Process Engineering Control & Manufacturing Issue 41 2019 by MH Media Global

Engineering Process

Control &

MANUFACTURING

PECM

Global Success Through Innovation Issue 41 2019 ÂŁ3.95 www.pecm.co.uk

BOOM OR BUST? - 12

RENEWABLE RESISTORS- 16

ETG - 40

Brexit will undoubtedly affect life in the UK in several ways. The nature and extent of its impact, however, is anyone's guess.

This has led to a large adoption of these applications, an especially poignant point in the face of current environmental issues.

The UK's leading machine tool supplier celebrated its 25th birthday in style, when it showcased its latest manufacturing technologies.

Rock Solid Pumps Huskyâ&#x201E;¢ - Durability when you need it most. Long Life and Low Overall Cost of Ownership High Flow Rates for Increased Productivity Fast and Easy Maintenance

DISCOVER ALL ADVANTAGES

WWW.GRACO.COM/HUSKY

Engineering Process

Sections

Control &

MANUFACTURING

Inside...

Inside Issue 41

Editors Choice

Automotive Engineering

Boilers & Maintenance

Control & Automation

Electrical & Electronics

Fasteners & Fixings

Fluid Handling

Gears, Drives & Motors

RENEWABLE RESISTORS

Health & Safety

Machining & Machinery

Measurement & Monitoring

News & Events

113

Process Technologies

124

Product News

128

Software & Systems

134

Storage, Handling & Distribution

138

Training & Recruitment

142

Valves & Flow Control

144

BOOM OR BUST? BREXIT’S IMPACT ON INNOVATION AND R&D

NEW MERCEDES-AMG FOURCYLINDER TURBO ENGINE FROM ULTRA-MODERN PRODUCTION

The world’s most powerful fourcylinder engine in series production, made in Affalterbach

THE EXTREMES OF ADDITIVE MANUFACTURING

When Norway based Kongsberg Maritime, a specialist in technology for use in extreme conditions, was designing a chassis for a subsea measurement instrument.

FOR MORE EFFICIENT PROCESSES: KHS DEVELOPS A DIGITAL CONTROL SYSTEM FOR PET BOTTLE PRODUCTION

Even on the most advanced machine there can be discrepancies in the distribution of PET bottle material in the stretch blow molding process.

“The Centre of Excellence for Strainer and Filtraaon Technology”

Low Loss Basket Strainer® Cartridge Filters Y-Type Strainers Mono-in-line / Basket Strainers Duplex Strainers (Rotagate® & Firplex®) T-Type Strainers

Coalescers & Seperators Pressure Vessels Flame Arresters Sight Glasses Silencers Spools

Materials available include: Carbon Steel & LTCS Stainless Steel 304/316 Cunifer Hastelloy 6MO Duplex & Super Duplex Stainless Steel Aluminium Bronze Inconel 625 & 825 Monel Titanium All Exooc Metals Catered For ISO9001:2015 ISO3834-2:2005 ISO29001:2011 ISO14001:2015 OHAS18001:2007 SSIP Safe Contractor

Issue 41 PECM

Engineering Process

The leading source for innovators in Technology, Manufacturing and Maintenance within the Engineering & Processing industry worldwide. Published bimonthly, a subscription to PECM magazine is essential for Process Engineers, Chemical Engineers, Instrumentation Engineers, Mechanical Engineers, Plant Engineers, Precision Engineers, Environmental Engineers & General Engineers, Companies and Organizations in the Food, Dairy, Beverage, Brewing, Semiconductor, Pharmaceutical, Biotechnology, Chemical, Oil & Gas, as well as all UK's major manufacturing units. Every issue of the magazine contains the latest news, in-depth features, together with product innovations and case studies showing how process engineers are implementing new technologies to reduce costs and impact on the environment. With over 140,000 readers worldwide the publication is widely read, recognized, and well respected within the Process, Engineering & maintenance industries. A subscription to PECM magazine is the industry's 'must have' publication.

Hardcopy Edition SUBSCRIBE TO 6 BIMONTHLY ISSUES OF PECM FOR JUST £27 •

The magazine gets delivered directly to your door once every issue is published

•

The quality of the hard copy enhances the reading experience

MANUFACTURING

Control &

The Team EDITOR IN CHIEF Antony Holter editor@mhmagazine.co.uk

EDITOR Elizabeth Hutton elizabeth@pecm.co.uk

STUDIO DIRECTOR James Sayer james@mhmagazine.co.uk

BUSINESS MANAGER Josh Holmes josh@mhmagazine.co.uk

STUDIO DESIGNER Richard Bland richard@mhmagazine.co.uk

SALES DIRECTOR Benjamin Dubois benjamin@pecm.co.uk Tel: 01227 936978

ACCOUNTS DEPT Alison Holmes accounts@pecm.co.uk Tel: 01227 936976

SALES MANAGER Alexander Arnold alexander@pecm.co.uk Tel: 01227 936975

PUBLISHING DIRECTOR Martin Holmes martin@mhmagazine.co.uk Tel: 01304 806039

DIGITAL MANAGER Jamie Bullock jamie@mhmagazine.co.uk Tel: 01227 936971

EDITORIAL ASSISTANT Charlotte Charlesworth charlotte@pecm.co.uk Tel: 01304 806039

To Subscribe please call 01304 806039

Digital Edition SUBSCRIBE TO OUR DIGITAL EDITION COMPLETELY FREE OF CHARGE Designed for the digital age, the magazine has been created for easy viewing on all electronic devices.

Please mention Process Engineering Control & Manufacturing when responding to items in this issue.

M H Media Global Ltd. Office 15, Innovation House, Discovery Park, Ramsgate Road, Sandwich, Kent, CT13 9FF

Tel 01304 806039 l Fax: 08721 152240 l www.pecm.co.uk

All our issues stored in one place: get unlimited access to our previous and future issues.

Every effort is made to ensure the accuracy and reliability of material published in Process Engineering, Control & Manufacturing however, the publishers accept no responsibility for the claims or opinions made by the contributors, manufacturers or advertisers.

To Subscribe please visit www.pecm.co.uk/subscribe

No part of the publication may be reproduced or transmitted in any form or by any means, mechanical, electronic (including printing), recording or stored in any information retrieval system without the prior written consent of the publisher.

Issue 41 PECM

EDITOR’S CHOICE

CUTTING-EDGE TECHNOLOGY RITTAL

REDUCING THE ENERGY OUTPUT OF MACHINE TOOLS No business should ever underestimate the large amount of energy consumed by machine tools. Cooling enclosures and spindles alone commonly account for more than 15 per cent of a company’s annual energy bill. A test installation at a CNC lathe has demonstrated that Rittal Blue e+ chillers significantly reduce energy consumption while also being simple and easy to use. Bosch Rexroth AG, a long-established global manufacturing company, runs an energy efficiency consultancy called GoGreen at its headquarters in the Bavarian town of Lohr am Main. GoGreen’s purpose is to examine and improve the energy efficiency of the company’s production plants worldwide. To this end, GoGreen works closely with institutes, as well as technology partners such as Rittal, to test possible solutions. One of the most important research projects which GoGreen is involved in is the “EtaFab” (energy efficiency, technology and application centre) project at the Technical University of Darmstadt. The project is headed by the University’s Institute for Production Management, Technology and Machine Tools (PTW); a facility that can closely replicate conditions and processes used in the Rexroth plant in Elchingen, allowing effective and accurate testing of potential innovations in areas such as improving the energy efficiency of machine tools.

Retrofitting CNC lathes

Ease of Use

Among the products made at the Elchingen plant are hydraulic pumps and motors for mobile machines. Many of the components for the hydraulic power units are manufactured on a CNC lathe which has a total connected load of 75 kVA and runs for up to six days a week in three-shift operation. CNC lathes need their spindles to be cooled to dissipate the heat generated by the drive technology – and this is typically achieved through liquid cooling. The GoGreen team examined what would be the impact of replacing the existing compressor cooling unit on the lathe, with a new Rittal Blue e+ Chiller. The Blue e+ delivers the cooling medium and its DC compressor, controlled by an inverter, generates the necessary cooling output in the chiller. A circuit then transports the cooling medium to the spindles.

The trial also highlighted how easy the Blue e+ is to operate.

An impressive increase in energy efficiency The test demonstrated that the Blue e+ could reduce energy consumption significantly. Leo Pototzky, GoGreen Project Manager, Bosch Rexroth, said of the trial: “The Rittal Blue e+ chiller consumes 50 per cent less electrical energy than the old chiller, while the saving achieved by the cooling unit in the enclosure even exceeded 80 per cent. This example shows us that a great potential still exists in many sectors.”

The control panel with its touch display communicates to operators in plain text, and in up to 21 different languages. This means that operators receive clear information and updates in status, which allows them to respond quickly to any issues. The Blue e+ App communicates with the cooling units via NFC (Near Field Communication, an international transmission standard based on RFID technology for contactless data exchange), allowing important information to be transmitted wirelessly; a functionality which is especially important when a number of chillers have been configured. It allows operators easy operational oversight and facilitates a swift response, if required.

Further information at www.rittal.co.uk and www.friedhelm-loh-group.com or on twitter @rittal_ltd.

The Perforex solution ENCLOSURES

POWER DISTRIBUTION

CLIMATE CONTROL

ww.rittal.co.uk

IT INFRASTRUCTURE

SOFTWARE & SERVICES

EDITOR’S CHOICE

VARIABLE SPEED DRIVES QUANTUM CONTROLS

WHAT ALL ENGINEERS SHOULD KNOW ABOUT VARIABLE SPEED DRIVE REPAIRS

Largest Load Test Facility in the UK at Quantum’s Repair Centre in Prudhoe

I’m sure we can all agree Variable Speed Drives are expensive pieces of equipment that require regular maintenance to minimize premature failure and maximize the life span of your asset.

Most companies that offer Drive Repair do not have the required load test facilities and hence they simply carry out a resistive load test which actually does not show if the IGBT’s are fully functioning as a power device.

However, all makes of Drives do fail and one of the most common faults is IGBT (Insulatedgate bipolar transistor) failure. An insulatedgate bipolar transistor is a three-terminal power semiconductor device primarily used as an electronic switch in Variable Speed Drives.

This leads to a very high percentage of IGBT drive repairs simply failing again as soon as they are fitted to the original application when load is introduced, leading to another repair cost and more costly downtime for your process.

When a drive suffers an IGBT failure the best practice is to replace all three devices, even if only one has actually failed, as the fault condition more often than not weakens the remaining devices which will inevitably lead to a further premature failure and more costly downtime for the user. So far, I’m sure I’ve not told you anything you don’t already know, but the real issue with drive repairs is this…it is imperative that each repair is fully load tested. This is important because each IGBT has a free-wheeling diode which you can only accurately be tested with a full inductive load test.

PECM Issue 41

In summary all engineers should only send their valuable variable speed drive assets to drive repair facilities that have fully qualified Drive Engineers who have attended the relevant manufacturers courses. But also insist that the repairer has suitable load test facilities, that they carry out a full load test on your drive and they give you the option to attend a witness test or at the very least request a video of the final test. Insisting on these simple steps for all your drive repairs ensures 100% that your drive is repaired correctly and fully functioning before you put back into service on your plant, thus ensuring minimum repair cost and minimises expensive lost production costs.

Replaced IGBT Modules must be Load Tested

Quantum Controls have an 8,000 square foot Drive Repair Facility near Newcastle with full load testing facilities and are Official Drive Service Partners for all major Brands of Drives. When you next have a Drive failure get in touch with our expert team for repair estimate. Kevin Brown, Owner, Quantum Controls

service@quantum-controls.co.uk 01661 835566 www.quantum-controls.co.uk

Variable Speed Drive Repair Any Where, Any Type, Any Size

Repair available for all makes of VSDs 12-month warranty included for all repaired drives Speedy turn-around - within 24 hours if needed Not just repaired - fully restored Load tested - certificates issued Fully qualified drive engineers carrying out repairs Installation and commissioning service available

Load Test Facility unique to Quantum

UKs largest drive spares stock Full video of each repair FAT available Certified Drives Service Partner Supplying, Installing, Commissioning, Maintaining, Servicing and Repairing Drives for over 25 years

Over 25 ABB Spares Suitcases stocked at Quantum

Free Drive Repair Cost Assessment! Worth £150 - Quote ‘PECMREPAIR’

Call our Service Coordinators on 01661 835 566 or email service@quantum-controls.co.uk Send your drive to: Quantum Controls, 6A Dukes Way, Prudhoe, NE42 6PQ

EDITOR’S CHOICE

WATER TREATMENT LOBO

VEOLIA WATER TECHNOLOGY The Problem: Veolia Water Technologies have more than 150 years’ experience in delivering water treatment service and solutions. Engineers, knowledgeable and trained on a wide range of water treatment systems support service packages, have created a range of flexible lifecycle support options to ensure they deliver lifetime support and deliver to their customers the peace of mind that comes from having a reliable service.

PECM Issue 41

Scaffolding services to Veolia Water Technologies are provided by outsourced companies. Reducing waste is a key goal for any business, often it’s simply by using a quicker and safer system and optimising the maintenance process. The managers at Veolia realise that costs must be reduced to ensure the overall plant viability, but safety cannot be compromised, and aluminium is not preferred on the plant.

The Solution LOBO Systemsâ&#x20AC;&#x2122; safe and secure platform product. The unique and patented clamp allows the system to be quickly assembled without the use of tools into any size or shape. Maintenance engineers can assemble, perform the task and dismantle the LOBO System before traditional scaffolding can be erected. The Benefits: Veolia managers expect to save significant costs by using the innovative LOBO product. This is because they do not have to rely on outsourced scaffolding companies, as their own maintenance personnel can assemble the LOBO System. The unique versatility of the LOBO System brings labour cost reduction, enhanced efficiency & performance. The LOBO System creates a safe working environment, which increases productivity and maximizes the return on investment.

UK & Europe and Rest of World: + 44 (0)1332 365666 North America: 1-800-640-5492 Email: sales@lobosystems.com

Issue 41 PECM

EDITOR’S CHOICE

R&D TAX CREDIT SCHEME MPA GROUP

BOOM OR BUST? BREXIT’S IMPACT ON INNOVATION AND R&D

Brexit will undoubtedly affect life in the UK in several ways. The nature and extent of its impact, however, is anyone’s guess. Regarding research and innovation, on the surface not much should change. The R&D Tax Credit Scheme is a government initiative and while it is subject to European Union rules, ultimately the money is provided by HMRC, so the amount of funding available for creative pursuits should not be affected.

Funding freedom According to the latest figures from the Office for National Statistics, UK spending on R&D rose by £1.6 billion in 2017 to £34.8 billion, placing it 11th in the EU for R&D expenditure as a percentage of GDP.

But Brexit will likely alter the entire business landscape for UK companies and these wider changes may indirectly affect the state of play for those looking to innovate.

While such figures are impressive, with an average of £527 spent for each person in the UK, the spending is somewhat restricted by EU regulations. R&D tax credits are classed as ‘state aid’ by the EU and as such there are currently limits on how much the government can hand out to companies.

Here innovation funding specialists MPA Group, look at the implications of Brexit on innovation and R&D in the UK, and whether the current political uncertainty will actually give way to a more prosperous environment for businesses.

Once the UK leaves the union, this cap is removed, opening the door to higher value handouts and less strict qualification criteria. Such a move would be welcomed by SMEs across the country and would signal to the world that the UK is strongly encouraging

PECM Issue 41

innovation. Plans to increase funding are already in place, with the government’s long term industrial strategy aiming to raise R&D investment to 2.4% of GDP by 2027. There’s widespread anxiety about the impact of Brexit on British industry and the government faces significant pressure to provide a boost for the economy. Investment in innovation would be a clear statement that the country is still thriving despite the political overhaul. With the government potentially looking to reallocate some of the money they currently send across to Brussels, there could be funds available for such action. Regardless of the nature of the UK’s trading relationship with the EU post-Brexit, innovation is always going to be vital for businesses to stand out and thrive in

competitive industry landscapes. If trade deals put UK companies at a disadvantage on the world stage, the need to be creative and forward-thinking increases tremendously. John Lowndes, Director at MPA Group International collaboration While international funding for UK research has fallen in recent years,from £5.6 billion in 2014 to £5 billion in 2017, it still comprises 14% of all investment in innovation. But it’s not just the financial connection to Europe that UK companies will have to cope without after Brexit, but the level of continental collaboration currently in operation at universities and research centres across the country. UK industry and innovation is revered across the globe, with our institutions producing world-leading work in every sector. Such breakthroughs are only possible by bringing together the best people from across both Europe and further afield. In fact, in the decade prior to the 2016 referendum, 50% of all UK research publicationsinvolved a coauthor from overseas. Moving forward, Brexit may make it more difficult for businesses to recruit staff from overseas and make cross-country projects rather impractical, if not impossible. There is talk of plans to only allow immigrants who earn over £30,000 to stay in the country and this could make it difficult for bodies to continue hiring skilled international research assistants and graduates as salaries for these jobs are generally below the threshold. Britain’s booming tech industry has given the country potential to dominate and grow in IT and many other sectors.

Mark Sewell, CIO of Microsoft recruitment partner Curo Talent, explains that for the many industries developing IT infrastructure, such as in financial services, there is concern that there may not be enough IT talent available to match increased demand. The average age of the IT workforce is increasing, and Britain’s education system is not producing an adequate number of skilled workers to replace these employees once they retire. This is exacerbated by Brexit and its restriction on access to talented EU-workers. To continue this development, businesses need IT workers with the skills to deploy the latest technology, unfortunately this talent pool may become limited. Such barriers may force businesses to seek ventures elsewhere. Even British companies might start to launch their innovative operations overseas, targeting countries which have both good R&D incentives and simpler immigration policies, allowing multinational teams to work without obstacles. Asian nations might be among those that benefit, with China and South Korea as potential suitors. In recent years, South Korea has been one of the world’s biggest investors in R&D and UK businesses could cash in on the country’s commitment to progress. Uncertain fortunes As with most aspects of Brexit, no-one really knows how the UK leaving the EU will impact on homegrown innovation. While some relevant policies will remain unchanged, such as the general R&D claim process, there are wider-reaching implications which could affect British researchers.

The UK has an excellent reputation for innovation and this could prove significant. If our economy suffers as a result of Brexit, the value of the pound against other currencies will fall. As such, global businesses may see British companies as attractive investments, as their quality services and projects will suddenly be available for smaller sums. This could potentially fill the void left by current EU funding. R&D tax credits and Patent Box relief will play a crucial role in establishing the UK as a creative force post-Brexit. Once EU funding for projects is removed, the importance of the domestic HMRC initiative will amplify tremendously, potentially causing a rapid increase in applications. Continuing and improving the financial incentives for businesses to spend time on R&D will ensure that the country continues to be at the forefront of innovation. MPA Group’s guidance on the R&D Tax Credit Scheme and Patent Box relief will help you see whether your company qualifies for the initiative. www.thempagroup.co.uk

Issue 41 PECM

EDITOR’S CHOICE

Start Capturing Data with a Simple Laser Mark Laser marking technology is a simple method of applying a permanent, unique ID to every component early in the manufacturing process, enabling data capture throughout the factory. Scan a 2D Data Matrix Code before each process within the factory to build a wealth of data, from operator and environmental data to images and CCTV footage. Use this data to analyse factory performance, improve processes and respond quickly to isolate quality deviations. No fixtures – contactless marking technology Simple to use and easy to integrate in a factory environment Fibre laser - low running costs, no maintenance, highly reliable Engrave and 100% quality check a Data Matrix Code in under 0.5 seconds 100% UK designed, manufactured and supported www.pryormarking.com

01732 762338

Power Electronics, Machines and Drives conference opens for bookings

Hydra-Cell® Pulse-less MT8 Metering Pump has ATEX Certification

PEMD 2020 is open for bookings! This popular conference covers new developments, research and innovations across the breadth of power electronics, machines and drives. You will hear from experts in 40 countries and meet over 450 engineers in the field. There are also a few exhibition spaces left for suppliers and solution providers to showcase their brand. Previous attendees said: “An important event in the power electronics, motors and drives community, both for academics and industry, so I would recommend anyone in the area to attend for the networking opportunities it provides.”A good place to be to catch with research on e-machines and power electronics.” Read more about PEMD and how you can be there on 21-23 April 2020 at www.theiet.org/pemd

The Hydra-Cell MT8 low-flow, high-pressure metering and dosing pump is now available with ATEX Zone 2 certification.

www.thedarcygroup.co.uk

Conforming to ATEX Group ll, Category 3, Zone 2, gas group (IIC) and temperature class (T5 or T4 depending on process liquid temperature), the MT8 is classified for use within explosive atmospheres consisting of a mixture of air and flammable substance in the form of gas, vapour or mist that is not likely to occur in normal operation, but if it does occur will persist for a short time only. For Category 3, Zone 2, a protective system isn’t always required. In this case, an oil level sight bowl is fitted to the drive side of the Hydra-Cell pump that enables easy monitoring by the end user. For more information, visit www.hydra-cell.co.uk

UP TO

heat 350°C resistant fans

Firewater Pollution Control Valve Contain firewater within site drainage system Can you contain firewater within your site drain network? Can you isolate drains at times of high risk?

CLIBOS-TR Series: High density rock wool insulation Heat-resistant paint coating Carbon laminated steel construction High-efficiency self-cleaning impeller Designed to move air & gases up to 350°C

Can your system be automated? Can you seal your site drain system in seconds?

Instant drain isolation

Use to contain firewater runoff

PECM Issue 41

Automated or manual operation

Retain pollutants and spills on site

Call: 01782 349 430 Email: sales@axair-fans.co.uk Visit: www.axair-fans.co.uk

All-round protection for your pumps with the ifm application packages.

Monitoring and Condition Based Maintenance of pumps

RANTY AR

years if m pr od

This complete solution makes your pumps ﬁt for Industry 4.0 • • • •

Continuous diagnostic: Full coverage of your critical assets at all times. Early diagnostics: Monitoring of imbalance, wear and overall vibration. Maximum efﬁciency: Permanent diagnostics helps keep your assets running efﬁciently. Easy integration: ifm provides individual solutions suited different types of pumps.

Reducing costs, avoiding unplanned downtime and optimizing processes: The ifm Application Packages. ifm – close to you!

Go ifmonline www.ifm.com/uk/application Issue 41 PECM

EDITORâ&#x20AC;&#x2122;S CHOICE

RENEWABLE ENERGY OPTIONS CRESSALL

RENEWABLE RESISTORS

In recent years, renewable energy options have become much more efficient and feasible. This has led to a large adoption of these applications, an especially poignant point in the face of current environmental issues. However, just like all other power generation methods these applications require resistors. Here Simone Bruckner, managing director at power resistor manufacturer, Cressall, explains the challenges in designing resistors for renewable applications. In May 2019, the UK went two weeks without using any coal to generate electricity. This was the longest period of time that the UK has not burned coal since 1880. A large part of this success was put down to the increasing availability of renewable energy sources such as wind, solar and tidal energy. Renewable technologies are reaching a level of maturity where they are heavily impacting many nationsâ&#x20AC;&#x2122; energy mixes. In fact, a few days prior to the coal-free period, solar energy accounted for 25 per cent of energy generated. With the recent news that E.ON UK plans to power more than 3.3 million customers with 100 per cent renewable electricity as standard, it is clear that renewable energy is starting to take the main stage and the growth of the sector is set to continue. This is reaffirmed by public perception, as a YouGov survey found that more than three in five Britons currently on a standard electricity deal would switch to a renewable electricity supplier if the price was reasonable.

PECM Issue 41

Although embracing renewables is great for the environment, it does face its own set of challenges. Each source of renewable energy is dependent on the environment around it, meaning that production can suddenly soar and require the system to be capable of dealing with a sudden influx of power. For example, wind turbines are generally connected to the distribution network through step-up transformers. When these are energised, high inrush currents occur. These currents cause overvoltages on the distribution network, likely damaging equipment upstream. Issues like these can be remedied by using technologies such as pre-insertion resistor (PIR) in the circuits. PIRs, such as those offered by Cressall Resistors, are a three-phase resistor, insulated for the full system voltage, typically 33kV and fitted with isolating devices as required. PIRs have a high thermal mass allowing them to absorb energy from high inrushes while still being compact enough to fit efficiently in a transformer substation. These problems also extend to solar power. For example, when installing new solar panels or disconnecting existing installations from the grid for maintenance, the panels continue generating electricity. As a result, discharging this excess energy must be prioritised to prevent damage occurring to the solar panel system. Resistors are crucial in safely dispersing this excess energy.

Dummy loads resistors transfer the excess energy into heat and release it into the environment to prevent the solar panel from overloading. Cressall offers a large range of different varieties of high-power dummy load banks that can be customised for diverse applications, such as low noise versions for urban locations. Once in operation many solar farms equip panels with small electric motors to maintain the cells at the optimum angle compared to the sun for the longest amount time, in order to maximise energy generation. As such, they require braking systems to ensure they are at the correct angle. For this reason, Cressall also provides dynamic braking systems that not only ensure correct positioning but also that the braking energy is not wasted but is put back into the system. Renewable energy is becoming an increasingly important part of our energy mix. The growth in the efficiency of these technologies means that adopting renewables becoming more achievable than ever. As these technologies develop, so too will the resistors that integrate into the current power network.

For more information on Cressallâ&#x20AC;&#x2122;s renewable energy offering, visit the website: www.cressall.com/renewables

EDITOR’S CHOICE

DS-OCT12-BLACKFAST_Layout 1 20/09/2012 16:28 Page 1

NEW: IGA-003-MC BINARY GAS SORPTION ANALYZER Hiden Isochema announces the release of the IGA-003-MC, for the fast and accurate determination of binary gas sorption isotherms. The IGA-003-MC is a turnkey system, featuring a gravimetric analyzer, coupled mass spectrometer, and an optimized gas delivery and sampling system. The IGA-003-MC uses the recently developed Integral Mass Balance (IMB) method, which represents a major advance in sorption analysis techniques.

Visit our New Website

Binary Gas Sorption Measuring multicomponent gas sorption equilibria is essential to characterize and assess adsorbents for a range of applications. Both the partial adsorbed gas quantities, and the gas adsorption selectivities at a range of gas compositions, are required to accurately model these separation and purification processes. Traditional methods are often time consuming and require large samples, but fast and accurate measurements, using only a few grams of material, are now possible using Hiden Isochema’s unique IGA-003-MC binary gas sorption analyzer.

Tel: 0208 339 7370 Fax: 0208 339 7371 Unit 5 Russell House, Molesey Road Email: sales@blackfast.com Walton-on-Thames, Surrey KT12 3PE www.blackfast.com

www.blackfast.com

•

Unique IMB method used to measure binary gas adsorption isotherms Single component and binary data can be determined in one experiment Only a few grams of sample required Precise control of pressure, composition and temperature conditions

•

• •

www.hidenisochema.com

LEADING PRODUCTS AND EXCELLENT SERVICE Tsubaki delivers innovative solutions that fit the most demanding industries and environments

PREMIUM DRIVE CHAIN

ANTI CORROSION CHAIN

LUBE FREE CHAIN

LARGE SIZE CONVEYOR CHAIN

ATC CHAIN

SPROCKETS

CAM CLUTCH/ FREEWHEELS

COUPLINGS

Tsubakimoto Europe B.V.

info@tsubaki.eu

TSUR_18391_ADV_Best Choiche_180x132mm_V2.indd 1

tsubaki.eu

Tsubakimoto UK Ltd.

sales@tsubaki.co.uk 09-10-18 14:05

Issue 41 PECM

EDITOR’S CHOICE

HOSE COUPLINGS DIXON

OFFERING THE RIGHT CONNECTION

Founded in 1916, Dixon is a premier manufacture and supplier of hose couplings, made to order hose assemblies, valves, manifolds, dry-disconnects, flame arresters, vents, bespoke fittings and other fluid transfer and control products. The company's global reach includes a wide range of products for numerous industries, including petroleum exploration, refining, transportation, chemical processing, food & beverage, steel, fire protection, construction, mining and manufacturing. At Dixon Europe based in Preston, Lancashire, we specialise in the support of bespoke engineered solutions from concept and design through to manufacture and delivery. Dixon’s ISO 9001 approved onsite manufacturing and engineering facilities

PECM Issue 41

means that new designs, animations and provide 3D modelling can be produced to support our customers coupled with a quality assurance underpinned by international standards and certifications. Dixon products can be relied upon, as quality control starts at the innovative design stage, and is further supported with technologically advanced engineering and manufacturing processes. Dixon will not compromise on high quality control, utilising assurance standards and inspection procedures at each critical step of the production process Dixon has been building a credible reputation for over 100years, demonstrating that it's a responsible manufacturer producing and supplying safe, reliable and long lasting

products. Open communication with customers and following through with solutions strengthens trust as a supplier of both current and future products. Dixon Europe are driven to provide ‘the right connection’ in meeting specific hose and coupling requirements across all industries. Their strength in service, technical support, training and advice ensure the correct specification of bespoke hose assemblies and couplings. To find out more about how Dixon can help you and the Dixon range head to dixoneurope.co.uk or contact our customer sales department on 01772 323529

Dixon Petrochemical Products Fluid transfer products for upstream, downstream and refining Dixon understands the technical intricacies across global markets and industries. The vast product portfolio enables our engineers to recommend and specify the correct components for material transfer applications. Very few suppliers have this depth of knowledge, experience and expertise. Dixon always has its finger on the pulse with liquid, air and bulk material transfer along with the varying requirements from clients in different markets.

Products: • Hoses and hose assemblies • Hose & pipe fittings • No-spill couplings • Safety breakaway fittings • Blow-Out prevention couplings • Hydraulic Fracturing: Low Pressure Systems • Loading arms • Liquid level sensing • Zero emission valves

Services: • Technical specification and applied knowledge • Hose and fitting identification • Global inventory and locations • Sales and technical support • In-house engineering & design • ISO 9001 accredited • Pressure Equipment Directive (2014/68/EU)

+44 (0)1772 323 529 • dixoneurope.co.uk •

• TECHNICAL EXPERTISE • UNCOMMON EXCELLENCE • DESIGN • CUSTOMER SERVICE • INNOVATION • MANUFACTURING •

EDITOR’S CHOICE

FASTER TOOLING & ASSEMBLY 3DPRINTUK

THE EXTREMES OF ADDITIVE MANUFACTURING When Norway based Kongsberg Maritime, a specialist in technology for use in extreme conditions, was designing a chassis for a subsea measurement instrument, it turned to 3DPRINTUK to help with the manufacture of key components. MEPCA found out more. Kongsberg Maritime is an international technology group working in the maritime, defence, aerospace and digital sectors. Kongsberg is at the forefront of pushing technology in extreme conditions, so it comes as no surprise that additive manufacturing has a role in their design process. As additive manufacturing grows and becomes a viable, recognised option for producing custom parts with a finish close to injection moulded parts, more and more design engineers are exploring and adopting selective laser sintering (SLS) technology to produce innovative products. As a result of this growth, the more engineers demand from the technology, the more investment is made to advance the capabilities of the method. Kongsberg Maritime delivers products and systems to merchant vessels and offshore installations for positioning, navigation, automation and handling systems, as well as products and systems for seabed surveying and monitoring, and fishing vessels and fisheries research. 3DPRINTUK specialise in low-volume production through additive manufacturing and in particular SLS. By 3D printing parts in SLS Nylon P12, and with very few restrictions in design, manufacturers can create components with reduced weight while maintaining strength. Users of the innovative method save on manufacturing costs thanks to material savings and assembly time reduction. In addition, clever design means that the number of components gets reduced and prototyping that used to take weeks can be done in days, in multiple variations, all branded with unique part numbers. Robert Kovacs, Senior Subsea Design Engineer at Kongsberg Maritime approached 3DPRINTUK when they started a new project to design a chassis for a scientific subsea instrument used in underwater positioning and mapping. “The part is a multi-functional product chassis, not just a simple bracket to join two things together. It has clever features and functionality that we would not get from a similar metal or injection moulded part,” explained Robert. “The chassis flexes

PECM Issue 41

extensively to allow a heat shrink sleeve to be placed around battery cells and a PCB, which simplifies assembly tremendously. To secure the product during transport and handling, a tiny slide-bolt arrangement allows for a zip-tie to be inserted, again greatly saving handling time and reducing risk.” Small printed extrusions act as standoffs, screw guides and screw anchors which make the whole assembly extremely rigid. Features such as these cost nothing during printing but save greatly on handling, assembly and repair. “Right from the start, deciding to 3D print this pivotal part in a new design meant that we were able to shrink the size of the product while integrating features and functionality that are simply not available through other manufacturing methods,” continued Robert. Robert was also able to save money on the cost of other products by nesting parts.

As well as price breaks for higher quantities, 3DPRINTUK allow users to nest parts around one another to take advantage of any unused space. The smaller the space users take up within the printer, the less they are charged. Summing up his experience of additive manufacturing, Robert concluded: “I believe that the biggest advantages when 3D printing parts are the time savings thanks to faster tooling and assembly, along with the ability to make far more intelligent parts. We would, of course, have these features and advantages if this part was injection moulded. But it is not possible to make an injection mould tool with all these features in one part, as it has too many details and undercuts in too many different directions.”

3dprint-uk.co.uk

need an alternative to injection moulding? custom plastic components

1-10,000 UNITS no tooling cost

what do you need?

Try our NEW online injection mould comparison calculator!

SLS 3D printing service. Low volume manufacture and one off prints. Fixtures & fittings, PCB enclosures, machine parts, jigs & clamps, end of arm tooling. Upload your part now for an instant quote!

www.3dprint-uk.co.uk/upload-and-quote

Compare your injection moulding quote to additive manufacture and see how much we can save you on part production costs using SLS 3D printing.

hello@3dprint-uk.co.uk

3DPRINTUK chosen to represent uk manufacture 2018

T. 0208 692 5208

EDITOR’S CHOICE

HEAT RESISTANCE AXAIR FANS

NEW HEIGHTS IN HEAT-RESISTANCE: CLIBOS HIGH TEMPERATURE FAN

In collaboration with supply partner Casals Ventilation, Axair has recently launched a new high temperature fan designed to handle the hottest air yet.

thicknesses of 150 and 200mm) and the thermal grooves of the casing, a thermal bridge is created which allows the internal heat of the oven to be dissipated.

