PECM - Issue 59 2022 by MH Media Global

Engineering Process

Control &

MANUFACTURING

FPT INDUSTRIA - 30

ABB - 46

FPT Industrial has inaugurated its new ePowertrain plant

ABB unveils smallest industrial robot with class-leading payload and accuracy

PECM

Global Success Through Innovation Issue 59 2022 £4.95 www.pecm.co.uk

INSPEKTO - 56 Challenges manufacturers can face in PCB inspection

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Engineering Process

Sections

Control &

MANUFACTURING

Inside...

Inside Issue 59

Editors Choice

Control & Automation

Electrical & Electronics

Facilities Management

Food Processing / Fluid Handling

Gears, Drives & Motors

Health & Safety

Machining & Machinery

Measurement & Monitoring

Process Technologies

Pumps

Switches & Sensors

Software & Systems

Valves & Flow Control

CGTECH

DFI

AM SOLUTIONS

BRILLOPAK

Vericut provides safe and optimised machining operations for the mercedesamg petronas formula one team AM Solutions brings wet blasting & fully automated post-processing to Formnext 2022

UPM COMMUNICATION PAPERS

Prioritising workplace safety in an unstable world

FPT INDUSTRIAL

ePowertrain plant opening and other product highlights

ABB

ABB unveils smallest industrial robot with class-leading payload and accuracy

Cover photo: Fanuc

DFI’s “new Smart Factory” introduces automated equipment and improves production capacity by 30% Why automation should not be feared

FANUC

VW Group shows faith in FANUC with order for 1,300 robots

INSPEKTO

Challenges manufacturers can face in PCB inspection

INFOR

The most important ingredients for a strategy to create the future-proof smart factory?

FORTRESS TECHNOLOGY

Insights gained from projects on the Sellafield-National Nuclear Laboratory project distilled into whitepaper

“The centre of excellence for strainer and ﬁltraaon technology”

www.bartonﬁrtop.co.uk Issue 59 PECM

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Micro-Coaxial Cables

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PTFE Yarns, Lacing Tapes & Cords

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Engineering MANUFACTURING

Control &

The UK’s leading specialist highperformance thermocouple and Process signal cable manufacturer Subscribe The UK’s leading specialist highThe company is a technology leader in fluoropolymer performance thermocouple and The UK’s leading specialist highThe leading source for innovators extrusion, high-performance taping and cable wrapping. in Technology, Manufacturing and signal cable The The UK’s UK’s leading leading The specialist specialist UK’s leading highhigh-specialist high- Related performance thermocouple processes includemanufacturer coverand sintering, colouring, Maintenance within the Engineering & performance performance thermocouple thermocouple performance and thermocouple and and signal cableand manufacturer Processing industry worldwide. applicationleader of various specialist Theetching company isthe a technology in fluoropolymer

EDITOR Elizabeth Hutton elizabeth@pecm.co.uk

SPECIALIST HIGH-PERFORMANCE SOLUTIONS

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

SPECIALIST HIGH-PERFORMANCE SOLUTIONS

Pharmaceutical, Biotechnology, Chemical, Oil & Gas, as well as all UK's major manufacturing units.

SPECIALIST HIGH-PERFORMANCE SOLUTIONS SPECIALIST HIGH-PERFORMANCE SOLUTIONS

signal signal cable cable manufacturer manufacturer signal cable manufacturer coatings. The range covers cablesand thatcable are resistant to extrusion, high-performance taping wrapping. The company is a technology leader in fluoropolymer Published bimonthly, subscription TheThe company company is aaistechnology a technology The company leader leader isinafluoropolymer in technology fluoropolymer leader in fluoropolymer extrusion, high-performance tapinginclude andand cable wrapping. flame, oils processes and chemicals which operate colouring, in ultra-high Related cover sintering, to PECM magazine is essential for extrusion, extrusion, high-performance high-performance extrusion, taping taping high-performance and and cable cable wrapping. wrapping. taping and cable wrapping. Process Engineers, Chemical Engineers, Related processes include cover sintering, colouring, Related Related processes processes include include Related cover cover processes sintering, sintering, include colouring, colouring, cover sintering, colouring, vacuum, and high radiation environments. etchingcryogenic and the application of various specialist Instrumentation Engineers, Mechanical etching etching and and thethe application application etching ofand various of various the application specialist specialistof various specialist etching and the application of covers various cables specialist coatings. The range that are resistant to Engineers, Plant Precision coatings. coatings. TheEngineers, The range range covers coatings. covers cables cables The that range that areare covers resistant resistant cables tocoatings. tothat are resistant to The range covers cables that are resistant to Engineers, Environmental Engineers flame, oils and chemicals and which operate in ultra-high flame, flame, oils oils and and chemicals chemicals flame, and and oils which which andoperate chemicals operate in ultra-high and in ultra-high which operate in ultra-high flame, oils and chemicals and which operate in ultra-high & General Engineers, Companies vacuum, vacuum, cryogenic cryogenic and vacuum, and high high radiation cryogenic radiation environments. environments. and high radiation environments. vacuum, cryogenic and high radiation environments. and Organizations in the Food, Dairy, vacuum, cryogenic and high radiation environments. The Team Beverage, Brewing, Semiconductor,

Every issue of the magazine contains the latest news, in-depth features, together INSULATION INSULATION & BRAIDING & INSULATION BRAIDING EXPERTS & BRAIDING EXPERTS with product innovations and case EXPERTS BUSINESS MANAGER STUDIO DESIGNER studies showing how process engineers Josh Holmes RichardSILICONE, Bland PFA, FEP, PTFE, ETFE, EFGLAS, PE, PU, are implementing new technologies PFA, PFA, FEP, FEP, PTFE, PTFE, ETFE, ETFE, EFGLAS, PFA, EFGLAS, FEP, SILICONE, PTFE, SILICONE, ETFE,PE, EFGLAS, PE, PU,PU, SILICONE, PE, PU, josh@mhmagazine.co.uk richard@mhmagazine.co.uk INSULATION & BRAIDING EXPERTS PVC, Taped & Sintered PTFE, to reduce costs and impact onSintered PVC, PVC, Taped Taped & &the Sintered PVC, PTFE, PTFE, Taped & Sintered PTFE, environment. Polyimide Polyimide & Aramid & Aramid Yarns, Polyimide Yarns, PTFE PTFE &impregnated Aramid impregnated Yarns, yarns PTFE yarnsimpregnated yarns Polyimide & Aramid Yarns, PTFE impregnated yarns and and Mica. Mica. and Mica. PFA, FEP, PTFE, ETFE, EFGLAS, SILICONE, PE, PU, SALES DIRECTOR ACCOUNTS DEPT PFA, FEP, PTFE, ETFE, EFGLAS, SILICONE, PE, PU, and Mica. With over 140,000 readers worldwide the Harrison James Alison Holmes Braiding Braiding materials materials include Braiding include glass, glass, materials quartz, quartz, include ceramic ceramic glass, quartz, ceramic PVC, Taped & Sintered PTFE, publication is widely read, recognized, PVC, Taped &accounts@pecm.co.uk Sintered include glass, PTFE, quartz, ceramic fibres fibres and and other other specialist specialist fibresyarns. and yarns. other specialistharrison@pecm.co.uk yarns. Braiding materials Polyimide & Aramid Yarns, PTFE impregnated yarns and well respected within the Process, Tel: 0203 907 9166 Tel: 01227 936976 Polyimide & Aramid Yarns, PTFE impregnated yarns fibres and other specialist yarns. Engineering &MARKET maintenance industries. and Mica. MARKET SPECIALISTS SPECIALISTS MARKET SPECIALISTS

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EDITOR’S CHOICE

SUCCESSFUL MACHINING CGTECH

Vericut provides safe and optimised machining operations for the mercedes-amg petronas formula one team The machine shop of the MercedesAMG PETRONAS Formula One Team relies on VERICUT verification, simulation and optimisation software from CGTech to guarantee the successful machining of its many high-complexity, high-value components. A VERICUT user for over two decades, the team has engrained VERICUT into its Standard Operating Procedures (SOPs), aware of the benefits it provides in reducing machine collisions and component scrap, while simultaneously optimising lead time. Today, the Machine Shop at the Team headquarters in Brackley, Northamptonshire, not only manufactures parts for the race cars, but also for several customer programmes, including other Formula One Teams and the INEOS Britannia Americas Cup sailing Team. “We are pretty diverse with our component supply, but in all cases reaction time is key: for our race car we sometimes only have 24 hours from design release to delivery,” reveals Machine Shop Manager Robert Brown. “VERICUT really helps as it gives us the confidence to start the machine running safely, enabling us to switch our focus onto another activity, such as writing programs or setting up tools for the next part. This is far preferable to requiring the presence of an operator at the machine, monitoring the cutting process to mitigate the risk of a collision.”

capability: “Some thought the cost cap would change the order of the grid, but the well-resourced teams with good structures and processes in place have continued to do well. At Mercedes, we’ve got leaner and doubled down on how much value we can extract from our time. As an organisation we are more efficient now than we were two years ago, before the introduction of the cost cap.”

Formula One Teams have been operating within a cost cap for the past couple of years, imposed by the FIA, the sport’s governing body, so the Mercedes-AMG PETRONAS Formula One Team cannot afford to be non-productive.

The Mercedes-AMG PETRONAS Formula One Team has 25 machine tools on site at Brackley, including: five-axis machining centres; five-axis turn-mill centres; four and three-axis milling machines; and four and two-axis CNC lathes.

“Today, more than ever, championships could be won or lost in the factory,” states Mr Brown. “Obviously without the right drivers we’re not going to win, but there’s a reason the sport currently has three dominant teams: because those teams can develop and engineer cars on a scale that no one else can match.”

