sweet-spot

The way the OEM world does business has changed. Especially in light of the pandemic, which highlighted significant vulnerabilities in global logistics and supply risks. Now, a universal drive towards real time manufacturing is resulting in UK manufacturers re-evaluating their offshoring business case in an effort to re-balance the geographical, cultural and linguistic flaws in their supply chain.

For customers served by Surrey-based technical injection and compression moulding specialist and tool design firm Broanmain Plastics, ‘rightshoring’, also referred to as ‘shoring resilience’, are the phrases of the moment. It’s an attractive middle-ground that enables OEMs to adopt a hybrid sourcing strategy that considers multiple factors. Including the end-to-end supply chain from tool design to moulding production, finishing and assembly, along with all the logistical processes and associated stock management costs.

Cucumber Lighting Controls is one of Broanmain’s newest customers that is making this hybrid rightshoring approach work for them. Very much a British business, the founding investment partners are eager to retain as much manufacturing domestically as feasible.

Since the two firms started collaborating in mid-2022, Broanmain has project managed the development of 11 moulding tools ready for Cucumber’s market launch of four innovative lighting control products next month. The team is already working in close partnership with Cucumber on subsequent product phases.

Moulding of the components will take place at Broanmain’s Dorking HQ, enabling Cucumber to call-off parts as required. The PCB assemblies meanwhile are being sourced from a trusted Chinese supplier with a UK-based distribution hub. Giving the astute lighting control firm a more balanced and economic risk structure.

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we’ve been able to apply this insight throughout our product development and use our muscle to configure a shoring supply chain model that is priced competitively, yet also gives us the dynamic localised production control and short lead times to flex to order patterns,” shares Cucumber’s Product Manager John Mercer.

Mitigating risks

As with many westernised economies, global competition has steered UK manufacturing to leverage its advantages. Investing in automation and hi-tech machinery, as well as meeting specialised local requirements, including project management and fast

turnarounds, is shifting the tide towards this blend of reshoring and outsourcing. For many Broanmain customers, the benefits of sending the toolmaking to China and reshoring ongoing production of the component are multiple. As well as being convenient and cost efficient, the export price differential as a result of shipping and reduced holding inventory can be significant.

Dealing with a supplier that’s located in another continent, where the culture, language and working practices are so removed from domestic manufacturers, can be a daunting prospect. However, thanks to its global manufacturing approach, Broanmain is able to manage the entire toolmaking process on behalf of clients, from start to finish.

“From our UK office we assist with the initial design of the component, which we send to China where the tooling is created. Our in-house engineers then scrutinise the design and make any changes,” explains Engineering Manager Kamil Stec. “Once the customer has signed off on the tool design, our tool partners manufacture the tool and ship it to us for sample tests.”

Just as OEMs need access to diverse skillsets, lessening over-reliance on a single import source can be sensible.

Product Manager at Cucumber Lighting Controls John Mercer briefs Kamil Stec on phase 2 of the tooling requirements for their innovative lighting sensors

Bringing production closer to its manufacturing site was a key rationale for Trend Control Systems, part of the Honeywell Group of companies.

For over five years, Trend’s climate control components - supplied to high-end hotels and commercial office buildings - are moulded, finished and part-assembled by Broanmain. Made to order and dispatched to Trend at least twice a week, the Trend team relies emphatically on a simple yet effective Kanban lean manufacturing technique to control stock levels.

Real time quality control

Another benefit of shorter runs and local production is increased quality and quicker reactions if they require a customisation. Operations Manager Thomas Catinat comments: “If there’s an issue with the component or consumer trends dictate a change, customers can call us, or even visit us on site. Our in-house tooling engineers can amend the component and run off a new batch, dispatching it within 24-hours. Waste is kept to a minimum and production schedules are tightly maintained.”

Broanmain’s involvement from the start of the toolmaking design process pays dividends further down the line, too. “Toolmakers have a complementary knowledge to moulders. When this expertise is combined together from the start of a project, every aspect of the design, moulding and finishing processes can be factored in. Including the materials the components will be made from, to the machine they will be

moulded on. Each stage and element plays a critical role in manufacturing the perfect component from the first shot onwards,” explains Thomas.

Reinvention for resilience

For 20+ years, the low cost offshoring model worked for many OEMs. Whilst lower wage and raw material costs were the initial attraction, many of these topline benefits have eroded; superseded by delivery on demand. In comparison to the off-shoring wave, it’s now evident that OEMs are no longer influenced on price and labour costs alone. Production skills, capacity, and the space to hold inventory are all equally important factors to consider when looking to derisk supply chains.