Listening to the requirements of customers in industries that have the challenge of extremely high temperature operations, a solution has been developed to move air and gases up to 350°C.

In this example of two CLIBOS-TR installed in a paint booth over, the difference in the internal and external temperature of the oven is illustrated in the thermal imaging.

APPLICATIONS The innovative use of high density rock wool insulation, heat-resistant paint coatings and carbon laminated steel means that the CLIBOS-TR series can withstand extreme conditions. Such environments include industrial ovens, furnaces, incinerators, boilers, paint booths and drying facilities for wood, ceramics, glass, barley and tobacco.

INSTALLATION EXAMPLE One of the most typical high temperature applications for the CLIBOS-TR series are paint booths. This type of installation has an oven for drying the paint once it is applied to the product. With the CLIBOS-TR fan, thanks to the rock wool (available in

PECM Issue 41

INCREASING PRESSURE WITH A SCROLL It may be the case that the installation in the oven or similar application needs a higher pressure than the medium pressure provided by the fan. In this situation, a higher air pressure can be achieved by adding the CLBC fan scroll with its corresponding suction cone, the CLBI. In addition to the CLBC scroll and CLBI cone, Axair provide a number of accessories for the CLIBOS-TR that allow it to be used in a wide range of high temperature applications. For example, ATEX switches, automatic bearing greasers, frequency speed controllers, rotation speed monitors and vibration monitoring systems. Contact Axair’s team to discuss your project or for more information about their high temperature fans.

www.axair-fans.co.uk sales@axair-fans.co.uk 01782 349 430

EDITOR’S CHOICE

EcoCooling Ltd EcoCooling provides an effective large space cooling alternative to refrigeration, at just 10% of the operating costs and 60% of the capital spend. The eco-friendly direct evaporative cooling and ventilation solutions enable you to maintain internal temperatures below 25°C all year round. Whether you’re looking for blanket cooling or spot cooling for workstations and production lines, EcoCooling’s systems are versatile and can be tailored to meet your specific requirements. With over 3000 installations worldwide, EcoCooling is an experienced UK manufacturer with solutions for a range of applications including warehouses, factories, gyms and large retail units. EcoCooling Ltd 01284 810 586 sales@ecocooling.co.uk www.ecocooling.co.uk

A new sales brochure presents the Cistermiser infrared urinal control valve Cistermiser’s market-leading IRC® infrared urinal flushing control valve is fully detailed in an informative new sales brochure, designed for ease of use by specifiers, installers and merchant counter staff. Fitted together with a robust and proven brass-bodied solenoid valve assembly, the IRC® sensor now features a compact body shape, an economy mode option to provide even greater water savings, a new-style mounting bracket for recessed installations and an improved design which allows clients to replace batteries in convenient fashion by simply removing the front fascia to access the battery compartment. The IRC® employs motion-sensing infrared to automatically control the flushing of cistern-fed urinals, minimise water wastage and ensure compliance with Water Regulations.

TRINAMIC Motion Control When digital information can be transformed into precise physical motion, previously infeasible use cases suddenly become possible, pushing the 4th Industrial Revolution: Advanced robotics, automation, prosthetics, and IoT, to name just a few. Nevertheless, efficiently turning digital information into physical motion requires more than simply transferring data into movement. Motor control technology needs to be easy-toimplement. It demands flexibility to support evolving device capabilities. And it needs to fit increasingly small form factors for new use cases. Trinamic achieves these critical requirements by turning key motor characteristics into competitive advantages for your devices, transforming digital information into perfect physical motion. www.trinamic.com/technology/what-ismotion-control/

www.cistermiser.co.uk

MCS Corporate Strategies Ltd For all R&D Tax Claims / Land Remediation / Patents / General Cost Recovery

MCS Corporate Strategies Ltd For all R&D Tax Claims/Land Remediation/ Patents/General Cost Recovery

www.mcs-corporate.com

01926 512475

gjw@mcs-corporate.com Issue 41 PECM

EDITOR’S CHOICE

NEW FACILITY IS OPEN AND FUNCTIONING TROY

THE TROY MANUFACTURING GROUP ANNOUNCE NEW STATE OF THE ART MANUFACTURING FACILITY

The Troy Manufacturing Group are pleased to announce the new Troy Manufacturing Facility is now open and fully functioning. The facility itself boast 26,583 sq. ft of state of the art workshop and office space. The site is situated in Baglan, Near Port Talbot; South Wales, with close links to the M4 for easy access and delivery to their customers. The facility has been fully refurbished, with the latest resin workshop floor, LED lighting throughout, shop floor welfare facility and locker room, optimised office layouts along with a visitor centre and board room. Troy Manufacturing Group have over 105 machines across various CNC milling & 5 Axis, CNC turning, high spec grinding, wire and spark erosion, high accuracy custom tool grinding and many types of manual machines. The team has a wealth of combined knowledge across the 47 staff members, which includes 25 highly skilled toolmakers, design engineers, mechanical installation fitters and project managers. They offer a wide range of services including project

PECM Issue 41

management, detailed specification of concepts, with design and manufacture of special purpose machinery. The site runs on twin shift basis with the scope to increase capacity as required, enabling the flexibility to fulfil orders based on any individual customer’s needs. However, what really sets the Troy Manufacturing Group apart is the team’s passion, experience and industry knowledge. This; combined with the facility’s state of the art machinery enables them to produce almost any component. The team’s reputation for excellence has given them the opportunity of working across a variety of engineering sectors including coin, medical, automotive, oil & gas, food & packaging, aerospace, rail and general machining. They currently work under ISO 9001:2015 accreditation. The company prides itself on a quality product delivered on time. Over the years they have built up strong working partnerships designing and producing components for some of the top names in manufacturing.

Their commitment to producing the best possible product and to helping their customer’s engineering visions be brought to life can be demonstrated with many previous customers testimonials.

If you would like any more information, please contact Andrew Snell; Head of Troy Manufacturing Group: 01792 862141 Andrew.Snell@bawengineering.co.uk

Over 40 years experience bringing engineering visions to life • Specialist in design & manufacture of jigs & fixtures, bespoke components and custom cutting tools. • Over 105 machines, covering various engineering disciplines. • Extensive capabilities including 5 axis milling, CNC turning, wire and spark erosion and precision tool grinding. • IS9001:2015 accredited. We’ve earned our reputation for engineering excellence working with some of the top names nationally and internationally in the oil and gas, automotive, aerospace, coinage and food industries. Our ability to manufacture almost any component and develop solutions to meet the most challenging requirements; enables us to create customised precision solutions for our customers. Our modern workshops and highly skilled engineers ensure we deliver finely crafted products to the highest possible standards. We are located near the M4 corridor with flexible shift working capacity; making us a convenient partner for all your precision engineering component design and manufacturing needs.

BAW PRECISION Precision Engineering +44 (0) 1792 862141 RG TOOLING Development & Prototyping +44 (0)1792 449892

Bring your engineering vision to life... Call us now to see how we can help you:

EUROGRIND Custom Tooling Solutions +44 (0)1792 862001

Manufacturing Group

www.bawengineering.co.uk

www.eurogrind.com

GLOBAL Precision Engineering +44 (0)1269 824570 Issue 41 PECM

EDITORâ&#x20AC;&#x2122;S CHOICE

FOUR CYLINDER TURBO ENGINE MERCEDES

NEW MERCEDES-AMG FOUR-CYLINDER TURBO ENGINE FROM ULTRA-MODERN PRODUCTION

The world's most powerful four-cylinder engine in series production, made in Affalterbach Affalterbach. Four wins: with an output of up to 310 kW (421 hp), the completely newly developed Mercedes-AMG 2.0-litre M 139 engine is the world's most powerful turbocharged four-cylinder engine in series production. With this engine, Mercedes-AMG has even exceeded the previously most powerful M 133 by 30 kW (41 hp). Maximum torque has also increased from 475 to up to 500 newton metres. With an output per litre of up to 155 kW (211 hp), the new MercedesAMG high-performance turbo engine even ranks ahead of many well-known supersports car engines. The new, highly efficient powerpack is produced on an innovative production line in Affalterbach, on the "One Man, One Engine" principle. The four-cylinder available in two output versions will ensure agile performance for the compact models of Mercedes-AMG: with 310 kW (421 hp) as the S-model and with 285

PECM Issue 41

kW (387 hp) in the basic version. This product policy logic has already proved successful in the V8-powered AMG Performance models, and more closely meets customer wishes. Apart from its performance figures, the new engine impresses with its immediate response. To this end the torque curve was carefully balanced ("torque shaping"): The peak torque of 500 newton metres (480 newton metres for the basic version) is available in a range of 5000-5250 rpm (47505000 rpm in the basic version). With this configuration, the AMG engineers have achieved a power delivery similar to that of a naturally aspirated engine for an even more emotive driving experience. The engine developers were also able to realise a dynamically increasing torque curve in the lower engine speed range, thereby improving agility. The increasing torque at higher rpm makes the engine more free-revving. Moreover, the high maximum engine speed (up to 7200 rpm) confirms the M 139 as a sports engine.

"We already set the benchmark in the segment with the preceding engine. This fundamentally new four-cylinder presented us with the challenge of doing even better. And we succeeded with a number of sometimes revolutionary solutions. With the M 139, we have once again impressively demonstrated the engine expertise of Mercedes-AMG. Not only is the output per litre unrivalled for a turbocharged engine, the high level of efficiency also demonstrates that the internal combustion engine still has further potential," says Tobias Moers, Chairman of Mercedes-AMG GmbH. Why "One Man, One Engine" was reinvented The new engine is entirely assembled by hand. On the first floor of the AMG engine manufactory in Affalterbach, a completely newly designed production line was installed in which Mercedes-AMG has brought the "One Man, One Engine" principle to a new level together with Industry 4.0 methods that incorporate the latest findings in ergonomics, materials handling, quality assurance, sustainability and efficiency. On the road to implementing Industry 4.0, AMG's hand assembly operation likewise follows the vision of "smart production". This excels with maximum flexibility, and is transparent and highly efficient. It safeguards and improves the quality of the engines and production processes using innovative and digital technologies. "We have completely revised the principle of "One Man, One Engine" for assembly of the M 139. The result is an ultra-modern production process that places the focus on people. To achieve this, we created the ideal working conditions in a bright, precisely organised and clean environment for our employees. This provides the best basis for continuing to ensure our high quality level even as the technology becomes more complex," says Emmerich Schiller, COO and member of the Board of Management at Mercedes-AMG GmbH.

Why a 180-degree rotation brings many advantages The new engine excels with numerous intelligent design features. Compared to the likewise transversely installed M 260 four-cylinder in the "35" models or the preceding M 133 engine, the new Mercedes-AMG M 139 is rotated around its vertical axis by 180 degrees. This means that the turbocharger and the exhaust manifold are now positioned at the rear, on the side of the firewall when viewed from behind. The intake system is therefore positioned at the front. This configuration allows the flattest possible and aerodynamically advantageous front section design. Furthermore, the new arrangement allows much improved air ducting with shorter distances and fewer diversions - both on the intake and exhaust side. How roller bearings improve the responsiveness of the turbocharger The new twinscroll turbocharger combines optimum responsiveness at low engine speeds with a high power in the upper rpm range. In addition to this, the turbine housing is divided into two flow passages which run parallel to one another. Together with the likewise divided ducts in the exhaust manifold, this makes it possible to feed the exhaust flow to the turbine separately. The aim is to prevent the individual cylinders from influencing each other negatively during load cycles, and to improve the gas cycle. The result is higher torque at lower engine speeds, and extremely good responsiveness. Furthermore, the shafts of the compressor and turbine have roller bearings for the first time as in the top output variant of the AMG 4.0-litre V8 engine in the AMG GT 4-door CoupĂŠ. Issue 41 PECM

The roller bearings reduce mechanical friction within the turbocharger to a minimum. The charger therefore responds more readily and reaches its maximum speed of up to 169,000 rpm more rapidly. How electronic charge pressure control optimises responsiveness With a maximum charge pressure of 2.1 bar (1.9 bar in the basic version), the 2.0-litre turbo engine is also the top performer in this respect. The electronically controlled wastegate (exhaust relief valve) allows the charge pressure to be controlled even more precisely and flexibly while optimising responsiveness, especially when accelerating from partial load. Numerous parameters are taken into account in this process. The main input signals for the wastegate control unit are the charge pressure, throttle flap position and the knocking tendency. The modifying signals include the intake air temperature, engine temperature, engine speed and atmospheric pressure. This also makes temporary boosting of the charge pressure (overboost) possible under acceleration. Fresh air is used in addition to oil and water to cool the turbocharger. This is directed specifically to the charger from the radiator grille, via the engine cover designed as an air deflector and ducts beneath the bonnet. The concept is based on the principles and experience gained with the cooling for the internally mounted turbochargers of the current AMG 4.0-litre V8 engines, starting with the AMG GT in 2014. In addition the turbine housing has integral insulation.

PECM Issue 41

The advantages of the crankcase The all-aluminium crankcase is a chill-cast unit which excels with outstanding material properties. In this process the molten aluminium is poured into the metallic mould using the effect of gravity. Thanks to its good thermal conductivity, the water-cooled mould allows rapid cooling and solidification of the melt. The result is a fine-grained, dense structure that guarantees very high strength. Complex interior geometries can be realised with the help of enclosed sand cores. The so-called closed-deck construction â&#x20AC;&#x201C; a design from motor racing ensures outstanding rigidity with low weight, and allows peak combustion pressures of up to 160 bar. The areas around the cylinders are mostly solid, and the cover plate is only penetrated by smaller ducts for the coolant and engine oil.

The crank assembly with a lightweight, forged steel crankshaft and forged aluminium pistons with optimised piston rings combines low friction with high strength. The maximum engine speed is 7200 rpm, and peak output is developed at 6750 rpm. The sump features baffle plates so that despite the larger sump, and even under high lateral acceleration forces, there is always sufficient engine oil to lubricate all the relevant components. Why the cylinder liners are coated with NANOSLIDE To reduce friction between the pistons and cylinders, the linings are coated using patented NANOSLIDE technology. This gives the linings a mirror-like surface for minimal friction, is twice as hard as conventional grey cast-iron liners and therefore makes them much more durable. NANOSLIDE was developed by Daimler AG, and is protected by more than 90 patent families and more than 40 patents.

The coating was first used for AMGâ&#x20AC;&#x2122;s M 156 engine, has benefitted further AMG engines for many years and can also be found in the Formula 1 engine of Mercedes AMG Petronas Motorsport. More information about Mercedes-Benz is available online at: www.media.daimler.com, www.media.mercedes-benz.comand www.mercedes-benz.com

Issue 41 PECM

EDITORâ&#x20AC;&#x2122;S CHOICE

INDEPENDANT SPECIALIST UK MANUFACTURER JTS LTD

MODULAR TEST CHAMBER FOR PRESSURE TESTING FACILITY

James Technical Services Ltd is an independent specialist UK manufacturer, with design and build undertaken in-house by a team of skilled engineers and technicians. We believe in working closely with clients to ensure the best outcomes for individual test needs, whether the requirement is for standard or bespoke chambers, containerised systems, or walk-in room. As a small company backed by over 40 years of experience in test chamber manufacture, we have the flexibility to adapt to all new and developing test requirements. As such, we are delighted to have been working on a project for KW Pressure Testing, part of KW Group, who provide testing services for the Oil & Gas Subsea, Oceanographic, Materials Science and Energy sectors. As part of their development of a dedicated test facility to provide high quality

PECM Issue 41

Illustration provided by KW Group

environmental and pressure testing services, the KW Pressure Testing brief was for a multi-purpose walk-in chamber to accommodate variable test loads and test specifications for their own clients. The conditions to be recreated require the chamber to operate at a temperature range of -70Â°C to +200Â°C, with test loads of up to 3000 kg, optionally loadable by crane. The chamber needed to be constructed with modular sections for ease of transport. JTS engineers developed an adaptable, modular roof system to facilitate test loads that exceed 2m high, or that need to be loaded into the test chamber by overhead crane. With a test area of 2m wide x 3m deep x 2m high the chamber provides a test facility that is energy efficient and versatile, whilst enabling the wide range of test specifications that KW Pressure Testing offer to their clients. Working closely with customers in this way ensures the best outcomes for individual test needs, whether the requirement is for standard or bespoke chambers, containerised systems, or walk-in rooms. With experience across a wide range of industries, and a varied client base, we are ready to help you achieve the best environmental test solutions for your products.

JTS also provides full after sales support, including operator training and ongoing technical support. We offer a variety of service and breakdown contracts, from a one off visit to ensure compliance with current Fgas legislation, to full scheduled maintenance and unlimited breakdown cover. JTS will structure a contract to suit the needs of the customer.

jts-test-chambers.co.uk

jts-test-chambers.co.uk 01874 711209

01874 711209 Issue 41 PECM

EDITOR’S CHOICE

Hellberg Safety – SECURE Active active listening headsets.

Konecranes launches three new lifting products

Hellberg Safety specialist PPE products include highly advanced hearing protection products, face protection and communication solutions for personal wellbeing on site.The SECURE ACTIVE headsets enable workers to communicate safely with colleagues, hear signals and other important information while protected from hazardous noise.

Konecranes has launched three new lifting products to reinforce its comprehensive range of material handling equipment. The new products are aimed at industrial customers in a broad range of sectors, including manufacturing, automotive and process industries. The S-series wire rope hoists, C-series chain hoists and M-series winches bring new technology and innovation to areas including motor drives, rope, reeving systems, clutches and brakes to deliver safer equipment which performs better, lasts longer and delivers greater operational savings. The S- and M-series cranes are equipped with sensors and the capability to collect and send data. S- and M-series cranes provide access to the yourKONECRANES portal, which is a digital service for operators, technicians and management, allowing customers to maximise functionality of their crane.

The built-in, level-dependent microphones provide perfect directional hearing with an electronic protection system that limits all sounds through the speakers to a safe sound level. The replaceable headband and ear cushions allow for regular replacement for a long lasting and high performing product. For optimal safety, communication radios and other sound sources can be connected via the external audio input. For more information on the Hellberg Safety product range, call the Hultafors Group UK Helpline on 01484 854788 or checkout the website www.hellbergsafety.com

Email: sales.uk@konecranes.com Website: www.konecranes.co.uk

DOSCH DESIGN – Your innovative partner for a successful 3D-experience Since 1995 DOSCH DESIGN has been a fixture in quality CG products by staying on the cutting edge in 3D-design, animation, architectural visualizations, print publishing or motion design. With its well-diversified product range DOSCH DESIGN supports CG artists in their daily work. Especially in the field of Mechanical Engineering, tool making or the automotive industry, 3D-Design has become an indispensable element. DOSCH DESIGN has developed a lot of helpful tools that make life easier for designers and have become an integral part of many users’ creative arsenal. The Company offers an extensive product range in 3D-Models, Textures, HDRIs, Viz Images or Audio Products. These tools are an important part of marketing for supply companies or manufacturers who want to visualize processes for publications, animations or instruction manuals. info@doschdesign.com www.doschdesign.com

QUALITY HINGES MANUFACTURER OF FDA APPROVED RUBBER COMPONENTS

TALK TO THE EXPERTS.

Fairham Mouldings Ltd, have been manufacturing FDA rubber products for the Food & Drink Industry for 20 years. Our Approved Food Quality materials can meet a wide range of temperature, chemical resistance and elastomeric properties expected in the manufacture of food stuff. Our Approved Materials have been carefully formulated and tested to the FDA regulations: CFR21 Section 177.2600. Testing has been successfully undertaken by an UKAS accredited laboratory: Smithers RAPRA UK. These results render them suitable candidates for USP Class VI (United States Pharmacopeia) testing. All moulding and mould making is carried out on our site in Blackburn, Lancashire.

PECM Issue 41

We pride ourselves in our expertise, quality and experience in the rubber industry. this has gained us the status of ‘Fit for Nuclear’ (F4N), the first rubber manufacturer to gain this award. Need more information or want to discuss your own precision rubber component needs. Call the Experts! T: 01254 663642 W: www.fairham.com E:enquiry@fairham.com

01827 63391 sales@goldwassallhinges.co.uk Whatever your hinge requirements, we offer a solution. Bespoke/Stock - UK maunfactured - Expert advice

Issue 41 PECM

EDITOR’S CHOICE

CABLE INNOVATION HEATSENSE CABLES

HIGH TEMPERATURE CABLE MANUFACTURING TECHNOLOGY REACHES A NEW LEVEL ABOUT HEATSENSE Established in 1984 by two engineers from Fothergill & Harvey in Lancashire, Heatsense has steadily built its reputation and is today regarded by many as the UK’s leading specialist manufacturer and supplier of thermocouple cables and extension wires. Many original customers continue to do business with Heatsense and a number of its original employees still work for the company.

CAPABILITIES Heatsense’s manufacturing capabilities cover a broad range of specialist high-performance thermocouple and signal cables that operate in extreme environments. The company is regarded as a technology leader in fluoropolymer extrusion. The company manufactures thermocouple cables and extensions wires, equipment wires, coaxial cables, multicore cables, micro cables and fine wires.

Current management acquired the business in 2014, relocated it to Greater Manchester and made significant investment in plant and equipment, broadening the company’s manufacturing capabilities. Throughout 2018, the company saw significant growth; acquiring new equipment and significantly expanding its workforce. Insulation materials include PFA, FEP, PTFE, ETFE, PEEK, EFGLAS, PE, PU, PVC, Taped & Sintered PTFE, Mica, Silicone, Polyimide & Aramid Yarns. Braiding materials include glass & ceramic fibres, other specialist yarns and various metals.

These cables are resistant to flame, oils, chemicals and operate in ultra-high vacuum, cryogenic, radiation and nuclear environments. The company offers a range of approvals that meet all internationallyrecognised specifications.

PECM Issue 41

Markets include automotive, aerospace, nuclear, medical, general industry and oil & gas. Highly customer focused, Heatsense offers a bespoke advanced technical design and manufacturing service, rapid response times, short lead times, low MOQ’s and competitive pricing.

Heatsense has achieved both ISO9001:2015 and ISO14001:2015 Accreditations since 2014 and is currently working closely with the NAMRC (Nuclear Advanced Manufacturing Research Centre) on the F4N (Fit for Nuclear) Approval Scheme. The company is also working towards AS9100:2016 and aims to be accredited in 2019. Call: (+44) 01706 767070 www.heatsensecables.co.uk

The UK’s leading specialist high-performance cable manufacturer We’re a technology leader in high-temperature fluoropolymer extrusion and material used in the manufacture of specialist high-performance cables that operate in extreme environments

INSULATION EXPERTS PFA, FEP, PTFE, ETFE, PEEK, EFGLAS, PE, PU, PVC, Silicone, Taped & Sintered PTFE, Polyimide, Aramid Yarns, Mica, Glass & Ceramic Fibre

MARKET SPECIALISTS

Automotive

Aerospace

Nuclear

Medical

Industrial

Research

PARTNERSHIP BUILDERS Advanced technical design & bespoke manufacturing service • Rapid response times • Short lead times • Based in the UK

• Service international partners • Competitive pricing • Low MOQ’s

*Registered owner of the world-renowned INTEMP trademark

Find us online: heatsensecables.co.uk or call: (+44) 01706 767070

EDITOR’S CHOICE

Humidity control expertise & experience......

Steam Humidifiers

Dehumidifiers

Adiabatic Humidifiers

...when knowledge matters. • • • • •

Improves manufacturing & storage processes Ensures stable conditions Equipment to suit all applications Full technical back up FREE site survey & consultation

www.humiditysolutions.co.uk

PECM Issue 41

Service & Maintenance

EDITOR’S CHOICE

DESICCANT DEHUMIDIFIERS HUMIDITY SOLUTIONS

NEW DEHUMIDIFIER RANGE FOR HUMIDITY SOLUTIONS

From 1st November 2019, Humidity Solutions will be the exclusive UK distributor for Denmark based Cotes, manufacturers of desiccant dehumidifiers.

products, but also the back up and support we will receive from the manufacturer in all our projects. We look forward to working with the Cotes team.’

Cotes design and manufacture robust, top quality absorption dehumidifiers for applications including cold stores and freezer tunnels, storage facilities, spray drying installations, lithium-ion battery production, food industry production facilities and wind turbines. Microprocessor-based control units and advanced sensors make sure Cotes dehumidifiers are easy to control, with the exact degree of automation applications require.

Humidity Solutions offers free of charge design, site surveys and quotations with a full range of after sales services such as installation, technical telephone support, servicing and planned maintenance. This allows the company to offer a full turnkey solution with peace of mind and support from design right through the unit’s working life.

Peter Lange, Export Sales Manager for Cotes, stated ‘we are delighted to have Humidity Solutions to represent us in the UK, and look forward to working with their team to provide specialist dehumidification solutions to their customers.’ John Barker, Managing Director of Humidity Solutions, added ‘the Cotes range allows us to further develop our dehumidification business in the UK and we are confident not only in the quality of the

Whilst Humidity Solutions already has extensive experience in dehumidification applications, including classic car storage, charcuterie production and pharmaceuticals, some of these markets are seeing significant expansion due to technological and environmental developments. Lithium-ion battery production, for example, is a rapidly expanding sector where very precise environmental conditions are crucial and relative humidity levels of less than 1% are required.

Humidity Solutions will be showcasing the Cotes dehumidifier range at Battery Tech Expo at Silverstone in March 2020, and, together with a representative from Cotes, will be giving a presentation at the show to explain the importance of humidity control in this industry. For more information about the Cotes range, or any of Humidity Solutions’ products or services, contact us at info@humiditysolutions.co.uk, or visit our website: www.humiditysolutions.co.uk

Issue 41 PECM

EDITOR’S CHOICE

SOLUTIONS FOR BEARING PROBLEMS GRAPHITE METALLIZING CORPORATION

PROVIDING LIFETIME COST SAVINGS AND SIGNIFICANT OPERATING ADVANTAGES OVER CONVENTIONAL BEARINGS

GRAPHALLOY, a graphite/metal alloy, is a family of materials used to manufacture bearings, bushings and other components for Machinery, Food Equipment, Pumps and Process Equipment. GRAPHALLOY materials are solid, uniform, self lubricating, non galling and operate in temperature extremes from -400°F (-240°C) to 1000°F (535°C) with a low coefficient of friction. GRAPHALLOY bearings are long lasting. Operating where oil and grease lubricated bearings seize and where plastics fail, these materials provide lifetime cost savings and significant operating advantages over conventional bearing materials. In some applications, these bearings have operated for up to 20 years without maintenance.

PECM Issue 41

A solution for the toughest bearing, bushing, thrust washer, cam follower, or pillow block bearing design problems, GRAPHALLOY is available in over 100 grades with specific properties that meet a wide range of engineering solutions and specifications. FDA acceptable grades for food contact equipment are available. NSF® International and WRAS (UK) certified grades of GRAPHALLOY material for use in municipal well pumps and water treatment plant applications are also available. Standard designs are available as pillow blocks, cam followers and bushings, but many GRAPHALLOY products are custom designed to the unique requirements of a specific OEM or retro-fit application.

GRAPHALLOY ® is the registered name of graphite/metal alloy materials manufactured by Graphite Metallizing Corporation under ISO 9001:2015 certification.

www.graphalloy.com

GRAPHALLOY® Bearings... We Go to Extremes

Handle High Temperatures and Harsh Operating Conditions with Ease. • • • • • • •

Survives when others fail Run hot, cold, wet or dry Corrosion resistant Self-lubricating Low maintenance -400˚F to 1000˚F (-240˚C to 535˚C) Ovens, furnaces, conveyors, mixers, dampers Yonkers, NY USA

H1 Yonkers, NY USA +1.914.968.8400

•

www.GRAPHALLOY.com

EDITOR’S CHOICE

LATEST IN MANUFACTURING TECHNOLOGY ETG

ETG CELEBRATES 25TH BIRTHDAY WITH SHOWCASE OF THE LATEST MANUFACTURING TECHNOLOGY The UK’s leading machine tool supplier celebrated its 25th birthday in style, when it showcased its latest manufacturing technologies. Engineering Technology Group (ETG), which recently acquired HK Technologies, threw open the doors of its Wellesbourne Headquarters to give over 450 industry delegates the latest insight into the world of turnkey solutions, with two new product launches, a UK debut for the Nakamura MX100 and an in-depth look at the latest additive manufacturing and wire EDM machines. Orders for four new CNC machines were taken during the two-day event, which was used to celebrate the firm’s milestone birthday and to reinforce the growing demand for ‘lights-out’ manufacturing, automation and machine tools that offer world class precision and increased flexibility. Sub-contract manufacturers involved in automotive, aerospace, medical and renewables were interested in the new Quaser UX500 twin pallet machine (with 15k to 24k rpm spindle), the dynamic 5-axis simultaneous machining power of the bavius TR80 Machining Centre and the compact footprint and powerful performance of the Chiron DZ15 machining cell. Reinforcing the turnkey excellence focus, there was also Hyfore workholding, Filtermist oil filters, Blum-Novotest laser measuring systems, a Robojob Turnassist and the latest robot from ABB present. Martin Doyle, Managing Director of the Engineering Technology Group, commented: “We wanted to make a big statement for our 25th and I believe we’ve achieved this, bringing the latest machine tools, automation and additive manufacturing technology to the UK. “Our customers are telling us they want more ‘lights-out manufacturing’, machines that take up a smaller footprint and twin pallet capability so they can work quicker and smarter.” He continued: “Yes, there’s a bit of uncertainty out there, but firms recognise the need to stay ahead of the rest of the world

PECM Issue 41

when it comes to technology. By investing in new solutions that we can bespoke to their requirements, they can reduce cycle times, improve lead times and look at taking on increasingly complex components.” “We have to aim to be an extension to their production team and this is our focus going forward. It was also great to see so many of our technical partners exhibiting their own unique products and services, including Hydrafeed, Ceratizit, Bott and Jemtech.” Industrial Revolution The ETG Open House gave the company the ideal opportunity to introduce its new business HK Technologies to the market, with technical experts on hand to talk through Balance Systems, the Mitsubishi Wire EDM MV12000, Markforged’s MetalX metal printer and X7 Desktop Series for composite printing and 3D Systems’ ProJet MJP 2500 plus that provides bespoke parts and industry-leading attention to detail. Gareth Jones, the new Managing Director at HK, used the event to promote the importance of educating industry to the true benefits of additive manufacturing and why more companies - both large and small - need to see it as a way of delivering prototypes and low/medium volume production. He also highlighted how additive technology fits into the ETG and Hyfore portfolio, offering manufacturers quick turnarounds for bespoke

workholding, jigs, fixtures, soft jaws and robot grippers. “When 3D printing first burst onto the scene, the sector got caught in the trap of making it too mainstream for domestic users, encouraging a scenario where we’d all own a printer at home and we’d start making our own mugs for example,” explained Gareth. “That’s not the reality. Instead, it needs to be seen as a next generation production technology, capable of producing repeatable quality, quickly and cost effectively. We’ve got a major task on our hands to get this message across and, one of our main aims for the future, is getting the technology out there and firms using it.” He concluded: “There are a lot of new materials being developed and released to support changing industrial applications, not to mention the implementation of easyto-use software. These factors – combined with the new technology and our internal technical experts – are helping us deliver tangible, bottom line results to our customers. It’s an opportunity the sector needs to make more of.”

For further information, please visit www.engtechgroup.com or follow @engtechgroup/ @hk_technologies on twitter.

HIGH PERFORMANCE CORIOLIS MASS-FLOWMETER Model HPC - Low Flow, High Performance The World’s Smallest Coriolis Flowmeter in Dual Tube Design for Liquid & Gasses

Key Features

Typical Applications

• For the smallest flow rates • 4 Sensor coils for extremely high resolution • High accuracy ± 0.1% of vol. MW • Temperatures up to 180 ° C • Pressure resistance up to 600 BAR • Very robust body • Insensitive to vibration • Variable installation concept • For use with the latest UMC4 transmitter

• Chemicals • Petrochemicals • Oil & Gas • Fuels & Additives • Pharmacy • Food & Beverages

01623 427701 www.kobold.com info.uk@kobold.com

• Dosing

Issue 41 PECM

EDITOR’S CHOICE

OEM ENGINEERING COMPANY SMARTWATER

A MODERN-DAY HORROR STORY

A gap has been identified in track and trace technology In January 2017, a Director of an international size OEM engineering company of specialist fasteners, became embroiled in a dispute with a major customer, who accused them of selling shoddy products. Apparently, one of their high specification bolts had been installed into a large turbine, which operated under extreme pressures. It was fitted by the customer’s highly skilled engineering team about six months earlier, who claimed that they had bought the bolt from an authorised Distributor of the OEM’s. Upon inspection at the Customer’s site, the OEM’s own engineers found that the bolt displayed their Company’s logo and, to all intent and purposes, it looked like a genuine bolt. However, as it had been fitted months previously, the Customer had thrown all the packaging away that contained the ‘track and trace’ production data.

PECM Issue 41

The Customer warned the Director to expect a claim for damages to the turbine and consequential loss, amounting to many tens of thousands of pounds. As a result, the Director alerted their Insurer of a potential claim and asked the Company’s Metallurgists to conduct tests on the bolt to confirm that it was a genuine bolt and, if it was, to try and identify what caused the problem, as there may be a potential recall of flawed products needed. The Insurer advised them that, whilst they were committed to pay out on the claim for damages up to the extent of the product liability cover, they would only do so if it was a genuine product. The Director realised that he was between ‘a rock and a hard place’. His Metallurgists could either determine that the bolt was

a counterfeit, negating the Company’s insurance cover leaving it liable to pay damages or find that it was a genuine but flawed bolt, resulting in the horrors of a product recall. The Metallurgists reported that they believed that it was a counterfeit, based upon the poor quality of metal used. He advised the Customer of the result and suggested that they should take their claim up with the Supplier of the counterfeit bolt. The Customer responded that his engineering team had already investigated, with the Supplier claiming that they had bought it from an authorised Distributor of the OEM. As far as they were concerned, the OEM was still responsible and they would not only take the matter to Court but cease all future business with the OEM.