“The enemy of Formula One cars is weight, so approximately 60% of our parts are made from various types of aluminium alloy,” says Mr Brown. “A further 30% are made from titanium, with the remaining 10% comprising steels, other alloys and plastics. Batch sizes of 8-12 are typical for our five-axis machines. Five-axis machining is our speciality and where the team gets its value from this department. We can get high-complexity parts up and running quickly, working

According to Production Engineer James Peddle, the cost cap has not changed this

PECM Issue 59

ADVANCED MACHINE TOOLS

closely with the design team to manage any iterations.” One of the principal challenges is minimising cycle times for these highly complex components without compromising quality. A recent case in point was a titanium front axle. “The cycle time for this part was in the region of 70 hours over five operations,” says Mr Peddle. “Due to the nature of the material, we were limited by the speed of machining. However, by using the latest machining methodology from one of our suppliers, we managed to reduce the lead time by 50%.” “We always get really good solid-model transfer from tooling suppliers into VERICUT for our simulations,” he adds. “Whenever we need a bespoke cutting tool, we can do the modifications virtually and seamlessly, and complete the simulation before we place our order for the tool, so we know for certain that it will work.”

ADDED VALUE There is little doubting the value that VERICUT adds to operations at the Machine

Shop of the Mercedes-AMG PETRONAS Formula One team. Mr Brown was with the company when the software first arrived over 20 years ago. “Previously we would export CNC code from our CAM system, alongside creating some CNC code conversationally and editing this together into a single CNC program, with all the risks that go with that strategy,” he explains. “We had too many collisions on the machines and too much scrap as a result of human error. But once we had VERICUT, we could export all of our CNC code from CAM and validate it (using VERICUT). The initial investment was all about reducing risk and over the years that thought process has continued. We know that better use of CAM and more use of VERICUT simulations will reduce errors and the risk of machine

THE PROCESS

PPMA Total Show 2022 is already shaping up to be the launch pad for a host of exciting new product introductions, industry firsts and debut showings. collisions. If code goes through VERICUT, we know it’s safe.” Today, tool transfer from the CAM session, through VERICUT and on to a tool sheet is virtually seamless at the MercedesAMG PETRONAS Formula One Team. The opportunity for human error, perhaps adding incorrect details or picking the wrong geometry, is significantly reduced. “It’s always been about reducing scrap and protecting machine tools, which are obviously very expensive assets,” says Mr Brown. “A new spindle is around £20,000 these days. We’ve damaged spindles in years gone by and, when we scrutinised the root cause, it was predominantly human error; someone manually editing a few lines of code incorrectly. Utilising VERICUT to simulate the CAM session has removed human error. Today, every CNC machined component is validated via VERICUT.”

When the Design department at the Mercedes-AMG PETRONAS Formula One team releases a CAD model, the Production Engineering team imports it into a CAM session where various templates exist for the different machine tool types. “We program within the context of the machine regarding travel limits, access and other parameters,” says Mr Peddle. “Once we’re happy with the program we postprocess it and use our CAM-to-VERICUT interface to replicate the set-up we created in the CAM software before running the simulation. We also use VERICUT’s AUTODIFF module to check for any excess material or gouging. This is important as we don’t want to reach the end of the program and identify that we’ve missed a section of machining or gouged the part. It would be difficult and increase risk to manufacture some of our parts without AUTO-DIFF, by solely relying on the CAM package.” He continues: “Another advantage of VERICUT is its simulation speed, which in our experience is far greater than the core CAM product. This ensures a much more efficient and flexible work stream, where we can be programming certain component features while simulating others.” Around 30 employees at the Mercedes-AMG PETRONAS Formula One Team are trained to use VERICUT, at various levels. Production Engineers might need to create, edit or interrogate sessions, whereas machine operators might only replay the simulation to identify what type of machining operation is coming next in the sequence.

Issue 59 PECM

“We operate multiple shift systems around the clock here at Brackley,” says Mr Peddle. “One of the key benefits of VERICUT is its ease of use, especially for staff who work unsupported, outside of regular hours. For example, the night shift might not have the same level of support available as those working shifts that cross our core hours. However, they can just open the software and easily see the entire simulation. They don’t need to be a software expert.”

REGULAR INVESTMENT The machine shop at Brackley replaces most of its machine tools on a 10-year cycle, but investing in a new machine is no problem for VERICUT. “CGTech has a good library of machine tool templates, so they can usually provide a template ‘off-the-shelf’ or create a bespoke version if required, based upon their extensive library,” explains Mr Peddle. “The support is always excellent, quickly resolving any issues we might have.” Adds Mr Brown: “CGTech regularly spend time on site with us, periodically though the year, integrating with our CAM team. They understand what we do here and what we need from VERICUT. We have a very strong relationship with them.” CGTech also has long-standing relationships with all of the major machine tool vendors, a factor that has proved beneficial to the Mercedes-AMG PETRONAS Formula One Team on more than one occasion. “We’ve recently done a lot of work reducing our five-axis milling cycle times,” says Mr Peddle. “CGTech has a really good

relationship with our machine tool suppliers, which meant they were able to gain access to certain machine parameters and build that information into our VERICUT projects, helping us to simulate the digital cycle time compared with the actual cycle time.” Mr Brown picks up on this important point: “Understanding how much a component has cost to make and what value it has as an asset to the Team has been a complex thing to learn over the past two years since the cost cap was introduced. We’ve had to create a new process where we now rely on VERICUT cycle times to help cost a component. Having really accurate cycle times exported from VERICUT has proved so important.” Adds Mr Peddle: “As VERICUT has evolved we’ve evolved alongside it, not just in terms of how we prevent collisions, but in reducing lead times and improving quality.” Another benefit of VERICUT is its independence of the CAM session. The For more information visit www.cgtech.co.uk

PECM Issue 59

programming stations in the office and on the shop floor at Mercedes-AMG PETRONAS Formula One Team have multiple screens, so users can work on CAM and VERICUT sessions in parallel. “Due to our compressed manufacturing lead times, we’ll routinely start machining a part before the program is complete, so we can be simulating while we are creating the next sequence of CNC code in the CAM session.” explains Mr Peddle. “We always have a finite amount of time, so we’ll begin roughing as soon as a part is released and get as far as possible before waiting for more code. It’s the only way we can achieve on-time delivery, which translates directly into the machine shop adding performance to the race car.” Concludes Mr Brown: “Tools such as our CAM system and VERICUT verification, simulation and optimisation software ensure we get the best result possible in the finite amount of time we have.”

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EDITOR’S CHOICE

POST-PROCESSING SOLUTIONS AM SOLUTIONS

AM Solutions brings wet blasting & fully automated post-processing to Formnext 2022 AM Solutions (a brand of the Rösler Group) is bringing some of its extensive range of additive manufacturing (AM) post-processing technologies to this year’s Formnext exhibition on booth C81 in Hall 12 15-19 November in Frankfurt. AM Solutions – 3D post processing technology is already respected as a dominant player in the field of postprocessing of AM parts made using the full range of AM processes and in a range of materials, be they plastics, metals, or resins. The company’s success is based on the fact that it has over eight decades experience supplying finishing (or post-processing) technologies for traditional manufacturing processes, and it is able to pragmatically address the unique characteristics of AM post-processing from this perspective. Among many other solutions, featured on the stand this year will be the S1 Wet technology, and also the S2 machine, both designed to undertake an array of specific postprocessing operations. Daniel Hund, Head of Marketing at Rösler / AM Solutions says, “What many manufacturers lose sight of when using AM is that using proven and time-worn finishing technologies (optimised to meet the specific needs of the 3D printing sector) is the best route to optimal surface finish and tolerance attainment. The goal whether using traditional manufacturing processes or AM is the same, namely to make end-use products that conform to design intent and are fit for purpose repeatably and cost-effectively. Let’s take a look at our S1 Wet technology which will be on display at Formnext, a versatile wet blast solution for cleaning and surface finishing. Wet blasting is largely neglected when looking at AM parts, but it is a clean, reliable, repeatable, and accurate process which creates parts with a consistently superior surface finish than alternative processes, and which is ideal for parts made using direct metal laser sintering (DMLS) and selective laser sintering (SLS). When it comes to powder removal on AM parts (even in hardto-reach internal channels and features) the

higher for AM produced parts than for conventionally machined parts as there is always some residual printing powder left on the parts.

S1 Wet immediately washes away anything that is adhering to the work piece. In terms of surface finish, the S1 Wet promotes smoother finishes while being more precise, consistent, and repeatable. Finishes are fine and uniform, with low surface roughness being easily attainable.” From a cosmetic surface finish perspective, the S1 Wet creates a smooth matte effect, and the less abrasive nature of process and lack of warping and bending allows for the attainment of much tighter tolerances. A key advantage is the versatility of the wet blasting process, as blast intensities and media concentrations can be easily adjusted to accommodate different materials and geometric structures to eliminate damage to part form and function. Because of this, it is advantageous for manufacturers to work with suppliers like AM Solutions — 3D post processing technology that have the knowledge and experience to advise on the numerous technical features that combine in a wet blasting process to ensure that precise and repeatable result on a wide variety of work pieces are achieved. The S1 Wet can process metal or plastic parts individually or in batches, has a small footprint, and an integrated media cleaning and recycling system that allows the re-use of the blast media. In addition, the process water is also recycled and it can operate in manual, semi-automatic, and fully automatic operation. Also, of enormous benefit is the fact that wet blasting is not affected by ATEX regulations as there are no dust explosion risks, a major headache when using dry blasting on materials especially titanium or aluminium. The risk of dust explosion is considerably

Also on display at Formnext will be the S2 machine, which promotes unique parts handling and fully automated post-processing for plastic components made on the full range of polymer powder bed AM systems. Users of the S2 simply place the plastic components to be processed into the machine and the rest is automatic. A special loop belt allows single piece flow and particularly gentle work piece handling, which ensures uniform cleaning, surface homogenization — and / or peening — of the work pieces in continuous mode operation. The integrated blast media recycling system guarantees consistently good processing results. The S2 does not discolour parts because the blast media is conditioned, and the loop belt is made from polyurethane. Hund concludes, “The S1 Wet and the S2 are just a couple of the many AM postprocessing solutions that we have on display at Formnext, and we are certain that we will have a solution that is ideally suited to any show visitor’s specific application. AM Solutions has the objective of allowing the manufacture of near net shape parts with superior surface characteristics without compromising part integrity. When this is achieved, the viability of AM as a production alternative will be recognised by a growing number of companies, and the technology will be in a better position to disrupt the traditional production paradigm. AM Solutions positions itself as a company working in the AM ecosystem which has this objective as its primary focus. We would welcome the opportunity of discussing your postprocessing needs at Formnext.” A team of AM Solutions experts will be on hand to meet with Formnext attendees on booth C81 in Hall 12. The company also invites attendees requiring pre-arranged 1-2-1 meetings to email formnext@solutions-for-am. com, so specific meeting times and dates can be confirmed.