Academics suggest that rightshoring – blending offshoring and reshoring - offers a balanced mix to achieve the optimum level of manufacturing efficiencies and productivity. By definition, rightshoring seems to be the obvious ‘catch all’ solution. However, manufacturing businesses evolve constantly. What’s the right choice for one, may not work for another. Likewise, what’s right for an OEM in 2023, may need rejigging again several years down the line.

Uncovering the right sourcing strategy can be fraught with risks. As Cucumber’s Product Manager corroborates, expert industry knowledge should never be underestimated. It also depends on other factors such as where the best skills are located. “For an OEM like ourselves, onshoring every aspect might

not be the most prudent, productive or cost efficient move,” claims John. “It’s critical to weigh up all the hidden costs, including managing the relationships with suppliers, order turnaround times, quality, wage inflation, export tariffs and even the volatility of exchange rates.”

Broanmain’s Managing Director Jo Davis concurs, summing up: “Just as OEMs need access to diverse skillsets, lessening over-reliance on a single import source can be sensible. For components that require a high level of innovation, close proximity to the manufacturer clearly reduces the logistical and quality management challenges. Yet, the intrinsic value of being able to diversify supply chains and leverage a hybrid rightshoring strategy which can flex and be controlled within the UK creates an inviting environment that drives future operational excellence.”

Having supported a number of customers to bring technical moulding projects closer to home, Jo advises OEMs to initially focus on where production capacity in the UK can be expanded. “In time you might gradually move the entire supply chain. Inevitably, taking a more considered approach builds confidence and ensures that quality is not compromised during the transition,” adds Jo.

According to Make UK’s The Facts annual analysis, domestic manufacturing continues to thrive, accounting for £183bn in output. In 2022, the UK retained its rank as the ninth largest manufacturing nation in the world.

www.broanmainplastics.co.uk

Broanmain Plastics is a specialist family-owned technical trade plastic moulder and one of only a few UK plastic moulders to offer thermoplastic, thermosetting and injection moulding from one facility.

Factoring in moulding parameters is essential in the tool design process, which Broanmain can oversee entirely from its UK toolshop

Innovative digital marketing group based in the UK installs ROE Jasper LED wall in fresh studio build

Midland Road Studios is home to broadcast studios which are designed with content creation in mind for live, virtual and hybrid events. The ROE wall is used for multi-purposes, from Croma key to global live stream presentations and immersive live feeds from HD 3D environments created by group company V-Ex.

V-Ex is a global leader in virtual exhibitions and is using its new studio to blend live elements into hybrid events. By using digital innovation in the form of the online V-Ex virtual venue and event platform the studio increases audience engagement, and blending the two enables its customers to reach a larger audience with more accessible content delivered in a more sustainable way.

After a successful trial with a ROE Black Onyx (BO2) 2.84mm pitch frame mounted LED wall system, group CEO Roland Renshaw was happy to sign off the investment in a new 2.6mm pixel pitch permanent-install 6x3m Jasper LED wall mounted system. This means that audiences from all over the world are captivated by the beautiful, dynamic visual medium created by the fidelity and hyper-realistic 4K visuals.

“High-quality, stunning-performance, slim profile and friendly technical support were all crucial in our decision making. The LED wall is ideal for those occasions when our customers want to bring their content to an audience wider than could ever attend a physical event,” says Group CEO Roland Renshaw.

With its high-quality, energy efficient HDR technology, it’s a class leading solution. The wall was simple to install with engineered but lightweight aluminium frames that lock together to form a rigid grid structure, supporting

a modular slim-line, space saving LED panel design. Each LED panel is held in place with magnets making them easy to install and service as they are mounted and removed from the front.

“Wiring, fixing and adjustment features used during install are all nicely engineered and allowed us to install and commission quickly with great results straight away” adds Roland.

Every four panels connect to a dedicated CPU that handles the rendering of V-Ex’s sophisticated, interactive digital environments while only drawing 170w per panel on average. This, in conjunction with the V-Ex studios, “Powered by Sunshine” initiative,

Above, the fidelity of the video wall combined with hyper-real 4k renders from V-Ex creates a stunning dynamic visual medium to enrapture audiences from around the world.

Below, the fidelity of the video wall combined with hyper-real 4k renders from V-Ex creates a stunning dynamic visual medium to enrapture audiences from around the world.

which makes use of solar energy, offers a low-carbon, low-operating cost solution. Especially when compared to physical event hosting, travel, and accommodation costs.

The demand for its service is growing since the installation of the 6m x 3m LED wall, so V-Ex has confirmed that it will be working with ROE in the near future to install a full extended reality (XR) setup with a video floor and additional video walls to enable an even more immersive broadcast and recording experience.

“Quality, performance and technical support were all crucial in making the decision” says Marketing + Technologies Group CEO Roland Renshaw.