The Director reported to his colleagues that not only was their insurance cover invalid but they also faced the loss of a major customer and being dragged through the Courts. After considering all their options, rightly or wrongly, through gritted teeth, the Board decided to settle. A nightmare situation for the OEM but, with the spread of counterfeiting across all engineering sectors, heightened by threat of 3D printing, what could they do to prevent it happening again? They called SmartWater. SmartWater is the most highly accredited company of its type in World, working closely with and trusted by both European and US Government agencies. We create millions of datasets in a liquid or solid format, which can either be embedded within a component or directly onto its surface, thereby providing it with a unique weather and fire resistant ‘forensic’ signature. It was noted that thousands of bolts passed along conveyor belts prior to packing. Consequently, a ‘robot’ arm with a misting head was inserted that sprayed every bolt with a unique forensic signature, assigned for the exclusive use of the OEM.

Despite bearing the OEM’s logo, this bolt was a counterfeit

The minimal costs and no disruption of the production process, with a distinctive ultraviolet indicator was added for easy onsite detection. Later on, the OEM decided to change the formula every production run, a simple process, so that the production data could be recovered, even years after the bolt had been fitted. In future, should a similar claim arise, SmartWater scientists could inspect the bolt and, through forensic analysis of the smallest speck, determine within hours whether or

not it was genuine and, if it was, recover all the production data. If challenged, the scientists would provide expert testimony in a Tribunal or Court in support of the OEM.

Contact SmartWater via: Telephone: +44 (0)333 320 7797 Email: supplychain@smartwater.com Website: www.smartwater.com/ engineering-solutions/

Issue 41 PECM

EDITOR’S CHOICE

UV CURE-IN-PLACE TECHNOLOGY HERNON MANUFACTURING

HOW TO USE CURE-IN-PLACE GASKET TECHNOLOGY TO IMPROVE OIL SHAFT SEAL PRODUCTION UV Cure-in-Place (CIP) gasketing technology was created to replace an inferior sealing process for automotive oil shaft seals or rotary seals. Direct contact with the shaft is secured using a rubber gasket while the exterior of the seal, where it meets the housing, has traditionally been sealed using a solvent based sealant. Solvents have well-known problems with toxic fumes and material loss due to evaporation. By contrast, UV CIP does not use any solvents. Instead, it is designed to be cured by UV LED curing lights, built by Hernon®. These lights are optimized to a specific wavelength for the sealant. Once cured, the bead for this application is soft and tack free, allowing the seal to adjust its form to fill the gap between gasket and housing. The dispensing and curing system for this sophisticated application was developed by Hernon Manufacturing as part of their Total Solutions approach. Hernon® experts coordinate mechanical engineering capabilities with precision chemistry to ensure a copacetic application process. The journey of components through the machine starts with an inbound conveyor where intelligent sensors track part locations. The sensors communicate to robotic arms when parts are ready to enter active stages. The steel components are picked up using simple permanent magnets. This method reduces the complexity of moving parts from stage to stage when compared to pneumatics or electromagnets and keeps energy usage to a minimum. The seals are first moved to a dispensing station where a robotic spindle arm rotates the seal under Hernon’s proprietary SureShot® 3000 valve. The valve dispenses sealant onto the spinning seal creating a controlled bead. With the bead in place, parts are moved to a UV curing station. To protect users, the parts are inserted into a protective housing before four high intensity UV LED lights cure the bead for specified exposure times. The final stage is a laser inspection where the bead location and width are analyzed. The bead is also checked to be smooth and contiguous. If the finished part meets all specifications it is transferred to a conveyor out of the machine. When oil shaft seals come off the outbound conveyor, they can be instantly used or packaged. Parts are processed at speeds of 12-15 parts per minute, depending on the size of the seal. The larger the size, the longer dispensing and curing times needed. With no solvents used in the new CIP sealant, production is more environmentally friendly, sustainable and much less messy.

Enquiries about UV CIP materials or application processes can be submitted at Hernon.com, emailed to sales@hernon.com or placed via phone at (888) 473-0217.

PECM Issue 41

Issue 41 PECM

EDITOR’S CHOICE

DIGITAL CONTROL SYSTEM KHS

FOR MORE EFFICIENT PROCESSES: KHS DEVELOPS A DIGITAL CONTROL SYSTEM FOR PET BOTTLE PRODUCTION Unit Mold Control yields further benefits with regard to the growing percentage of recyclate used in PET bottles in particular. “Process accuracy reaches its limits with containers such as these,” Haesendonckx says. “As the material quality varies when recycled PET is used, the bottle becomes less and less stable the less the preform weighs or manufacturers have to use heavier preforms to ensure stability.” With the new system weights can be reduced while retaining bottle stability, claims Haesendonckx. “Unit Mold Control effectively compensates for discrepancies by identifying any unwanted material displacement during wall thickness inspection and automatically counteracting this.”

Even on the most advanced machine there can be discrepancies in the distribution of PET bottle material in the stretch blow molding process. This has an impact on the bottle quality and production efficiency. In order to optimize these parameters KHS recently developed Unit Mold Control in cooperation with US company Agr International inc. (Agr). This digital, automated process control system, connected with the KHS controller, now individually regulates the respective blow stations in KHS’ InnoPET Blomax series, thus minimizing any fluctuations in quality during stretch blow molding. This results in improved bottle stability coupled with lower preform weights. This had proved something of a challenge to date, especially where containers with a high recycled PET content are used. On a stretch blow molder the amount of wear on the individual blow valves used can vary. This means that the bottles blown with the same also change throughout the service life of the stretch blow molder depending on the station used. In the production process this can cause discrepancies in the distribution of material and thus to differing thicknesses of bottle wall. To date parameters could only be

PECM Issue 41

adjusted for the entire machine and not for each individual station. With the new digital Unit Mold Control system manufacturers optimize their blow molding process by making individual settings for each station. “This enables material distribution to be more precisely controlled per station, thus minimizing variations in the wall thickness from mold to mold by more than 30%,” explains Frank Haesendonckx, head of Technology at KHS Corpoplast. Unit Mold Control adjusts settings fully automatically To this end, Unit Mold Control inspection technology constantly measures the material distribution in each bottle and adjusts the settings for optimization fully automatically. “With this system deviations in the individual mold stations are identified. By applying an algorithm the degree of variability is reduced without operator intervention and possible incorrect settings are avoided,” states Haesendonckx. Furthermore, the data captured from the individual mold stations provides valuable information for the condition-based maintenance of valves, stretching systems or mold shells, for instance.

Partner Agr is also convinced by the joint new development. “Our commitment to the global beverage market is to provide innovative process control solutions for the factory floor,” says Robert Cowden, COO of AGR. “In doing so we’re helping to constantly optimize processes and improve production line efficiency and productivity by reducing unplanned downtime, labor content per produced container and energy costs.” Unit Mold Control is available as an option for KHS InnoPET Blomax Series IV and V stretch blow molders and has already successfully proved itself on the market several times over. Furthermore, the new system – whose industrial property rights are held by KHS and Agr – can also be retrofitted into existing plant machinery.

For more information go to: www.khs.com/en/media Subscribe to our newsletter at: www.khs.com/en/media/publications/ newsletter.html

EDITOR’S CHOICE

SAFE, EASY & CONVENIENT Blackfast’s room temperature blacking process is both safe. easy and convenient to use. The process has been developed for safe and reliable use in metal working facilities, so it is no longer necessary for parts to leave the production site for finishing by an outside contractor. Unlike conventional methods of blacking it is non-hazardous. Blacking of iron and steel provides a corrosion resistant finish without dimensional change.

This is attractive for machined parts manufactured to tight tolerances. where plating or painting would not be acceptable. As it is very important that the components are clean and free from grease before using the blacking process, Blackfast also offers a range of degreasers from solvents to water based and rust removers. 020 8339 7370 www.blackfast.com

WHEN THE GOING GETS TOUGH…

Litre Meter now distribute the Lake Monitors range of VA meters for a variety of applications including bidirectional flow, high temperature and high pressure. The Basic unit is rated to 116°C and 240 bar in brass. High temperature versions rated to 315°C and high pressure versions to 410 bar are in stainless steel.

There are versions for pneumatics, hydraulic test analysis and phosphate ester measurement, too. Call today.

www.litremeter.com

x Issue 41 PECM

EDITOR’S CHOICE

RESHORING PROCESS ALBERT JAGGER

ALBERT JAGGER RECIEVES THE GREEN LIGHT TO BEGIN RESHORING PROCESS BACK TO THE UK One of Britain’s largest manufacturers and suppliers to the commercial vehicle bodybuilder, boat builder, agricultural and engineering industries, has received the green light to reshore up to one-million overseas products per year back to the UK. Procuring investment from its parent company Albert Jagger Holdings, Albert Jagger Engineering has used the funding to begin the extensive process of reshoring its Antiluce product range from China. Citing a change in the Group’s business strategy, the production of Antiluce Fasteners will return back to Albert Jagger Engineering’s manufacturing facility in Vincent Works, Bloxwich for the first time since the early 2000’s. The process of reshoring involves transferring a business operation that was moved overseas back to the country from which it was originally relocated. As such, Albert Jagger will able to produce more efficiently with less scrap – saving both time and cost to its manufacturing operation. Further efficiencies have also been introduced in the company’s assembly process with additional investment in the latest automated assembly. Taking approximately six months, the first phase of the reshoring process has commenced and is already benefiting the UK marketplace with shorter lead times, whilst also ensuring quality and price meet the needs of Albert Jagger’s customer base. Founded in 1953, Black Country based Albert Jagger Engineering specialise in manufacturing high quality parts with a comprehensive range of materials to produce Antiluce Fasteners, paddle handles, body mounting brackets and spring bolts. In house capabilities such as CNC machining enables the state-of-theart engineering company to offer comprehensive services with a team of highly skilled machinists, metal fabricators and welders that are central to all projects. Key to the company’s engineering services, CNC machining has allowed Albert Jagger

PECM Issue 41

Engineering to keep up with the current shift within the manufacturing industry that now demands a diverse range of machining needs. The state-of-the-art machinery works with a range of materials including mild steel, stainless steel, aluminium and nylon and provides consistent accuracy and in the manufacturing process of components that are produced to the highest of quality. In order to continue providing their high-quality offering, Albert Jagger have invested in two CNC machines – the Citizen Cincom L220 machine and the IMECA Boss 338 HD bar feeder – to further fine-tune their engineering capabilities and enable them to manufacture components to precise specifications. Maintaining a quality management system compliant with ISO 9001:2015 requirements, the company’s revered engineering history allows Albert Jagger Engineering to provide versatility and diversity from their site in Walsall, West Midlands. Having teamed up with the Manufacturing Technology Centre to deploy 5S, lean and six sigma into Albert Jagger Engineering, the company has recently refurbished their entire UK engineering facility using virtual reality technology to remap the layout of their shop floor. Further investment into Albert Jagger Engineering is expected in the near future which will subsequently be devoted to additional staff training, the latest automation software, acquiring a CMM machine and improving the company’s 3D printing capabilities. Mark Hilton, Operations Director at Albert Jagger Limited commented: “We at Albert Jagger Limited have made a conscious choice to return our manufacturing process back into the UK in order to improve control over every stage of the production line. “The review of our business strategy is in response to the uncertain economic climate governed by political turbulence, with the objective of ensuring the future of Albert Jagger Engineering is secure for years to come.

“By bringing everything in house we are now have the capability to regulate batch quality control more efficiently by dramatically decreasing lead times – which would range anywhere between four to six months in China. “Such a significant lead time can provoke issues ranging from the unreliability of product quality or increased risk of supply chain disruptions. Now this lead time has been cut to between seven to ten days, Albert Jagger Engineering has the complete control over providing the seamless service to its customer base for which is strives whilst having the added benefit of keeping all associated costs such as warehousing and packaging in house at a reduced rate. “Returning the business’ manufacturing process to British shores also means we are able to produce bespoke parts for our customers more efficiently and tailor to the needs of the consumer. “We have taken this approach to ultimately take back control – and as a result we are now able to take something from sheet metal, manufacture our product and sell to our customers without concerning ourselves with the added complexities from the supply chain. Equally, this gives us the ability adapt what we offer to suit our customer’s product rather than the customer being forced to work within any constraints.

www.albert-jagger.co.uk

EDITOR’S CHOICE

RMIG is the world's largest manufacturer and supplier of perforated metal and its related products. We know our customers’ requirements for price and quality and meet their demands with uncompromising service. Not only do we offer standard and bespoke perforated metal sheets, we are able to offer you a range of secondary operations as detailed below. Complete solutions With a continued investment in the latest equipment and a network of professional partners we are able to produce prime quality products and solutions – from a simple perforated sheet to the fully formed and coated custom made part.

Levelling For some applications a high degree of flatness is required, we have processes in place to ensure our perforated coils and sheets meet with your most demanding requirements. Rolling and forming We can roll, bend and form perforated sheets to match your design. Aesthetic finishes and protective coating We can offer powder coating and hot dip galvanizing solutions to meet your specifications. For more information please contact us www.rmig.com email: info.uk@rmig.com Tel: 01925 839610

Cutting We can cut and shape perforated sheet to meet the needs of your final application.

Issue 41 PECM

AUTOMOTIVE ENGINEERING

ALUMINIUM DEMAND MADC

GROWING ALUMINIUM DEMAND FORECASTS THE FUTURE METAL REQUIREMENTS OF EVS AND HYBRIDS For anyone keeping pace with the automotive sector - or general news for that matter â&#x20AC;&#x201C; it's easy to predict the future. Electrification is here to stay, with sales of full EVs and hybrids growing exponentially year on year. This revolution has forced OEMs to create entirely new vehicle platforms to accommodate new, innovative powertrains - resulting in mass redesigns across all of the major brands. This focus on delivering optimised platforms for future dynasties of electric vehicles is bringing aluminium components to the fore, and of course, the Tier 1 suppliers such as Mark Aluminium Die Casting (MADC) who provide them. The aluminium industry is experiencing a growth in demand from the world's major car manufacturers. According to Aluminium Insider, in 2018 OEMs were utilising an average of 250 kg of aluminium per EV vehicle, totalling an overall 250,000 tons usage throughout the year. EVs are forecast to reach a 30% market share by 2030, which translates to a projected demand for aluminium up to 10 million tons from car manufacturers that year. 1 CRU Group estimates that hybrid and electric vehicles incorporate 25-25% more aluminium in designs that traditional internal combustion engine cars. 2 Aluminium is displacing steel as the metal of choice in electric car manufacture. So, what are the key benefits of aluminium that are pushing this growing demand? A key concern for designers of new hybrid or EV vehicles is lightweighting. A lightweight design offers inherent benefits because it helps to offset the mass of the batteries and the powertrain of the vehicle. A reduced weight means less power is required to deliver performance, offering downsizing opportunities, while overall range between charges is also increased. Making an electrified design more lightweight delivers a cycle of benefits that improve overall usability and efficiency â&#x20AC;&#x201C; a key concern for widespread public adoption. Roughly, the density of aluminium is half that of steel, so by utilising aluminium body panels, floor plans, sub frames, heat sinks, water pumps and oil pumps, OEM's can deliver substantial weight savings.

PECM Issue 41

Aluminium offers a host of other benefits. OEMs are reporting that aluminium can deliver twice the energy absorption of steel in a crash situation, improving safety characteristics.3 As battery technology advances, aluminium is being brought to the fore in new designs. Aluminium enclosures for EV batteries are being introduced to market4, while scientists are now developing highly efficient aluminium based air flow battery technologies for eventual widespread introduction. Everywhere you look in the hybrid and EV sector, aluminium is the one commodity everyone wants. What does this mean for Tier suppliers then? Fundamentally, aluminium's growth is an opportunity that Tier suppliers cannot afford to miss. It's one that has been seized by Colwyn Bay based MADC, which has been providing aluminium die cast water pumps and oil pumps to support the latest generation of hybrid vehicles reaching the market. To support EV's, the business casts thousands of heat sinks for OEMs, which aid

in dissipating the thermal energy produced by the electric power train. Over the past few years, the business has had to adapt to a changing automotive landscape, a process that all suppliers will have to undertake, following the path of their OEM customers. David Lewis, Plant Manager at MADC, was approached for comment: "Whichever way you interpret the automotive sector at the moment, supply of aluminium components is only going to grow. Ultimately, it falls to businesses, such as ourselves, to provide the increased casting capacity and speed of delivery to ensure this growth in demand is handled smoothly. For both OEM and Tier suppliers, aluminium is becoming a top priority, and will remain so for the foreseeable future."

Tel: (0)1492 544201 Web: www.madc.eu Email: info@madc.eu

AUTOMOTIVE ENGINEERING

COMPOSITES IN CAR MANUFACTURING EXEL COMPOSITES

COMPOSITES FOR CAR PART MANUFACTURING The US Environmental Protection Agency (EPA) mandated in 2012 that the national automobile fleet should average 54.5 miles per gallon by 2025 in order to reduce reliance on fossil fuel and minimize emissions, many other nations have also implemented similar new standards. To meet these new standards the automotive industry has had to find new ways to make lighter cars without sacrificing their strength and structural integrity.

due to the high demand for lightweight vehicles and components. This trend, called light-weighting, seeks to use innovative materials to reduce the weight of products. As a result, composite materials are being increasingly used in production, especially for automotive parts and components.

Here Jari Sopanen, Regional Manager at leading composites manufacturer Exel composites, explains why one of the best replacements for steel is thermoset components.

According to the American Composites Manufacturers Associations, fiberglass is one of the key reinforcing materials used in the US thermoset composites industry. Thanks to its durable properties, it is a good replacement for steel in vehicle structural components, including drive shafts, bumpers and roof beams

Thermoset composites are formed using glass, carbon, or aramid fibers, which are then combined with resins such as polyesters, vinyl esters, epoxies, or phenolic resins. These composites are used in various industries, but are particularly prominent in the manufacturing of aircraft and spacecraft parts.

Reducing component weight is crucial for raising the efficiency of automotive systems. For example, carbon fiber has comparable properties to steel, but is only one-fifth the weight. Regardless of the mode of transport, it is easy to see the benefits that shaving this amount of weight from a vehicle will achieve.

Thanks to research and development in the aerospace sector, composites are also being used across other forms of transportation

Additionally, when directly compared to steel, composite materials can meet or surpass the automotive industry’s material property demands, including low coefficients of thermal expansion for heat conduction, dimensional stability for shape retention, corrosion resistance in wet conditions, and high-impact strength to withstand repeated use.

Sourcing Custom Parts overSeaS • Low cost • Low risk • Small quantities • High quality

The low weight of composite components also helps provide good sound baffling and an overall quieter performance. One type of car that can massively benefit from composite components are electric vehicles (EVs). Batteries are heavy and, although technology is advancing at a blistering pace, it is highly likely that the bulk battery weight will not decrease as any miniaturisation will be used to install more batteries to increase range and power. Minimizing component weight is, therefore, critical and fiber glass and carbon fiber alternatives are incredibly suitable for this light weighting, especially for EVs. For example, EV batteries must be held in special boxes to protect them but also to prevent any discharge from shocking passengers.

Blue Diamond has spent 40 years perfecting an overseas custom parts supply chain offering high quality with small initial orders (500 pieces), low cost at minimal risk.

023 8025 8966 | www.blue-diamond.co.uk

Metals are conductive, which makes them unsuitable whereas most composites aren’t, meaning that when made from composites, which possess a higher strength to weight ratio, they are perfect for this application. Due to EVs current limited distance range, shaving off weight can produce strong marginal gains. Composites are gearing up to feature in more than just structural components for cars.

For more information on composites and to begin your journey to implement composite components visit our website and get in touch: www.exelcomposites.com

Issue 41 PECM

BOILERS & MAINTENANCE

Riello’s premix burners now up to 3MW Riello RX premix packaged burners are now available in outputs up to 3MW, offering NOx levels of less than 40mg/kWh, with high turndown ratios of up to 8:1, across a wide range of models. Riello RX burners feature an exclusive design that includes a patented woven wire gauze ‘sock’ covering the combustion head cylinder. Gas and combustion air are mixed upstream of the combustion head and then pass through precision-located ports and the gauze ‘sock’ to ignite on the external surface of the combustion head. This arrangement enables a very compact flame with a diameter directly related to the burner firing rate, ensuring precise heat control and optimum efficiency at all loads. For further information visit www.rielloburners.co.uk

Specialist food processing company gains from Lanemark process gas heating expertise

Lanemark gas burner technology helps to optimise wool processing

South Wales based Express Contract Drying (ECD) is now gaining from Lanemark Combustion Engineering’s gas burner technology on a series of drying operations.

Each Lanemark installation can deliver required temperatures of between 180°C and 200°C, with excellent heat up and temperature stability characteristics. The systems demonstrate the suitability of Lanemark’s process gas burners to deliver precise process heating objectives in specialist sectors of the food processing industry.

The company has installed a TX tank heating system at Thomas Chadwick and Sons Ltd. – part of Standard Wool UK – who supply processed blended wool to customers around the world. Reflecting increased business for the company, the system is delivering tangible gains in both energy usage and process efficiency, compared to an older system that it has replaced, with the focus on the production of wool grease, a natural by-product of the wool washing operation. The 100 tonnes of wool processed each day by Thomas Chadwick and Sons produces around one tonne of wool grease which clearly plays a key part in the company’s services to customers. In turn, this is dependent upon processing operations that are efficient and economical – key objectives that are now being fulfilled by the Lanemark Combustion Engineering process gas installation.

www.lanemark.com

“We supply dried food flavourings and colourings via five process lines which create an emulsion that is then heated by Lanemark’s duct (DB) burners,” says Nick Ball, Operations Director at ECD. “It is vital we control the heated air temperature to reflect variations such as volume, type of emulsion and the nozzle size.”

Gas Process Burners Lanemark gas burner systems offer users reliable, high efficiency, process heating solutions. FD Series Packaged Oven/Dryer Burners Specifically designed for process air heating applications in convection ovens and dryers High turndown/short flame lengths providing accurate process temperature control High efficiency gas + air modulation, gas only modulation and simple high/low control options Heat Input Range: 9 kW – 1550 kW

• • • • FD-C high turndown oven/

FD-E low cost high turndown

dryer air heating burners.

oven/dryer air heating burners.

FD-GA modulating gas + air

TX Series Gas Fired Process Tank Heating Systems High efficiency (80%+) heating of all types of spray and dip process tanks Compact high efficiency small diameter immersion tube heat exchangers occupying minimum tank space Accurate performance modelling using Lanemark TxCalc design software Heat Input Range: 15 kW (1½") – 1150 kW (8")

• • • •

Midco HMA Series Air Replacement or “Make-Up” Air Heating Burners Direct fired, high efficiency burner systems, for high volume air heating applications such as paint spray booths, ovens and dryers. Supplied either as Midco burner heads for OEM system integration or as Lanemark DB or FDB complete packaged systems including modulating gas valve trains and controls Wide range of firing rates to suit alternative temperature rise and air velocity system requirements DbCalc system design software

•

process air heating burners.

• •

Midco HMA high efficiency,

high turndown, air replacement or “make-up” air heating burners.

TX high efficiency small diameter immersion tube tank heating systems.

Lanemark Combustion Engineering Limited Lanemark House, Whitacre Road, Nuneaton, Warwickshire CV11 6BW United Kingdom Tel: +44 (0) 24 7635 2000 Fax: +44 (0) 24 7634 1166 E-mail: info@lanemark.com www.lanemark.com

52 PECMAdIssue 411 X4620 Lanemark SDAW.indd

•

COMBUSTION ENGINEERING

31/08/2016 09:04

eco OWER AC

LTD

Med

ica

100

Wa tt

60 W lly Ap att E prov e xter nal d

Enc

lose

Wa tt

DIN

Rai

Me 30

dica

Wa lly Ap tt O pen prove d Fra me

POWER SUPPLIES UK based company

Next day delivery

Over 23 years experience

Ecopac (UK) Power Ltd, Unit 4, Ridgeway, Crendon Industrial Area, Long Crendon, Buckinghamshire, HP18 9BF

www.ecopacpower.co.uk

Call our EXPERT TEAM today! +44 (0) 1844 204420 or email us at info@ecopacpower.co.uk

Issue 41 PECM

CONTROL & AUTOMATION

CONVEYOR SYSTEMS ENE LTD

TOGETHER, WE KEEP INDUSTRY MOVING ENE Limited is a family run business, established in 1996 that has evolved to meet the ever-changing demands of the food industry. Our team has grown from 4 employees to 60+ today. ENE’s specialised team is experienced in our field, enabling us to deliver high quality products with a reliable service. We strive to meet the ever-changing needs of our customers, therefore if you give us your requirements, we will design from concept to purpose. Our special purpose machines include Spiral Conveyors, Convergers, Labelling & Sleeving Systems, Divergers, Packing Conveyors, Lazy Susan’s and Bone Pullers. We supply all conveyor belt types to suit the specific application.

We work closely with the food sector and our catalogue has standard and bespoke systems…. Working closely with the food sector we offer practical efficient solutions. By understanding demand from our customers and their production lines, we have created a catalogue of standard and bespoke systems. With our fully equipped facility and a team of expert technicians, we manufacture all parts inhouse. Our range covers the Meat Processing, Poultry, Seafood, Fruit & Veg, Dairy, Baking, Confectionery and Pharmaceutical industries. As the Forbo agent in Ireland, our belts guarantee the consistent support of your HACCP concept and production. From Conveying, Processing to Packaging we have belt types to suit all processes; such as mixing, cooling, weighing, metal detecting and packaging. There you can exploit your quality productivity potential to the full.

Product Features

PECM Issue 41

•

Smooth surface allows cleaning to microbiological level and clean-in-place process

•

Sealed edges and tension members prevent ingress of microbes

•

Kevlar tension members provide high strength, low stretch

•

Tough polyurethane construction

Water and chemical resistant

Meets FDA material requirements for wet food contact

•

Stainless steel lacing

PosiLace™

Plastic rivets

•

Meat and poultry and dairy certifications

•

Runs on most plastic modular pulleys

•

Optional sidewalls and flights available

Production of conveyors and complete systems across Ireland, the UK and Europe… ENE Limited specialize in the production of conveyors, labelling machines and complete systems for use across Ireland, UK and Europe with a dedicated team and one of the best Stainless-Steel manufacturing facilities in Ireland. We are perfectly placed to provide expert design, manufacture and installation services with the ability to fabricate all types of machine components, laser cut parts in stainless steel and aluminium.

We can offer…. DURABILITY

EASE OF USE AND MAINTENANCE

•

Top resistance to hydrolysis

•

Incision-proof belts that are easy to clean

•

Good resistance to fruit acids

•

Hard-wearing belts for use in abrasive environments

Belts with large open areas for washing and drying

•

Fray-free edges

Blue belts for fast checking processes that don’t strain eyes

•

Belt edge sealing

VARIETY OF APPLICATIONS AND VERSATILITY •

Homogeneous belt bodies

•

ProLink Modular belt series

•

Different patterns for inclined conveying

•

Belts for deep freezing sections (cooling towers)

•

Special Troughable belts for coagulation

•

HACCP belts with excellent release characteristics

•

Belts suitable for knife edges and ones with patterns

•

Belts with profiles and side walls

A WIDE RANGE OF BELTS…. •

Check-Weigher belts of equal thicknesses and exceptionally precise splices that make endless belts superfluous

•

Elastic belts for use in packaging machinery with homogeneous structures and easy to clean surfaces

•

Light-permeable belts for visionsupported robot systems (pick & place)

•

Temperature-resistant belts for use in shrinking tunnels and round belts

ENE Limited Unit 24, Scarva Road Industrial Estate Banbridge, Co. Down, BT32 3QD info@eneconveyors.com www.eneconveyors.com +44 (0) 28 4062 2215

Issue 41 PECM

CONTROL & AUTOMATION

PROCESS AUTOMATION SOLUTIONS TF AUTOMATION

TF AUTOMATION FOCUSES ON PROCESS AUTOMATION SOLUTIONS IN 2019 AS WELL AS COMMUNITY ENGAGEMENT

TF Automation design, engineer and manufacture process automation solutions, supporting a wide range of manufacturing industries from, aerospace and automotive through to medical, food, printing and packaging. Investment in the latest automated manufacturing technologies is a key issue for many of our customers who see it as a viable strategy to tackle skills shortages while maintaining the agility to stay competitive in a global market and we work closely with them to ensure cost effective and efficient solutions. Projects this year have ranged from product identity and traceability to product assembly and testing using robotics plus numerous work-stations for product testing. This has meant our continued involvement in the supply chain for the automotive industry as well as aerospace, plus heating/plumbing products and personal protection.

PECM Issue 41

The need to improve process and productivity is a constant challenge for all our customers. Our focus is on providing solutions to reduce the risk of human error in tasks that are constant, predictable and repetitive. We engineer and program our machines to perform tasks over and over again, offering accuracy and repeatability far superior to the same task carried out manually, thus ensuring increased output and efficiency. Community engagement is a key ethos for TF Automation and following on from the success in 2018, the company has taken part in Bradford Manufacturing Week - a unique event set up by Bradford Chamber of Commerce to engage local students with manufacturing and engineering companies in Bradford. TF Automation hosted over 100 GCSE and A level students over one week, showing them some of the technology incorporated into the machine build process and discussing manufacturing and engineering as positive and engaging career choices.

TF Automation has always worked with the local education providers, through apprenticeships as well as graduate placements and internships. With over 40 yearsâ&#x20AC;&#x2122; experience, our strength is in our assessment and understanding of the requirements of each project, end user and operative. We take the time to consider all possible solutions for clients, ensuring that both their expectations and their clientsâ&#x20AC;&#x2122; are met and the optimum solution provided.

To find out more or to discuss your next automation project with our design team, contact us on 01274 308005, email us at info@tfautomation.co.uk or visit our website www.tfautomation.co.uk.

PROCESS AUTOMATION EXPERT PROVIDING BESPOKE SOLUTIONS

TF Automation design, engineer and manufacture process automation solutions, ranging from full manufacturing units to specialist components all engineered to integrate fully with existing production lines. With over 40 years’ experience, we support a wide range of manufacturing industries, providing special purpose machinery designed to clients’ bespoke requirements. Our engineering and design expertise is extensive and we offer the latest technology across a wide rangeof disciplines, with all projects carried out in-house, from concept design created in Solidworks 3D CAD tocommissioning and installation.

SERVICES • • • •

In-house design In-house manufacture Testing & commissioning Programming

EXPERTISE • • • • •

Assembly & testing Process automation Robotics & product handling Product identification Manual workstations

INDUSTRIES

FOOD & BEVERAGE

AUTOMOTIVE

AEROSPACE

PRINTING

PACKAGING

MEDICAL

T: 01274 308005 E: sales@tfautomation.co.uk www.tfautomation.co.uk

TEXTILES

DEFENCE

HEATING

Issue 41 PECM

CONTROL & AUTOMATION

MOM SOFTWARE ABB

CONTINUOUS OPERATION EXCELLENCE

Food and beverage production is becoming continuous to keep up with rising demands. To maintain the flow of products and to make sure there are low levels of waste, spoilage or contamination inside a continuous system, automation must be integrated into the production line. Here Darcy Simonis, industry network leader for ABB’s food and beverage segment, showcases how producers can implement continuous production. Due to tight profit margins, success in the food and beverage industry today requires large capacities with low running costs — making continuous production a perfect fit. This system of production allows manufacturers to better benefit from economies of scale as the cost per item drastically decreases as larger quantities are produced. Continuous systems have many benefits over more traditional batch processes - the major being consistency. As the product is constantly flowing along the same production line, there are no changes in quality between batches. This constant flow also requires less labor, as there is no equipment downtime because every part of the production line is in continuous use.

PECM Issue 41

Even scheduled temporary downtime, which isn’t caused by failure, requires equipment to go through thorough cleaning regardless of how much it has been used.

In the food and beverage industry beverage, soft drink production is the most prominent section to have embraced continuous production.

History of continuous production

For example, in soft drink production suspension conveyor lines can be used to move bottles through different stages, such as filling in an effort to prevent spillage from the bottle’s main orifice.

The industrial revolution was the birthplace of the concept of continuous production. Powered machines allowed cotton mills to reduce the number of steps needed to turn raw material into finished products. How-ever, without the necessary technology there was only so much that they could automate. Chemical and oil was the first modern industry to truly use continuous production in the early 19th century. This was only possible thanks to great jumps in process control technology that was developed to tackle industry specific problems. Changing production in this way allowed the industry to vastly improve its capacity while reducing costs. Recent steps to improve process control has seen greater levels of automation devel-oped, lowering the barrier of entry for all industries looking to engage in continuous production.

Making sure that the bottles are all in line when being transferred from the normal belt to the suspension conveyor is a delicate task, requiring multiple pieces of automation. The bottles must travel on a belt that moves at a variety of speeds to slowly spin the bottles against one of the walls so that they can be picked up by the suspension line. This requires delicate motors and motor control to ensure that the motors are at the correct speed to prevent bottles from being tipped over and clogging the production lines. This method, though complicated, gives outstanding control over the filling process reducing waste.

Continuous control Control must be achieved on both a micro and a macro scale to fully see the benefits of continuous production. On the more micro production focused level there are, for example, soft starters, motor controls and power quality applications. These will make sure that the critical systems run smoothly and are protected from power surges or sags. To this extent, ABB provides a full suite of automation for implementing continu-ous production. Continuous systems benefit larger automated facilities with many pieces of automation. These are, however, also challenging to control on a macro scale because with many different pieces of automation working simultaneously keeping track of all these parts can be a daunting task. They also generate vast quantities of data, that when analyzed can give detailed insight into production that can help improve the system. For this reason, it is important to have a strong manufacturing operation management (MOM) software in place.