For further information, please visit www.solutions-for-am.com

PECM Issue 59

NEW range of Hygienox lecterns

Designed for ISO 14644 ygienic standards Designed with creativity and obsessive attention to detail, for tomorrow’s ultra-sterile spaces, today: • 316L-grade steel with smooth finish • Full welding and sealing • All burn marks removed • Ultra hygienic, easy clean design From Teknomek, renowned for outstanding products, service and support.

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EDITOR’S CHOICE

SOLID & ABRASIVE HANDLING? NORTHRIDGE PUMPS

Why seal less pump technology is Key We are often approached by customers with difficult to pump fluids, which they are having difficulty finding a solution for. Problematic characteristics include high viscosity, abrasiveness, and high concentrations of solids. This will almost certainly require a pump which can deliver specified volumes of liquids without being affected by changing fluid characteristics such as its thickness, consistency or varying solid concentration. Some products may require altering to ensure they can be pumped either by the addition of another fluid such as water, agitation or heating. One such example is wax, which in its natural state is solid requiring heating to flow. Heating is typically performed inside a tank or heating vessel, once the optimum temperature is reached, the wax can flow into the pump for either transferring to another location on site, for spraying or another process.

APPLICATION BACKGROUND We were approached by one of the World leading technical consultancies to the oil and gas industry with a unique requirement. One of their processes involves coating the insides of pipework with a hot wax and sand mixture, normally 5 to 10% concentration. They heat the wax in a large tank to 70°C to lower the viscosity enough to ensure it flows, they then need a wax pump to move 1000L/hr while producing 6 bar pressure to spray it through nozzles evenly across the pipework.

LOW MAINTENANCE POSITIVE DISPLACEMENT PUMP DESIGN Our FMP30 peristaltic pump is an excellent solution for this application due to its seal-less and valveless design. They are outstanding at handling viscous, abrasive and solids laden fluids as there is only one component internally that encounters the fluid - the rubber hose.

As the internal rubber hose is the only wearing part, it makes maintenance quick and simple while the stocking of spare parts is low cost. The internal rollers rotate at a slow speed and squeeze/contract the hose to force the fluid through at pressure. The motor speed is reduced via a gearbox making the operating speed of the unit very low, this extends the life of components when handling abrasive products such as sand, a huge benefit with this application.

CONSIDERATIONS FOR ABRASIVE FLUID HANDLING The unique pumping action enables selfpriming, the absence of a mechanical seal allows dry running without damage and the lack of valves means there is no risk of clogging, all extremely useful characteristics

when handling difficult fluids or for difficult installations. As the internal rubber hose is the only wearing part, it makes maintenance quick and simple while the stocking of spare parts is low cost. As wax turns to a solid once cooled, this is something that could easily occur if the operator forgets to clean the unit and leaves the wax inside, the hose therefore adds another huge benefit for this client as is it the only component that needs to be changed in the event this happens. Should this occur in other designs then it would involve the costly replacement of major parts or even possibly a complete replacement, making the handling of wax a very risky venture. To reduce downtime as much as possible, we advised this customer to keep a spare hose in stock along with silicone grease for lubrication to ensure the unit is quickly back in action should wax accidentally be left inside the pump to set. If you are looking to handle viscous, solid laden fluid of high viscosity and are unsure of the most suitable way to handle such fluids, visit www.northridgepumps.com or call us on 01773 302 660 to see how we can help.

For further information, please visit www.northridgepumps.com

PECM Issue 59

We’re pump specialists, so you don’t need to be

Chemical Pumps Engineered for Your Process Optimise performance with specialist support

Industry knowledge and application expertise across dispensing, dosing, full containment, gentle handling, blending and transfer, means whatever the problem, it’s likely we’ve seen it before. So we can help you solve it sooner. ++ Accelerated Accelerated stator stator wear wear ++ Clogging Clogging ++ Changes Changes to to fluid fluid consistency consistency ++ Flow Flow Reduction Reduction ++ Inconsistency Inconsistency in in finished finished product product ++ Inaccurate Inaccurate transfer transfer of of chemicals chemicals ++ Leakage Leakage || Liquid Liquid separation separation ++ Product Product Wastage Wastage ++ Seal Seal wear wear or or failure failure ++ Valve Valve Blockage Blockage or or unintended unintended Opening Opening

We’ve We’ve been been engineering engineering sanitary sanitary pumps pumps for for sectors sectors such such as as distilling, distilling, brewing, brewing, food food manufacturing/processing, manufacturing/processing, and and more, more, for for 20+ 20+ years. years. We We understand understand industryindustryspecific specific processes processes and and know know what what itit takes takes to to optimise optimise performance performance through through betterbettersuited suited pump pump design design -- giving giving you you complete complete peace peace of of mind. mind.

EXPERT GUIDANCE:

Our Our expert expert engineers engineers understand understand your your process process and and guide guide you you through through the the options, options, so so you you can can confidently confidently select select the the most most suitable suitable chemically chemically resistant resistant pump. pump.

Want to optimise performance sooner? Speak to one of our specialists.

+44 (0) 1773 302 660

sales@northridgepumps.com sales@northridgepumps.com || www.northridgepumps.com www.northridgepumps.com

EXAMPLE PRODUCTS: ++ Acids Acids ++ Alkalis Alkalis ++ Coagulants Coagulants ++ Corrosive Corrosive ++ Chemical Chemical Sludge Sludge ++ CO2 CO2 ++ Flammable Flammable ++ Flocculants Flocculants ++ Oxidisers Oxidisers ++ Pyrophoric Pyrophoric ++ Refrigerants Refrigerants ++ Solvents Solvents ++ VOC VOC with with low low NPSH NPSH ++ Water Water Reactives Reactives

EDITOR’S CHOICE

ENERGY AUDITS THORITE

Cut costs and improve asset reliability Companies looking to combat soaring energy costs can achieve concrete longterm savings by conducting an energy audit, says compressed air and fluid power specialist Thorite. Thorite’s specialist Energy Saving Solutions service has helped customers across all industry sectors identify where energy consumption can be significantly reduced to rein in costs. The Thorite team carries out ISO 11011 certified energy audits, tailored to individual plant requirements. These can include a range of checks including compressed air generation and preparation analysis, air quality analysis, leakage detection and pressure drop management. Every opportunity to eliminate energy waste is identified and bespoke energy efficiency options recommended, with detailed analysis of what savings and efficiencies they can offer. Solutions to reduce energy consumption include: • Customising air pressure to operational need to prevent ‘non-working’ air consumption. • Identifying pressure needs within process actuators and isolating zones where pressures can be lowered. • Regulating air supply, for example by programming a digital system to respond to inactivity and pause supply to avoid air waste. • Programming blowers to operate only when required or in pulse mode. One Thorite customer saved £100,000 a year in energy costs by installing a sensor and optimising the blowing process across all production lines. • ‘Quick-fix’ pneumatic system efficiencies such as optimising component size. • Installing a voltage optimiser to prevent excess energy use caused by potential over-supply from the National Grid. • Installing simple software upgrades

Every opportunity to eliminate energy waste is identified and bespoke energy efficiency options recommended, with detailed analysis of what savings and efficiencies they can offer. to expand the master controller in compressors, without the need for further hardware investment, making air generation more intelligent, dependable and efficient • Installing customised smart systems control panels which offer specific optimisation to ensure high productivity and efficiency for process-driven enterprises.

Mark Yates, of Thorite, says: “Rising energy prices mean the cost of an audit can be quickly offset by reduced energy consumption and the return on investment is likely to be months rather than years. “Reducing energy consumption helps ensure that assets are operating at optimum efficiency, which extends lifespan and reduces maintenance costs. “The environmental benefits of reducing carbon emissions are another key factor to consider for those with a commitment to embedding sustainability in their operations.

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

PECM Issue 59

EDITOR’S CHOICE

Healthy building, productive people!

Affordable cooling with no chemical refrigerants Low running costs giving high Indoor Air Quality (IAQ)

www.seeleyinternational.com uksales@seeleyinternational.com +44 (0)115 9635630

PECM Issue 59

Work smarter, not harder

ERGONOMICS | ESD | LEAN treston.com

A workspace that adapts to your needs, not the other way around.

Suitable to any environment, application and industry. Concept workbench

The widest range of accessories on the market. Future-proof

Multiple sizes and combinations available. Productivity and well-being

DESIGN YOUR PERFECT WORKSTATION

The Treston 3D Configurator can be used to design an industrial or technical workstation that best meets your needs. To get started, all you need is a mobile phone or a computer with an internet connection; no downloading is required and using the software is free.