Vacuubrand’s high-quality and reliable range of chemistry diaphragm pumps

Available in the UK from Labtex, Vacuubrand manufactures a comprehensive range of laboratory and instrumentation vacuum pumps, gauges and controllers for both coarse and fine vacuums.

Vacuubrand’s first priority is to offer sophisticated equipment which meets the highest quality, professional standards expected of a modern laboratory. For example, ‘intelligent pumps’ make lab work more efficient, allowing chemists and technicians to focus their attention on other tasks.

The versatile Vaccubrand chemistry pumping unit, PC 3001 VARIO select

• Unsurpassed performance

• Uncompromising chemical resistance

• Fully automatic evaporations

• Minimal operating and maintenance costs

• Whisper quiet

• Environmentally friendly, without oil and water consumption

• The Vacuubrand Chemical Resistance Chart

• Chemical resistance is essential when working with aggressive gases and vapors.

www.labtex.co.uk

Discover the range of chemically resistant, durable, and highly efficient chemistry diaphragm pumps, from VACUUBRAND

Avilable in the UK from Labtex , Vaccubrand engineer and produce almost all of their pump and controller components at their facility in Germany. This enables Vacuubrand to quickly respond to the wide variety of demands from different laboratories, offering tailor-made solutions, and also ensures a consistent approach to the quality of their design and manufacturing processes.

Vacuubrand relies on a range of cutting-edge technology and machine tools to produce a large selection of products, including rotary vanes, diaphragm pumping units, chemistry vacuum systems, vacuum gauges and controllers, as well as valves and components of the innovative VACUU-LAN local vacuum network.

• Contamination-free conveying and evacuation

• Outstanding chemical resistance

• Whisper quiet

• High pumping speed close to ultimate vacuum

• Long diaphragm life, maintenance-free drive system

• Extra low vibration

www.labtex.co.uk

The UK’s Laboratory Equipment Experts

20 reasons to select a WG20 geared motor

WEG releases technical features of WG20 gearbox range

Selecting a geared motor requires countless technical considerations. To simplify purchasing efforts for buyers, global manufacturer of motor and drive technology, WEG has released 20 Reasons for Choosing WG20 Geared Motors. The guide explores the essential considerations for selecting a geared motor and why, in today’s manufacturing landscape, choosing a future-proof gearbox is essential. The guide can be downloaded at www.weg-WG20.com.

Geared motors are arguably the most important type of drive in the processing and manufacturing industry and WEG’s latest guide has been released to assist technical buyers when purchasing this equipment. The guide explores the key aspects of previous WEG geared motor manuals, while focusing on the newly launched WG20 range and its new technical features.

WG20 is the first geared motor range to be completely developed in-house by WEG. The guide explores the specific technical advantages of the WG20 range, including the gearboxes energy efficiency ratings, power ratings and predictive maintenance options. The guide also covers important factors such as the global certifications of the gearboxes to ensure standard compliance.

20 Reasons for Choosing WG20 Geared Motors is one guide in a series of four whitepapers to accompany the launch of WEG’s WG20 range. In addition to the technical features of the WG20 range, the guides cover everything you need to know about gearbox units — whether you are a mechanical engineer, plant operator,

maintenance specialist or technical buyer.

“Geared motors are used in a wide variety of applications, machines and systems,” Marek Lukaszczyk, marketing manager

for Europe and the Middle East at WEG. “Yet, the more varied the applications, the more varied the demands are on the drive. The WG20 geared motor range from WEG has been developed to meet all the complex requirements found in industry.”

“The guide is free to download and provides a high-level review of WG20 motors and has been released to help buyers make purchasing decisions. The guide includes important information about operational costs, predictive maintenance and how WG20 can be switched to different voltages around the world meeting many requirements for international markets.”

Further information on WEG’s WG20 range can be found on the company website. The guide 20 Reasons for Choosing WG20 Geared Motors, can also be requested via this link.

WG20 is the first geared motor range to be completely developed in-house by WEG.

Portable Fume Extraction, Ventilation and Cooling Solutions

Where fumes, smells or dust occur, our Miniveyor Air VAF series fans can move contaminated air out of a confined space or building. They effectively exhaust fumes, ventilate confined spaces, and increase the flow of fresh air.

VAF-COOL evaporative coolers offer an alternative solution to conventional refrigeration systems or air conditioners.

The coolers are portable so provide a highly flexible solution, and their low energy consumption means they are economical to use, kinder to the planet, and unlike air conditioners, they don’t rely on a closed environment, so can be used in more open spaces, such as warehouses, factories, event spaces, agriculture building, and sports arenas.

Pushing the boundaries of desalination efficiency

Over the past two decades, desalination plants have become bigger, more costeffective and twice as energy efficient. Innovations in pump technology from Sulzer have played a critical part in the transformation of the sector.