MOM software is crucial for proper control over large systems, the software will be able to collate the data from all pieces of automation and analyze it. This data processing allows operation managers gain insight into the overall working and health of their plant. This insight will not only help the to continuously improve production methods by showing how processes can be streamlined but also create an easy method to begin implementing predictive maintenance. Once set up, it can allow operation managers to understand how to optimize the micro automation to benefit the macro scale of the operation. Continuous production methods have come a long way since the start of mechanization. The level of control that can now be achieved allows for extremely complex tasks to be carried out without the need of stop-start batch processes. This reduces overhead and makes production more cost-effective. However, at the same time the complexity of modern food and beverage production requires installing quality pieces of automation is paramount to making continuous production the right choice.

www.abb.com

Issue 41 PECM

CONTROL & AUTOMATION

NEW Network-Capable Absolute Encoder from BEPc For EtherCAT communication in a precision absolute encoder, we’ve got your solution.

BEPc’s Model A58 features networking capability and is EtherCAT ready. With its minimal setup, you can install these encoders quickly and easily. The model A58 offers :• • • • • • •

58mm packages Shaft or Hollow Bore construction Variety of mounting options Flexible, low cost, and network-compatible industrial Ethernet solution on Maintains position information even in power-off scenarios Up to 16 bits single turn resolution Up to 43 bits multi-turn resolution

Call BEPc today to learn how an EtherCAT absolute encoder can fit your application.

Web: www.encoder.co.uk Tel: +44 (0)1978 262100 60

PECM Issue 41

OVER 35 YEARS OF INTEGRATIVE AUTOMATION SOLUTIONS

PRODUCTIVITY 1000

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

Quality products, expert advice www.lamonde.com

020 3026 2670

sales@lamonde.com Issue 41 PECM

CONTROL & AUTOMATION

MATERIAL HANDLING SPECIALIST BS HANDLING SYSTEMS

BS HANDLING SYSTEMS COMPLETES SORTATION PROJECT FOR NEW PRETTYLITTLETHING WAREHOUSE

Leicester based materials handling specialist, BS Handling Systems, has completed a sortation project for online fashion retailer, PrettyLittleThing. Due to rapid growth, the online retailer has relocated its logistics operation to a new 600,000 sq ft warehouse in Sheffield. In addition to needing extra storage capacity, PrettyLittleThing also required a sortation solution to sort parcels by both carrier and service type. The project has seen BS Handling System install in a bespoke pink colour: •

60 metre powered belt conveyor with two 180 degree bends

•

6 x 22 metre long conveyor feeder chutes in-between packing benches

PECM Issue 41

The conveyor chutes allow workers to place completed parcels onto the conveyor next to their packing bench. The chutes then feed parcels onto the main carousel line. The far side of the carousel features sortation bins which enables workers to sort parcels by both carrier and service type ready for worldwide despatch. Ben Hulme, Head of Operations, PrettyLittleThing concludes: “The conveyor system is tailored to our sortation needs and enables us to handle our peak volumes without any issues. BS Handling Systems were very flexible with the project and met our strict installation deadline.” Telephone: +44 116 289 4958 Web: www.bshandlingsystems.com

CONTROL & AUTOMATION

Ram Universal Digital Services Combine IIoT With Any Industrial Process Ram Universal Ltd & Flowrox Digital Services is a new way to combine your process and IIoT (industrial internet of things). Through Flowrox Malibu™ online portal, Digital Services provide real-time information from the site. Remote access allows to manage, measure, analyse and compare the processes or devices from anywhere with a computer or any handheld device. Smart valves, smart pumps and filters are next generation solutions delivering data and information in order to provide reliable and cost-efficient production. The real-time information from site results in optimized production, maximized output and minimized unplanned shutdowns. Flowrox Digital Services IIoT-technology can be integrated to any existing process equipment and control systems and is fully compatible with third party equipment. It is not meant to replace current systems like DCS and SCADA.

Fraser Technologies A sunset date has now been set for nPB (normal Propyl Bromide) of the 4th July 2020. After this date, its use is banned, unless an authorisation has been granted for a specific use and no alternative is available. nPB is a solvent commonly used in the cleaning and degreasing process for the aerospace, precision engineering, medical, optical and electronic industries. If you’re still using nPB, now is the time to act and look into alternative solvents. Fraser Technologies supply a range of new generation solvents which are safe, very economically friendly and meet the new F Gas regulations making them the idea replacement solutions for nPB. Contact us today! Tel: 01506 443058 Email: sales@frasertech.co.uk www.frasertech.co.uk

www.ramuniversal.co.uk 01455 285428 sales@ramuniversal.co.uk

The New Desoutter Transducerised Nano Driver This innovative transducerised electric screwdriver can deliver torque between 2.82 N•cm and 80 N•cm across three models. The Nano Driver is equipped with a newly developed seating detection function ensuring each fastener is applied perfectly, without causing damage to the host material. This is particularly useful when working with delicate or brittle materials. Since accurate repeatability is safety critical, the Nano Driver is second to none with its internal transducer. It measures and controls the torque and allows for production communications protocols, such as, Fieldbus, Profinet, and Modbus. Information from the Nano Driver is integrated into existing data capture systems; ensuring all production parameters are fully traceable. Tel No – 01442 838999 website www.desouttertools.com /www.desouttertools com/?s=nano+screwdriver

HMI Industry 4.0. The new generation for the factory automation

Connected CR1000 and CR3000 HMIs The CR1000 and CR3000 automation HMIs from Red Lion combine an ever expanding list of over 300 industrial drivers with the intuitive Crimson 3.1 development platform to create an operator experience designed to easily adapt as needs change and operations grow. CR3000 HMIs also offer data logging, secure web server and SQL query capabilities, enabling you to easily transform your equipment into a connected solution for improving manufacturing efficiency. Visit www.redlion.net/HMI to learn more.

Issue 41 PECM

CONTROL & AUTOMATION

SCADA CONTROL SYSTEM PRODUCTS 4 AUTOMATION

SCADA KEEPS ON EMBRACING NEW TECHNOLOGIES TO IMPROVE AND EXTEND ITS CAPABILITIES

Ethernet connectivity and HMIs have driven change through SCADA control systems, making them radically easier to design, install and operate, thus lowering the cost of ownership for operators. The physical appearance of SCADA (supervisory control and data acquisition) control systems has changed notably over the last 10 years, but then so have control panels… Traditionally each control panel whether for a machine or a control station for an entire plant was built as a bespoke item and included a range of dials, gauges, controls and pushbuttons. There was usually a unique schematic with integral indicator lamps that showed the status of the plant or machinery under control. Making custom physical panels is time consuming and therefore expensive. Furthermore, they are inflexible, so if changes are made to the plant or machinery substantial changes almost always had to be made to the control panel. Today all of this can be replaced by one or more off the shelf graphics display screens or, as they are more commonly known, human machine interface (HMI). Often these are touchscreen operated, although some operators prefer to have separate controls.

PECM Issue 41

The display screens can vary from simple LED read outs, to large format high resolution flat screens upon which can be displayed a vast array of schematics, data (real time and/ or historic), warnings and alarms. They can also be used to call up videos (instructional or live feeds from cameras around the plant), instruction manuals and augmented reality displays. Their data processing power means they can turn raw field data into up-to-theminute, easily understood, high level plant and process information so that operators know the precise status of machinery and processes. The screens are often also set up to provide access to the internet, to interface with other plant and machines and/or to interface with IT systems providing enterprise management, raw materials management and dispatch logistics. Multiple HMI screens dotted around the plant provide further easy access, alongside central control rooms and possibly even in remote or off-site management offices. Usually the various levels of function are protected by different passwords so that only authorised personnel can see higher levels of information and make major changes to plant settings, while operating personnel still have access to all appropriate information and functions.

Ethernet Simultaneously with the HMI revolution there has been a shift behind the scenes of SCADA installations, namely the adoption of rugged Industrial Ethernet and other singlecable technologies. Put simply, Ethernet is a communications solution that has the potential to massively reduce the wiring needed within a control system. It can do this because an Ethernet cable is able to transmit signals from multiple devices, whereas conventionally each device required its own dedicated cable. This can cut installation time, cost and effort by very significant amounts and often reduces hardware costs. Further – and probably more important in the long run – Ethernet makes system reconfiguration very much simpler, so that plant and machinery can be easily altered to meet changing needs. In fact, it is fair to say Ethernet often reduces systems re-wiring from a job of great complexity to one of plug and play simplicity. This enables and encourages frequent plant reconfiguration so that it is constantly reoptimised to meet changing market requirement. Enabling emerging technologies like HMIs and Ethernet are just two aspects of how modern SCADA has evolved to become simple, adaptable and very cost effective.

www.products4automation.co.uk

Electromagnetic Flowmeter MIM Series All metal design

Stainless steel version

°F °C

Flow and temperature measurement

Monitoring function

∑

Total and partial quantity counter

2 configurable outputs

Display operation also with gloves

90°

Rotating colour display

Space saver

01623 427701 www.kobold.com info.uk@kobold.com Issue 41 PECM

ELECTRICAL & ELECTRONICS

SWITCHTEC’S ENCLOSED FUSED SWITCH DISCONNECTORS OFFER A COMPACT SOLUTION WITHOUT COMPROMISING ON QUALITY Now available with Rotary Isolator and separate Fuse Holder, Switchtec’s NTFS enclosed fused switch disconnectors offer improved performance at a more competitive price.

All of the NTFS enclosed fused switch disconnectors are supplied in a high quality IP65, RAL 7035, pale grey painted, mild steel enclosure and for versatility, they have removable top and bottom gland plates.

The NTFS Fused Switches use the industry standard combination of Rotary Isolator linked to a DIN rail mounted fuse holder fitted into an IP65 metal enclosure.

The switches offer an IP20 level of internal protection with their touch proof terminals. They have a door interlocked, padlockable facility deployable in the operating handle ‘off’ position and are supplied with a door earth lead. All products conform to IEC609473, are certified by UL, EAC, CCC, and are CE approved.

This enables Switchtec to offer a cheaper solution whilst maintaining the use of high quality components ensuring there is no compromise on quality. As a result of Switchtec’s experience and knowledge of the marketplace, its vast supplier network and buying power, it is able to source the components at a more competitive price and passing this on to its customers. Fitted with high quality Telergon switches & Mersen Fuse Holders, the packaged enclosures are available in ratings 32A, 63A, 80A and 125Amp ex-stock.

Aimed at electrical contractors, equipment manufacturers and machine builders, the fused switch disconnectors provide a solution where general switching duties are required. They are suitable for control switches for multiple circuits and for use in resistive load applications as main circuits for machines, heating equipment, lighting, ventilation and air-conditioning.

Lascar – Inventors of the USB Data Logger Believe it or not, there was once a time before USB conquered the world, when connecting any sort of data recording equipment to your PC risked turning into a lengthy and frustrating process, even if you had the right hardware to hand. But back in the early 2000s, Lascar’s engineering team realised that USB was set to revolutionise data connectivity. The company had already developed advanced versions of its panel meter range that logged data as well as displaying it. So why not make the leap to a pure data-logging product, one that thanks to USB would just plug-in-and-go? The simplicity of these temperature data loggers prompted an obvious choice of brand name for the new range: EasyLog. But it wasn’t until after the EasyLog range hit the market that Lascar realised it had created a world-first: the USB data logger. www.lascarelectronics.com/data-loggers +44(0)1794 884567

PECM Issue 41

Switchtec’s knowledgeable field sales engineers are available to provide application advice and product choice assistance as are the company’s in-house sales and design team.

Tel: +44 (0) 1785 818600 E-mail: sales@switchtec.com Fax: +44 (0) 1785 811900 Web: www.switchtec.com

POWER DISTRIBUTION UNITS ISO 9001: 2015 Quality Assured

Custom Offering

Steel Construction

CUSTOM DESIGN SOLUTIONS FOR INDUSTRIAL APPLICATIONS

Quick delivery

Olson have a robust and reliable range of power distribution solutions for industrial environments including innovations such as our retractable suspended units. We offer a wide range of different power and data distribution options up to 63A for single and three phase inputs plus a custom design and manufacture service. • Welded robust Zintec steel case • Finished in tough powder coat paint – standard and custom colours available • UK manufactured • Heavy duty design for industrial applications

NEED SOMETHING CUSTOM MADE? WHATEVER THE APPLICATION WE CAN PROVIDE THE SOLUTION

+44 (0)20 8905 7273 sales@olson.co.uk olson.co.uk

Designed & manufactured in the UK

ELECTRICAL & ELECTRONICS

ESSEX BASED IMPORTER FOREMOST

ONLINE CONFIGURATOR ENABLES CUSTOM ENCLOSURES TO BE BOUGHT THROUGH DISTRIBUTION

Foremost Electronics, the engineeringled Essex based importer and specialist distributor of electromechanical components, celebrates 30 years of Electronic Component sales in the UK in November 2019. Founded in 1989 as a direct importer and specialist distributor of switches, keypads, joysticks, connectors and other electromechanical products, they have witnessed many technology breakthroughs and major changes to how products are designed-in and sourced. One area of particular significance is the design and supply of enclosures. Standard moulded plastic and cast metal boxes have largely been replaced by more aesthetically pleasing modular enclosures and the world of industry standard 19” racks has been transformed. Industrial control, utilities, instrumentation, test and measurement, rail and transportation equipment all make different demands on enclosures. These include resistance to moisture, dust and vibration, temperature control, EMC shielding, cable access, subracks, DIN-Rails and other internal fittings. As a channel partner for nVent Schroff, Foremost offers designers access to the world’s 1st Online 3D Sub-rack Configurator and Cad File generator.

PECM Issue 41

This comprehensive suite of online tools allows users to configure a bespoke enclosure and sub-rack simply and quickly using the intuitive and smart online design tool. The configuration process is broken down into stages; •

•

Rack type and Front Panel – Security and defense, Advanced Physics, shock and vibration proof, Test and Measurement, Audio/video, Broadcast, Mobile and Stackable Sub-racks, and card locks and retainers dependent on application

The resultant custom designed enclosure provides the user with a proven solution and all relevant documentation including 30 native CAD files, 2D and 3D drawings and complete bill of materials (BOM). The BOM is then simple to order from Foremost. A demonstration video is available to guide designers through the process. The enclosure specified by the configurator creates files which may be used directly in the manufacturing process, including 3D printing if required. Designers can easily modify or copy a saved configuration and different project lists can be managed in parallel for multiple designs.

The process from design to delivery is fully automated and the manufacturing facilities are capable of processing the digital data from the configurator through to delivery with no human interaction, requiring zero paper and compliant with industry 4.0. The final design is issued with a unique part number which is permanently allocated to the configuration on all documents. The design is costed automatically by the Schroff internal ERP system which can then generate a quotation or be ordered for direct manufacture. Enclosures designed using the configurator are available on the same leadtime as a standard configured product, even with custom modifications. For less demanding enclosure requirements Foremost Electronics has a micro-site, enclosures4u giving designers a direct source to standard cases and more complex standard, modified and customised enclosures including the first enclosure compliant with the embeddedNUC™ standard which features an innovative “Flexible Heat Conductor” (FHC) integrated cooling solution and is compatible with 1U embedded NUC enclosures.

www.4most.co.uk

Industrial Quality Power Supplies

TMDC Series DC-DC Converter 20, 40 & 60 Watts output power 9-36V or 18-75V DC input range 5V,12V, 24V or 48V DC output versions Fully encapsulated, chassis or DIN rail mounting

TCL-DC Series DC-DC Converter 12, 24 & 60 Watts output power 9.5-18V or 18-75V DC input range 5V,12V or 24V DC output versions DIN rail mounting

TIS Series AC-DC Converter 50 to 600 Watts output power Selectable 115/230VAC input range 12V, 24V, 48V or 72V DC output versions Optional redundancy module, signals module or DC UPS. Full safety approvals

TSPC Series AC-DC Converter 48 to 480 Watts output power Selectable 115/230VAC input range 12V, 24V or 48V DC output versions Full safety approvals and ATEX approval for hazardous locations

TSP Series AC-DC Converters 70 to 600 Watts output power Universal (up to 90W) or auto select AC input 12V, 24V or 48V DC output versions Optional external redundancy modules. Full safety approvals and ATEX certification for hazardous locations.

TSP Series Function Modules Redundancy Module enables two units to operate in parallel mode. Buffer Module allows hold up time up to 4 seconds depending on load. Battery Controller Module enables TSP to be used as AC-DCâ&#x20AC;&#x2C6;UPS.

TEX120 Series AC-DC Converter 96 & 120 Watts output power 85-264VAC (85-375VDC) input range 12V or 24V DC output versions IP67 & NEMAâ&#x20AC;&#x2C6;4X rated for harsh outdoor environments. ATEX approved

TSPC-UPS Battery Backed AC-DC 240 Watts output power Selectable 115/230VAC input range 24V DC 12A battery backed output 12V external lead acid battery outdoor environments. ATEX approved Full safety approvals and ATEX approval for hazardous locations

TIB EX Series AC-DC Converters 80 to 480 Watts output power Universal 85-264 VAC input with Power Factor Correction. 12V, 24V or 48V DC output versions. Full safety approvals and ATEX & UL Hazloc certification.

www.powersolve.co.uk

Tel: 44-(0)1635-521858 Email: sales@powersolve.co.uk

ELECTRICAL & ELECTRONICS

REVERSIBLE USB-C CONNECTOR CLIFF

NEW USB-C FEEDTHROUGH CONNECTOR FROM CLIFF ELECTRONICS’ IS REVERSIBLE Cliff Electronics announces the addition of a FeedThrough version of the industry-standard USB-C connector which can carry data and power on a single cable. The Cliff USB-C connector has no up or down orientation and the connector cannot be mis-inserted. Able to connect to, and power devices including a native DisplayPort, MHL, or HDMI device, the 24-pin USB connector system has a double-sided rotationally-symmetrical design. Connection to both sides of the connector is made using off-the-shelf, standard USB-C male leads. In common with the rest of Cliff’s extensive range of FeedThrough connectors, the new USB-C version may be mounted into an industry standard XLR connector panel cut out, simplifying system design and improving product aesthetics. The USB-C connector may also be fitted to Cliff’s purpose built 19” rack panels providing systems integrators with fast and convenient system assembly. Cliff’s XLR format FeedThrough connectors take advantage of the standard 24mm panel cut out widely used in audio and broadcast systems and which is finding increasing popularity instrumentation, medical and industrial applications due to the format’s flexibility, security and reliability. The new Cliff USB-C connecter may be mounted to the front or rear of control panels and supplied with plain or countersunk mounting holes. Dan Walker, General Sales Manager, of Cliff Electronics, comments; “USB-C has been widely adopted as the standard connector for supplying data and power between devices and systems. With our new FeedThrough version, all users have to do is line up the connector properly to make the connection, it never needs to be rotated for correct operation - the “right way” is always up.” Cliff’s Feedthrough connectors now provide Analogue, Digital and Optical Feed-Through connectivity in formats including VGA, Mini DisplayPort, Firewire, GJ45, HDMI A-A and 50 ohm BNC versions, USB2 A-to-B and B-to-A “gender change” sockets high speed USB Type – C, USB3 to USB3 in all gender changing configurations - A-A, A-B and B-A. Also available are all popular data and Ethernet

PECM Issue 41

connectors including USB 2.0 and 3.0, LC and SC fibre (Duplex & Simplex), UTP and FTP RJ45s in both Cat6 and Cat5e (shielded and unshielded), Toslink, RCA Phono and HDMI and blanking plates. Cliff Electronics are market leaders in the design, development and manufacture of connectors, leads, test lead sets and accessories for a wide range of markets and supply major international OEMs.

Cliff can also provide a wide range of leads including test and instrumentation, audio, instrument and power. All versions of Cliff’s XLR footprint connectors are in full production and available direct from Cliff and via major Distributors in the UK and Europe.

As a UK manufacturer Cliff can respond quickly to customer’s needs for both standard products and custom designs. Cliff manufactures audio, optical and power connectors and accessories, general industrial connectors, foot pedals, lighting connectors, terminal posts and connection blocks, motors, fans and assembly aids.

For more information call +44 (0)1737 771375, email sales@CliffUK.co.uk or visit Cliffuk.co.uk

4Most Electronics: Importer and specialist distributor of E-MECH products

CABINETS & ENCLOSURES UK Primary source and Channel partner for Nvent Schroff nVent Schroff electronic cabinets are designed to help you keep your systems running smoothly for the long term. Including industrial controls, electrical components, data communications and electronics in virtually any environment. Thousands of standard products as well as tailored solutions with the lead times you need to keep your project on schedule.

19 Inch Cabinets

Metal Enclosures

Systems & backplanes

Online Configurator

Industrial & Commercial, Cooling / Heating, PCB Accessories & Retainers, Subracks, Cases & Front Panels, Power Supplies and accessories.

View the complete product range online: www.4most.co.uk For further details please call or email us on: T +44 (0) 1371 811171 E sales@4most.co.uk W www.4most.co.uk Part of the 4most Electronics Technology Group: evconnectors.com | enclosures4u.com | ipjoysticks.com

FASTENERS & FIXINGS

NEW RANGES OF STAINLESS AND SPRING STEEL FASTENERS SD Products Ltd is a third generation family owned business with over 40 years of experience as a stockist distributor of specialist fasteners, we supply product across all industries. The corner stones of our business are Quality Products at Competitive prices with Service and Supply requirements tailored to our customers’ needs. As our business continues to grow we constantly aim to expand our extensive product catalogue. A brand new range of 12-150mm safety clips is now available from SD Products website. These fasteners are manufactured from high grade spring steel, offering excellent stress and corrosion resistance, as well as ability to withstand considerable forces without any distortion. High yield strength of spring steel in our safety clips allows them to return to their original shape, even after substantial deflection, twisting or compression, without suffering any significant deformation. Safety clips are well suited for both domestic and industrial applications and can be easily installed or removed by hand. Several new lines of stainless steel connector bolts and nuts have been added to our furniture fastener range. Connector bolts are designed to be used with connector caps nuts - nut applying an axial clamping force and the

shank of the bolt acting as a dowel, pinning the joint against sideways shear forces. Our connector bolts are suitable for a variety of furniture applications, flat low profile bolt heads allowing for a decorative finish. We have increased our range of mild steel slab base t-nuts and added a new range of stainless steel 4 pronged t-nuts. T-nuts have a wide range uses – ideal for automotive, domestic, furniture and industrial applications. Durable, reliable and low in cost, these fasteners are

designed to securely anchor particle or composite materials like wood and plastic to a workpiece. Produced from high quality mild and stainless steel, t-nuts from SD Products are sturdy and hard-wearing.

www.sdproducts.co.uk

TR FASTENINGS SHOWCASES SPECIALIST RANGE OF ENCLOSURE HARDWARE PRODUCTS more hazardous industries and conditions, including on-and off-shore Oil & Gas sites and Energy plants.

TR Fastenings (TR), the global specialist in the design, engineering, manufacture and distribution of high quality industrial fasteners, offers a broad range of enclosure hardware products for use in a number of applications in industries including Telecoms, Oil & Gas, HVAC and Transport. As an increasing number of industries use cabinets, secure boxes and other enclosure units to house electronics, wiring and other systems in public places, there is also a need for high quality enclosure hardware and mechanisms to be an integral part of the design. TR’s extensive range features locks, locking systems, gaskets, hinges, latches, handles, clamps and terminals. Products in detail: • Locking systems are used on large door spans where one handle operates multiple locking points. These systems are modular, providing flexibility for customising to different door sizes. • Locks provide a single locking point with a variety of keys to suit the differing inserts available. • Hinges are commonly used to connect a door to its frame or supporting object, to provide a point upon where it can rotate open and closed.

PECM Issue 41

Additional applications of enclosure hardware include: • Medium Voltage Switchgear • Data Centre & Server Rack Cabinets • Electricity generation/transmission/ transformers • EV Charging Units • Clamps are typically used to connect electrical conductors such as cables or terminals. • Gaskets can be used as edge protection, or to provide a seal between 2 surfaces (such as a door and a frame), with a wide range of profile types and fixing methods depending upon the application. • Accessories such as rod guides enable door features and locking systems to be customised and tailored to suit individual sizes, shapes and settings. These products are used in numerous applications across various industries, including both on board and track / roadside in rail, bus and other transport solutions, in cabinets housing heating and ventilation (HVAC) equipment and in telecoms enclosures. The products can also be used in

Kevin de Stadler, UK & Ireland Sales Director, TR Fastenings, comments: “As new technology, equipment and applications are developed throughout different industrial sectors, there is an increasing need to make sure they are kept safe, especially in settings where they may be exposed to dangers such as severe weather, corrosive atmospheres, tampering or theft. Our enclosure hardware products not only increase the safety of the contents inside an enclosure or cabinet but also improve other factors such as ease of installation and access for maintenance teams.”

www.trfastenings.com

FASTENERS & FIXINGS

SPOTLIGHT STAR FASTENERS

HUCKTAINER® - DESIGNED SPECIFICALLY FOR JOINING COMPOSITE PANEL

Hucktainers encapsulated grey to match rear door frames and panels

Hucktainer - Encapsulated & Powder Coated with all collar options

The Huck® Hucktainer is a two-piece specialty fastener that has been designed specifically for composite board, fiberglass reinforced plywood (FRP) and metal clad composite panel applications.

Range Force), air-powered (Huck 2055 or FAR FHU2000) or hydraulic models (Huck HK32002 c/w 2480L). Comfortable, ergonomically designed grips minimize muscle strain and the possibility of repetitive strain syndrome.

The Hucktainer fastener installs with a consistent pressure, therefore reducing the potential for crushing or crazing of the panel, the operator does not have to worry about under or over tightening as they would with a nut and bolt. With the addition of a restrictor shim they can be success installed into lightweight panels.

The benefits of using Hucktainer: -

Conventional threaded fasteners may only engage a few threads when joining thin sheets, allowing panels to separate in response to vibration. By contrast, Hucktainer’s unique, direct-tension installation process provides consistent clamp, ensuring accurate tension and a secure, durable connection, time after time. The two-piece fastener (pin and collar) are inserted into the prepared hole and the installation tool is applied to the pintail. When the tool is activated, the rotating action of the nose assembly allows the collar to twist freely and the collar is swaged onto the spiral lock of the pin, this allows the fasteners installation to take place in a controlled way. Requiring only a few seconds to install, Hucktainer fasteners reduce assembly time. Unlike impact wrenches, the tools used to install Hucktainer fasteners are relatively quiet and are available in a choice of battery (Huck

•

Fast, quiet and easy installation

•

Installs with consistent pressure, reducing crushing or crazing on composite board.

•

Spiral lock system, breakaway pintail ensures constant installation values are achieved

•

J63 plating adds additional resistance to corrosion - free from hexavalent chrome and is compliant with European directive EU 2000/53

•

The integral weather-resistant seal keeps contaminants from invading the joint

•

Direct metal-to-metal contact when installed eliminates the transverse vibration often found in conventional nuts and bolts

•

Maintenance free joints. Hucktainer can never be over-torqued or under-torqued

•

Once installed, the low-profile finish on both sides ensures reduced risk of catching on clothes, skin or goods

•

Improves health and safety – can replace welding

•

Shorter grips available for today’s thin metal-clad panels, as thin 10.36 mm (grip 8).

•

Custom coloured encapsulation, offers UV fade-resistant protection as well as increased corrosion protection. The increased head diameter spreads the load to further eliminate panel crushing. Star Fasteners can colour match to any colour and with low minimum order quantities and fast turnaround, it is a very cost-effective fastening solution

•

Star Fasteners in-house powder coating facility allows Hucktainer heads to be coloured to match to any project, for example, the panel, trailer rear frame, or just to add further corrosion protection

•

Tamper-resistant, TIR compliant

•

RoHS compliant

Where is the Hucktainer fastener being used? For truck trailers truck bodies, cargo containers and other structures fabricated from composite panel, the Hucktainer provides the ideal fastening solution. Compared to conventional nuts and bolt installations, which can loosen in highvibration environments the Hucktainer fastener has proven to be a dependable fastening solution; application opportunities are endless. Tel: +44(0)1159324939 | Email: sales@starfasteners.co.uk | www.starfasteners.co.uk

Issue 41 PECM

FLUID HANDLING

FLOTRONIC INTRODUCES ‘ONE NUT’ BARREL UNLOADING Flotronic has introduced a new barrel and drum unloading system, combining the unique ‘ONE NUT’ pump with their barrel unloading skid. The new system enables you to pump highly viscous materials out of your barrel at significantly increased flow rates. This system is built around our ‘ONE-NUT’ sanitary style pump which is based on our 3A and EHEDG design. This style of pump has already proven itself in the hygienic / sanitary industries and is a match for any environment or process where avoidance of product contamination is paramount. The system can be Cleaned in Place using the pump itself or an external CIP rig or, because of the ‘ONE NUT’ design of the pump, it can be easily stripped down for cleaning. “Using an inflatable seal, the system ensures minimal wastage is achieved and the minimum of product remains in the barrel.” Says Leighton Jones, Sales Director, Flotronic Pumps. “As the seal inflates it creates an excellent seal while moving down the barrel and at the end of the process it deflates for easy removal. There is less hold up compared to other systems, which means you can empty challenging viscous fluids from full size drums in a matter of minutes, improving productivity with increased profit potential.”

This hygienic hands-free control of the unloading is efficient and reliable using proven technology, with application across the food, beverage and pharmaceutical industries. Flotronic provide bespoke systems to customer requirements and can cater for any fibre, metal or plastic 200 litre/55 gallon drum or similar. The barrel unloading skid can be fully mobile or fixed in place, with the system designed to suit your needs, including roller systems if required.

Fluid Carrying

Flexibility Articulated Torsion Pipework In Hoses Rotating Cylinders

Swivel Joints Swivel joints allow pipework to pressure 1/4” to 40” and beyond. Vacuum to over 20,000psi. Stock and bespoke production. Unique bearing/seal design for longer life. ISO 9001 CE marked where applicable.

Tel:

Bingswood Trading Estate Whaley Bridge | High Peak | SK23 7LY | UK

PECM Issue 41

+44(0)1663 735003

E-mail:

www.flotronicpumps.co.uk

Labtex supplies leading laboratory products including HUBER liquid temperature control systems, DIEHM glass reaction systems to 100 litres, PREMEX and AMAR high pressure autoclaves, POPE wiped film or short path evaporators and distillation systems, Nutsche filter dryers, BOLA labware in PTFE and other technical plastics, Vacuubrand vacuum pumps, ASECOS storage solutions for hazardous materials to BS EN 14470-1 and SICCO desiccators. We also work with LLG Germany, the 3rd largest lab supplies distributor in Europe and have a catalogue of 20,000 items from over 200 respected brands.

4 types of interface. 16 process streams. 150,000 barrels per day. Zero margin for error.

This is why level matters. Reliable interface level measurement keeps production flowing. If water and oil are not separated effectively, you face processing problems, equipment failures, production loss, fines and shutdowns. That’s why Magnetrol® matters. Our technologies are proven to accurately measure total level and emulsion layers, from upstream gun barrel tanks to downstream boots. So you get effective separation and true process optimization. That’s critical. Because when it comes to interface, level matters.

Download the new Interface White Paper at interface.magnetrol.com

FLUID HANDLING

STEAM GENERATION CYCLE MAGNETROL

ARE SUBTLE INEFFICIENCIES CONDENSING YOUR BOTTOM LINE? In many process industries, as much as 60% of total energy consumption goes to the production of steam. Our newly updated white paper on the steam generation cycle shows how better level instrumentation can improve efficiency, reduce fuel consumption, lower costs, and prevent production downtime. To identify key areas in the steam generation cycle, condensate recovery system and waste heat recovery process where cost-effective instrumentation solutions offer a tangible return on investment over the short-term. The goal is to reduce heat rate, environmental impact, fuel and water consumption, water treatment and maintenance costs in commercial and heavy industries where steam generation is essential to the production processes. Although plausible, it is rare to identify a single source of inefficiency related to poor-quality level controls that impact a company’s bottom line in the doubledigit percentile. More so than not, it is these small incremental opportunities for improvement across various aspects of the steam generation cycle, condensate recovery system and waste heat recovery process that ultimately equate to substantial savings.

respectively. Additionally, better level control technology at the boiler side eliminates energy losses resulting from unnecessary blowdown to prevent carryover conditions.

• Reduced water consumption, treatment, discharge and inventory management • Improved boiler/steam drum control – energy savings and steam quality • Reduced fuel consumption – waste heat recovery • Energy management – fuel gas, combustion air and compressed air flow • Hardware protection & maintenance – pumps and pump seals Oftentimes, the hidden maintenance costs and inefficiencies associated with a technology’s vulnerabilities (sustained operation in high pressure and temperature steam environments; chemical exposure; errors due to the complexity of the measurement itself and subsequent calibration requirements) are overshadowed by the day-to-day operation of these processes.

PECM Issue 41

Regardless of the scale of an operation –commercial power generation or small scale boiler system, leveraging the inherent attributes of an instrument’s fundamental technology in both the shortterm (engineering, upfront cost, installation and commissioning) and long- term (maintenance, day-to-day practicality and energy management) present simple and cost-effective approaches to maximizing the return on investment in the system itself. Estimates of up to 49 percent of the energy can be recovered through the use of flash steam routed to heat exchangers or the deaerator to preheat boiler makeup water or support the deaeration process,

Optimizing boiler, deaerator, heat exchanger/condenser and blowdown usage relative to level control primarily affects fuel economy by better managing the amount of energy required to produce high quality steam for any given task. Seamless response to changes in demand and reducing maintenance associated with the instrumentation or damage to hardware are residual benefits that have their own financial ramifications; hence, should also be considered when implementing any technology. The return on investment time frame can vary depending on the scale of the operation as well as the time spent maintaining aging instrumentation.