3D.Treston.com

EDITOR’S CHOICE

You could be entitled to R&D Tax Credits The R&D Tax Relief scheme is basically a form of tax relief that may reduce your company or organisation’s Corporation Tax bill. Tax relief can be claimed on a wide range of R&D projects – even those that ultimately proved unsuccessful. It’s quick and easy to determine if you might be able to make a claim for R&D Tax Relief. But 97% of eligible businesses don’t check or claim – don’t let your business miss out in this way!

www.mcs-corporate.com | charlotte@mcs-corporate.com | +44 (0)1926 512475

• Clean hygienic design • Stainless Steel • Easy to clean • Minimum maintenance • High performance • Low energy

PECM Issue 59

quality products for mechanical & fluid power home

contact

productlist

about us

catalogue

jbj Techniques, specialist manufacturer & distributor of high quality products for the mechanical power transmission & ﬂuid power sectors. Established 1974

etting the most out of your machinery often depends on close integration between all components, with the correct speciﬁcation of couplings between them to ensure proper shaft alignment, optimise performance and minimise wear. The experts at jbj Techniques guide us through the design considerations for coupling hydraulic pumps to prime movers. www.jbj.co.uk/hydraulic-adaptors.html

Small Individual Components

Large Combinations

www.jbj.co.uk

EDITOR’S CHOICE

RELIABLE VALVE SOLUTIONS GEMU

Ultra-filtration and Partial Softening in Water Treatment VALVE SOLUTIONS FOR DRINKING WATER TREATMENT

In a successful municipal water treatment application that treats 300m³ of water per minute, GEMÜ provides reliable valve solutions for ultra-filtration and partial softening processes.

PROCESS DESCRIPTION Ultra-filtration UF

After coarse filtration, the water is fed to the Ultra-filtration passing through porous membranes with a pressure drop of 0,1 - 0,8 bar. This retains the finest solids, turbidity and pollens, as well as bacteria from passing through the membrane. However, the water containing dissolved ingredients such as hardness components or minerals, and small molecules can still pass through.

Partial softening and regeneration

Ion exchange reduces the concentrations of hardness components (calcium and magnesium), and undesirable substances such as nitrates, sulphates and chlorides, by half from the sanitized water. Carbonic acid is generated as a by-product and dissolves into water and carbon dioxide (CO2). The pure-water degasifier then removes the excess CO2 before transferring the treated water to a pure-water container and feeding it into the municipal water supply following UV sterilization. This reduces the water hardness from a hard level (480 ppm CaCO3) to a medium level of 240 ppm CaCO3. Raw water enriched with CO2 is used as a regenerating agent for the mixed-bed filter reversing the direction of the exchange process where high pressure dissolves CO2 to create carbonic acid. The carbonic acid is then fed in the counter current over the mixed-bed, regenerating the ion exchanger resin. About 95% of the CO2 required for regeneration can be recovered and fed back into the process.

GEMÜ PRODUCTS IN USE

All treatment processes for both raw and treated water distributions use GEMÜ 480 Victoria series butterfly valves (up to DN 400), GEMÜ D450 plastic butterfly valves

Water treatment plant

GEMÜ butterfly valves in ultra-filtration plant range, GEMÜ 717 manual plastic ball valves and GEMÜ LSC limit switch box for quarter turn actuators.

WHY GEMÜ?

GEMÜ offers the next generation of rubber lined butterfly valves, the R480 Victoria series, as a direct replacement for the GEMÜ 480, offering multiple enhanced product features. Thanks to its flow-optimized and sleek disc design, the R480 series achieves higher flow rate factors. This reduces the pressure loss, giving the butterfly valves greater energy efficiency. The PTFE-coated bushes reduce torques, not only allowing further savings through lower actuator costs, but

also making the valves significantly more durable and therefore increasing longevity. Furthermore, the technical optimization of the liner improves tightness, which guarantees bubble-tight sealing and resistance to slipping. With its wide range of valves and accessories, as well as measurement and control instrumentation, GEMÜ provides an optimal solution from a single source, saving the customers time, effort and cost not only in logistics and installation but also in documentation. In addition, plastic butterfly valves and ball valves used in this application are available in various actuator and material versions.

Tel: 01925 824044 | Email: enquiries@gemu.co.uk | Web: www.gemu.co.uk

PECM Issue 59

EDITOR’S CHOICE

SAFETY CULTURE UPM COMMUNICATION PAPERS

Prioritising workplace safety in an unstable world We know that encouraging a positive safety culture starts with strong employee leadership roles, who can then present these practices in a concise and thorough way to ensure all workers apply policies in a consistent way throughout the company. This, in turn, can ensure good industrial relations within a team. It is a group responsibility to help protect our people and environment. By putting good practices in place to manage safety, it will help reduce the number of injuries in the workplace.

By Anu Ahola, Senior Vice President Operations, UPM Communication Papers Manufacturing comes with its set of hazards and controlling those hazards to keep employees safe on the job can be challenging. Each year, nearly three million workers die due to occupational accidents and diseases, and hundreds of millions more suffer non-fatal injuries at work, according to the latest report of the UN agency in the occasion of World Day for Safety and Health at Work 2022. The disruption caused by COVID-19 catapulted businesses and managers into unknown territories. It has therefore become critical to keep an eye on the future and develop a strong safety culture now, in order to face tomorrow’s challenges.

EVERYONE MUST BE ON BOARD

Workplace safety is extremely important for every industry because employees both desire and are entitled to work in a safe and well protected environment. It is an integral part of any operational system. Ultimately, it is essential for all industries to adapt and prioritise health and safety principles in order to promote the wellbeing of both employers and employees. However, ensuring that rules and regulations are followed to protect your workers is sometimes easier said than done. We, as employers, are asking a lot from our workers: they have to place safety first and at the same time, efficiency. And safety is an everyday job: the bottom line is being relentless in pursuing flawless operations. We all have to follow a lot of standard operating procedures that require a great dose of discipline from every worker involved. And everyone must be on board, otherwise it won’t work. We know that if one employee alone doesn’t follow one of the safety rules, it can affect the entire team and potentially have disastrous repercussions on the whole operational chain.

That’s why having a great safety culture is so important. Building a resilient safety culture within an organisation is one of the biggest challenges which Safety Managers have to contend with, but if you can get your workers on board and actively involved with health and safety, it will not only enable you to meet your legal obligations effectively, but also lower injury and fatality rates and improve employee wellbeing. Prioritising it as a company-wide effort can certainly be an ongoing effort, but it’s a policy that can reap huge rewards and successes when it becomes part of a company’s DNA.

THE IMPORTANCE OF A POSITIVE APPROACH TO SAFETY

The mission is to achieve zero accidents, but I believe it can only happen with a positive approach to safety. Companies have to shift away from a safety culture of blame and avoidance, where workers behave safely only if they’re made to feel like they have to, to a culture where employees are encouraged to take personal ownership over safety and understand the importance of choosing to engage in safe behaviours – A culture where safety practices, observations and innovation in the area of safety is celebrated.

The latest UN report on the topic, titled Enhancing social dialogue towards a culture of safety and health, found that during the pandemic, governments that prioritised active participation of employers’ and workers’ organizations in OSH governance, were able to develop and implement emergency laws, policies, and interventions. Collaboration and communication are crucial to ensuring new measures are both acceptable to, and supported by, employers and workers, meaning they are more likely to be effectively implemented in practice. At UPM, we actively involve all employees in every aspect of safety with companywide efforts, but also locally at the mills and offices, where safety is an integral part of the daily work.

ENHANCING ORGANISATIONS’ RESILIENCE

Prioritising safety not only prevents injuries, but also builds morale and improves overall employee health. Many studies show that it also helps attract and recruit the best employees. A good health and safety record is a source of competitive advantage: it attracts partnerships, builds trust in your reputation and brand and secures longterm benefits for you, your business and the wider community. However, companies need to understand that while success must be celebrated, there is always room for some improvement. Putting in place systems for continuous development will not only ensure the safety of employees, but also enhance organisations’ resilience in an unstable world.

For further information, please visit www.upmpaper.com Issue 59 PECM

EDITOR’S CHOICE

Industry 4.0 Machine Data Collection SPECIALISTS IN DESIGN, MANUFACTURING AND DISTRIBUTION OF SEALS FOR THE GLOBAL MARKETPLACE High-performance seals for rotary, reciprocating & static applications

— — — — —

Increase production Make effective production decisions Highlight production bottlenecks Schedule machine maintenance Automatically calculate OEE Realtime shopfloor view Live export to Excel Web based clients

All specification, design and manufacture carried out in-house in our 24/7 manufacturing facility OEM engineered seal design – typically 3-5 days versus 8-10 weeks industry standard Over £2.5m of semi-finished material and finished sealing products kept in stock www.m-seals.com TECHNICAL DISTRIBUTION CENTRE

TECHNICAL INSPECTION CENTRE

ENGINEERED SEALS DIVISION

Leicester

Newcastle

Sheffield

+44 (0) 116 275 4720

+44 (0) 191 422 4200

+44 (0) 114 243 2777

Cambridge Numerical 8 Royce Court, St. Ives, PE27 3NE 01480 468 639 sales@cnc.uk.com Control www.cnc.uk.com/mdc-max

we make ideas come to life

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.

Cutting We can cut and shape perforated sheet to meet the needs of your final application. 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 tel: 01925 839610 | email: info.uk@rmig.com | www.rmig.com

PECM Issue 59

World Leaders in Selective Soldering

PILOT

JADE MKII

Entry-level, benchtop, single point selective soldering system

Elementary, exible, single point selective soldering system

ORISSA FUSION

SYNCHRODEX PRO LINE

High speed, in-line, multi-platform selective soldering system

Enhanced, exible, in-line, modular selective soldering system

Pillarhouse International Ltd.

www.pillarhouse.co.uk

Rodney Way, Widford, Chelmsford, Essex CM1 3BY UK

Tel: +44 (0) 1245 491333 Email: sales@pillarhouse.co.uk

Pillarhouse USA, Inc.

www.pillarhouseusa.com

201 Lively Blvd, Elk Grove Village, IL 60007 USA

Tel: +1 847 593 9080 Email: sales@pillarhouseusa.com

Pillarhouse (Suzhou) Soldering Systems Co., Ltd.

www.pillarhouse.cn

105 Weixi Road, Suzhou Industrial Park, China 215127

Tel: +86 512 6586 0460 Email: sales@pillarhouse.cn

EDITOR’S CHOICE

BOOSTING PRODUCTION AMAZON FILTERS LTD

Investment sets UK manufacturer on course for global growth Amazon Filters, which makes filters and housings for process industries across the world, has taken on new premises and equipment to boost production capacity. Manufacturing and delivery capability are being strengthened from this autumn with a 7,000 sq ft warehouse and office alongside the company’s main production facility. The move gives the 37-year-old firm seven industrial units in a row at the Albany Park industrial estate in Camberley, Surrey. Taking on more space is the latest stage in a substantial investment programme that has already driven innovations in production line activities including welding and the automation of cartridge pleating and assembly. A powered lifting platform was installed in 2021 to help with the welding of larger filtration housings. Providing a 1,000kg load capacity, the adjustable, motorised platform complements kit used for auto seam welding, planishing and manipulating of plate-rolled tubes. Welding processes have also been improved thanks to a large weld bay for making mobile skid assemblies. A new metalworking hub features a component shop with CNC machining and cutting cells, a press cell and a sheet metal shop. And despatch and delivery operations have been strengthened with the addition of a mezzanine platform for storage and stock control. “Our investment programme is there to underpin and increase our ‘quick and able’ manufacturing capacity and delivery capability,” says Neil Pizzey, Managing Director. “By introducing state-of-the-art production line equipment and extending our factory floor space, we can turn orders round more quickly, especially larger ones,

of senior in-region business development managers for both the Asia-Pacific territory and the Americas.