Antonio de la Torre explores the advances in pumps that have supported the optimization of desalination plants.

The changing climate, rising populations, economic growth and increased urbanization are all contributing to water scarcity across much of the world. In recent decades, many regions have turned to seawater desalination to provide their populations with sufficient fresh water for agricultural, domestic and industrial purposes.

Previous innovation

Surging demand has been the catalyst for continual innovation in the

desalination industry, and there is no better example than the changes in the design and technology of seawater reverse osmosis (SWRO) plants since the beginning of the 21st Century.

In 2001, a 50’000 m3 per day SWRO plant was considered quite large. While there were a few larger facilities in operation around the world, most were significantly smaller. An SWRO train with a capacity of 15’000 m3 per day was considered huge and Pelton turbines were the dominant energy recovery technology.

At the time, a high-pressure RO pump delivering 600 m3 per hour with an efficiency of 83% was a considerable technical achievement.

An efficiency revolution

20 years on, the specific power consumption of SWRO plants has been

reduced from 6 kWh per m3 to less than 3 kWh per m3. Improvements in membrane performance and the use of new energy recovery devices have been crucial in that doubling of energy efficiency, but advances in pump technology have also played an important role.

As one of the world’s leading pump specialists, Sulzer has been involved in the RO sector for many decades. Constantly pushing the boundaries of pump design and providing reliable, high-performance equipment to major projects worldwide.

The use of wear parts made of polymeric materials with good tribological properties, for example, have enabled efficiency improvements of 2% to 3%. Advanced materials have also paved the way for the introduction of productlubricated bearings that require no

The role of advanced pump technology in the evolution of the desalination industry

oil or grease. That saves operators the expense and complexity of forced oil lubrication systems, reduces the risk of product contamination and enables state-of-the-art efficiency without compromising reliability.

Improvements in hydraulic performance have been achieved by replacing axial split casing pumps with ring section designs. Initially, this approach was only applied to smaller RO trains, but these pumps are now available with capacities of up to 1’000 m3 per hour for larger trains.

Hydraulic improvements came also in low pressure applications, where traditionally single stage, double suction pumps were traditionally used. Today, even at higher capacities, users are now choosing cost-effective end suction overhung pump designs with higher efficiencies and extremely good suction performance in a highly reliable way.

Pump control technology has improved dramatically too, thanks to the availability of reliable and cost-effective variable speed drives. These give users the flexibility to run pumps over a wider range of operating conditions, minimizing the need to regulate flows via valve throttling. They also allow pumps to operate closer to their best efficiency point, avoiding unnecessary impeller trims that can have a negative impact on overall efficiency. While the first variable speed drives used in the industry were affordable only for low voltage drivers for low pressure pumps, the availability of medium voltage drives has extended the benefits of this approach to high-pressure pumps.

Economies of scale

Perhaps the most important driver of improved pump efficiency in RO plants

leading to substantially reduced specific consumption has been scale, since the efficiency of a centrifugal pump increases with its capacity. The first opportunity to capture scale advantages came with the introduction of larger RO trains, which increased from a maximum of 15’000 m3 per day in 2001, to 25’000 or even 30’000 m3 per day.

The next opportunity came from a change in system architecture. The creation of the Pressure Center concept allowed the introduction of very large pumps that supply multiple RO trains through a manifold system. Plants using this design were first introduced in the mid-2000s and it has since become the standard approach for large SWRO facilities.

Sulzer has been supplying high pressure pumps for such Pressure Center concepts from the beginning. Utilizing a twostage solution, the high-pressure pumps used in those first Pressure Center facilities had a high-pressure flow of around 2’500 m3 per hour and achieved efficiencies of around 88%. Today, Sulzer is delivering high-pressure pumps for the largest plants with capacities in the range of 3’500 to 4’000m3 per hour and efficiencies above 90%.

While efficiency improvements on the high-pressure pump are getting close to the physical limits, potential improvements are coming from other pumps services in a SWRO plant. This performance is being matched by the company’s latest low-pressure end suction pumps, used in other continuous services like the intermediate, the lowpressure booster or the second pass pumps, which can also achieve efficiency ratings of more than 90%.

The desalination sector is continually advancing, with incremental improvements in scale, efficiency and reliability. Each new project aims to reach the limits of performance, and every year the sector finds ways to push those limits just a little further. As a leading player in the pump industry and a longstanding partner to the sector, Sulzer is proud to play its own part in that ongoing improvement process. Ultimately, everyone has one common goal: delivering more affordable fresh water to the people that need it most.

For more information, visit www.sulzer.com

As a leading pump specialist, Sulzer has decades of experience in the RO sector

Sulzer’s design and manufacturing expertise tailors each pump to its application

A choice of pump designs ensure the most efficient solution for each project