Download the white paper today. www.steamgen.magnetrol.com

FLUID HANDLING

NoTap

LABTEX

A method for working on pressurised pipes

We are now distributing the advanced metering pump range developed by the highly regarded and innovative Heidelberg based company, ProMinent. This exciting new specialism will further enhance our ability to offer solutions for an increasingly wide range of scale-up processes. The foundation of ProMinent’s global success story is highquality products based on decades of engineering expertise, an in-depth understanding of applications and continuous innovation. The modular ProMinent range, integrated into carefully designed solutions, will enable customers in a wide range of industries to achieve maximum safety and efficiency in their production processes.

sound, sustainable and cost-effective solutions for metering technology in the pharmaceutical, chemical and manufacturing sectors.

id ev

Traditionally, modifications to pipe systems or repairs to leaking pipes or valves cause major inconvenience or high cost. Often these works involve draining down whole buildings and lengthy refill with attendant venting & de-aeration. Often the process can take many days to complete and re-commission.

h h te

tc co Wscaan the

Greg Smith, Managing Director at Labtex, said “ProMinent group’s position as a global market leader means a continuous commitment to excellent products and services and an obligation to think and act responsibly. It is a real privilege to be working with such a great company, with an innovative culture and commitment to excellence, very similar to ours. I look forward to the journey ahead.” Sales & Service 01484 600 200 info@labtex.co.uk

We share Prominent’s commitment to environmentally

It offers great advantages to the Contractor and client alike – economy – no inconvenience or long shut downs. NO TAP – is quick – clean - positive. Work is confined to where it is required.

NO TAP engineering goes to the heart of the problem on pressurised pipe-work by being effective in the right spot. It eliminates drain downs, refilling and venting. It accomplishes your solution in an interval of time that other methods fail to achieve. Further information contact our sales dept: C. A. Baldwin & Co, Valan House, 146-154 Wells Way, Camberwell, London SE5 7SY 020 7703 2138 info@cabaldwin.com www.cabaldwin.com

... always an intelligent solution

WESwivel Joint

For large bore articulated pipework Available in Carbon or Stainless Steel & Hard Anodized Aluminium

Produced in our UK factory in sizes 2” to 24” nominal bore, this 16” ASA150 WESwivel articulating ﬂanged coupling serves ‘Compact’ in S/S with custom M27 to allow a full 360 degree, low Caphead Bolts friction rotation of the assembly with minimum reduction in bore size. This is attained through precisely machined components and high grade stainless steel ball bearings. Originally designed for use in

COMPRESSION FITTINGS ORIGINAL RANGE Sizes 15 -100mm

fuel systems such as “FSUs” or Floating Suction arms, and articulated storage tank roof drains; the WESwivel’s components can be re-conﬁgured a number of ways to suit various environmental factors and applications. For example, Viton® primary and secondary seals can be selected and installed - so that the swivel joint is capable of handling oils & fuels with up to 100% aromatic content.

QUICK RANGE Sizes 15 -50mm

LEAK SEALING CLAMP Sizes 10 -100mm

Malleable

WESwivel ‘Style40’ conﬁguration for a Floating Suction Unit Hard Anodized Aluminium version

sales@we-couplings.com

Tel: 01257 475101 www.swivel-joint.co.uk

DZR Brass

TAPPING CLAMP

Malleable

DZR Brass

For detailed information contact our sales department: C. A. Baldwin & Co. Ltd., Valan House, 146-154 Wells Way, Camberwell, London SE5 7SY Telephone: 020 7703 2138 Fax: 020 7701 8436 info@cabaldwin.com www.cabaldwin.com

PECM Quarter page, CABCO.indd 1

Issue 41 PECM 77 10/03/2016 10:38

FLUID HANDLING

FOOD FACTORY HAZARDS SEEPEX

SAFETY FIRST – 6 FOOD FACTORY HAZARDS THAT CAN BE REDUCED WITH PC PUMPS

As an alternative to traditional manual labour, progressive cavity (PC) pumps can automate some of the key processes on food manufacturing sites. Here, Lesley Eaton, Marketing Executive for PC pump specialist SEEPEX UK, explains how this is helping to derisk six of the main food factory hazards… 1.

Slips and trips

Pumping liquids and pastes significantly cuts the risk of spillage, reducing the likelihood of a slip. Thanks to their gentle, low shear handling action, PC pumps are also able to transfer viscous products or those containing large soft solids efficiently without damaging them; further decreasing the chance of the factory floor becoming a slip hazard. 2. Conveyors By switching to a PC pump, food producers can also transfer solid foodstuffs, such as whole chicken breasts. By automating the handling of such products and eliminating the need for conveyors, the risk of operator injury is significantly reduced. 3.

Manual handling

Manual waste handling is particularly suitable for automation, reducing the number of people required to handle foodstuffs.

PECM Issue 41

SEEPEX has delivered automated, fully enclosed, piped waste removal systems to a number of food manufacturing sites, including Natures Way Foods. 4.

Workplace transport

Enclosed, piped waste removal systems such as that mentioned above eliminate the need for fork lift trucks entering the food production site. Instead, waste can be piped directly out of the factory and straight into a collection vehicle, away from high traffic areas. 5.

Corrosive and abrasive materials

Using a PC dosing pump to automate the dosing of ingredients reduces the risk of exposing irritants to the skin. Cleaning chemicals can also irritate and even cause respiratory problems. Many PC pumps – such as SEEPEX’s latest hygienic pump, the BCFH – now come with cleaning in place as standard, meeting the exacting requirements of the food industry without compromising employee safety. 6. Noise Such is the noise impact created by airoperated diaphragm pumps – exacerbated by the fact that they are often left to run continuously – that manufacturers supply them with sound screening.

By contrast, PC pumps – which only run when needed – emit considerably fewer decibels. Requiring no sound screening, they pose a lower risk to employees’ hearing. The cost of doing nothing While replacing manual labour with intelligent PC pumps and automated waste removal systems will increase operational efficiency and reduce costs, it is also clear that it brings significant safety benefits to food manufacturing sites. With the average fine in the 10-month period following the introduction of the new sentencing guideline increasing from £40,500 to £221,700, can any food business afford to not make the switch? www.seepex.com

GEARS, DRIVES & MOTORS

ABSOLUTELY DRIVEN NEW RANGE OF DRIVES AND VARIABLE SPEED GEARBOXES

For further information and sales contact Greg Smith on 01484 600200 or greg@labtex.co.uk

ATEX compliant to EC Directive 94/9/EC

Distributed in the UK by:

www.labtex.co.uk

COST EFFECTIVE FAIL SAFE POWER OFF BRAKE FOR E-PARKING SG Transmission has developed a 40 mm diameter static holding brake (12Volt DC, 0.6Nm Torque) for a German automotive customer as a parking brake with fail safe power-off braking. The approach is a fully automated production process with single part feed, including an air gap pre-set during the manufacture process with reduced part count for simpler assembly.

The spring applied brake has been optimised to: - reduce complexity of parts - reduce manual handling - reduce cost - cover high quantity needs of over 100,000 pieces per year

Call us on 01388 770360 or visit www.sgtransmission.com with your requirements.

The electrical connection is with integrated terminals.

Cross+Morse

Power Transmission Manufacturing Specialists Since 1984

◊ Manufacturing up to 1450mm diameter ◊ Turning - CNC lathes, Vertical Machining Centre ◊ Gear Cutting - Hobbing, Planing, Shaping Gears ◊ Bevel Gears, Helical, External & Internal cut Gears ◊ Rack Shaping, Broaching, Keywaying ◊ Vertical Boring, Centreless & Rotary Grinding ◊ Bore Honing ◊ Induction Hardening

◊ Drilling & Tapping ◊ Large stocks of Transmission Drive components ◊ CAD - CAM Design & Development ◊ ISO 9001 : 2015

Yes we can make it.

Cross + Morse. Shady Lane, Great Barr. Birmingham. B44 9EU sales@crossmorse.com Tel: +44 (0)121 360 0155 Fax: +44 (0)121 325 1079 www.CrossMorse.com

Issue 41 PECM

HEALTH & SAFETY

REMBE SAFETY DAYS REMBE

REMBE EXPLOSION SAFETY DAYS 2019 FOCUS ON THE FOOD AND BEVERAGE INDUSTRY

The event series “REMBE Safety Days” will continue this year. In the last years explosion safety days focused on Explosion Safety for spray dryers as well as for the woodworking industry. This year’s focus is on the food and beverage industry, specially the daily challenges in the food-, sweet-, grainand convenience product plants as well as soft drink factories and breweries. The REMBE Explosion Safety Days combine the latest topics and presentations, top rank speakers as well as an extraordinary evening event. It is a two-day networking event to exchange experiences and protection approaches. A broad range of perspectives are required to obtain a holistic picture regarding Explosion Safety in the food and beverage industry. This is why the speakers at REMBE Safety Days 2019 include operators, OEMs, insurance companies and authorities.

PECM Issue 41

One of the highlights at the event is the live explosion demonstration carried out by REMBE Research + Technology Center GmbH. The event will be held in English due to the international audience. In addition to theoretical explanations and practical experience reports, a key importance is also placed on providing sufficient time for the personal exchange of information.

About REMBE the REMBE Alliance introduces itself REMBE is mostly associated with REMBE GmbH Safety and Control - the specialists for explosion safety and pressure relief worldwide.

The most important data at a glance

The company with approx 250 employees worldwide, headquarter in Brilon (Germany) and numerous subsidiaries worldwide offers customers cross-industry safety concepts for systems and equipment.

Event period: 19 + 20 of November 2019

Four other companies are also engaged under the REMBE family brand:

Place: 59929 Brilon (Germany)

•

REMBE Research & Technology Center GmbH

Participation fee: 890 € - if more than 2 participants from a single company attend, there will be a 30% discount for each additional participant

•

REMBE Advanced Services + Solutions GmbH

•

REMBE Kersting GmbH

•

REMBE FibreForce GmbH

Hotel costs: around 65 € / night incl. breakfast

www.rembe.com

T +49 2961 7405-0 info@rembe.de

Made in Germany

Your Specialist for

PRESSURE RELIEF and

EXPLOSION SAFETY

Consulting. Engineering. Products. Service.

Gallbergweg 21 | 59929 Brilon, Germany F +49 2961 50714 | www.rembe.de

MACHINING & MACHINERY

Above, lightweight oval gear flowmeter for F1 racing cars. Below, Atrato ultrasonic flowmeter for automotive applications

MANES CONTROLS LTD Manes Controls Ltd

Manes Controls Ltd have a long-established reputation and expertise in control system design and manufacture, we now bring all this experience to our range of standard inverter drive products.

Unit 504, Phoenix Park Ind Estate, Phoenix Close, Heywood, Lancashire, OL10 2JG

Please have a look at our full range of motor speed control panels now available to purchase online with 3-5-day delivery times. These panels can be used for various applications such as conveyor belts, fans, centrifugal pumps, hoists, mixers, grinding machines and many more………….

Tel: +44 (0)1706625500 Fax: +44 (0)1706625588 mail@manesindustries.co.uk www.manescontrolsltd.co.uk

SEAMLESS

Industrial Flooring !

le p m i S e d Ma • • • • • •

Repair & resurfacing or new build Anti-static, anti-bacterial, slip & chemical resistant Impact, abrasion & point load resistant high bay category 1 and 2 Hardwearing and durable colour matched flooring Fast Nationwide installation minimum downtime FREE survey & uncomplicated warranty

www.respol.co.uk CONTRACTORS HEALTH & SAFETY ASSESSMENT SCHEME

Accredited Contractor www.chas.co.uk

PECM Issue 41

High pressure flowmeters from Titan Enterprises have, over the last decade, been widely used in the hydraulic test systems of F1 racing cars to measure fluid flow. A high-performance engine company also uses Titan flow meters to monitor the oil flow lubricating its turbo units on the test bench. Formula 1 engines typically have no cooling fans and therefore need to reliably run at temperatures in excess of 200°C. Measuring the high flow of coolant water at these elevated temperatures, without causing an undue pressure drop in the system, is another example of an automotive flow measurement development undertaken by Titan. Using the inherent very low pressure drop of their Oval gear flow meter design – Titan produced a 200°C, 50 L/minute flow meter with a pressure drop of less than 100mBar to solve this challenging application.

Call the industrial flooring experts on 01952 740400

TITAN ENTERPRISES

A few years ago, one racing team turned to Titan as it did not trust the fuel flow figures being returned from their engine suppliers fuel management systems. For this application a very lightweight oval gear

flowmeter was designed to be installed safely in the fuel tank of the racing car. Designed to be immune to immersion in fuel and the very noisy electrical environment of a racing car. this flowmeter has provided accurate flow measurement over an extended period of time. In addition, a growing number of engine and car manufacturing companies have benefited from using Titan’s Atrato ultrasonic flowmeter for both diesel and petrol measurement on test stands and in engine development. Because the Atrato does not have a contorted flow path. and fuel passes straight through the flowmeter. it can uniquely operate at the same bore as the fuel lines. This reduces the pressure loss and keeps “dead” fuel volume to a minimum.

For further information on optimised flowmeters for high performance Formula 1 racing cars and for other automotive applications please contact Titan Enterprises on +441935-812790 or sales@ flowmeters.co.uk..

HYDRAULICS & PNEUMATICS/MACHINING & MACHINERY

LQ2 Series

for ultra reliable, dripless connections

FEATURES Colour coded thumb latch High flow capacity n Redundant multilobed seals n Locking hose barb n n

TECH GROUP â&#x20AC;&#x201C; 119 MOULD HEATERS It is also a fact that a reasonably well maintained mould heater can have a fairly long and healthy life-span. Dan Horne, the General Manager at Renmar Plastics Machinery, is still sending mould heater spare parts to a company for a machine which is approaching thirty years old. However, this is an exception; there are not many companies who are prepared to keep, a relatively inexpensive piece of equipment that long. Most companies have a replacement policy and one of the most progressive is Dublin based Tech Group, part of West Pharma, who manufacture a wide range of Consumer, health care, and medical products. Over the past seven years, as part of their own replacement policy, Tech Group has purchased a total of 119 specially modified mould heaters. The modifications include an advanced control panel which allows communication between the mould heater and injection moulding machine through a chosen protocol, different control valves for dealing with the process water and a customer specified paint treatment. Renmar Plastics Machinery is the UK distributor for the AEC range of

Designed specifically for

liquid cooling applications, the LQ2 offers a high

flow capacity to optimise liquid cooling system

performance. LQ2 uses valve technology that

eliminates drips and is

able to withstand long term mould heaters and the reason why Tech Group has chosen to base their mould heater replacement policy around AEC, is reliability. Practically every other competitive range of mould heaters will have a heat exchanger and water reservoir. With this arrangement, the build-up of sediment is inevitable which means a reduction in efficiency and frequent maintenance. The AEC mould heaters from Renmar have a pressurised system which means that flow rates are much higher, mould heating is more consistent thanks to turbulent flow and there is no sediment build-up to worry about. For more information please contact Renmar Plastics Machinery on 0844 6933225.

use. For more information contact Tom Parker Ltd.

BENEFITS n

Simple one hand operation

Protection against leakage

Withstands extended periods of connection Reinforced tubing used in liquid cooling applications

Sales: 01772 255109 | Online: tom-parker.co.uk Request a catalogue: marketing@tom-parker.co.uk Issue 41 PECM

ONDS DIAMONDS DIAMONDS DIAMONDS OREVER AREFOREVER FOREVER ARE FOREVER ARE

The diamond stands The atdiamond a crossroads. industry Two stands The at a crossroads. industry Two stands at The diamond industry stands at diamond a crossroads. Two D RELAYR COBORN RELAYRAND ANDCOBORN RELAYR COBORN AND industry COBORN trends are affecting its future trends - the increasing affecting influence its future trends - the are increasing affectinginfluence its influence future trends areare affecting its future - the increasing THE DIGITIZING DIAMOND THE DIGITIZING DIAMOND THE DIAMOND DIGITIZING THE DIAMOND of digital technologies and of digital growing technologies significance and ofthe digital growing technologies significance and the g ofthe digital technologies and the growing significance OGETHER INDUSTRYTOGETHER TOGETHER INDUSTRY TOGETHER INDUSTRY of lab-grown diamonds. Redefining lab-grown business diamonds. models Redefining of lab-grown business diamonds. models Redefin of of lab-grown diamonds. Redefining business models

becomes a necessity in times becomes of digital a necessity disruption. times becomes digital a necessity disruption. in times of becomes a necessity in in times of of digital disruption.

Through our long-term partnership Through with our long-term relayr, we are partnership Throughwith our with long-term relayr, partners are Through our long-term partnership relayr, wewe are shaping the future of theshaping diamond shaping industry the future together. shaping diamond the industry future together. of the diamo the future of of thethe diamond industry together.

THE RELAYR SOLUTION THE HELPS RELAYR COBORN SOLUTION TO:THE HELPS RELAYR COBORN SOLUTION TO: HE THE RELAYR SOLUTION HELPS COBORN TO:

Determine and resolve machine Determine failures and inresolve advance. resolve machine Determine failures and resolve advance. machine Determine and machine failures in in advance. By utilizing relayr’s AI-based analytics, utilizing Coborn relayr’s is AI-based ableByanalytics, utilizing analytics, relayr’s Coborn is able an ByBy utilizing relayr’s AI-based Coborn isAI-based able to provide preemptive service provide to its preemptive customers. preemptive service to provide preemptive customers. service t to to provide service to to itsits customers. Offer machines with guaranteed Offer performance machines with and guaranteed Offer performance machines performance with and guaranteed Offer machines with guaranteed and availability targets. Each machine availability comes targets. withEach an Each machine availability comes targets. with Each an machin availability targets. machine comes with an insurance policy to support insurance these guarantees. policy support insurance these guarantees. policy to support thes insurance policy to to support these guarantees. Utilize the pay-per-use business Utilize model the pay-per-use for its business business Utilizemodel the model pay-per-use Utilize the pay-per-use forfor itsits business equipment. Coborn‘s diamond equipment. grinding machines Coborn‘s diamond equipment. grinding Coborn‘s machines diamond g equipment. Coborn‘s diamond grinding machines are not sold but made available for sold a usage fee. made available are not sold a usage but fee. made fee. available areare notnot sold butbut made available forfor a usage

born is Established a leaderininin the 1941, supply Coborn Established a leader in in 1941, the supply Coborn isthe a leader in thedesigned supply Established 1941, Coborn is aisleader in the supply Coborn designed firstCoborn Reciprocating Coborn designed Grinding first Coborn Reciprocating designed Grinding the first Recip thethe first Reciprocating Grinding amond tooling machines industry. Asdiamond an oftooling machines tooling industry. for theAs diamond As an tooling industry. As an of of machines forfor thethe diamond industry. anproducing machine for Polycrystalline machine for Diamond producing tools. Polycrystalline machine for producing Diamond tools. Polycryst machine for producing Polycrystalline Diamond tools. is at the equipment heartsupplier, ofsupplier, the global it at is at equipment the heart supplier, of global it is at theare heart ofCoborn’s thefor global equipment it is the heart ofCoborn’s thethe global machines designed processing machines the designed Coborn’s machines processing are designed Coborn’s machines areare designed forfor processing thethe owth and diamond development. industry’s growth diamond and development. industry’s growth and and development. diamond industry’s growth and development. world’s two hardest most world’s extreme two materials: hardest and most world’s extreme two materials: hardest materials: and most e world’s two hardest and most extreme lobal Coborn position with a unique, over global 90% global Coborn position has with a unique, over global 90% positiondiamond with over 90% Coborn hashas a unique, position with over 90% diamond and its structurally similar diamond sister cubic its structurally boron nitride. diamond similar sister and its cubic structurally boron nitride. similar andand its structurally similar sister cubic boron nitride. orted throughout machines being the exported world. exported of machines throughout being exported world. throughout the world. of of machines being throughout thethe 80% ofworld. all high value diamonds 80% of all polished high value ondiamonds diamonds 80%are ofare all polished high value 80% ofare all high value polished onondiamonds a Coborn scaife. a Coborn scaife. a Coborn scaife. a Coborn scaife.

BUSINESS OUTCOMES. INCREASED REVENUES from a pay-per-use business model providing easier access to new markets.

INCREASED PRODUCTIVITY through process optimization.

INCREASED CUSTOMER SATISFACTION thanks to proactive rather than reactive support.

REDUCED MAINTENANCE COSTS with predictive maintenance delivering an increase in machine uptime.

MAKING THE MOVE FROM CAPEX TO OPEX. Thanks to its cooperation with relayr, Coborn is moving away from the limitations of the capital expenditures (CAPEX) model. The operating expenses (OPEX) model offers flexibility and scalability. The benefits are numerous: NO LARGE UPFRONT INVESTMENT IN EQUIPMENT STABLE AND PREDICTABLE FINANCIAL FORECASTS GREATER COST TRANSPARENCY FOR CUSTOMERS HIGHER MACHINE RELIABILITY, AVAILABILITY, AND PERFORMANCE HIGHER CUSTOMER SATISFACTION THANKS TO PROACTIVE SUPPORT

â&#x20AC;&#x153;We met with relayr, and the thing that stood out was the ability to be proactive to really use the diagnostics in the machine, to identify that a problem was developing. I was just blown away by the potential." Steve Westlake COBORN Managing Director

coborn.com sales@coborn.com

MACHINING & MACHINERY

MOUNTING MAINTENANCE COSTS KMT

KMT REBUILD FOR CNC WIRE BENDING MACHINE

When a well-used CNC wire bending machine became the source of mounting maintenance costs the end user turned to KM Tools (KMT) for a frame-up rebuild. The aim was to update what was originally a quality machine to modern performance and reliability standards at a much lower cost than a replacement. As experts in rebuilding and refurbishing machine tools for original equipment manufacturers (OEMs), KMT was also able to deliver the repair on a lead time far shorter than the potential wait for a new replacement. A detailed assessment of the machine established that it was at the end of its service life due to normal use. Most major mechanical components required rebuilding or replacing, while the control system was obsolete with no current manufacturer support. The machine frame itself was found to be in good order, so with the causes for failure clear, KMT was able to quote accurately for

PECM Issue 41

a complete refurbishment project, with the confidence that the result would be the return of a quality, reliable machine. Constant use had taken a toll on the machine’s wire feed mechanism, with the wheels and shafts comprising the two straightening rolls in urgent need of replacement. KMT refreshed the system with brand new components, bringing this integral part of the machine up to its peak efficiency. The slew rings were also found to be in a poor state of repair after 20 years of constant service, so KMT sourced high quality replacements to specification. Replacement of the outdated control system was another priority. Therefore, KMT installed a 4 axis Omron CNC system, so the machine could reach the latest electronic control standards. The replacement also served to simplify the wiring process, ensuring that maintenance conducted in future could be carried with ease and in a reduced time frame.

Adrian Degg, Engineering Director at KM Tools commented on the project: ‘This is typical of the kind of rebuild projects we take on at KMT. The customer was losing money due to the high levels of maintenance needed to keep the machine operational, so we were called in to offer a solution. Generally, we build new machines, or update machines that are well built but worn, so with some expert attention they can be brought right up to current mechanical and electrical standards.’ An equivalent new CNC wire bending machine would typically cost £350,000 with an expected 4 month wait before delivery. However, through a policy of ‘rebuild and refurbish’, KMT can offer the same solution for a fraction of the cost, with a lead time of generally between 8-10 weeks. Tel: + 44 (0) 1538 752 561 Fax: +44 (0) 1538 751 915 Web: www.kmt.tools Email: sales@kmt.tools

MACHINING & MACHINERY

REDUCED LEAD TIMES ROTAMEC

ROTAMEC ENABLES REDUCED LEAD TIMES WITH INHOUSE COMPONENT MANUFACTURING SERVICE

Sourcing spare parts and replacement components from an OEM can take time. When having the right part available makes the difference between critical equipment running or not, waiting simply isn't an option for operators. Rotamec, a leading electro-mechanical service provider to the engineering sector, is aware of the pressures facing maintenance engineers and provides its customers with access to a dedicated component manufacturing service; which minimises lead times to promote asset uptime. Operating a 24/7 service to help customers keep critical equipment running, Rotamec has invested heavily in CNC and manual tools for a responsive in-house machining and fabrication service. The business can react quickly to provide a single replacement component or a batch run of thousands. To ensure a short lead time regardless of order quantity, Rotamec operates multiple XYZ CNC lathes, XYZ CNC mills, Colchester manual mills and slotting machines. All are manned by qualified and dedicated engineers. This breadth of equipment and expertise allows the business to offer machining, punching, forming, milling, turning, thread cutting and welding to exacting standards.

Rotamec engineers employ a tailored approach with regards to providing components for each individual order. This ensures that if a component is highly specialised or has peculiar dimensions, an optimum part can be produced regardless. Via reverse engineering and accurate CAD drawings, CNC machines can produce complex parts with virtually zero variation and high repeatability. All CAD drawings are saved on file for future orders.This capability also allows Rotamec to carry out complete repairs of existing components. Components can be refurbished to provide a cost-effective alternative to replacement, with Rotamec particularly specialising in the repair of critical shaft journals and large conveyor rollers. Obsolete components that may no longer be available can also be reverse engineered, easing the stress of trying to source unsuitable equivalents. Despite the short lead times, Rotamec ensures that all components that leave the factory are OE quality or higher. All parts are subject to a stringent quality inspection process, which ensures every component is of the optimum specification. This means that speed of delivery is matched by ease of installation and longevity, as each component offers seamless integration with the intended machine.

Ryan Davis, Machine Shop Manager at Rotamec Cheddar Branch, adds: "Our flexible machine capacity, expert engineers and rigorous quality levels mean we can offer the same consistency of service for the manufacture of a single component, a batch production run or a comprehensive component repair. Most of our customers face hurdles when it comes to specifying from an OEM, but we have tailored our service to offer consistently reduced lead times â&#x20AC;&#x201C; in many cases down to a matter of hours." www.rotamec.com

Issue 41 PECM

MACHINING & MACHINERY

SPECIALISTS IN TOOLS & GAUGES WISEMAN THREADING TOOLS LTD

WISEMAN THREADING TOOLS LTD SPECIALISTS IN TOOLS & GAUGES FOR SCREW THREADS We have been supplying threading tools and gauges since 1987. Together with supplying plain plug and ring gauges this is all that we do, we therefore consider ourselves to be specialists in this field. We supply worldwide. We hold extensive ready stocks that include all of the standard stuff that others offer, but also includes taps, dies, die nuts, die head chasers, thread rolls and gauging for threads not normally available 'off the shelf '. Our real time stocks can be checked and purchased online at www.threadtools. com Just enter the thread details into the search box on the home page. You will be directed to the item, if stocked, or to our specials, (custom manufacture), sales team. who will quote to supply at competitive rates, in good time. As an account holder you can also order online from our listed in stock items, at your normal terms. We realise that you need the right item at the right price and quality, and in a reasonable time frame. We are geared to provide that. We can ship stocked items same day. Our experienced sales staff can assist and advise you on any technical issues. We welcome enquiries from resellers and can offer terms to suit. WISEMAN THREADING TOOLS LTD

11 Padgets Lane South Moons Moat Redditch B98 0RA UK 0044(1527)520580 sales@threadtools.com www.threadtools.com

PECM Issue 41

Threading Tool Specialists

HSS DIES & DIE NUTS Large shelf stocks for all Standard and many Special Threads. Check our stocks online.

THREAD CUTTING AND ROLLING HEADS and parts and repair service

THREAD ROLLS FOR ALCO & FETTE HEADS. READY STOCKS CUSTOM MANUFACTURURE

HSS TAPS Huge Stocks for all Standard threads CUSTOM MADE taps our SPECIALITY! We stock taps for many non standard (SPECIAL) threads All types; Spiral flute and point, Fluteless, Left Hand, etc, etc.

Wiseman Threading Tools Ltd 11 Padgets Lane, South Moons Moat. Redditch B98 0RA Worcs UK 004(0)1527520580 sales@threadtools.com www.threadtools.com

THREAD GAUGES all types. Large stocks for standard and SPECIAL threads. Any non stocked can be quoted for custom manufacture.

CHASERS FOR COVENTRY & LANDIS TYPE DIE HEADS Ready stocks for most size heads most standard and some special threads Geometry available for most materials. Custom manufacture our speciality!

MEASUREMENT & MONITORING

ISO 17025 Calibration Services

Hand Held Temperature Probes

Accredited calibrations for pressure, electrical, flow and air velocity instruments via UKAS Laboratory 0604, offering reliable, quick turnaround and affordable sensor calibration for process & control instruments. Many of the calibrations are also available as onsite services, both traceable and ISO 17025 accredited. Bespoke services are available for thermal uniformity surveys of for ovens, freezers and autoclaves.

Comprising of a handle, 2 metre coiled cable and mini plug. They are suitable for use in corrosive material tests and high temperature molten metal measurements. A comprehensive selection, including:

Further extensions to our UKAS accreditation schedule are in process to extend our scope of calibration services soon. The accredited flow rigs and wind tunnels continue to offer world leading measurement uncertainty for UKAS air velocity calibrations on pitot, thermal, vane, cup, omni-spherical and ultrasonic anemometers across 0.05 to 80 m/s and for air and fluid flowmeters. Web: www.youngcalibration.co.uk/calibration Email: ay@youngcalibration.co.uk Tel: 01273 455572

Sensor device and method for detecting gear damage in rotating elements in housing GTR-01 The company PCE Process Control Electronic GmbH in cooperation with DELTEC electronic GmbH has developed a sensor device and a method to detect damage to rotating parts in a closed housing. Tests on ferromagnetic gears have been suc-cessfully carried out so far. The housing was made of die-cast aluminium. The pro-cess uses magnetic fields: Electromagnets generate magnetic fields, while a Hall sensor picks up the resulting fields. A special evaluation program determines whether a defective part is present. The damage can, for example, consist of a par-tially or completely broken tooth or a crack. Device options allow the speed and di-rection of rotation of the rotating part to be determined. The device can also be used for continuous monitoring on machines. Phone: 07841/5373 www.pce-achern.de

PECM Issue 41

• • • • • • • • • • •

General Purpose Probe Spring Loaded Thermocouple with Copper Disc Tip Stainless Steel Air Probes Right Angled Probe Ceramic Tip and Coiled Element Right Angled Probe and Copper Disc Tip Needle Probe T-shaped Moving Air Probe Surface Probe Penetration Probes Pipe Clamp Probe

Labfacility are the UK’s leading manufacturer of temperature sensors, thermocouple connectors and associated temperature instrumentation and stockists of thermocouple cables. www.labfacility.com

HBM data acquisition amplifier module operates under harsh conditions Test and measurement expert HBM has expanded its range of data acquisition modules with the SomatXR MX1609TB-R. This amplifier is part of the industry standard’s SomatXR family, and provides engineers with a reliable and flexible solution to measuring temperature, particularly in harsh operating conditions. With 16 channels and a sample rate of up to 100 kS/s per channel, the MX1609TB-R is shock resistant with an IP54/IP67 degree of protection, which makes it ideal for use in measurement tasks within a wide range of applications, such as mobile measurement and tests with off-highway vehicles, stationary measurements, tests on infrastructures and field tests in harsh environments. For further information, please contact HBM on +44 (0) 1525 304980 or via email: info@ uk.hbm.com or visit the HBM website at www.hbm.com

API Launches Laser Tracker Rental and Rent-To-Own Programs API offers Laser Tracker in a rental program, which allows manufacturers to gain access to API’s benchmark RADIAN laser tracker to perform specific measurements, alignments and calibration tasks or overcome periods of bottleneck for its own portable measurement equipment. API trackers can be rented with metrology software or own software daily, weekly or for longer periods. API also provides a unique rent-to-buy program, interesting when company’s equipment investment process is lengthy but the need for a laser tracker is immediate. API Europe also performs on-site measurement services in addition to performing laser tracker accuracy verifications in the field and laser tracker calibrations at its certified laboratory. Please contact: info.eu@apimetrology.com or call +49 6221-7298050

Advanced elbow scanner added to rental fleet Ashtead Technology has added the Olympus FlexoFORM™ pipe elbow scanner to its rental fleet of Non Destructive Testing equipment. “This is part of a major investment in our NDT fleet,” says NDT Market Manager Steve Drake. “The FlexoFORM is an extremely important addition because it complements our other pipe inspection equipment and provides a solution for many particularly challenging applications. “Pipe elbows are susceptible to damage from issues such as flow-accelerated corrosion (FAC), but they can be difficult to inspect because their shape changes from convex to concave, and of course pipe diameters vary widely.” The scanner can be used with an OmniScan® MX2 or SX instrument to measure remaining wall thickness, and detect corrosion pitting and mid-wall laminations or inclusions. www.ashtead-technology.com

MEASUREMENT & MONITORING

END OF INDUSTRIAL IOT SOLUTIONS CAPTION DATA

GOT MODBUS? GET INSTANT REMOTE MONITORING & INTERNET OF THINGS!

Adding connectivity from your devices to a cloud based IOT portal to manage your assets has never been easier! Using products and the IOT platform from Caption Data Ltd in Worcester provides an “out of the box” or “plug and play” solution with immediate access.. Once their NanoULTRA Edge product is connected to your target device (RS232 or RS485) and powered up, all of the configuration work is then done via the SmartHub. There is no need to connect to the device directly with a PC to configure Modbus communications. This can all be achieved, securely via any browser using any Smart Device. So no software to buuy or load! What exactly can you do via the SmartHub in terms of Modbus configuration? • •

Quickly chose controllers from a drop down menu Add new controllers with a list of Modbus registers

•

Set baud rates, stop bits etc.

•

Save Controllers which can be recalled at any point in the future with new NanoULTRA systems

•

Configure registers for both read and write functions

•

Add up to four different slave devices to any one NanoULTRA e.g. Power meter, flow meter, environmental sensor all communicating to one NanoULTRA

•

Configure what Users (as opposed to administrators) can view

•

Select which registers you wish to monitor at high frequency

•

Apply bit masks to data strings and associate to alarm messages

All of which adds up to improved competitive advantage, improved profits and reduced risks!! Caption Data supply a host of global engineering businesses with their IOT solutions, and provide a one stop shop.