We now expect to double our capacity for pleated filters to support our reach into global markets. and take the opportunity to target specialist sectors that previously would have been out of scope. We now expect to double our capacity for pleated filters to support our reach into global markets. “Investment in manufacturing here in the UK complements our recent appointments

“This is all about improving our ability to service an ever-growing list of global industries that rely on processing engineering and high-quality filtration for critical liquid and gas applications. “They include municipal water, the oil, gas and renewable energy sectors, food and beverage, and the manufacturing of biopharmaceuticals, chemicals and liquid coatings. “In terms of geography, we are now doing far more business in sales territories beyond our traditional heartlands of the UK and Europe, so strengthening our presence in new markets makes a lot of sense.”

For more information, visit www.amazonfilters.com or call 01276 670600.

PECM Issue 59

FIRST CLASS SERVICE WORLD CLASS FILTERS

PROCESS FILTRATION SPECIALISTS Amazon is a manufacturer and global supplier of a comprehensive range of microfiltration filter cartridges and filter housings for critical liquid and gas applications in various industries.

Trusted

Innovative

Expert

Quick & Able

Bringing quality & security to customers globally

Process filtration We know how

Supplying innovation not commodities

Manufactured & delivered when needed

Amazon filters Ltd.

Albany Park Estate, Camberley, Surrey, GU16 7PG, ENGLAND Tel. +44 (0) 1276 670 600 Email. sales@amazonfilters.co.uk Web: www.amazonfilters.com

EDITOR’S CHOICE

SMART AIR INJECTION Case Study

SEEPEX

SEEPEX SAI optimises dewatering plant Scottish Water’s Kinneil Kerse WwTW produces an estimated 4,701 tds of dewatered sludge which is conditioned with lime for use as fertiliser on land. The sludge operation at this site has been funded and is operated by Veolia who are contracted by Scottish Water. In 2021, as part of a modernisation project delivered by Veolia, two competitor’s progressive cavity (PC) pumps were installed to feed dewatered sludge into a SEEPEX lime mixing pump.

HTU for Cyclic Pressure Testing Appli

CONVENTIONAL: Piston or progressive cavity pumps – shown below, as well as chain, belt or screw conveyors.

SEEPEX’s Smart Air Injection vs Conventional Technologies

The Department of Civil and Structural Engineering at The Univ Discharge pipework High pressure and reservoir unit that was remains full able to deliver the pressure and flo High energy consumption Blockages After a short search online, they discovered through the Cat Pum was the only suitable solution for their cyclic pressure testing app

Dewatered sludge

Our customer explains the application: Lubricant

“The HTU will form part of a system which will be used for fatigue

of water distribution pipes. Specifically, the HTU will supply wate pressure to a separate system of valves. These valves will alterna STATE-OF-THE-ART HANDLING OF DEWATERED SLUDGE water pressure in the pipe specimen between the HTU supplied SMART AIR INJECTION: SEEPEX progressive cavity (PC) pump and compressor using dense phase conveying and near-atmospheric pressure. This system is designed to have a m operating pressure of 20 MPa and a loading frequency of 3 Hz. The MB Air Systems test unit would effectively be operating as a constant pressure su compressor

Low discharge pressure Discharge pipework emptied at shutdown

BLOCKED PIPEWORK AFTER COMMISSIONING

Excellent energy efficiency Controlled air flow Minimum air consumption

The HTU from Cat Pumps is a robust compact mobile high-pressu high-pressure pump and motor/gearbox assembly. An inbuilt 50 p After commissioning turn feeds a high-pressure distribution manifold, which incorpora the new pumps, the site gauge. The HTU has an inbuilt pressure relief valve that will preven began to experience An incorporated pressure release valve allows the pressurised w regular blockages in the SEEPEX PC pump handling dewatered sludge discharge pipework which pressure test has been completed. The HTU benefits from corrosio affected feeding the it practicaldowntime in most settings. It is highly reliable and low en and maintenance pressure requirement than conventionalmakes reducing lime mixing process and Lubricant costs. an easy to service pump, which is backed by availab technology. from having sludge disposal. To clear the blockages the pipework had to be dismantled service information, helping to minimise system down time. and the site incurred additional costs associated with the hire of a mobile lime dewatering unit. Veolia approached SEEPEX for a solution. After assessing the installation, it was clear that the high friction losses generated when pumping 22-25 % DS sludge through 55m pipe length with a 3m. elevation including 3x 45° and 5x 90° bends were affecting the pumps’ performance. To address this, SEEPEX offered a trial for their Smart Air Injection (SAI). SAI is an energy efficient system that combines a SEEPEX open hopper progressive cavity pump with pneumatic dense phase conveying technology. The system is able to transport 16-40% DS dewatered sludge up to 1,000m. with a lower operating

BLOCKAGE FREE SOLUTION FOR SLUDGE CAKE TRANSFER

Commenting on this project, Veolia said: “We were very happy to work with Our customer advised: SEEPEX to get this SAI system installed. It SEEPEX UK installed and commissioned given our site a solution to a difficult the trial SAI system to demonstrate its Cat has Pumps provided excellent support in selecting the pump and issue and resolved Webeing use this system with the availab effectiveness. Within the first 30 minutes offor my application whileit.also compatible daily and it is beneficial to our day to day operation, SAI had cleared out all existing working environment.” blockages and continued to perform.

“

SEEPEX retrofitted the SAI system to the COMBINED SERVICE AND SUPPORT competitor’s equipment. This included: Case Study Specifications SEEPEXApplication and MB Air Systems have joined SEEPEX SAI controls and MB Air Systems’ forces to deliver mission-critical, energyHTU E22488 compressor and air receiver, both efficient and market-leading technology companies being part of Ingersoll Rand.Cat Pumps Pump Model: 5CP41110CSS for conveying applications. Our conveying

systems are fully supported Pressure: 200 barby a trained The SAI system has proven to be robust team of Field Service Engineers for 6.8 aftermarket l/min and reliable overcoming the existing Flow: service, installation and pumps’ performance issues, enabling Fluid: support. Together weWater offer our customers the sludge to be processed for land our combined experience and technical Ambient disposal. In addition, SAI enables the Temperature: expertise, providing one interaction point discharge pipework to be emptied when Drive: and one contract – for 3 kW 230V 50Hz Single Phase a streamlined idle, removing the risk of blockages, thus project.

For further information, please visit www.seepex.com

PECM Issue 59

For more information on HTU, call us on 01252 622031 or visit w CAT PUMPS (U.K.) LTD.

from having an easy to service pump, which is backed by availability of replacement parts and oil, as well as relevant technical service information, helping to minimise system down time.

EDITOR’S CHOICE

Our customer advised:

HTU for Cyclic Pressure Testing Application

“Cat Pumps provided excellent support in selecting the pump and motor combination that provided the performance needed for my application while also being compatible with the available power supply.”

The Department of Civil and Structural Engineering at The University of Sheffield Case Study Application Specifications were looking for a complete pump, motor, HTU E22488 and reservoir unit that was able to deliver the pressure flowrate required for their cyclic Cat Pumps Pump Model: and 5CP41110CSS pressure testing experiment. Pressure: 200 bar After a short search online, they discovered Flow: 6.8 l/min through the Cat Pumps (U.K.) website that the Fluid: Cat PumpsWater Hydrostatic Test Unit (HTU) was the Temperature: only suitable Ambient solution for their cyclic pressure testing application. Drive: 3 kW 230V 50Hz Single Phase

lication

Our customer explains the application: “The HTU will form part of a system which usedlooking for fatigue of water will be the water pressure in the pipe specimen versity of Sheffield were for testing a complete pump, motor, For more information on HTU, call us on 01252 622031 or visit www.catpumps.co.uk/engineered-packages/htu.asp distribution pipes. Specifically, the HTU will between the HTU supplied pressure and owrate required for their cyclic pressure testing experiment. CAT PUMPS (U.K.) supply LTD. water at a set pressure to a separate near-atmospheric pressure. This system FLEET BUSINESS PARK,that SANDYthe LANE,Cat CHURCH CROOKHAM, FLEET, HAMPSHIRE GU52 8BF, ENGLAND mps1(U.K.) website Pumps Hydrostatic Test Unit (HTU) system of valves. These valves will alternate is designed to have a maximum operating P: +44 (0)1252 622031 • F: +44 (0)1252 626655 • sales@catpumps.co.uk • www.catpumps.co.uk pressure of 20 MPa and a loading frequency plication. 22165 PN 99APPUK017 Rev A 2/22 of 3 Hz. The hydrostatic test unit would effectively be operating as a Pump System constant pressure supply.” Pressure regulator with variable pressure setting

e testing er at a set ate the pressure maximum hydrostatic upply.