And what could this mean to your business? •

Improved customer service levels

•

A helicopter view of your assets with single click drill down to individual units to manage them

•

Faster, less onerous commissioning, with less time on site

•

Better resolution of customer issues

•

Improved spares & maintenance sales

You can contact them on +44 (0)1905 754078 or at solutions@captiondata.com and find lots more information at www.captiondata.com

Issue 41 PECM

MEASUREMENT & MONITORING

SAFE ELECTRICAL SWITCHING PYROPRESS

EXPERTS IN HAZARDOUS AREA INSTRUMENTATION Established more than 60 years, Pyropress is a leading UK based designer and manufacturer of weatherproof and ATEX/IECEx certified switches and transmitters for measuring pressure, differential pressure, vacuum, temperature, level and flow. Its quality, reliable and durable products incorporate proven design techniques and technology to provide safe and reliable electrical switching of alarm or control circuits within flameproof (Exd), Intrinsically safe (Exia), marine or industrial areas and are available with SIL2 certification to customers worldwide. All ranges are available with SIL2 approval and have a documented failure rate of 1 failure per million hours of operation. They have also been certified both IP66 and IP67 in line with the latest standards.

DEVELOPMENTS FOR ATEX AND IECEX SWITCHES

Pyropress has added new features to its Perseus range of ATEX and IECEx switches for use in hazardous areas which is now available with a stainless steel housing for the first time. “We have added an adjustable differential setting capability to the Perseus range of Exd flameproof switches and Exia intrinsically safe switches. It allows fine tuning of compressor cycling in air conditioning and HVAC applications for example and has other uses where hysteresis control is required,” says Stephen Burns, Managing Director Pyropress Limited. “The same module allows two switches with separate settings. There is also the option of a second M20 electrical entry. The Perseus range has been available with only black anodised aluminium for 10 years so introducing the stainless steel housing completes the entire offering. Pyropress are able to offer custom switches and transmitters to suit different applications across all industries and we hold sufficient stock to manufacture millions of combinations to suit specific applications. The Perseus range of switches is available in pressure, temperature, level and flow variants and is fully certified to the European ATEX 2014/34/EU and International IECEx for explosion proof (Ex d) and intrinsically safe (Ex ia).

PECM Issue 41

They are available for operating pressures starting at 0.4 mBar, for ultra low pressure, vacuum and differential pressure and reaching 800 Bar on the high pressure range. Pyropress offers many options and variants for applications where gas, vapour, powder and dust are present. For further details contact us or your nearest Pyropress distributor.

NEED IT FAST?

We offer an Express Manufacturing Service for our switches which can mean having a bespoke sensor delivered within 48 hours of

order placement. We can also offer products that are customised to your application. We have full onsite design, machine shop, manufacturing, and calibration facilities, enabling a fast response, and all backed with our highly commended customer service. Between 11th – 14th November 2019, Pyropress will exhibit at ADIPEC in Abu Dhabi, an exhibition devoted to the oil and gas sector. www.pyropress.com

PERSEUS PRESSURE SWITCH Exd or Exia ATEX/IECEx certification | Stainless steel or black anodised aluminium housing to IP66 & IP67 standards | 316 Stainless steel wetted parts | M20 x 1.5 ISO electrical connection | Other threads available via adaptors | Select housing material, certification, pressure range and process connection |

ATEX / IECEx AS STANDARD

SPDT MICROSWITCH

EXD (FLAMEPROOF) OR EXIA (INTRINSICALLY SAFE) AVAILABLE

316 STAINLESS STEEL WETTED PARTS

BLACK ANODISED ALUMINIUM OR 316 STAINLESS STEEL BODY

VITON DIAPHRAGM

RANGES BETWEEN 0.1 BAR AND 800 BAR

ADJUSTABLE SETPOINT WHILST OPERATIONAL

M20 X 1.5 (F) ELECTRICAL ENTRY

STAINLESS STEEL

ULTRA LOW, LOW AND DIFFERENTIAL PRESSURE RANGES ALSO AVAILABLE

BODY OPTION PICTURED

PRESSURE RANGES & PRICING PRICE

CODE

RANGE

MAXIMUM PRESSURE

ALUM

0.1 - 1.5 bar

12 bar

£250

1.2 - 4.2 bar

12 bar

0.2 - 3.0 bar

3.0 - 9.0 bar

0.4 - 6.0 bar

PRICE

CODE

RANGE

MAXIMUM PRESSURE

ALUM

£315

30 - 180 bar

500 bar

£280

£345

£250

£315

70 - 420 bar

500 bar

£280

£345

25 bar

£250

£315

4.0 - 14 bar

700 bar

£315

£380

25 bar

£250

£315

10 - 36 bar

700 bar

£315

£380

50 bar

£250

£315

28 - 108 bar

700 bar

£315

£380

ST.ST.

6.0 - 18 bar

50 bar

£250

£315

50 - 200 bar

700 bar

£315

£380

8.0 - 34 bar

50 bar

£250

£315

115 - 455 bar

700 bar

£315

£380

15 - 90 bar

500 bar

£280

£345

200 - 800 bar

1000 bar

£315

£380

The design features a simple form of adjustment. The switch is factory set and shipped at a mid-range falling and adjusted upon receipt. The set point can even be safely adjusted whilst the switch is electrically connected and in the hazardous area.

PART NUMBER BREAKDOWN PF61

Bespoke variants are available.

Contact sales@pyropress.com

HOUSING

PROCESS CONNECTION

S = 316 STAINLESS STEEL

1 = 1/4” BSP.P FEMALE

A = BLACK ANODISED ALUMINIUM

2 = 1/4” NPT FEMALE

CERTIFICATION B = Exd ATEX / IECEx FLAMEPROOF

to discuss alternative microswitch, diaphragm, process connection, range and electrical entry options.

RANGE CODE

O = Exia ATEX / IECEx INTRINSICALLY SAFE

T: +44 (0)1752 333933 | sales@pyropress.com www.pyropress.com

MEASUREMENT & MONITORING

FLIR T860

FLIR

THERMAL CAMERA STREAMLINES INDUSTRIAL INSPECTIONS

FLIR Systems has announced the FLIR T860, its latest addition to the high-performance T-Series family. This new thermal camera is the first to feature onboard Inspection Route software, ideal for streamlining inspections of critical assets, including power substation components, distribution lines, manufacturing equipment, or facility electrical and mechanical systems. By running a pre-planned route through the camera, thermal inspectors can spend less time in the field and face less hassle when creating survey reports. Featuring the FLIR T-series camera platform’s award-winning design, the T860 has an ergonomic body, a vibrant LCD touchscreen visible from low angles, and an integrated color viewfinder for sun glare conditions. The 640×480-resolution thermal camera incorporates FLIR’s advanced Vision Processing™, including patented MSX® and UltraMax® image enhancement technologies to provide enhanced image clarity with half the image noise of previous models. Pairing the T860 with an optional 6-degree telephoto thermal lens allows users to inspect energized

PECM Issue 41

targets from a safe distance or measure small targets with greater precision. This thermal camera includes advanced measurement tools such as one-touch level/ span and laser-assisted autofocus, which helps users quickly find problems and make critical decisions. It also features an onboard routing system that works with the FLIR Thermal Studio advanced reporting software to create numbered, labeled inspection routes that users can create from the camera. This system allows users to record temperature data, thermal, and visual imagery in a logical sequence for faster troubleshooting and repair. A key feature of the T-Series product line is its ergonomic design, which reduces the strain of full-day inspections. A 180-degree rotating lens platform helps users diagnose hard-to-reach components at substations and on distribution lines. The T-Series also offers tools to optimize workflows, including Wi-Fi streaming to the FLIR Tools® mobile app for Android and iOS, in-camera GPS tagging, voice annotations, and customizable work folders.

The T860 camera includes the new subscription-based software, FLIR Thermal Studio Pro. This professional-level program provides access to all the time saving features and benefits of FLIR Thermal Studio Pro as well as free software upgrades. The FLIR T860 camera is now available for purchase through established FLIR distribution partners. For more information on the FLIR T860, please visit www.flir.com/ t860. Founded in 1978, FLIR Systems is a worldleading industrial technology company focused on intelligent sensing solutions for defense, industrial and commercial applications. FLIR Systems’ vision is to be “The World’s Sixth Sense, creating technologies to help professionals make more informed decisions that save lives and livelihoods. For more information, please visit www.flir.com and follow @flir

MEASUREMENT & MONITORING

TEMPERATURE SENSORS LABFACILITY

LABFACILITY TEMPERATURE & PROCESS TECHNOLOGY

Labfacility manufacture a wide range of temperature sensors to suit your application. A large range of Thermocouples in IEC or ANSI calibration, PRT's, Detectors, Environmental Sensors and Hand-Held Sensors / Thermometers are available to buy, for immediate despatch, from www.labfacility.com Thermocouple Connectors We are Europe's largest manufacturer of thermocouple connectors and accessories in IEC, ANSI and JIS Colour codes. The full range of connectors are available from stock for immediate despatch. Thermocouples We offer an extensive range of Thermocouples, in numerous sizes all in IEC or ANSI colours. Products include Mineral Insulated, Fine Wire Versatile, Fabricated & Specialist Thermocouples together with a range of moulded-on Thermocouples.

100

PECM Issue 41

Thermocouple Cable / Wire We offer a wide range of thermocouple, PRT and extension cable / wire in stock for immediate despatch. Thermocouple cables are available in IEC or ANSI Colour codes. Insulation types include PFA, PTFE, PVC & Fiberglass. L60 Thermocouple & Fine Wire Welder The Thermocouple Welder, manufactured by Labfacility, is a compact, simple-to-use instrument designed for thermocouple and fine wire welding. In-House Calibration Traceable to ISO17025 (UKAS) calibration standards, Labfacility offer a choice of a 3 or 5 point traceable calibration using our inhouse calibration facility, you can select any temperature points between -10°C & +200°C. Thermometer Kits with Meter Products include the HVAC Standard and PRO kits, Type K general purpose thermocouple kit and two multi-purpose kits with optional moulded on probes or hand-held temperature probes.

Catering Kit also available with High Accuracy Chef Thermometer and optional Type T probes. Company Profile Labfacility are the UK’s leading manufacturer of Temperature Sensors, Thermocouple Connectors and associated Temperature Instrumentation and stockists of Thermocouple Cables. The Company has been trading since 1971 and is ISO 9001 accredited. We have two UK sites – West Sussex and South Yorkshire and export to over 85 countries. In addition to the stocked items, Labfacility also offers bespoke Temperature Sensors. View our website to see our Custom Built Sensors & Gauge Configurators page. We are specialists in the design and manufacture of custom-built temperature sensors at our 18,000-square foot Yorkshire plant located in Dinnington. Shipments are made to world-wide destinations daily; technical and application advice is always freely available. www.labfacility.com

Leaders in temperature measurement

Labfacility are the UK’s leading manufacturer of Temperature Sensors, Thermocouple Connectors and associated Temperature Instrumentation and stockists of Thermocouple Cables. Thermocouple Connectors

A comprehensive family of IEC / ANSI / JIS colour coded miniature and standard connectors, accessories, panels, terminal and barrier blocks: all manufactured by Labfacility Plugs & Sockets, / Quick Wire / Panel Mount / Fascia Sockets/ PCB Mounting / Duplex / High temperature

Temperature Instrumentation

Labfacility have always been associated with high accuracy temperature measurement manufacture. L60 Thermocouple & Fine Wire Welder Bench Top Instrumentation Temperature & Humidity Transmitters Data Loggers Environmental Instrumentation & Sensors

Temperature Sensors We manufacture a wide range of temperature sensors to suit your application. An extensive range of Thermocouples, PRT’s, Detectors, Environmental Sensors and Hand-Held Sensors / Thermometers are also available to purchase online for immediate despatch.

Thermocouple & PRT Cable/Wire A range of IEC / ANSI colour coded thermocouple cables / wire and PRT cables / wire to suit various applications. The range consists of the following: PVC, PFA, PTFE & Glassfibre insulated cables. We also offer retractable curly leads and extension leads.

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

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

MEASUREMENT & MONITORING

SAFE WATER TEMPERATURES – TM ELECTRONICS AND GUERNSEY HOSPITALS Like many other health Trusts and local authorities, States of Guernsey hospitals have adopted a new low cost water temperature monitoring system for the prevention of Legionella. The TC Wall Port System – designed by thermometer manufacturer, TM Electronics (TME) - has been installed on a number of the wards at the Princess Elizabeth Hospital to monitor subordinate loops, situated behind panels which previously would have to be removed every time a temperature was taken. “We’ve been very impressed with the Wall Port System,” says Clive Martin, Head of Estates “which we use with TME’s legionella thermometer kits and dual purpose surface/immersion probes to monitor water temperatures across the estate.” TC Wall Ports are miniature, wall-mounted thermocouple sockets which speed up and simplify temperature testing of hard to reach water assets like concealed pipework, thermostatic mixing valves, subordinate loops and high-level water storage tanks.

Each port measures just 52 x 52 mm and houses either a single or double thermocouple connector, which is then linked to a water outlet using a fine wired fixed surface, air or immersion sensor. Temperatures are taken by simply plugging a hand-held thermometer into the port, delivering instant results with no loss of accuracy from up to 20 metres away. Paperless Recording TC Wall Ports are also ideal for enabling a paperless method of temperature recording. This is easily achieved by applying a label with a unique configurable barcode to each port. Temperature readings are recorded using TME’s MM7000-2D Barcode Scanning Thermometer. This portable, Bluetooth thermometer has a fast built-in barcode scanner, is battery powered and operates without Wi-Fi. Up to 1,000 readings can be stored at a time, with results downloaded using Bluetooth or USB connection. Software included with the thermometer ‘translates’ the barcodes into readable data and transfers it into a CSV file. Data can then be easily accessed and stored on either stand-alone or Cloudbased systems.

NEW Double Socket Wall Port for unblended hot and cold water pipes TM Electronics UK Ltd (TME) +44 (0) 1903 700651 sales@tmethermometers.com www.tmethermometers.com

ADFORS The company ADFORS belongs to the Saint-Gobain Group, the largest supplier of materials and building technologies worldwide. ADFORS focuses on the construction and industrial markets and offers solutions based on a complete assortment of textile and coating technologies using synthetic and natural fibres. They are the global market leader in the field of technical textiles and provide solutions which have been precisely adapted to customer requirements.

APPLICATION/ TASK:

During quality control on wallpaper coating machines for glass-textile wallpaper, it is necessary to control the straight- ness of the wefts at an average of once per hour. The frequency should be adjusted using a potentiometer as the machine speed can vary between 12-40m/min. The web width which has to be illuminated is two meters.

SOLUTION/ RESULT:

The decision was made to use the stationary stroboscope RT STROBE 12000 LED (A6-12210). At a distance of 60cm, the whole web width of two meters can be inspected.

102

PECM Issue 41

Offset weft threads are checked online using the stroboscope at a speed up to 40m/min. In the past, to inspect this offset, the machine speed had to be reduced which led to a loss of production. It is now possible to carry out the inspection at full speed.

RHEINTACHO Messtechnik GmbH · Waltershofener Str. 1 · D - 79111 Freiburg phone +49 761 4513 0 · fax +49 761 445 274 · www.rheintacho.de

MEASUREMENT & MONITORING

RTR-500 SERIES T&D CORPORATION EUROPE

VERSATILITY FOR DISTINCT MONITORING SOLUTIONS: THE RTR-500 SERIES

Along every step of the supply chain, wireless data loggers from T&D Corporation offer a flexible solution for multiple purposes. The Japanese market leader for wireless data logging systems presents the RTR-500 series, which includes 13 different types of loggers as well as four types of wireless base units, and a wireless portable data collector – all of which are incredibly easy to combine. T&D Corporation designed the EN 12830-approved RTR-500 product family for various monitoring needs. It consists of dust and water-resistant wireless data loggers, devices for communication and error-free data collection, as well as inclusive cloud services and software. The small and robust data loggers are made for monitoring

differing parameters, including temperature, humidity, CO2 content, luminance, UV, 4-20mA, voltage and pulse. Simultaneously, they monitor different temperature zones in various locations, with measurements automatically documented and stored. Base stations are available in GSM, USB, Ethernet (WLAN or LAN) versions, alongside mobile data collectors. Up to 100 data loggers can be connected to one base station, and repeaters can be used to strengthen data signals over distances longer than 150 metres. The slogan “Let the cloud work for you” inspired T&D Corporation: With its measuring instruments, constant monitoring and documentation of HACCP, security is easier than ever, whether it is the cold chain during

transportation, warehousing of sensitive goods or supervision of sales cabinets and refrigerators. As it is automatically updated, cloud computing makes data monitoring incredibly simple by overcoming time and distance issues, and is easy to share. The free of charge T&D cloud was established in 2010 and has since been developed to offer additional valuable features: The T&D WebStorage Service and appropriate apps enable unlimited and mobile access to current readings and saved records.

www.tandd.com www.webstorage-service.com

Issue 41 PECM

103

MEASUREMENT & MONITORING

MMS® INSPECTION SERIES FISCHER INSTRUMENTATION

NACE: CORROSION COSTS $2.5 TRILLION ANNUALLY Every year, corrosion causes an economic damage of more than $ 2.5 trillion worldwide. Therefore, the prevention of corrosion, is an issue that plays an important role in many areas. The new MMS® Inspection series that is optimized for corrosion protection reliably supports the inspector in assessing corrosion-exposed components and in jobs that involve checking of corrosion protection. Corrosion is the deterioration of a metal as a result of chemical reactions between it and the surrounding environment. This leads to a functional impairment of the metallic component over time. Accordingly, rust formation on a railroad track is not harmful, since the function of the rail is not diminished. However, a pipe which has become leaky due to pitting corrosion is clearly defective, since the safe transport of liquids is no longer guaranteed. The same applies to the maritime sector, where material surfaces attacked by corrosion on ship walls can quickly become a safety risk. There are serious consequences caused by corrosion in engineering structures such as bridges. If the steel structure corrodes without any control, a bridge can quickly become a threat to those who move on it. Furthermore, there are economic advantages to implementing proper corrosion prevention methods. In order to protect metallic materials against environmental influences and thus corrosion, in most cases coating with suitable corrosion protection material is sufficient. The expense for this – passive – corrosion protection is relatively low in relation to the costs caused by corrosion such as loss of value, downtime, dismantling, etc. For companies and institutions saving on corrosion protection, it usually becomes expensive to repair the damages afterwards. This is especially so for structures that are very difficult to access after installation, such as offshore wind turbines. Corrosion protection involves regular inspection and checks for proper functioning. This means that inspectors and service personnel need to use targeted measurements to inspect if the quality of the corrosion protection coatings still meet specified standards. With regard to coating thickness gauges used here, both magnetic induction method and eddy-current testing have established themselves as standards worldwide.

104

PECM Issue 41

MMS® Inspection DPM (Dew Point Meter)

MMS® Inspection SPG (Surface Profile Gauge)

1) NACE International, impact.nace.org The MMS series offers a third model, the MMS (2016)Inspection SPG. This gauge measures according to the “Peak to Valley” method,of meeting ASTM D 4417-B Rusting, the formation iron oxides, is a and US Navy NSI 009-32 standards. The surface profile well-known example of electrochemical depth influences the amount of paint needed. If the peak to valley distance is too big, the applied paint layer may corrosion. not be thick enough on the peaks. Additionally, the profile infuences the adhesion of the paint on the surface.

Magnetic induction is the method of choice The MMS series offered as a of set non-magnetic of three to enable for measur ing theisthickness better corrosion protection. They are the only device layersonon baseIPmaterials, themagnetic market that meet 65 protectione.g. requirements includeplastic, dust protection and water layerswhich of paint, galvanized orproof. hot-dip galvanized layers on steel and iron. The eddy The MMS Inspection offers one-handed operation and provides immediate feedbackfor by means of light, vicurrent method is suitable electrically bration and sound. The auto rotate function allows the non-conductive layers on non-ferrous corrosion inspector to view measurement results at all metals, such as e.g. paint, lacquer or plastic important angles. on aluminium. Depending on the version, modern gauges such as the newly developed MMS® Inspection series from Helmut Fischer offer both measuring methods. Helmut Fischer has made every effort to ensure the convenience of the user. For this reason, international measurement standards such as SSPC PA2 (Level 1-5), IMO PSPC, ISO 19840, Australian AS 3894.3-2002 or Swedish IS 1841 60 are firmly integrated as pre-configured batches or measurement specifications via the software. The dew point measuring device MMS® Inspection DPM, which belongs to the same series, measures the dew point before the corrosion protection paint is applied. This helps to ensure that the coating is applied under proper environmental conditions. If the conditions are not suitable, premature corrosion may occur or the paint may peel off as a result of poor adhesion.

MMS® Inspection DFT (Dry Film Thickness)

Inspection SPG. This gauge measures A big advantage of the MMS® Inspection series is the according the “Peak Valley” intuitive usertointerface for allto systems. Themethod, software guides theASTM user step step through meameeting D by 4417-B and the USindividual Navy NSI suring programs and shows him how to proceed with 009-32 standards. The surface profile depth each measurement. Thus, the devices can be handled influences amount of paint needed. If the reliably eventhe by untrained personnel. peak to valley distance is too big, the applied Helmut Fischer has designed this series of gauges to paint may not beinspection thick enough on easthe makelayer corrosion protection considerably ier. ThisAdditionally, enables many companies the world tothe peaks. the proaround file infuences avoid corrosion damage andon thethe resulting loss of value. adhesion of the paint surface. The MMS series is offered as a set of three to enable better corrosion protection. They are the only device on the market that meet IP 65 protection requirements which include dust protection and water proof. The MMS Inspection offers one-handed operation and provides immediate feedback by means of light, vibration and sound. The auto rotate function allows the corrosion inspector to view measurement results at all important angles. Intuitive user interface for all systems. The software guides the user step by step through the individual measuring programs and shows him how to proceed with each measurement. Thus, the devices can be handled reliably even by untrained personnel. Helmut Fischer has designed this series of gauges to make corrosion protection inspection considerably easier. This enables many companies around the world to avoid corrosion damage and the resulting loss of value. www.fischergb.co.uk

Absolutely reliable. Even under harsh conditions. THE NEW MMS® INSPECTION SERIES

Corrosion protection starts well before the first coat of paint. The corrosion kit MMS® Inspection comprises three devices that are needed before, during and after surface coating. With the SPG, you can reliably measure the surface profile. The DPM provides all the necessary data for determining the dew point. The powerful DFT is your mobile companion for all coating thickness tasks (ferrous and non-ferrous substrates). www.fischergb.co.uk

MEASUREMENT & MONITORING

LINE OPTICS FOR INCREASED MEASURING SPOT SIZE

LumaSense Technologies is now Advanced Energy

IMPAC pyrometers Series 6 Advanced represent the “flagship-class” of smallsized infrared thermometers by Advanced Energy. Different models are available with integrated LED display, laser targeting light, view finder, or integrated color-TV camera. All prepared for exact temperature measurements, covering a wide range of industrial applications. Besides the standard optical heads these pyrometers are optionally also available with integrated line optics. These special optics feature a significantly wider measurement spot in shape of a line and provide additional advantages, especially for wire production or pouring stream applications. The line shaped spot guarantees that vibrating or oscillating wires or a moving pouring stream do not move out of the pyrometer’s target spot.

Thereby the wires respectively the pouring stream need to be aligned diagonally to the line shaped spot. For wire production the orientation of the line spot is vertical for MB 14 with a temperature range from 600…1400°C For measuring steel pouring streams the orientation of the line spot is horizontal for MB 25 from 800 °C…2500°C. In combination with the fast response time of 2 ms the respective temperatures can be measured reliably, even at highspeed processes.

LumaSense Technologies, Inc., one of the world’s most trusted providers of innovative temperature and gas sensing devices was acquired by Advanced Energy, a global leader in highly engineered, precision power conversion, measurement and control solutions, in September 2018. Legacy LumaSense products are now part of the Advanced Energy family, adding a line of photonicbased measurement and monitoring solutions that are synergistic with Advanced Energy’s leading precision power and control technologies in both semiconductor and industrial markets. LTI-info@aei.com www.advancedenergy.com/products/ temperature-measurement/

Best-in-class sensors by HBM HBM is a world leader in developing and producing sensors and transducers to meet your specific needs. n■

Strain gauges are available for widely differing applications and at short notice

n■

Load cells and force transducers measure static and dynamic tensile and compressive loads - with virtually no displacement

n■

Torque sensors and transducers measure torque precisely

n■

Pressure transducers can be used in hydraulic and pneumatic equipment

n■

Displacement transducers measure precisely in the µm range and allow simple displacement monitoring

n■

Strain transducers measure high forces

n■

In addition: We develop and manufacture customized transducers that meet your specifications

Measure and predict with confidence. This is what we stand for. Further information: www.hbm.com/eu-sensors

n 6151 n www.hbm.com KingdomnLtd 0208 515 n6000 info@uk.hbm.com n www.hbm.com HBM TestHBM andUnited Measurement Tel. +n 49Tel. 6151 803-0 Fax +49 803-9100 n info@hbm.com

106

PECM Issue 41

Compact

Compact - high temp

Full bore with Compact Electronics

www.kobold.com 01623 427701 info.uk@kobold.com

Quality Engineered Instruments

Compact

Magnetic Inductive Flowmeters from

Full bore & Insertion - Smart, Hart, ATEX

MEASUREMENT & MONITORING

SICK VISIONARY S STEREO CAMERA SICK

SICK STEREO CAMERA MAKES LIGHT WORK OF ROBOT INTEGRATION SICK has extended its innovative family of 3D snapshot vision sensors with the launch of the SICK Visionary S stereo camera, enabling precise, high-speed capture of 3D colour images for integration into robot guidance and quality inspection applications. The SICK Visionary S 3D snapshot camera combines stereoscopic vision with projected structured illumination to capture up to 30 high-resolution 3D images every second and output colour and depth values directly to a PLC or robot controller. With a working range up to 2.5m, the IP67-rated SICK Visionary S is ideal for a variety of rugged industrial uses. Its real-time, rapid streaming of high-resolution RGB and depth values makes light work of 3D recognition and dimensioning tasks for both moving and stationary objects. So, it is an ideal partner for robotic bin picking, palletising and de-palletising applications, as well as for quality and completeness checking on high-speed consumer goods lines. “The Visionary S addresses the need for an accurate 3D Snapshot camera that extends the options for machinebuilders and system integrators to engineer robot guidance solutions. Its rapid on-board image processing and 50 ms response times makes fast picking frequencies possible at an accessible price/ performance level. “Add its powerful visualisation tools, Gigabit Ethernet interface, wide compatibility with communications protocols and common programming languages, and you have a versatile and intelligent partner for 3D vision integration. It’s easy to adjust the camera and filter settings and to configure with SICK’s SOPAS software engineering tool.” Because it delivers high-resolution 512px x 640px depth and RGB image values in one snapshot, using the Visionary S means there is no need for an actuator and 3D information can also be output for stationary objects. The Visionary S’s colour intensity perception together with depth values with an accuracy of up to 0.7mm also mean high-quality data can be provided for quality inspection purposes. The Visionary S’s high-efficiency structured illumination delivers reliable depth data in ambient light conditions. With a working range of between 0.5m to 2.5m and a ~50°x 60° angle of view, the Visionary S is well-suited to a widerange of industrial and intralogistics uses.

For more information about the SICK Visionary S please contact Andrea Hornby on 01727 831121 or email andrea.hornby@sick.co.uk www.sick.co.uk

108

PECM Issue 41

MEASUREMENT & MONITORING

T860 EN 180x132.indd 1

22/10/19 17:36

CODEL

Monitoring Solutions

Internet of Things / Remote Monitoring/ Asset Management • ANY DEVICE • ANY BROWSER • NO SOFTWARE TO LOAD

Continuous Emission Monitoring Road, Rail and River Tunnel Monitoring Biomass and Raw Gas Monitoring Safety and Process Control To get your IOT project underway, talk to the IOT people • 10 YEARS, • 1000’S OF SYSTEMS • MILLIONS OF DATA POINTS/DAY • 15 COUNTRIES • 100’S CUSTOMERS

www.captiondata.com solutions@captiondata.com

Tel +44 (0)1905 754078

EnergyTech TunnelTech

SmartCem

CODEL live

www.codel.co.uk sales@codel.co.uk

+44 (0)1629 814351 Issue 41 PECM

109

MEASUREMENT & MONITORING

ULTRA LOW-RANGE DIFFERENTIAL PRESSURE SENSORS FURNESS CONTROLS

PRESSURE DECAY LEAK TESTING

Furness Controls are UK manufacturers of ultra-low-range differential pressure sensors and leak testing equipment. Founded in 1963, the company has become world-renowned for its range of multifunction leak testers, flow testers and differential pressure transmitters, and for their UKAS-accredited calibration laboratory.

between the flow of air through a leak, and the flow of more viscous liquids such as water or oil. In fact, if the rate of air-leak is low enough, a water-carrying device such as a tap can safely be regarded as leak tight. This is why most standard test parameters for such devices are given in air leak rates such as cc/ min at a given pressure in bar.

For leak testing, Furness Controls has developed a range of automated instruments capable of detecting very fine air leaks through the differential pressure decay method. With this approach, products are pressurised, isolated from the pressure source and monitored for very small changes in pressure over time.

Not only are Furness Controlsâ&#x20AC;&#x2122; leak testers sensitive, due to their differential pressure sensors, over time they have developed many other features such as automated test cycles, industrial communications, programmable electrical I/O and pneumatic outputs. The latest line of instruments can happily run an entire test station or be controlled through a PLC. They have large colourful touch screens for ease-of-use, and support multiple ancillary test types such as blockage tests, ramp tests, sealed-part tests, and bell tests. The applications for pressure decay leak detection are too numerous to list, and cover most industries, but a sample of the latest solutions the company has provided include: Airconditioning pumps, automotive fuel lines, EV batteries, surgical robotics and military radio enclosures.

By using a differential sensor, comparing the pressure in the item against a reference, very low pressure drops can be measured, equating to a mere 0.01 ml/min in some applications. For manufacturers, the key realisation is that air decay testing is applicable across a range of leak test problems; there is a well-defined relationship

110

PECM Issue 41

Flow testers are also a major product line for Furness, with a range of touch screen instruments recently released in parallel with the leak testers. These instruments use laminar flow elements to accurately measure flows in products such as heat exchangers, gas burners and exhaust systems. With a range of high accuracy pressure transmitters, laminar flow elements, Pitot tubes and calibrators, Furness Controls aims to provide the complete solution for the testing and measurement in the arena of low flow and pressure, and have been innovating in the field for over 50 years. www.furness-controls.com +44 1424 819 980

Innovating in the field of testing, measurement and control for 50 years

Leak Testers

Leak Testing instruments for production testing of components and assemblies Touchscreen interface • Multi-step tests Industrial Comms • Programmable I/O Leak • Flow • Sealed-part testing

Low Range Pressure Transmitters

A range of differential pressure transducers suited to the measurement and control of air/gas flow and pressure, with an accuracy better than 0.25% even in the ±50 Pa range

Pitot Tubes and Laminar Flow Elements Classic Prandtl style Pitots, averaging Pitots and laminar flow elements in a variety of sizes

Furness Controls Ltd., Bexhill, England E: sales@furness-controls.com T: +44 1424 819 980

Calibration

Our portable calibrator has a pressure range of 0.01 Pascals to 20 kPa, and flow range from 1 ml/min to 2000 l/min

www.furness-controls.com

MEASUREMENT & MONITORING

NEW Double Socket Wall Port for unblended hot and cold water pipes

New from Niton UK

XL2 Plus

Verify metals more easily in the dust and wet. www.nitonuk.co.uk 01256 397860 info@nitonuk.co.uk

Visit us at RWM Stand 4J34

20/08/2018 ADVANCED PORTABLE DEWPOINT HYGROMETER FOR DRY COMPRESSED AIR & INDUSTRIAL GASES

SepOct2018_Advert_PECM.indd 1

Experts in trace moisture measurement, Alpha Moisture Systems launch a powerful feature packed Portable Dewpoint Hygrometer which offers fast & accurate measurement of dewpoint and moisture content in dry compressed air and industrial gases. The SADPmini2 range of Dewpoint Hygrometers.

112

PECM Issue 41

•

Full colour screen displaying multiple units simultaneously

•

View display screen on smart phone or tablet via dedicated App

•

Desiccant Dry-Down Chamber for fast response

•

Automatic Calibration

•

Units selectable in °C, °F, ppm(v), ppm(w), g/m3 or lb/ MMSCF

•

Full data logging capability

•

Real time logging with screenshot feature

•

Wireless Bluetooth & USB connectivity

•

Wireless printing to dedicated printer

•

Rechargeable, 150 hours use in continuous operation

•

Strong, durable and rugged, IP66 construction www.amsystems.co.uk info@amsystems.co.uk

14:04:53

NEWS & EVENTS

Helping you improve safety, efficiency and compliance

LEARN

SOLVE PROBLEMS

EEMUA’s goals are member focused and aimed at helping you to operate safer sites with a skilled and competent workforce. EEMUA provides a broad-based resource for all those for whom good practice in a range of industries is a critical feature – engineers, purchasers, specifiers and those involved in training.

Publications

Industry news

On-line Information training conveyed through technical committees, working groups, forums and seminars Courses

SHARE EXPERIENCES

You can rely on EEMUA to help improve your safety, effciency, regulatory compliance, and bottom line.

Upcoming EEMUA event: Storage Tanks Seminar 28 November 2019 – Chester

Learn more on the benefits of EEMUA membership – contact membership@eemua.org Book online today www.eemua.org

TECHSIL LAUNCH NEW OPTICALLY CLEAR FLEXIBLE ADHESIVE FOR BONDING DISPLAYS

Adhesive suppliers, Techsil have launched a new optically clear, low viscosity, UV curable adhesive into the UK market. Manufactured by Panacol, Vitralit® 50004 is a one-component acrylic adhesive so it requires no mixing. The adhesive has been designed to use for bonding display screens in electronic devices and laminating optics. This adhesive offers the optimal balance of high strength bonding with full re-workability. Vitralit® 50004 adheres to a variety of substrates including coated glass, PET and other plastics and films. Its low viscosity

means that it can fill cavities fast without trapping air. The adhesive cures quickly with very little shrinkage, meaning there is less residual stress between substrates. Techsil have expertise in many diverse adhesive applications including UV curing adhesives. They offer comprehensive customer support from selecting the right adhesive, on-site testing facilities to transitioning to volume production and beyond. www.techsil.co.uk

TECHSIL LAUNCH NEW BIOCOMPATIBLE PLASTICS ADHESIVE WHICH FLUORESCES ORANGE

Vitralit® 7311 FO is a transparent acrylic adhesive that cures under UV or visible light. It offers very high bond strength to many plastics including PC, PVC, PMMA or ABS, and also glass and stainless steel. With low viscosity and capillary flow characteristics, Vitralit® 7311 FO can bond large surfaces and applications with narrow gaps. Under low intensity black light (365 nm wavelength), Vitralit® 7311 FO fluoresces orange. This allows in-line inspection for

quality control. The bright orange contrasts with plastics possessing a natural blue fluorescence or colour. Thanks to modern photo initiators Vitralit® 7311 FO cures within seconds which works well in high volume production. For optimal curing the Bluepoint LED eco, manufactured by Panacol’s parent company Hoenle, is recommended.

www.techsil.co.uk

Issue 41 PECM

113

NEWS & EVENTS

Alloy Heat Treatment Alloy Heat Treatment is the UK’s only specialist in the heat treatment of aluminium alloys. With more than 40 years’ experience as a subcontractor, the company is focused solely on heat treating aluminium products, rather than other metals. It offers a range of treatments to change the internal properties and strengthen the aluminium product. Dudley-based Alloy Heat Treatment works with a diverse range of customers, mainly Tier 2 and 3 companies in the aerospace and automotive industries. The company holds NADCAP, AS 9100 accreditation, and preferred supplier status to many companies such as helicopter manufacturer Leonardo. www.alloyheat.co.uk

New Gas Flow Control Valve Features Zero Bleed Technology We are delighted to announce the addition of the VRG flow control products to our portfolio and, in particular, the world leading VRG gas control valve positioner featuring zero vent whilst stationary. In traditional systems a small amount of gas bleeds out due to the pressure of the gas opening and closing the valve. With the VRG system that doesn’t happen – if it’s not moving, it doesn’t bleed. The obvious benefits can be seen in both environmental and financial savings. The no-vent feature, compared to a venting system, will make an annual CO2 saving which is the equivalent to taking 3 family-sized cars off the road! And of course, you no longer have to pay for the gas that just bleeds out saving approximately £900 each year. For further information: www.ftpipelinesystems.co.uk Tel: +44 (0)1543 416024 enquiries@ftpipelinesystems.co.uk

Nelson Automotive rebrands as Avistud Global automotive stud welding leader Nelson Automotive has announced a complete rebrand of its business to customers, stakeholders and industry peers. The newly launched brand, AVISTUD, reflects the total separation of the Nelson Automotive business from the brand of its former industrial parent Nelson Stud Welding. Nelson Automotive was initially created as a standalone automotive company following the sale of Nelson Stud Welding from Doncasters to Stanley Black & Decker in April 2018. Henning Stams, chief executive of AVISTUD, said: “The automotive industry is demanding more speed and flexibility from its manufacturing processes than ever before. We have adapted our business to meet the automotive sector’s requirement for more lightweight, high-strength materials, electric vehicles and faster manufacturing processes.” www.avistud.com

114

PECM Issue 41

Brammer Buck & Hickman Wins Contract With Gas Turbine Engine Company A substantial new contract with Trac Precision Machining Ltd., for the supply of tools and consumables, and other associated products, has been awarded to Brammer Buck & Hickman, one of the UK’s leading suppliers of industrial maintenance, repair and overhaul (MRO) products and services. Trac Precision Machining is part Chromalloy, which delivers innovative solutions designed to reduce manufacturing and operating expenses and extend the life of gas turbine engines. It works with OEMs, commercial airlines, the military, plus oil, gas and power companies. For more information, please go to www.bbh-rubix.com

New fume extraction systems meeting latest HSE welding requirements New from Wilkinson Star, one the of the UK’s largest independent distributors of Welding and Industrial Equipment, is the F-Tech Fume technology product range of high vacuum fume extraction systems and welding torches. Welders and operatives can be exposed to welding fumes, grinding dust and oil mist in the working environment. It is therefore obligatory for employers to create safe and healthy working conditions for operatives by reducing these health risks. The F-Tech Fox is a high vacuum dust extraction system offering a portable solution to extract dust from manual welding and grinding processes. The F-Tech range is available through Wilkinson Star’s extensive distributor network. For further details please contact Wilkinson Star on 0161 728 7900 or visit wilkinsonstar247.com.

Re-shored contract boosts UK manufacturing Essential Supply Products (ESP), one of the UK’s major converters of tissue products, including paper hand towels and toilet rolls, has re-shored production of its tissue dispensing units from China. The product is a range of plastic tissue dispensers that reduce tissue wastage in non-consumer markets. UK technical injection moulding specialist, Talisman Plastics, now provides a turnkey solution with significant benefits. This move means ESP has been able to halve lead times, reduce stocking levels and carbon footprint and introduce greater control and flexibility into the supply chain. This is the latest in a series of contract wins for Talisman Plastics that has seen the company increase sales by 15% over the last 18 months. 01684 892892 sales@talismanplastics.co.uk www.talismanplastics.co.uk

NEWS & EVENTS

BESPOKE ENCLOSURE DUDLEY INDUSTRIES

CASINGS AND ENCLOSURES – WHEN BESPOKE IS BEST

Whilst an ‘off the shelf’ enclosure may look good value on the surface do you find you are needing to make too many adjustments and compromises to make it work? The team at Dudley Industries looks at when a bespoke enclosure may prove more cost effective. At Dudley Industries we are a company synonymous with quality sheet metal engineering having carved out a niche in providing OEM bespoke enclosures and casings across multiple industries. Andy Marsh, design and engineering manager comments ‘over the years we’ve found that many of our customers were frustrated with the compromises they needed to make using standard enclosures, the internal space was limited and the access points weren’t exactly where they needed to be, making the whole process more complicated than it needed to be’.

The term ‘bespoke’ often conjures up impressions of expensive but at DI we operate a lean manufacturing process that ensures efficient throughput, reducing lead times and helping to keep costs down. Our continual investment in the latest equipment ensures efficiency at all times. We are proud to offer flat bed and 5 axis laser cutting, presses ranging up to 400 ton including a hydraulic press. Our ABB robot ensures we can linish quickly and consistently. Our team of design engineers use smart technology including 3D CAD to take your enclosure specification through to CNC manufacturing layouts, providing prototypes along the way to ensure the design is just as required. We’re here to support you; we want to work collaboratively with you to ensure you get the very best output. All our company practices and procedures are externally accredited to ISO 9001:2015, in addition to applying a ‘right first time’ DFM and DFA philosophy.

We are currently working with major businesses providing bespoke casings and enclosures for equipment ranging from high end scientific laboratory instrumentation through to parts for the transport infrastructure. Whatever stage your products are at, our team are at your disposal. As part of Rentokil Initial PLC, you can tap into our expertise and resources of a FTSE100 listed company with the skills of an engineering team honed since 1942. So, before you compromise on a standard product, consider how a bespoke casing solution may be ideal for your project. It might just prove to be more cost effective and provide a longer term solution. If you would like to talk to our design team about your project call us on 01253 738311 or visit our website at dudleyindustries.com

Issue 41 PECM

115

NEWS & EVENTS

READY FOR ELECTRIFICATION PP CONTROL & AUTOMATION

PP CONTROL & AUTOMATION ON COURSE FOR £3M OF NEW BUSINESS WITH ‘READY 4 ELECTRIFICATION’ SUPPORT Tapping into expert academic support is helping a manufacturing outsourcing specialist access up to £3m in new business in the niche vehicle sector.

“As an SME, we don’t have the immediate available resource to research into such new and complex vertical market sectors. That’s where WMG comes into the equation.”

PP Control & Automation (PP C&A), which already works with many of the world’s largest machine builders, is one of the first participants of the Ready 4 Electrification Programme run by WMG, at the University of Warwick, and is already reaping the benefits of an initiative designed to get the supply chain ready for new opportunities.

He continued: “They have the experts in the field, who have the technical/commercial knowledge and understanding, not to mention a host of new contacts. We have a long-standing relationship with WMG so had no hesitation in becoming one of the first firms in the country to take part in Ready 4 Electrification.

The company has completed a feasibility project that assesses how ready it is to enter the automotive electrification arena, identifying barriers to overcome and, importantly, opportunities where it can transfer its technology and engineering expertise into the marketplace.

“Feasibility has been completed, with the next step being to finalise a strategic project we can work together on that will help us gain commercial advantage in the sector.

Information gained here has already been used to successfully approach and secure work for two customers involved in niche vehicle manufacture, with PP C&A supplying electrical box builds and cable assemblies, as well as using its design for manufacturing experience to support standardisation in order to reduce variety and complexity. “There is such a groundswell of movement towards reducing emissions in the automotive sector that we knew it was a market we had to try to get involved in and electrification appears to be doing most of the driving,” explained Tony Hague, Chief Executive of PP Control & Automation.

“We’re already delighted with the results. Two new contracts with niche vehicle manufacturers have been secured and there’s another in the pipeline…it has been a great start.” WMG’s Ready 4 Electrification programme is supported by the WMG Centre High Value Manufacturing Catapult and provides assistance to support companies of all sizes to make the most of opportunities in electrification. The initial support is awareness sessions followed by part-funded feasibility studies to help firms develop their EV roadmap and to provide masterclasses in key disciplines, including batteries, motors, power electronics and supply chain capability. From there participants can benefit from a strategic project that will deliver action plans around collaborative R&D, Knowledge Transfer Partnerships and Internships, with manufacturers also able to access technical support with production processes and rapid prototyping. Simon Garwood, Innovation Manager at WMG, added his support: “PP Control & Automation is a fantastic example of how the intensive research and coaching provided by the Ready 4 Electrification programme can upskill teams in companies and deliver real

116

PECM Issue 41

commercial advantages in a short space of time. “Our experts understand the pressures faced by manufacturers and how important it is to tailor the support to overcome specific barriers and unleash the potential in our supply chain. “We can deliver data, research and access to networks of specialists, not to mention the world class advanced test and manufacturing facilities available at WMG.” He concluded: “The UK has a fantastic opportunity to lead the world in vehicle electrification, but we can only achieve this vision if industry taps into the vast academic expertise and research at their fingertips.” Ready 4 Electrification has already reached over 200 companies through four regional networking events, with another three planned for 2019. It has visited over 50 firms and is currently completing in-company pilot feasibility projects. In total, it has the capacity to support over 200 businesses between now and 2020.

For further information, please visit www.ppcanda.com or www.warwick.ac.uk/wmg

NEWS & EVENTS

ROTAFLOW COMPLETES LOADING ARM JOB FOR WILHELMSEN As a swivel joint specialist, Derbyshire-based Rotaflow are often called in to find solutions to problems that lie beyond the expertise of many engineering companies. One such example involved the design and manufacture of a bespoke swivel joint complex for Wilhelmsen.

operations of the ships. This would require multiple swivel joints on the arm to give several degrees of freedom in motion. The boat and crane ends had been designed by different companies, so Rotaflow had to design and manufacture a solution that allowed two completely different designs to work together.

Rotaflow were called in to design articulated pipework to supply water for a fire suppression system on the crane booms on two bulk carrying vessels. The crane had to be able to swing over 90 degrees in both directions, as well as up and down whilst allowing water to travel along its length. The system had to be retrofitted around existing equipment, meaning that spatial constraints provided a design headache.

In writing, these issues seem easy enough to deal with, but when you consider the Rotaflow engineers had to design a solution that allowed a crane to extend to over 16 feet in length, but had to retract to less than 8 feet between connection points in a crowded deck space, the realities of the issue become clearer.

Innovative solutions to complex problems are what Rotaflow do best, so the design team set to work.

As the hose supplies a fire suppression system, reliability is paramount – there’s no room for sub-par engineering.

There were two major issues the engineers working on the project had to overcome…

The design and manufacture had to be perfect. Rotaflow had plenty of experience of dealing with this from previous projects, but the added dimension of making the hose articulate at a number of points added a level of complexity many other companies just weren’t willing to deal with.

The limited space in which the crane had to operate – it had to be long enough to satisfy its own operational needs, but be able to fold away into a small enough space to allow normal

The solution wasn’t an easy one – numerous iterations of the design were created and computer-modelled but each one had issues. The final design is constructed from stainless steel with a total of five swivel joints. It can extend to facilitate the crane’s full range of motion yet fold down to a small space allowing normal day-to-day operations of the ship. After building and extensive in-house testing, the design was sent off for installation on the ships, under the supervision of Rotaflow engineers. Thankfully the hard work was rewarded with a very successful integration of the parts. www.rotaflow.com

WE’LL HELP IDENTIFY EVERY R&D OPPORTUNITY As an independent consultancy, we help businesses and institutions to access the government grants and incentives they’re entitled to.

liaising with HMRC, we’ve helped hundreds of SMEs and large corporates to get the funds they need to support innovation and improve cash flow.

Could your company qualify for widely available funding?

A STRESS-FREE EXPERIENCE FROM START TO FINISH

From R&D claims, Patent Box to Land Remediation and Creative Industry tax relief, publicly funded incentives and grants are a valuable resource for businesses – yet so many fail to claim. Is your company one of the 97% of businesses that incorrectly assume they can’t apply for funding to support their innovative work? Don’t miss out on the potential of this valuable financial support simply because you didn’t choose to make a quick call! We’re here to help you… We know that perceived barriers such as complicated reporting requirements and a lack of awareness or difficulty in identifying eligible activity can stop businesses from accessing this crucial funding. But we can do all that for you… With our proven track record of successful client claims and extensive experience

At MCS Corporate, we take care of the full process, ensuring that it’s smooth and hassle free at every step – to reduce the impact on you and your team. Speak to one of our friendly experts today and let us: • Find grants and incentives in your sector. • Evaluate your eligibility. • Identify the criteria you need to meet to get funding and assistance. • Prepare and submit full applications and documentation on your behalf. • Liaise with the awarding body, including HMRC, on your behalf.

WHY CHOOSE TO PARTNER WITH MCS?

MCS Corporate has years of experience working in the Research & Development cost recovery sector. We’re specialists in identifying and submitting eligible claims for R&D Tax Credits/ Allowance, Patents, Creative Industries and Grants on behalf of our clients.

We have a proud track record of success and proven capabilities in securing larger-thanexpected claims returns. Better still, we work on a success fee only basis – meaning there’s no risk to you. We’ll do all the work and charge a fee only when your claim is successful.

GIVE US A QUICK CALL TODAY – THAT’S ALL IT TAKES!

Research, innovation, new products, process design and business development are driven by the range of valuable funding schemes that are readily available for companies of all sizes and in all sectors. We partner with ambitious companies to extend the global, domestic, technological and economic effects of their work. You can read a selection of case studies and view additional resources on our website. Take 10 minutes to get in touch and we’ll be able to quickly and efficiently assess your funding eligibility.

Give us a call today: 01926 512 475 Visit: www.mcs-corporate.com

Issue 41 PECM

117

NEWS & EVENTS

BOGE Compressors appoints new Sales Manager, UK & Ireland

Premium optical components that meet every specification

BOGE Compressors is delighted to announce the appointment of Russell Frost as Sales Manager, UK & Ireland. Russell joins the Yorkshire-based business bringing over 25 years’ experience within the compressed air industry, where he has held various senior leadership roles. BOGE’s 112 years heritage as the leading German-engineered air compressor specialist was a huge draw to Russell. He says: “BOGE is a premium brand and it feels like it has always been there. As you talk to manufacturers across industry, you get a sense that they really trust BOGE technology and the experience the team brings. I am excited to work with them all.”

Knight Optical is the engineer’s first choice for on-spec, high-quality optical components. Renowned for their exceptional reliability and unparalleled precision, our optics are tested in-house in our state-of-the-art Metrology Laboratory to guarantee compliance with your specification. With components covering the visible, ultraviolet (UV), near-infrared (NIR) and infrared (IR) spectrums, we offer a range of optics to meet the demands of the most complex of projects. From Lenses, Prisms and Mirrors to Windows, Beamsplitters and Filters – plus much more – not only do we offer a wide-ranging portfolio of stock components, but we also provide custom-made optics manufactured to your precise requirements.

He adds, I am eager to continue their legacy and lead them to even bigger and better opportunities in 2020 and beyond.”

www.knightoptical.com info@knightoptical.com 01622 859444

For more information, visit www.uk.boge.com/en

COMPLETE MORE PROJECTS FASTER. EACH ON TIME AND WITHIN BUDGET! It’s tempting to think that every company’s projects run over time and over budget. Yet they don’t. There’s actually a significant sub-set that consistently deliver projects twice as fast as their competitors—when adjusted for headcount. Critical Chain reveals what they have in common— and how to apply their secrets within your own company. You’ll learn these companies achieve performance breakthroughs with a more rudimentary approach to planning! The secret is a radically different approach to project execution. Learn crucial project management insights •

Why you need to spend less time planning projects, not more!

•

How the secret of finishing projects sooner is to start them later!

•

Why you must eliminate multitasking and feed each resource one discrete task at a time

•

How to use uncertainty as a strategic planning and management tool

118

PECM Issue 41

We work closely with our clients to solve their challenges with ontime delivery, and complete more projects faster, finishing each on time, to scope and within budget. To find out more, get a free copy of Critical Chain by Eli Goldratt author of The Goal. For more information and to claim a free book, please visit www.goldratt.co.uk/ pecm or call us on +44 (0)1234 834510

Signposting to Success: Brammer Buck & Hickman to Offer New Signage for Customers Brammer Buck & Hickman, the UK’s leading supplier of industrial maintenance, repair and overhaul (MRO) products and services, is delighted to see the development of a new safety signage offering in partnership with international sign and label manufacturer, Brady Corporation.The Brammer Buck & Hickman range covers safe condition signs, fire exit and assembly signs, first aid signage, general prohibitive signs, mandatory signs, danger and hazard signs and multi message signs. In addition, Brammer Buck & Hickman has a range of signs targeted for construction and site safety, which includes stanchion signs, construction banners, roll top signs, maintenance and scafftag, ladder and tower inspection signs. For more information please go to www.bbh-rubix.com or call Brammer Buck & Hickman on 08450 510 150.

WES LTD LAUNCHES DEFINITIVE WATER INDUSTRY GUIDE TO CHEMICAL BUNDING

Chemical dosing specialist, WES Ltd, has published an in-depth white paper explaining the necessity for chemical bunds, examining the choices available and highlights the responsibilities of businesses toward their provision and maintenance. The white paper from WES ltd, The definitive guide to chemical bunding in the water industry, focuses specifically on chemical storage bunds in the water industry. A chemical storage bund can be described simply as a structure

which underlies and forms a wall around an area containing hazardous chemicals or liquids. Its purpose is to provide secondary containment in the event of a leak. It prevents the spread of leaking liquids and so gives operators time to find and remedy a leak’s cause.

For further information on WES products and services, visit www.wes.ltd.uk

NEWS & EVENTS

ELECTRICAL SAFETY MARTINDALE PR

MARTINDALE’S NEW PROVING UNITS VERIFY SAFETY AND CALIBRATION IN ONE Now available from Martindale Electric – one of the most trusted brands in electrical safety – are the latest PDS and PDSX Series of proving units. Smaller, lighter and with new options for calibration checking test equipment, Martindale’s next generation PDSX proving units, enable contractors and maintenance teams to safely and simply prove the operation of voltage indicators, two pole testers and test lamps plus common 18th Edition tester functions. The PDSX Series includes an additional CALCHECK feature for verifying the calibration consistency of multifunction installation testers providing confidence in the performance of all essential test equipment before and after measurement. CALCHECK makes it easy to verify the insulation and low resistance ranges on 18th testers on-site, making it ideal for identifying potential calibration issues with test equipment prior to certifying a new wiring installation or carrying out a condition report. This is a valuable procedure recognised by electrical contractor assessment bodies to ensure reliable results and avoid unnecessary and expensive retests.

Sensors 5th Annual

Commercializing Next Generation Sensors for Real-World Applications DECEMBER 10 - 12, 2019

HILTON SAN DIEGO RESORT & SPA • SAN DIEGO, CA

HEALTHCARE APPLICATIONS STREAM

Cambridge Innovation Institute

MANUFACTURING STREAM

EMERGING APPLICATIONS STREAM

SensorsGlobalSummit.com

Safe electrical working requires the use of a voltage indicator that has been proven with a suitable proving device before and after use to ensure the instrument is working correctly in accordance with the Electricity at Work Regulations. Having de-energised and locked off a circuit prior to maintenance, it’s essential to prove your tester before and after you’ve proved the circuit to be dead in accordance with safe isolation procedures. The easiest and safest solution is to use a proving unit matched to the voltage indicator which can supply the full voltage range of the tester wherever you are working. Fast and easy to use, immediately supplying the full test voltage on contact, Martindale’s new proving units are suitable for proving two pole voltage indicators, and test lamps with voltage measurement ranges up to 440V and 690V. Featuring all the benefits of the industry standard Martindale PD440 and PD690, the new PDS and SX series of proving units come in a durable over moulded, low profile case, and include an MG3 detachable magnetic hanger, which enables the unit to be positioned securely nearby, ideal where space is limited or access difficult. For simplicity the S Series have a single voltage output while the SX Series output voltages are stepped with individual LED indicators for each voltage level from 50V to 690V. The voltage levels are matched to common two pole tester thresholds, ideal for identifying potential voltage tester calibration issues. For added ease of use, the new units are also colour coded so that the voltage output can easily be identified and matched to Martindale voltage indicators and test lamps which share the same colour coding. Complete with alkaline batteries and a carry case, the latest ranges are supplied with a two-year guarantee. Martindale Electric offers a comprehensive range of portable appliance testers, voltage testers, proving units and locking off devices to ensure compliance with the Electricity at Work Regulations for the safe maintenance of plant and equipment and the safe operation of electrical appliances.

For more information, please contact Martindale Electric on 01923 441717 or visit: http://martindale-electric.co.uk/

Issue 41 PECM

119

NEWS & EVENTS

HEALTH & SAFETY AT WORK INSTITUTION OF OCCUPATIONAL SAFETY & HEALTH

IMPROVING PRODUCTIVITY, EFFICIENCY AND REPUTATION

Could your business benefit from greater productivity, increased efficiency, reduced costs, enhanced reputation and a safer workplace? If so, now is the time to invest in IOSH’s Managing Safely, the market-leading safety and health course for businesses of all sizes.

•

It has been delivered worldwide for over 25 years by a huge network of training providers. It is tried, tested and trusted. And there’s more: •

•

It’s thorough but flexible. With the consequences of safety and health failure potentially fatal, you cannot rush training. Our three-day course takes the right amount of time to get learners up to speed. It’s available face-to-face or via e-learning to suit your business needs. It’s business focused. IOSH works with business leaders in the development of flexible courses to ensure they deliver the insights and efficiencies you need to gain a competitive edge. It’s unique. Managing Safely combines practical step-by-step guidance with an engaging and inspirational approach that will make your managers think afresh about how safety and health can positively impact the whole business.

120

PECM Issue 41

It’s contextualised. The content of the course and the scenarios that are explored will directly reflect your sector, workplace and even factors relating to your geography or business demographic. So, it’s easy to put everything they’ve learned into practice.

It’s a vital achievement and demonstrates that they have the knowledge to be more efficient, productive and safe in the workplace – to the benefit of all.

It’s world-class. IOSH is the Chartered body for safety and health professionals and the quality of the training and the content of the course reflects that.

Here’s why:

Why IOSH?

•

Track record. Managing Safely from IOSH is the market leader in safety and health and we’ve trained 172,000 delegates on 23,000 training courses in 76 countries.

•

Vision. We can help you prepare for tomorrow. The world of work is transforming at a rapid pace and we want to ensure that you are ready to embrace those changes and profit from them rather than being left behind.

•

Status. We are a global organisation with 47,000 members in 130 countries, many of whom are business owners themselves, and we represent their views to governments and regulatory bodies to make sure business can continue to drive the positive change we all need and deserve.

Who should attend? This course is for anyone who manages or supervises people, in any industry sector or environment. They’ll learn to: •

assess risks

•

control risks

•

understand responsibilities

•

understand hazards

•

investigate incidents

•

measure performance

They’ll learn about the ‘why’ as well as the ‘how’. Why should we look out for our colleagues? Why should we continue to innovate? How can I make a difference? Successful delegates are awarded an internationally-recognised IOSH Managing Safely certificate.

www.iosh.com

There’s a reason Managing Safely doesn’t cut corners The consequences of rushing health and safety training can be fatal. So Managing Safely takes exactly the right amount of time to get participants up to speed. That’s why our three day health and safety course is the most popular for line managers, in any sector, worldwide.

Managing Safely Tried. Tested. Trusted. www.iosh.com/managingsafely

Kecol Pumping Systems Kecol Pumping Systems offers solutions to many product transfer problems – read on to find out more.

ecol Pumping Systems Ltd are manufacturers of Air driven, Positive Displacement Piston Pumps and Priming Devices in polished stainless steel or carbon steel, for transferring high viscosity nonflowable products from drums and containers as used in the cosmetic, food, pharmaceutical, chemical and general industries. Products in drums or similar sized vessels that normally need to be heated in order to reduce the viscosity - can be transferred cold. Products with a viscosity up to 10,000 Poise can be transferred (cold) using the Kecol Maxiprime Pump and follower plate system and is also used to transfer pastes and products that stick to the inside of an open top drum, wiping the inside of the drum or vessel, eliminating product waste. Kecol Air Powered Drum Pumps and transfer systems are suitable for all standard size closed top or open top drums and can be adapted to suit open top containers with an internal diameter up to 1200mm. Non contact parts as well as contact parts are available in polished stainless steel, clamp - type construction is also available for hygienic applications. Typical applications in the food industry include transferring tomato

The inside of a standard 200 litre Open Top Drum is wiped clean – as the drum is emptied – with minimal product waste

puree, concentrated fruit juice, honey, fruit pastes, biscuit creams, jams, butter, margarine, sweet mince meat, sausage meat and meat pie fillings with cooked vegetables. Applications in the pharmaceutical and cosmetic industries include transferring mascara, petroleum jelly, face creams, base creams, magnesium hydroxide, aluminium hydroxide, toothpaste, lip-gloss waxes and suntan lotions.

Kecol’s articulated pump systems

The Kecol Follower plate system will also work on 200 litre Open Top Drums fitted with an aseptic bag – wiping the bag clean

Applications in the chemical and general industries include the transfer of paints, resins, adhesives, polymers, latex, high viscosity grease, mastic’s and inks – all pumped cold without pre-heating the products. As manufacturers, Kecol Pumping Systems can offer solutions to your particular product transfer problem, by offering a bespoke system designed to exceed your particular production requirements for single drum/vessel use or multi drum use.

Kecol Pumping Systems Ltd Faraday Drive Bridgnorth Shropshire WV15 5BJ T: 01746 764311 E: sales@kecol.co.uk www.kecol.co.uk

T HE HO M E OF V IS C O U S P UM PIN G S OL U T I O N S

Kecol have over 25 years of experience in handling all types of viscous products in the food, pharmaceutical and cosmetics markets, as well as general industrial applications.

A sample of products we already pump… ✓Honey ✓Petroleum Jelly ✓Mascara ✓Sauces ✓Lanolin ✓Lip Gloss ✓Essences ✓Eye Ointment ✓Meat Paste ✓Paraffin Wax

T: +44 (0)1746 764311 E: sales@kecol.co.uk W: www.kecol.co.uk

✓Face Scrub ✓Teething Gel ✓Tomato Puree ✓Medical Adhesives ✓Veterinary Creams ✓Fruit Paste ✓Toothpaste ✓Malt ✓Jam ✓Wax

PROCESS TECHNOLOGIES

UK FIRST LASER WELDER FABDEC

FABDEC LEADS IN INNOVATION WITH UK-FIRST LASER WELDER and sits alongside further investments in a new 200 tonne 4 metre hydraulic press and PV solar panel installation to generate electricity for its manufacturing plant. Chris Powell, managing director at Fabdec, said: “We are always looking for ways to improve our manufacturing process and drive the industry forward through innovation. Bringing this new machine to the UK market further demonstrates this commitment. “This investment allows us to scale up effectively following a very successful year and takes the business to a new level by increasing capacity, safety, improving the working environment and quality. Stainless steel heat transfer product manufacturer Fabdec has demonstrated its commitment to innovation by investing in a state-of-the-art laser welder, the first of its kind in the UK. The purchase of the Pillowplate laser welding system will allow Fabdec to increase capacity and manufacture both standard and bespoke heat exchanger plates up to 2 metres wide by 7 metres long for dairy, brewery, winery & other process industries that require cooling, heating and heat recovery applications. This investment marks a period of expansion for Fabdec following strong annual results

“It also means that we can further improve our sustainability credentials, which is something that we’re incredibly passionate about. “We are already experiencing the benefits of the new machine since its installation and we’re incredibly excited to lead the way for British manufacturing on this front.” “More customers are using our core competencies in stainless steel vessel manufacture & heat transfer technology to provide them with bespoke solutions rather than using standard products.”

Fabdec has been at the forefront of stainless steel heat transfer products since 1960, manufacturing a range of products across the water heating, dairy and brewery sectors. They manufacture stainless steel process tanks up to 50,000 litres; have their patented 3S technology for water heating & a range of heat recovery products. The company has been based in Ellesmere for 59 years, where all research, design and manufacturing are undertaken to create bespoke systems for customers. They also have offices in Germany, Russia & Poland. In the Fabdec group are Cookes Fabdec Ltd. who install & service milk cooling systems & also install & service air conditioning units. 6IX Fabdec Ltd. serves the brewery sector with high quality vessels including design, consultancy, installation & after sales service Fabdec were winners of the Shropshire Business Awards for Manufacturing Excellence in 2018 & winners of International Growth Through Export this year. For more information please visit: www.fabdec.com

124

PECM Issue 41

Pre-plumb ☞ ☞ Heat ☞ ☞

Also from Fabdec:

175l - 500l indirect Two heating zones standard Recovery Solutions Integrated Venturi - no need to add expansion vessel Pioneers, innovators and market leaders in efficient unvented water heating Pre-wired

Unvented water heaters

teel In stainless s

Pre-plumb

Also from Fabdec:

☞ ☞ ☞ ☞

Also fromPre-plumb Fabdec:

175l - 500l indirect Two heating zones standard Integrated Venturi - no need to add expansion vessel Pre-wired

Pre-plumb

☞ 175l - 500l indirect ☞ Two heating zones standard ☞ Integrated Venturi - no need to add expansion vessel ☞ 175l Pre-wired ☞ - 500l indirect

☞ A comprehensive rangezones of water ☞ Two heating standardheating spares

EXCELSIOR

☞ Integrated Venturi - no need to add expansion vessel ☞ Pre-wired

☞ A comprehensive range of water heating spares Designed and manufactured in the UK

Brewery Vessels

Milk Cooling Systems

CustomEquipment Quality stainless steel for Quality vesselsBeer

☞ A comprehensive range of water heating spares

w.fabdec.com/waterlanding www.fabdec.com/waterlanding

Ltd oad

e G

Accreditation: Fabdec Ltd

Accreditation:

www.fabdec.com/waterlanding Grange Road Ellesmere Shropshire SY12 9DG

www.fabdec.com/waterlanding

(0) 1691 627200 (0) 1691 627222 Fabdec Ltd Grange Road es@fabdec.com Ellesmere Shropshire Fabdec SY12Ltd 9DG

Grange Road Tel: +44 (0) 1691 627200 Ellesmere Fax: +44 (0) 1691 627222 Shropshire Email: sales@fabdec.com Fabdec 3S SY12 9DG Tel: +44 (0) 1691 627200 Fax: +44 (0) 1691 627222 Fabdec 3S Email: sales@fabdec.com

Tel: +44 (0) 1691 627200 Fax: +44 (0) 1691 627222 Email: sales@fabdec.com

Accreditation:

Milk cooling systems Accreditation:

Industrial Associate

Water heating systems Excelsior Brochure 2019_v1

Industrial Associate

Excelsior Brochure 2019_v1

Industrial Associate

Fabdec 3S

Water heating systems

hure 2019_v1

#Britishmade #Britishbeer

Water heating systems

PROCESS TECHNOLOGIES

FILTRATION RANGE SEPURA TECHNOLOGIES

SEPURA BRAND DISTINGUISHES GENUINE FILTRATION RANGE

With continued product development and enhancement, the unique and original SEPURA™ range continues to lead the market in oil/water separation solutions.

As the sole manufacturer of the only authentic SEPURA series, the filtration firm’s approach has always been one of constant evolution.

Since the first SEPURA™ oil/water separator was developed over fourteen years ago, others have attempted to imitate its success producing units that might look similar to the untrained eye. Bowman Stor’s owner and managing director, Richard Potts, is keen to stress that buyers should beware of inferior products designed to look like SEPURA equipment sometimes using the same colour finish. “Just because it’s blue it doesn’t mean it’s a SEPURA separator,” says Richard.

SEPURA’s flagship unit, the SEP60, was the world’s first fully disposable separator a single use, compact, quick fit unit which out performs equipment more than twice its size. Since then the firm has continued to grow the range and now produces the largest range of medium and high capacity separators on the market.

“If there is no SEPURA badge on the front, it isn’t a genuine SEPURA product.” And only SEPURA branded separators, manufactured exclusively by global filtration specialists Bowman Stor, contain the revolutionary, SILEXA™ the internationally patented media which set the new standard in condensate treatment, providing industry with a cleaner, lighter, more adsorbent media. Bowman Stor continues to manufacture SILEXA at its ISO 9001 2015 accredited UK production facility; a fully sustainable, renewable material made from recycled waste glass.

126

PECM Issue 41

Bowman Stor’s Winning Formula Bowman’s ongoing drive for quality and improvement is also receiving recognition from some of the most influential voices in industry. The Walsall based firm was the proud winner of the International / Enterprise of the Year Award at this year’s prestigious Nachural Summer Business Ball and Awards. Against significant competition, the filtration specialist received acknowledgement for its continuing research, innovation, growth and performance. The awarding body also took into consideration glowing endorsements from a selection of Bowman’s customers.