Test pipe, volume 1to 4 litres

Pump

Water reservoir at atmospheric pressure

”

3 position direction control valve, switching between high pressure and atmospheric pressure to product 5 Hz cyclic pressure in pipe Pressure vent line

The HTU from Cat Pumps is a robust compact mobile highpressure system utilising the highly reliable and long-lived Cat Pumps high-pressure pump and motor/ gearbox assembly. An inbuilt 50 litre water supply tank feeds the high-pressure pump, which in turn feeds a high-pressure distribution manifold, which incorporates a pressure regulator and an easy-to-

read calibrated pressure gauge. The HTU has an inbuilt pressure relief valve that will prevent the unit from achieving pressures exceeding the system design. An incorporated pressure release valve allows the pressurised water to be released back to the supply tank after a hydrostatic pressure test has been completed. The HTU benefits from corrosion resistant wetted components and hoses. Its low noise operation makes it practical in most settings. It is highly reliable and low energy consuming. A great feature for the HTU is that it benefits from having an easy to service pump, which is backed by availability of replacement parts and oil, as well as relevant technical service information, helping to minimise system down time. Our customer advised: “Cat Pumps provided excellent support in selecting the pump and motor combination that provided the performance needed for my application while also being compatible with the available power supply.”

www.catpumps.co.uk

ure system utilising the highly reliable and long-lived Cat Pumps litre water supply tank feeds the high-pressure pump, which in ates a pressure regulator and an easy-to-read calibrated pressure nt the unit from achieving pressures exceeding the system design. water to be released back to the supply tank after a hydrostatic on resistant wetted components and hoses. Its low noise operation The HTU from Cat Pumps is a compact mobile high-pressure system utilising nergy consuming. A great feature for the HTU is that it benefits the highly-reliable and long-lived Cat Pumps high-pressure plunger pump. bility of replacement parts and oil, as well as relevant technical

High-Performance Pressure Testing

Typical Features: • Cat Pumps high-pressure plunger pump • Pressures ranges up to 689 bar • Choice of three-phase or single-phase motor nd motor combination that provided the performance needed • Pressure regulating valve • Pressure relief valve ble power supply. • Calibrated pressure gauge • Pressure release valve • 25 or 50 litre plastic water tank

”

Benefits: • Highly reliable, low energy consuming, easy to service pump • Corrosion resistant wetted components and hoses • Low noise operation • Mobile and compact design • Robust frame design Model shown is for illustrative purposes only. • Sturdy wheels

Actual unit may vary significantly depending on customer specification.

Cat Pumps – Protecting Your Pumping Systems

www.catpumps.co.uk/engineered-packages/htu.asp

Issue 59 PECM

EDITOR’S CHOICE

HUCK FASTENERS ®

STAR FASTENERS

An Array of Solar Fastening Solutions With a recent drive in the industry to move towards more sustainable methods of energy and power generation such as solar, fasteners are often overlooked in the design process, despite playing a crucial role in connecting multiple components. Here, Star Fastenings outlines its range of Huck® fasteners specifically designed to withstand the harsh environments in solar applications and why architects and fastener suppliers should be ready with solutions now. Efficient and effective technologies are key to the successful integration of renewables; to ensure affordability, cost-effectiveness, as well as the continuity and security of our energy supply and grid stability. The durability and reliability of solar structures is of paramount importance. Fasteners play a crucial part in the overall success of a project frequently connecting multiple components to create securely fastened joints. These connection points need to be sturdy enough to transmit both static (snow), and dynamic loads (wind). Wind and vortices that introduce energy to the solar array at just the right frequencies can create dynamic loads that can quickly overwhelm the system, causing catastrophic failure. The solar sub-frame, racking and tracking assemblies are important components as they provided the core structure and strength and are often subjected to great stresses and strains. They must survive years of environmental exposure without compromise in performance, any effect on the structural integrity can mean many hours of lost energy production and costly repairs. Often, the most vulnerable point on a design is where there is an interface or join between components. Nuts and bolts have over centuries been used in wide range of applications, both intricate assemblies through to mammoth installations. Bolted joints are designed to achieve a specific tension. The bolt acts as a spring to generate and retain preload in the joint. If the bolt is not stretched or elongated correctly by both the tool and the operator, targeted preload cannot be achieved and maintained. Even when installed and

PECM Issue 59

PV Fastening options

Huck® BobTail® - Unmatched installation speed - less than 2 seconds per fastener - Five times the fatigue strength of conventional nuts and bolts

- No pin break required for installation, leaving no corrosion-prone area of bare metal - Unmatched level of vibration resistance - Can be pre-assembled by hand to lightly assemble the structure, then finally swaged with the installation tool.

Self-Grounding BobTail - All of the features of the standard Bob Tail plus self-grounding capabilities - Eliminates the need for complex grounding assemblies - reducing inventory, installation time, and costs - Simple visual inspection confirms proper installation

Magna-Lok® Hole Filling Structural Blind Fastener - Complete hole-filling rivet (CHFR) specifically designed for solar application moisture resistant - Wide grip range accommodates large variations in joint thickness - Unique mechanical lock ensures the integrity of the fastener in loaded conditions - Simple visual inspection confirms proper installation

Huck BOM ® - Highest strength blind oversized mechanical fastener - Used as a replacement for welding - Effective for blind-side joining applications - Vibration resistant; will not loosen over time

Huck® LockBolts®, an alternative fastening solution.

Fasteners play a crucial part in the overall success of a project frequently connecting multiple components to create securely fastened joints. checked, the installed values of the fastener can vary significantly. After installation often self-loosening takes place, this is when the threaded fastener loosens by rotation as a result of repeated slippage in the joint. Wedge washers and pre-applied high strength adhesive can often help, but these are an additional component and expense. Typically, a physical post-installation inspection is necessary to ensure that all bolts are tightened to specification, a visual check of a nut and bolt does not ensure it is correctly torqued. On a solar farm for example, there are likely to be thousands of fasteners, so additional checks postinstallation would be costly and time consuming.

There are significant differences in strength and performance between the two main types of fasteners, threaded and Lockbolts. HuckBolts® (also known as LockBolts) offer distinct advantages over traditional threaded fasteners for connecting permanent PV racking system joints. Huck fasteners are precision-engineered to deliver unmatched installation speed, fatigue life and vibration resistance, tested and proven in solar arrays around the world. Known for their industry-leading shear and tensile strength, HuckBolts deliver consistent clamp at every point of any installation. They have been designed to be tamper proof for an additional measure of security for valuable PV panels.

Huck LockBolt Installation HuckBolts such as BobTail® consist of two parts, a pin, and a collar, but use an entirely different installation method to nuts and bolts. During installation the direct metalto-metal contact of the hardened metal pin and the swaging of the collar into the pins locking grooves, eliminates the loosening effects of transverse vibration. Specially designed installation tooling (driven by pneumatic, pneudraulic or battery power) is used to install the fasteners.

Agricultural Solar Barn Recognising the cost associated with assembly time, HuckBolts installations are extremely fast; typically, just two seconds. The time saving by utilising HuckBolts is significant when considering the large number of potential fastening points. It could be argued that the cost of the HuckBolt fastener and installation tools are more than those of a nut and bolt, but when considered, the high fatigue strength of HuckBolts means that fewer are needed. Joint integrity is not compromised, and overheads are quickly saved in other areas. Post-installation, HuckBolts only require quick visual inspection, saving even more time and cost.

Structural Integrity: Consistent, High Clamp Force Each HuckBolt performs identically in terms of strength and clamping force. Unlike other mechanical fasteners a HuckBolt’s clamping force is determined by the by the stretching of the pin and swaging the collar into the pins locking grooves during installation.

HuckBolt Key Benefits Irrespective of whether threaded fasteners or HuckBolts are chosen, the most effective method to prevent self-loosening is to ensure that the mechanical properties of the joint are correctly determined and that there is sufficient clamp force present on the joint interface; it must be enough to resist the applied loading and prevent the joint from slipping. However, by installing

Aeres Green High School, Almere Amsterdam HuckBolts, an engineer can count on many benefits including: • Will not loosen even under extreme vibration. • Maintenance free joints – no need to torque or re-torque. • Lower lifetime total cost of joint - high shear and tensile strengths for increased joint fatigue life. • High speed, easy to install systems can reduce production time by 75%. • Improves health and safety - replace welded joints. • Tamperproof – once installed cannot be removed without specialist tooling. Love or loath then, solar panels are definitely the way forward, whether that is in the form of huge solar farms, or as part of the architectural landscape. Where

space is at a premium, placing solar panels on rooftops or more visible areas such as facades is going to be a necessity. Conventional ways of fitting and fastening solar panels will be challenged, buildings of the future will be at least in part, solar architecture buildings. The future strategy of solar is dynamic, and it’s a great time to explore how Huck fastening technology can become a component of solar design of the future. Specialists in the supply of Huck Fasteners, Star Fasteners are proud to be the UK’s largest Huck fastener distributor. Working with a diverse range of end users and distributors from across a wide variety of industries. We are also an accredited Huck tool service and repair centre; expert technical knowledge and a large tool hire fleet complements our service.

Tel: +44(0)1159324939 | Email: Sales@starfasteners.co.uk | www.starfasteners.co.uk Issue 59 PECM

EDITOR’S CHOICE

PRODUCT HIGHLIGHTS FPT INDUSTRIAL

ePowertrain plant opening and other product highlights

FPT Industrial has inaugurated its new ePowertrain plant, the carbon-neutral site fully dedicated to the production of electric axles for heavy commercial vehicles, electric central drives, and to the assembly of battery packs for light commercial vehicles and buses. Electric Axles for HCV - eAX 840-R. Designed for Nikola Tre, engineered for customers’ needs Installed for the first time on the Nikola Tre BEV, the eAX 840-R is a dual-eMotor axle for vehicles up to 44 tons GCVW (Gross Combined Vehicle Weight) which guarantees high performance and efficiency, reliability, and low TCO, with long oil change intervals and a rated service lifetime of up to 1,200,000 km. LCV Central Drive - eCD 140. Integrating an electric drive system into existing conventional vehicles FPT Industrial’s engineering team has designed a lean, integrated central drive system for light commercial vehicles and minibuses in order to guarantee easy

integration into existing platforms. For rear-wheel drive applications, as with all Brand products, the eCD 140 is extremely durable, efficient, and reliable (up to 350,000 km, with lifetime oil fill). Battery packs Thanks to the company’s know-how and its partnership with Microvast, a market leader in ultra-fast-charging, long-life battery power systems, the Brand has started battery pack development and production for commercial vehicle, minibus, and bus applications, featuring multipack options for both goods and people transport missions. eBS 37 - Battery pack for zero-emission urban mobility The 37 kWh FPT Battery Pack for LCV and Minibus applications is a modular battery pack that incorporates Microvast cells and modules with unique lithium-ion technology offering impressive energy density and depth-of-discharge (95%), with advantages in terms of reduced battery weight. Thanks also to NMC (Lithium Nickel

Cobalt Manganese) technology, the most high-performance solution to date (for commercial vehicle applications), the eBS 37 offers quick charging/discharge times. The high flexibility due to in-house BMS and modular solutions makes FPT battery packs adaptable to individual mission requirements. eBS 69 - Battery pack for zero-emission people transport The 69 kWh FPT Battery Pack for bus applications is a modular battery pack that incorporates Microvast cells and modules with unique Lithium-ion technology offering impressive energy density, for best-inclass performance in city bus applications. Thanks also to NMC (Lithium Nickel Cobalt Manganese) technology, the most versatile, powerful, and high-performance solution to date, the eBS69 offers quick charging/discharge times. Once again, the high flexibility due to in-house BMS and “modular” solutions makes FPT battery packs adaptable to different applications, from city to intercity Buses.

For further information, please visit www.fptindustrial.com/global/en

PECM Issue 59

EDITOR’S CHOICE

LensConnect … Zoom, Focus & Iris remote-controllable from PC Introducing the award-winning computar LensConnect Series

Precise adjustment of Focus & Iris USB connector standard Inspection while moving focus

• Easy Installation • High Resolution at any position • Superb stopping accuracy

• Outstanding repeatability • Low voltage and current • Superior and versatile interface

Connection Diagram

computar-global.com catalyst of optics

info@cbcuk.com 020 8457 2618

ViSWIR … Bringing Visible & SWIR into Focus Introducing the award-winning Computar ViSWIR-Series

ViSWIR Hyper APO Features: • Capable of fully corrected focus shift in visible and SWIR range (400nm - 1700nm) • Achieves spectral imaging with a single sensor camera by simply syncing the lighting • Floating design adjusts focus for different wavelengths • 8mm, 12mm, 16mm, 25mm, 35mm* and 50mm* (*2023)

ViSWIR Lite Features: • High transmittance at whole wavelength of 400nm - 1700nm by adopting hyper wideband AR coat • Outstanding cost-performance for single-wavelength lighting & narrow-band imaging • Compact design • 5mm, 8mm, 12mm, 16mm, 25mm, 35mm, 50mm

computar-global.com catalyst of optics

info@cbcuk.com 020 8457 2618

EDITOR’S CHOICE

A TRUE WARRANTY WILKINSON STAR

JASIC 5 Year Warranty Charter on all models There is no compromise on the quality of JASIC equipment..such is our confidence in this technology we can offer an unparalleled 5 year ‘true’ warranty on all models. Jasic’s manufacturing site is over 80,000m2 and is arguably the largest and most modern inverter manufacturing base in China.

team of technicians in our JASIC Technology Centre. • We have the facility to test products extensively on load banks and can validate machines to certification requirements.

How do Wilkinson Star provide such an industry leading product guarantee?

EQUIPMENT QUALITY WE ARE SERIOUS ABOUT PRODUCT QUALITY. SOUND PERFORMANCE AND RELIABILITY IS WHAT YOU CAN EXPECT FROM JASIC PRODUCTS

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• The manufacturer has invested millions of dollars into cutting edge integrated test laboratories on site – JASIC undergoes 42 individual tests to meet high quality standard.

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• If required, Wilkinson Star will arrange at its expense to collect and return your JASIC product to carry out service or repair in our workshops

• Jasic’s 4 centre strong R & D facilities has been ranked as the most progressive facility along with being the first welding laboratory awarded UA certification by China from TUV Rhineland.

BE VIGILANT WHEN PURCHASING EQUIPMENT WITH EXTENDED WARRANTY

UNPARALLELED AFTER SALES SUPPORT

JASIC’s warranty is a true 5 years; this means a problem at 6 months, 3 years or 4 years 11 months is treated with the same level of care.

NO OTHER DISTRIBUTOR CAN MATCH US ON THE LEVEL OF SERVICE FACILITY INVESTMENT MADE IN THE UK • Wilkinson have 50 years’ experience in servicing welding equipment. Our state of the art service workshop facility and our 16 strong after sales service team offer the most recognised technical support in the welding industry. All equipment is fully supported by Wilkinson Star trained technicians. • No other UK wholesaler can repair inverter boards to component level. At Wilkinson Star we have a dedicated

WITH JASIC 5 MEANS 5

CUSTOMER CONFIDENCE CARE IS OUR BYWORD AND YOUR PRODUCTIVITY IS OUR PRIORITY • We provide a dedicated technical support line which you can call for any technical support queries

No extensions. No additional costs…… just 60 rolling months of product peace of mind ALL YOU NEED TO DO IS REGISTER YOUR PURCHASE AT JASIC.CO.UK FOR 5 YEARS PEACE OF MIND – IT’S REALLY THAT SIMPLE

• If on site support is needed we provide this through our highly trained technicians who cover the country • We can also interchange power sources to keep you up and running

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

PECM Issue 59

CMY CMY

The smart valve sensor with a direct link to your valve

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Simplified, more convenience: direct connection to the control valve he he MVQ201 MVQ201 puts puts an an end end to to complex complex cabling cabling and and long long cable cable runs runs :: Via Via aa separate separate M12 M12 connection, connection, the the valve valve sensor sensor has has aa direct direct connection connection to to the the actuator. actuator. The The result: result: Quick Quick and and simple simple installation installation and and reduced reduced position position data data failure. failure. Thanks Thanks to to IO-Link IO-Link technology, technology, the the valve valve can can be be controlled controlled easily easily and and directly. directly. Another Another advantage: advantage: Via Via IO-Link, IO-Link, the the MVQ MVQ constantly constantly transmits transmits position position and and diagnostic diagnostic information information from from the the valve. valve. This This allows allows condition-based condition-based maintenance maintenance planning. planning. Unplanned Unplanned and and costly costly downtimes downtimes can can be be prevented prevented efficiently. efficiently. ifm ifm –– close close to to you! you!

Go ifmonline ifm.com / uk

EDITOR’S CHOICE

CUSTOMISED POST PROCESSING 3DPRINTUK

By Nick Allen, Managing Director, 3DPRINTUK In the final article in this series on post processing, I just want to take the time to round up with some post processing options that are available for 3D printed parts that we do NOT offer here at 3DPRINTUK. In the previous article (Part 2), we focused on automated post processing solutions that support higher volumes of 3D printed parts and reducing the cost per part with quality finishes. That said, sometimes high volumes are not the prerequisite and a more customised approach is required.

PAINTING

Bespoke finishing options for single or very small volumes of parts do not fit within our remit, but for clients that want our price / quality for the production of their parts there are specialised and bespoke post processing solutions available to them. The following is not an exhaustive list, but I think

There is no getting away from the fact that the results can be absolutely astonishing, but the trade-off here is that a finish of this levels requires a great deal of time and effort per-part (not to mention mess and technical skill), whereby the outcome

PECM Issue 59

it covers the most popular bespoke post processes, namely painting, hydrographics, texturing, CNC milling / machining, electroplating.

As bespoke finishes go, painting a 3D printed part can provide a very accurate, almost “photo-realistic” finish. This is particularly important for marketing prototypes and small volume — or singular — artistic models.

is more relevant than the cost-perpart economics of mid- to high-volume production. Whichever 3D printing process you select to produce parts for painting they will require post processing to achieve the smoothest possible surface finish. This can include filling, sanding and priming the part. This is generally to remove support materials and / or refine the surface finish to smooth it and/ or eliminate any defects present on the surface of the part. If you are using a filler material, some fillers do not set completely and can affect the paint. Another thing to bear in mind, is sanding a 3D printed part by hand removes material

unequally from the part, which means that the dimensional accuracy of the part can be affected. Wearing a mask is also highly recommended for sanding. Then there is the question of DIY or contract out the paint finish? The application and the required outcome will be the determining factor here. For example, for an art installation versus an architectural model. For DIY painting finishes, paint selection is important, specifically choosing a highquality acrylic paint, which can be used with a choice of brush, airbrush or spray paint. There are lots of Youtube videos out there for beginners. Alternatively, there are a range of professional services that utilise highly skilled model makers, of which there are a good number that are familiar with the specific finishing requirements for 3D printed parts. For this, you generally need to build in extra time for delivery.

HYDROGRAPHICS Also called hydro dipping or immersion printing, as its name suggests, this is a water-based surface printing technique for 3D objects that has been developed over centuries. It can be applied to 3D printed parts to produce stunning customised finishes on parts and models. It’s a bit messy

TEXTURING

As bespoke finishes go, painting a 3D printed part can provide a very accurate, almost “photorealistic” finish. and difficult to achieve standardized finishes on multiple models, but hydrographics is not really about standardisation. Any 3D printed part will need to go through the same post processing stages as for painting as outlined above to achieve the smoothest surface finish possible, plus primer. As with painting, the quality of the surface finish will determine the quality of the hydrographics, so a great deal of sanding and/or smoothing by other means is required to eliminate any supports, layer lines or rough surface. Subsequently the part is dipped in a tank of water that contains the hydrographic design using speciality inks, controlled water temperature and the application of an “activator” chemical. The results can be stunning, but again there is a time and mess trade-off.