Single Source Customers who want the superior condensate filtration associated with genuine SEPURA separators and filters can ONLY obtain them through SEPURA’s designated distributors. In the UK, MFE (Multi Factor Europe) is the exclusive distributor of the range, as well as replacement service kits & third party SILEXA service kits. To place an order or for further information on SEPURA’s unique range of filtration products contact:

t: 01978 855995 e: sales@mfeuk.co.uk or visit our website: sepura-technologies.com

the art of oil/water filtration

There are many oil/water condensate solutions on the market, many of them blue. But only one can do this... • removes more will remove oil content to below 10ppm • lasts longer extends filter life by 20%

NEW from SEPURA™ Connect up to 8 inlets to your SEPURA Condensate Unit

• cost effective 3rd party service kits that out-perform genuine OEM products

Only SEPURA separators contain the superior SILEXA™ filtration media that makes all of this happen.

Genuine SEPURA™ products can only be purchased from our exclusive UK distributor

t: 01978 855995 e: sales@mfeuk.co.uk

PRODUCT NEWS

7 MILLIONTH FASTENER ZORO

LEADING SUPPLIER TO INDUSTRY CELEBRATES 7 MILLIONTH FASTENER SOLD

Zoro UK, a leading supplier of fasteners, fixings, tools and equipment for industry, is celebrating the sale of its 7 millionth fastener since it commenced sales in December 2017. Chris Matenaers, Marketing Director of Zoro, said: “We value being a reliable part of a supply chain, supplying fasteners to UK industry. Our next day delivery and quality named brands ensure we help to keep the manufacturing production chain moving without unnecessary downtime.” Zoro supply fasteners to the aerospace, automotive, marine, power, construction, science and rail industries. Fasteners are essential to each of these industries, and their reliability is essential to their sector. The reason for so many different kinds of fastener, says Chris Matenaers, is that the composite used to make the faster determines its qualities.

128

PECM Issue 41

Mr Matenaers continued: “There are so many varieties of fastener as they are different shapes, have different tips and heads, are made up of different materials and have different properties. For example, screws in the marine industry must be able to withstand salt water corrosion, and so would be different to those needed in the aerospace industry.” Zoro is a one-stop-shop for more than 250,000 industrial consumables, tools and business supplies with free next day delivery throughout the UK on many of its lines, and currently has almost 50,000 different types of fasteners on its website. Mr Matenaers said: “We are excited to be celebrating the sale of our 7 millionth fastener. After introducing our new Order Subscription service, we are expecting to sell over 8 million fasteners this year.” The addition of the new Order Subscription service will be a boon for customers as it will cut down time spent reordering, reduce human error and ensure smooth production.

www.zoro.co.uk

PRODUCT NEWS

DRIVE COUPLINGS REICH DRIVE SYSTEMS UK LIMITED

STAY ALIGNED TO AVOID PROBLEMS IN THE DRIVE TRAIN For drive couplings to be fully effective, it is essential that not only is the correct type of coupling specified for the application, but that the coupling is also correctly installed and aligned. Although certain coupling types are designed to accommodate some shaft misalignment or displacement in service, like any other piece of equipment, they do have limitations. Failing to ensure that a coupling is properly aligned, or has levels of misalignment outside of the manufacturers specifications, will result in premature failure of the coupling and potentially other drive train components. With a widely accepted figure of 50% of rotating equipment failures attributed to misalignment, David Proud of Reich Drive Systems UK discusses the importance of selecting the right coupling and also adhering to manufacturers specifications. The term coupling alignment is best described as ensuring as far as possible, a finely toleranced and common rotational centreline between the shafts that are to be coupled together. Achieving this will allow them to transmit power efficiently and operate reliably over extended periods. There are a number of different types of misalignment that can contribute to problems within a drive train. These may include angular, axial, radial or in extreme cases, a combination of one or more alignment issues. The reasons for misalignment can be varied, ranging from gradual movement of machinery over time or even just the fact that the drive train was not properly aligned at the time of installation. As for any other piece of engineering machinery, drive couplings should be installed and maintained in line with the original manufacturers recommendations. Spending time ensuring that a drive coupling has been correctly fitted and aligned will pay dividends in the form of long and reliable service. There are of course a number of different methods of aligning a drive coupling, ranging from using basic tools such as straight edges and feeler gauges, right through to sophisticated laser alignment systems. The benefits of using

laser technology include the fact that many laser shaft alignment systems utilise software that can calculate accurate values for any adjustments that need to be carried out to achieve perfect alignment. At the end of the day, the important factor is making sure alignment is within specification, regardless of the method used. Misalignment outside of the coupling’s specification will cause it to wear at an accelerated rate. In addition there is the potential for negative impact on other components, for example bearings, causing them to fail prematurely. There may be instances however where it is not possible to achieve perfect shaft alignment and in cases such as this, the choice may be to select a flexible coupling such as Reich’s MULTI MONT SELLA. These pluggable claw couplings have a long history, having been field proven over a number of decades. With the capability to compensate for axial, radial and angular misalignments, as well as absorb shocks and vibrations these couplings can help to mitigate the effects of alignment errors and vibration. (Reich’s Multi Mont Sella is one of a range of flexible caw couplings, which can help mitigate the effects of shaft misalignment) Additional benefits of this type of coupling are the ease of assembly and alignment, their

maintenance free design and the capability to change the flexible elements radially, without the need to de-couple the drive train elements. With a history spanning over 70 years, REICH-KUPPLUNGEN has built up unrivalled expertise in the design and manufacture of drive couplings for use across a wide range of industries and applications. The company has earned an enviable reputation not only for the quality and performance of their product range, but also for their ability to provide application and customer specific solutions through the company’s D2C (Design to Customer) philosophy. Reich are also always happy to provide advice on all aspects of coupling selection and integration, including recommendations on how best to avoid issues from misalignment. For more information please contact: Mr David Proud General Manager Reich Drive Systems UK Limited Unit 4, Bankside Business Park Coronation Street Stockport Cheshire SK5 7PG Telephone +44(0) 161 714 4191 Website - www.reich-uk.com

Issue 41 PECM

129

PRODUCT NEWS

FUME EXTRACTION SYSTEMS WILKINSON STAR

MORE NEW FUME EXTRACTION SYSTEMS MEETING LATEST HSE WELDING REQUIREMENTS New from Wilkinson Star, one the of the UKâ&#x20AC;&#x2122;s largest independent distributors of Welding and Industrial Equipment, is the F-Tech Fume technology product range of high vacuum fume extraction systems and welding torches. Welders and operatives can be exposed to welding fumes, grinding dust and oil mist in the working environment. It is therefore obligatory for employers to create safe and healthy working conditions for operatives by reducing these health risks. The F-Tech Armur is a high vacuum dust extraction system offering a mobile solution to extract dust from manual welding and grinding processes. The Armur unit features a high performance German motor and a choice of 3 mtr suction Armoflex or Armotech cantilever arm and a user friendly digital panel with hour meter, clogged filter alarm. This unit offers E12 99.5% filter efficiency and comes with a 5 year warranty on both 110V and 230 V models. The F-Tech Pocket is a portable extraction unit designed to extract and filter fumes

from welding processes, micro dust, vapours and odours. At only 20kg, it is a robust unit with a practical long handle perfect for site work and those difficult to reach areas. This unit has a 2mtr hose fitted with a plastic extraction nozzle. The Pocket also has a filter efficiency of E12 99.5% and comes with a 2 year warranty. Additional features include a hourmeter and it is available in 110 and 230 Volt. The F-Tech Fox is a high vacuum dust extraction system offering a portable solution to extract dust from manual welding and grinding processes. Offering a 5 year warranty the Fox unit offers automatic cleaning of the filters which are manufactured in Europe and offer a long service life. The robust tandem motors offer pure efficiency in providing a vacuum over 20,000 Pa to extract and filter harmful welding and grinding dust. An auto start/stop unit is also available to reduce noise levels and energy consumption when the unit is not running.

The Fox will also run two welding torches simultaneously. The F-Tech range of fume extraction MIG welding torches are of Swiss manufacture. They offer the user more extraction efficiency at the welding source. Available in 300, 400 and 500A air/water cooled versions in 3, 4 and 5 mtr euro fittings. The F-Tech range is available through Wilkinson Starâ&#x20AC;&#x2122;s extensive distributor network.

For further details please contact Wilkinson Star on 0161 728 7900 or visit wilkinsonstar247.com

130

PECM Issue 41

NEW

W MEETING NTEION HSE LEGISLA

F-TECH FUME EXTRACTION SYSTEMS

F-TECH FUME EXTRACTION MIG WELDING TORCHES

Exclusive Supplier for UK and Eire

FOX ARMUR POCKET

starparts.sales@wilkinsonstar.com • +44(0)161 728 7922 Wilkinson Star Limited, Shield Drive, Wardley Industrial Estate, Worsley, Manchester M28 2WD • +44(0)161 793 8127 • www.wilkinsonstar247.com

* Wheel Mounted Units

PRODUCT NEWS

Senix offers the most flexible and versatile ultrasonic sensors for level and distance measurements. The Senix ToughSonic sensors all include SenixVIEW software which allows for over 60 parameters to be optimized for level and distance applications.

For general distance ranging and benign liquid level applications, including irrigation, flood monitoring, dimensioning, object detection or selection, roll diameter and general industrial automation.

For measuring the level or volume of liquid chemicals in open or closed tanks. Applications include inventory, batch control, high or low alarms and the pickup or delivery of chemical products.

For more information about our ultrasonic ToughSonic, ToughSonic CHEM and SafeSonic intrinsically safe loop-powered sensors please visit us at: www.senix.com

Senix Corp. 10516 Route 116, Ste. 300 Hinesburg, VT 05461 USA Tel. +1 802-231-0627 customer.service@senix.com

T H E C O M PA N Y O F E X C E L L E N C E Coler Supply Solutions (Intl) Limited is a UK based Company that have been involved in manufacturing for over 35 years. We have recognised that the service needs of our customers are changing; as they are competing in an increasingly competitive global market.

UVC STERILISATION - CLEAN, DRY & EFFECTIVE SANITISING Cutting Edge Services are proud to work in partnership with SterilAir, the world-leading manufacturer of revolutionary UVC sanitising technology for the food industry. SterilAir’s UVC sanitisers are HACCP and FDA compliant solutions, providing clean, safe, chemical-free disinfection with minimal costs and energy usage. Our exclusive range includes evaporator disinfection systems to directly target any type of surface, air recirculation systems for rooms with low convection, belt surface disinfectors designed to integrate perfectly into your production

132

PECM Issue 41

line and fully submersible immersion systems ideal for sterilising water tanks and cooling towers. Our expert team of specialists and field service engineers provide full installation and servicing to meet your exact requirements. SterilAir UVC solutions are available now exclusively from Cutting Edge. www.cuttingedgeservices. co.uk 01772956249

We cater for this growing trend for Global procurement via our overseas manufacturing facilities, whilst still offering UK manufacture & supply when requested or indeed if this is the most cost effective business solution. Our largest overseas facility is based in Wuxi in China (pictured overleaf ) in which we have offices & have been successfully trading with for over 12 years. This facility comprises 550 staff is fully accredited to ISO 9001, ISO14001 & are currently in the final stages of achieving TS16949. We believe that our growth & success has been generated by our vision of providing

our customers with key manufacturing & procurement solutions often that they previously felt could only be completed in house or was indeed impossible. With this philosophy of building upon the firm foundations of good customer service in the key areas of competitive pricing, quality components & schedule adherence, we have realised this & hope to provide you with our engineered solutions for your engineering & procurement problems. +44(0)1827-712910 INFO@COLER.CO.UK Please see our new website at www.coler.co.uk

GREASOMATIC GREASOMATIC96 96 ®®

The only Single Point Automatic Lubricator The only Single Point Automatic Lubricator manufactured in Great Britain

manufactured in Great Britain

Optimise lubrication with Greasomatic®96 MANUAL/GREASE GUN LUBRICATION •

• • • •

No further need for costly time consuming manual lubrication. Labour saving/less labour intensive maintenance. Improved health and safety. Reduction in lubricant consumption. Lessen environmental impact.

ASSET RELIABILITY/CARE • • • •

Reduced costly downtime and failures. Improved production performance. Extend asset life. Reduce maintenance costs.

RATIONALISE/SIMPLIFY •

Ensure the correct lubricant is being used in the correct quantity, in the correct place at the correct time.

•

No more cross contamination of lubricants.

•

No more ingress of contaminates into the application.

Free Site Survey - Please Quote PECMWY1 Wymark Ltd, Runnings Road Industrial Estate, Cheltenham, Gloucestershire GL51 9NQ England Telephone: +44 (0) 1242 520 966. Fax: +44 (0) 1242 519 925. Email: sales@wymark.co.uk Web: www.wymark.co.uk

SOFTWARE & SYSTEMS

CORERFID & NETWORK RAIL CORERFID

SOFTWARE SPECIALIST HELPS NETWORK RAIL KEEP TRACK OF ROLLING STOCK

CoreRFID is rolling out a system of tags and readers for Network Rail, which owns and runs Britain's railway network.

CoreRFID and Network Rail will continue working together as new rolling stock comes into operation.

The RFID based system automatically assits in identifying rolling stock as it passes over monitoring sites across the rail network. The tags, which can be read over long distances whilst the rolling stock is moving, are coded to Network Rail's precise specifications and this enables assets to be matched to corresponding records in Network Rail's asset management systems.

The contract follows a recent project with Serco for the Caledonian Sleeper rail service it operates between London and a number of Scottish cities. CoreRFID supplied 100,000 RFID access cards for the passenger cabins, which improves the customer experience and security.

The solution also helps Network Rail distinguish between its own assets and a those of other operators' rolling stock using the same rail infrastructure. The readers and tags are able to fully function in all weather conditions and cope with vibration and contamination caused by dirt and grease.

134

PECM Issue 41

Network Rail operates and develops Britain's railway infrastructure, covering 20,000 miles of track, 30,000 bridges, tunnels and aqueducts and thousands of signals, level crossings and stations, including the UK's largest 20 stations. CoreRFID's director Richard Harrison comments: â&#x20AC;&#x2DC;Our work with Network Rail shows the versatility and robustness of

RFID technology in the most challenging circumstances. â&#x20AC;&#x2DC;It also demonstrates our ability to undertake asset management projects on a large scale and to design and deliver a reliable solution tailored to client's specific needs.' www.corerfid.com www.networkrail.co.uk

Pinnula

UNIPLAN ERP ACCELERATES YOUR GROWTH Enquiry Manager CRM/Prospect/Task Manager Stock Management Plan Capacity/Scheduling Resource Management Bill of Materials Production Control Job Costings Process Management Packing & Shipping Serial Numbering Barcoding & Labelling Shop Floor Job & Time Tracking Full Batch Traceability Procurement/Sales Full Accounts/Payroll/HR Bank Integration Dashboard Analytics

Plus much more!

Flexible System Add and remove modules as your business evolves

Uniplan ERP is a modular, scalable and flexible Manufacturing System designed to suit your business as it evolves and grows. Add functionality and users as the business develops. We provide functionality rich software which can be configured to best match your business processes. We have years of experience in implementing systems and can manage a full implementation from start to end. Uniplan ERP will deliver both greater efficiency and control to your business.

Experience Savings We have been building ERP Reduce costs through systems for over 40 years critical process management

www.pinnula.co.uk | sales@pinnula.co.uk | 01709 839933

SOFTWARE & SYSTEMS

COMPREHENSIVE ERP SYSTEM SAPMAN

IF YOU MAKE STUFF WE’LL HELP YOU MAKE IT IF YOU HAVE A WARHOUSE WE’LL HELP YOU MANAGE IT IF YOU HOLD STOCK WE’LL HELP YOU CONTROL IT

Buying an ERP system used to be a major capital expense, potentially running to tens of thousands of pounds for an up and running system. The cost of the software purchase and associated consultancy made it a hugely considered financial outlay. For manufacturers looking for a rapid Return On Investment – this was a major obstacle for many businesses : together with the desire to spend their CapEx budgets on modern machinery and increased manufacturing capacity rather than software!

For companies that want the software “out of the tin” - and do not require any bespoke programming – a system install and set-up, including training and data conversion would be around £2,950. Our licencing is £50-£75 per month (depending on user numbers) with no minimum contract obligation. Additional users can be added as required and, indeed, reduced. A key market for us is Sage users. Sapphire Manufacturing Systems Ltd. The developer of Sapmanv12 has been an Authorised Sage Developer for over 20 years. So most of our users run on Sage50 and Sage200, and we

still have some clients on Sage Line 100 yet to upgrade. One of the great advantages of Sapmanv12 for Sage users is that users can benefit from multi depot stock and full Serial Number and Batch Traceability without the need to upgrade their accounting engine from Sage50 to Sage200. This is an additional cost saving benefit We can demo the software remotely via Team Viewer or organise a visit to your premises or you can visit our Bristol Demo Suite : call us on 0333 456 12 12 to have a chat

A MANUFACTURING AND STOCK CONTROL SYSTEM FOR SAGE USERS 136

PECM Issue 41

At its core Sapman v12 is a sophisticated Manufacturing, Warehousing and Stock Control solution. This modular product provides extensive facilities for Stock Control, Sales and Purchase Order Processing, Warehouse Management, Bill of Materials, Works Order Processing, Engineering Control, MRP and CRP. With the Microsoft SQL database engine at its core this product provides a leading edge business management solution. Our highly skilled team has 20 years of experience resolving our customers’ Assembly, Manufacturing Control and ERP requirements, their Stock Control and Warehouse Management needs using our advanced, effective and efficient software solution. Sapman v12 fully integrates with Sage’s Accounting solutions: Sage 50 and Sage 200. It also provides an upgrade path from Sage 100.

disposable BBQs our customers rely on Sapman v12 to run their businesses.

Sapman v12 is highly customisable to operate with virtually any business model. With successful installations in a huge range of industry types from manufacturers of medical products to

Sponsored development of specific functionality is possible where customers require some modification to allow the software to exactly map their business’s operational model.

SAPMAN V12 AND SAGE 50 IT ALL STARTS WITH A SALES ENQUIRY! SELL IT

with collapsible/expandable nodes

Quotations: Quote ( including price breaks)& Drawings & Pricing : v12 can attach drawings to the Quote

SFDC Shop Floor Data Capture : using barcodes v12 manages the job though the shop floor

SoP : The Sales Order Processing gets underway

WiP With Shop Floor Data Capture SFDC v12 knows :

MAKE IT

What Material/Subcomponents have been used, Who has worked on the job and on what machine - Get Material, Labour & Machine Variances & produce management reports -

Stock : Stock Enquiry : Check material Needs : Make to Order or Ex Stock? If not it may generate a Purchase Order for more Stock If the Sale item is Make To Order (MTO) then the Works Order Processing routine kicks in v12 is suitable for Batch Manufacturing, Make to Stock, make to Order, Kanban & service works Stock values from v12 update Sage50 Nominal Ledger PoP Purchase Order Raised Purchase Invoice received & Sage 50 updated for Nominal Codes, Purchase Ledger and VAT WoP The confirmed order has to be manufactured & v12 produces the works order BOM V12 produces the BoM : tree-view

Every stock issue is linked to an original GRN - ensuring full Serial Number and Batch Traceability

WHAT THEY SAY “We really like the Shop Floor Data Capture system which enables us to see the current status of any Works Order live and onscreen.” Alan Saitch, Managing Director, Lada Engineering Services Ltd

“V12 offers us greater productivity, improved communications with third parties and the interconnectivity between the various menus and our Sage Accounting software makes operating our company infinitely easier.” Colin Mallard, Finance Director, Lakeland Laboratories Limited

Stock Finished item is booked into Stock v12 knows where it is; it covers multiple sock locations and stock with Sub Contractors Stock values per client defined categories can be up dated to Sage50 Nominal at client defined times

“V12 was a complete transformation for our business back in 2014, with the added bespoke service and repair package designed by the SMS team the customer input and traceability became seamless.” Mike Perkins, Managing Director, Encoders UK Ltd

SEND IT Stock Stock records updated, Despatch note raised; Certificates of conformity produced Sales Invoice raised & Sage 50 updated

For more information on Sapmanv12 please visit our website at Sapmanv12.co.uk Email us on info@sapmanv12.co.uk Or please telephone us on : 0333 456 12 12

for Nominal Codes, Sales Ledger & VAT Issue 41 PECM

137

STORAGE, HANDLING & DISTRIBUTION

PROTECTION OF EQUIPMENT IN TRANSIT PROTECHNIC

CASE SOLVED

Protechnic have been manufacturing specialist cases in the UK for over 30 years and during that time have developed a number of unique products that are ideally suited for the safe protection of equipment in transit. Keith Judson MD takes up the story: It takes a long time to build a company from a standing start and even longer to establish a reputation for quality and service, but I am proud to say that Protechnic has become one of the industry leaders in bespoke case design and manufacture. Much has changed since the inception of Protechnic some 30 years ago, but we still hold true to our values of continual development and improvement, one of our axioms is that 'you should not let your last good idea be your last good idea' and our expert team of engineers are always looking for ways to develop our products, and incorporate the latest materials technology, our design ethos is to make our cases stronger, lighter and more cost effective, always with a keen eye on what the customer needs. In our quest for excellence we have such pioneering products as the Smart Case, Exo Case, Nio Case, MultiPad. The Exo Case, in particular, is a patented product and is truly ground-breaking in the world of transit cases. We take great pride

138

PECM Issue 41

in the quality and service, and accordingly we are ISO 9015 accredited, and we are fully committed to the concepts of continual improvement as enshrined in the latest ISO standard. We know from experience that a successful company is not just about great products - it is about the ability to connect with and listen to the needs of our customers. Our bespoke design and finish service enables us to fully customise our solutions to match the technical requirements. It is testament to our customer service that we are still supplying some very long-standing customers from the early days of Protechnic. Together with our bespoke products, we have a vast range of injection moulded, vacuum formed and roto moulded cases that enable us to offer the perfect solution across many industries including, oil and gas, aerospace, MOD, medical, automotive and many more, in fact just about any application that requires the safe transit of equipment. Our capability extends to foam engineering and we are able to specify and design the case interior to suit the requirement, based on the fragility of the equipment to be housed and the shock/ vibration characteristics of the application. Our product designs are driven by our customers, from a simple transit case to very

involved designs for transporting highly valuable and delicate equipment. We treat every requirement with the same ideology â&#x20AC;&#x201C; what would be the best solution for our customer. There are many drivers in a case design, it may be cost, strength, weight, protection, aesthetics, timescale and we operate in a very wide range of industries that bring their own particular demands, but our skilled team of design engineers will establish the essential criteria in sufficient detail to allow our estimators to offer the most competitive solution. Please contact us to discuss your requirements. Protechnic Ltd, Unit 1 West End Trading Est Blackfriars Road, Nailsea, BS48 4DJ Tel: 01275 811310 sales@protechnic.com

BESPOKE CASES BUILT TO LAST A team of industry experts, driven by a passion to innovate and succeed.

BESPOKE CASES BUILT TO LAST

A team of industry experts, driven by a passion to innovate and succeed.

MADE TO MEASURE MADE CAD ENGINEERING and skilful engineers using TO Qualified MEASURE latest 3D CAD software technology. CAD ENGINEERING

WATER-JET QualifiedTECHNOLOGY and skilful engineers using Efficientlatest accurate and fast panel 3D CAD software technology. and foam prduction. WATER-JET TECHNOLOGY

accurate and fast panel FOAMEfficient ENGINEERING and foam prduction.

Masters in bespoke protective foam inserts.FOAM ENGINEERING

Masters in bespoke protective foam

ENGRAVING inserts.

sales@protechnic.com

Fully customisable and detailed ENGRAVING engraving service. Fully customisable and detailed

sales@protechnic.com

UV PRINTING

(+44) 01275 811 310

engraving service.

UV PRINTING UV printing to make your final printing to make your final productUVunique. product unique.

Delivering safe and reliable Delivering safe and reliable

products meet ISO 9001 products thatthat meet ISO 9001 high-quality standards.” high-quality standards.”

(+44) 01275 811 310 www.protechnic.com

www.protechnic.com

Protechnic Ltd Protechnic Ltd Unit 1, West1,End Trading Unit West End Estate Trading Estate Blackfriars Road, Nailsea Blackfriars Road, Nailsea Bristol, BS48 4DJ Bristol, BS48 4DJ (+44) 01275 811 310 (+44) 01275 811 310 sales@protechnic.com sales@protechnic.com

CBM CONNECT™ is the premier online knowledge sharing community for CBM professionals, dedicated to provide you with educational articles, tips, tutorials, videos, interviews, webinars and white papers. • • • • • • • •

Alignment & Balancing Condition Monitoring Management Lubrication Motor Testing Oil Analysis & Wear Particle Thermography Ultrasound Vibration Analysis

12,000+

Live Session Attendees

1000+

Educational Videos and Articles

Become a contributor in the global CBM community! Go to www.cbmconnect.com and click on Contact Us!

CUSTOMIZE YOUR LEARNING PATHWAY &

CREATE YOUR FREE PROFILE www.cbmconnect.com

500+

Contributors

12,000+

Live Session Attendees

1000+

Educational Videos and Articles

500+

Contributors

Become a contributor in the global CBM community! Go to www.cbmconnect.com and click on Contact Us!

CUSTOMIZE YOUR LEARNING PATHWAY &

CREATE YOUR FREE PROFILE www.cbmconnect.com

THE 2020 CBM CONNECT® CONFERENCE SCHEDULE: MIDDLE EAST 2020

SOUTH AFRICA 2020 9 - 12 MARCH SOUTH AFRICA Johannesburg, South Africa

Johannesburg, South Africa Radisson Blu Gautrain Hotel

MIDDLE EAST Abu Dhabi, UAE

EUROPE 2020 Amsterdam, Netherlands

Amsterdam, Netherlands Novotel Amsterdam Schiphol Hotel

CHINA Wuxi, China

Kuala Lumpur, Malaysia

Indianapolis, IN

MEXICO 2020

19 - 22 OCTOBER

Melbourne, AUS

Pullman Melbourne Albert Park Hotel

Indianapolis, Indiana Hyatt Regency Indianapolis

AUSTRALIA 2020 AUSTRALIA

Pullman Wuxi New Lake

14 - 17 SEPTEMBER USA

The Westin Kuala Lumpur

Melbourne, Australia

Wuxi, China

USA 2020

13 - 16 JULY Kuala Lumpur, Malaysia

The Westin Abu Dhabi Golf Resort & Spa

8 - 11 JUNE

MALAYSIA 2020 MALAYSIA

Abu Dhabi, UAE

CHINA 2020

11 - 14 MAY EUROPE

30 MARCH - 2 APRIL

7 - 10 DECEMBER MEXICO Monterrey, MX

Monterrey, Mexico MS Milenium

www.thecbmconference.com

TRAINING & RECRUITMENT

STEAM SPECIALISTS SPIRAX SARCO

STEAM SPECIALISTS CELEBRATE 30 YEARS OF PROFESSIONAL ACCREDITATION STEAM SPECIALISTS CELEBRATE 30 YEARS OF PROFESSIONAL ACCREDITATION

Leading steam solutions provider, Spirax Sarco, is celebrating three decades of courseaccreditation from City & Guilds Group. Beginning in 1989, the relationship was born out of a decision by The Dairy Trade Federation and City & Guilds to introduce a skills testing scheme for the validation and accreditation of maintenance engineers in the dairy industry. This led to the introduction of a nationally recognised certificate. Sally O’Connell, Training Centre Manager at Spirax Sarco, explains, “At that time, Spirax Sarco was the only authorised provider of the Steam Plant Maintenance training for the scheme. In the 30 years since, we have continued to develop the course and gain accreditation for both our Steam Plant Maintenance and our Steam Boiler Plant Fundamentals (Shell Boiler) courses.”

142

PECM Issue 41

“By working with City & Guilds, we have been able to create tailored courses that meet our customers’ needs,” says Sally. “As City & Guilds is a strong quality brand and recognised by our customers as such, it is fantastic for Spirax Sarco to be so closely aligned with them. “The underpinning quality assurance and credibility within the industry is incredibly important to us and our customers. Having our courses accredited by City & Guilds therefore provides us with a unique selling point for our training offering and ensures that our delivery remains consistently high,” Sally says. Kirstie Donnelly, Managing Director at City & Guilds Group continues, “City & Guilds is a world leader in skills development with 140 years of unrivalled experience. Our purpose is to enable people, organisations and economies to develop their skills for growth.

We are proud to have maintained a relationship with Spirax Sarco for three decades, accrediting their skills training and highlighting the quality process and credibility that learners are actively looking for.” “As we move through the coming decades, we will work to strengthen our relationship with City & Guilds and bolster the courses that we put forward for accreditation. Our aim is to use the knowledge and expertise on both sides to create suitably accredited courses for the steam industry”, Sally concludes.

To find out more about Spirax Sarco’s range of training courses, please visit: www.beta.spiraxsarco.com/ global/en-gb/training

ADVANCED MANUFACTURING SKILLS FOR THE FUTURE Additive Manufacturing | Automation and Robotics Business Improvement | Digital Construction | Digital Manufacturing

We deliver more than 20 courses in the latest innovations in manufacturing and industrial technologies, both online and at our state-of-the-art training facility in Warwickshire.

e training@the-mtc.org

t 02476 701774

VALVES & FLOW CONTROL

STEAM EQUIPMENT EXPERTS VALSTEAM

A STRONG PASSION FOR DEVELOPING EQUIPMENT AND FOR SOLVING PROBLEMS Focused on providing groundbreaking products for industrial steam and fluid systems, the Valsteam ADCA project has been in the market of steam equipment for more than 35 years. Valsteam ADCA started as an industrial plant for pipeline and steam boiler house contractors. Already building pressure vessels and auxiliary equipment in-house, Valsteam ADCA has grown up to become steam equipment and valve manufacturers, using the knowledge acquired along the years, and can now assure the complete production cycle: design, machining, welding, assembly, tests, quality and packaging for a very wide range of products.

GIVING NEW WORLDS TO THE WORLD Right from the start, the family owned Portuguese company had a strong passion for developing equipment and for solving problems. Today, Valsteam ADCA has two production facilities with a total manufacturing area of 22 000 square meters, located in a small village in the ocean side of Portugal, and are currently growing again, expanding their main production facility. The team today consists of almost 90 people that together drive the Portuguese caravel along the five continents and more than 80 countries, with the same ambition their ancestors were driven by: to reach more and to give new worlds to the world!

A “ONE STOP SHOP” Up to now, the company consolidated a very wide range of products and solutions for steam and other industrial gases and liquids, present in the process industry. Today, the company stands as a “one stop shop”, with more than 6.000 different products and more than 15.000 product parts for all kind of industries. From standard and non-standard series to tailor-made products, Valsteam ADCA is one of the European companies with the largest range of products, which can be divided into six sections: • Steam traps • Pressure reducing valves • Control valves • Pipeline ancillaries

144

PECM Issue 41

• Special construction equipment • Adcapure: the hygienic/sanitary line, a complete range on its own, specially dedicated to industries with high purity standards, such as the food, chemical, cosmetic and pharmaceutical industries.

PRODUCING LOCALLY, SUPPLYING GLOBALLY Valsteam is nowadays a global company, but kept the best that a family owned business can have: agility in developing new products, flexibility in production and proximity to staff and clients. The requests of customers for different special products meet in the company the willingness and determination to accept new challenges, which is evident in the company’s vision to always look to and invest in state of the art machinery and advanced engineering software, that allow the continuous increase of the factory’s productivity and the quality and efficiency of the products.

For more information and to check the latest news, visit www.valsteam.com

Background : Dark color

VALVES & FLOW CONTROL

STEAM SYSTEM OPTIMIZATION PROGRAM Steam System Optimization Program (SSOP®) is TLV’s flagship assessment service, a sustainable asset management program that continuously optimizes the performance of the entire steam system through visualization. In this program, TLV’s consulting | Engineering | Services (CES) specialists assess and provide visualizations of the performance of clients’ steam systems, optimise these steam systems with innovative solutions, and implement longterm management programs to ensure that the system remains sustainable. The goals of SSOP® are to improve safety, reliability and profitability by minimizing condensate problems and steam loss, thereby reducing plant energy use and CO2 emissions. Through SSOP, TLV is helping plants build a low-carbon society.

VISUALISATION By expressing the performance of the steam system through visual aids, CES specialists expose problems and make clear how the system can be improved.

SSOP® CAN HELP YOUR PLANT… Reduce CO2 Emissions

By designing and implementing a clear system of appraisal, management, and inspection, CES specialists ensure that the steam system remains consistently and continuously optimized and sustainable.

• Stop steam loss

• Phase 1 - Optimize all condensate discharge locations.

• Eliminate problems caused by condensate

• Phase 2 - Optimize all steam applications such as steam-using equipment, tracing.

• Prevent unexpected equipment failures

• Phase 3 - Optimize the entire steam system.

POTENTIAL STEAM SAVINGS

To ensure that your plant makes the most of this valuable resource, it is of upmost importance that you optimize your entire steam system. The key concepts of steam system optimization are:

Oil Refineries & Petrochemical Plants: 4.6% (Steam generation: approx. 640 t/h *)

PECM Issue 41

* Average potential steam savings identified through surveys

SYSTEMATISATION

STEAM IS AN ASSET

146

Background : Light color

General Industrial Plants: 12% (Steam generation: approx. 4-40 t/h *)

• Improve energy efficiency Improve Safety, Reliability

• Eliminate water hammer • Improve equipment longevity Increase Profitability • Increase production efficiency • Reduce operating expenditure • Mitigate production bottlenecks www.tlv.com

CORIOLIS

MASS GAS

ULTRASONIC

VORTEX

omega.co.uk/flow

MAGNETIC

AND MORE...

hygienic furniture & equipment

ENJOY ‘TEKNOMEXCELLENCE’ Adjective: to save you time and money by designing and making intelligent, outstanding hygienic furniture and equipment.

Reduced dirt traps

Easy access from both sides

Diamond bracing doesn’t collect dirt

Higher tie bar position for easier cleaning

Central tie bar, rear rail or undershelf option

For more information get in touch today Quality

Value

Service

W: teknomek.co.uk T: +44 (0) 1603 788 833