This is a bit of a weird one — whereby textures *can* be added to 3D printed parts as a post process. But the question must be asked does it need to be done this way or can you design the required texture into the part and print it? One of the greatest advantages of 3D printing is that you can design this sort of complex detail into a part with little to no economic difference in the cost of the part. This is particularly relevant for functional textures of parts that are required for added strength, or grip, or traction etc. If the rationale is the aesthetic, again, is it possible to include in the design. For fine details and tolerances, however, sometimes the best outcome can be to apply it post build via etching, routing, or grinding methods, but these processes do add time and cost.

CNC MILLING / MACHINING This is generally a post process used for metal parts (note it can also be an alternative production method for metal parts). However, it is also possible to utilise it as a post process for polymer parts to achieve specific goals. It is not a particularly cost-effective method for finishing high volumes of parts, but can be useful for critical applications that require precise accuracy. Issue 59 PECM

Combining 3D printing and CNC machining can provide a reliable and repeatable method for achieving tight tolerances for critical specifications, for example for aerospace or medical components. For example, if a completely flat, surface to surface connection is required. Services are available for both 3- and 5-axis machining of 3D printed parts. Part complexity and the finish requirements generally tend to dictate which process is required. One important note for this approach is to build in excess material on the 3D printed part to accommodate machining down to the exact tolerances, particularly if fine features or thin walls are involved. The downside to this is additional waste material, but it is not that much different to sanding.

ELECTROPLATING / METAL PLATING This is a particularly useful finish for 3D printed polymer parts. It is a relatively complex process and requires specialist equipment and skills. However, there are a number of service providers now that have dedicated facilities to provide this solution. Most polymer materials can now

achieved by specialist companies, with an example below.

Combining 3D printing and CNC machining can provide a reliable and repeatable method for achieving tight tolerances for critical specifications be electroplated, but you should discuss material selection directly with the solution provider. Electroplating offers a realistic metal finish that can provide the benefits of both plastic and metal including added strength and reduced weight. In addition, electroplating protects polymer parts against corrosion, improves electrical conductivity and reduces friction. The aesthetic finish is generally excellent. An alternative solution to full electroplating to achieve the look of metal is metallic spraying. Again, this can be

ROUND UP To round up this series of articles on post processing, it seemed fitting to provide insight into alternative solutions that are available for a more customised approach to 3D printed parts — even though that’s not our thing. The over-arching aim of the series has been to provide 3D printing users, whether in-house or contracted out, with a comprehensive resource when it comes to post processing, the pro’s and cons and the options available. As ever, the choice will come down to the application and the dominant requirements to fulfil it in the most time- and costeffective way. If you want to discuss any post processing requirements for medium and higher volumes of parts, reach out to our technical customer service team today.

For further information, please visit www.3dprint-uk.co.uk

PECM Issue 59

EDITOR’S CHOICE

Specialist Training for the Storage Tank Industry Live online, classroom, in-house or e-learning • • • •

Gain or renew your 5-year Certificates of Competence* Courses based on EEMUA 159 English, Dutch, German and French language options Select from courses throughout 2022 and 2023, including:

TankAssessor courses*

TankInspector courses*

14-18 November 2022 – in English – live online 23-26 January 2023 – in English – classroom – Manchester, UK 6-9 February 2023 – in Dutch – live online 27-30 March 2023 – in French – classroom – Près de Paris, FR 24-27 April 2023 – in German – classroom – Hanover, DE

7-10 November 2022 – in English – live online (for CST, Americas)) 28 November - 1 December 2022 – in English – live online

Above ground flat bottomed storage tanks A guide to inspection, maintenance and repair

Publication 159 Edition 5

TankIntro courses 12-14 December 2022 – in English – live online

Storage Tanks e-learning On-demand – in English and in Dutch

Storage Tanks Seminar 24 November 2022 – in English – Chester, UK

More choices, information and registration at www.eemua.org and events@eemua.org

The new Tricor PRO Plus Series

The new Tricor PRO Plus Series of Coriolis Mass Flow Meters is an accurate and highly repeatable meter with the smallest installation length on the market for installation into systems where space is limited. The TCD transmitter offers greater robustness, performance, diagnostics, and connectivity options. With a modern HMI interface and excellent logging functionality, the DSP transmitters provide users with an efficient configuration and analysis tool. PRO Plus Series Features: • High dosing accuracy due to short response time (max. 10 ms) • 100 Hz refresh rate makes this series suitable for pump monitoring and fast response control • Extremely short installation length makes for an easy fit in most configurations • Excellent zero stability for drift-free accuracy and longterm reading assurance

• Extensive diagnostics and self-monitoring, including empty pipe detection Sizes from ½” to 2”. Available for Litre Meter, call 01296 670200, now. www.litremeter.com

Issue 59 PECM

EDITOR’S CHOICE

SUSTAINABLE SOLUTIONS SUNCOMBE

Continuous innovation to meet latest bio-waste treatment needs “There are no shortcuts in bio-waste treatment,” asserts Steve Overton one of the directors at Suncombe, which recently celebrated 60 years of supplying cleanin-place (CIP), bio-waste treatment and control systems to its global customer base. “But it is no longer enough to ensure the equipment meets all the rigorous safety and bio-hazard regulations, it must also offer more sustainable and flexible solutions,” he says. So Suncombe has and continues to undertake the continuous development of its cleaning and critical process systems. These include PureVessel™; Containerised EDS; MicroEDS™; and a range of Utility Panels. Here we take a quick look at these recent innovations. PureVessel is a range of systems for sanitary and sterile liquid storage, preparation, thermal treatment and mixing, typically required in the biopharma sector, laboratories and research institutes. These systems have been developed to operate within the Hybrid bioprocessing model, in which a bio processing facility employs a combination of single use technologies (SUT) and stainless steel multi use equipment. There are advantages in employing re-usable stainless steel equipment. The company has developed a pre-validated combination of PureVessel.

PureVessel

PureCIP™ or MobileCIP® can be individually ‘plugged’ into the automation system, allowing the CIP/SIP to recognise the PureVessel being cleaned and select the optimum cycle. Containerised EDS systems were developed at the height of the Covid-19 pandemic. These high specification biowaste effluent decontamination systems (EDS) were designed, built and commissioned in an extremely short timeframe to help expand the vaccine production programme at a global manufacturer. Normally vaccine production areas require a dedicated EDS for BSL3 biowaste, housed within secure containment rooms. However, due to the fast-track nature of this project, there was no time to build these. So Suncombe developed EDS which could be mounted in purpose-built containerised modules, with full containment barriers built inside. These modules also incorporate many features, to meet essential requirements for a BSL3 biowaste treatment system MicroEDS is a low volume biowaste decontamination system for treating BSL 1, 2 & 3 waste using an innovative batch process allowing positive release of all of waste. A buffer vessel is used to provide a centralised collection facility, while a set volume batch heat treatment facility is used to treat the effluent in batches at variable settings. The MicroEDS has been specifically developed to fit into new facilities or to be retrofitted into existing facilities and is designed to operate from a single 13 amp 230 Vac plug (150 and 300 versions) using established electrical heating technology.

MicroEDS Suncombe was one of the world’s first manufacturers of Utility Panels. These, custom designed panels are used for service entry, utility entry, CIP and SIP routing and also for utility piping and control, outside of the clean area. This enables the removal of equipment and instruments from the production areas, locating them in service areas to provide additional production area space and allow remote maintenance. “With all these innovations we are enabling our clients to meet modern production challenges and, through improved design and control systems, meet environmental targets by increasing efficiency and better water and energy use. It is no longer just about the best treatment solution, but also about how we go about that and the flexibility we can bring to the processes we provide,” explained Steve Overton.

Containerised EDS For further information, please visit www.suncombe.com

PECM Issue 59

Mobile Vessels Utility Panels Solution Preparation Skid Recovery Cleaning in Place Static Cleaning in Place Mobile Cleaning in Place Chemical Storage & Distribution PH Neutralisation GMP Pre-fabricated Pipework

SUNCOMBE

PRODUCT PORTFOLIO

Static Vessels Mixing Vessels GMP Process Systems Biowaste Decontamination Continuous Biowaste Decontamination

USP Water Storage & Distribution Containerised Process System Batch Biowaste Decontamination

External Chemical Storage & Distribution Hot Water Skid Hose Washer Ultrasonic Washer IBC Wash Station

GMP Parts Washers Drum / Pallet Washer IBC Wash Booth

Immersion Washer

• Engineering Excellence since 1961 • One of the originators of Cleaning In Place in the United Kingdom in the 1950s • Pioneers of Hygienic Processing, Effluent Treatment, Washing, Cleaning & Sterilising • Worldwide network of sales and service agents • UK Design and Manufacture to CE, cGMP, ASME BPE, EHEDG, GAMP, ATEX, FDA • In-house personnel for all disciplines • Motivated, dedicated and experienced Long Term Workforce • Single point of contact for all aspects of a Project

w w w. s u n c o m b e . c o m

EDITOR’S CHOICE

INCREASED FLEXIBILITY SUNCOMBE

Sustainable Water Heater Adds Electric Functionality Suncombe – the critical process systems specialists, has announced the global release of the updated GMP Water Heating Skids incorporating the option to provide electrical heating utility in addition to steam and oil. The increased flexibility of the system enables its use in further GMP areas in the biopharma sector and other critical processing sectors. Following extensive work with blue-chip clients and sector partners, who requested the ability to incorporate sustainable technologies in their water heating applications, Suncombe offer options to incorporate electrical heat pumps, regeneration and recovery heating to achieve corporate sustainability goals. With variable temperature settings up to 125°C and flowrates of 1,000 litres per minute or more, the versatile control system allows configuration of temperature controlled, regulated flowrate and pressure during heating, storing and distributing of hot water for process and utilities. Encompassing traditional and innovative processes and technologies, the updated GMP Water Heating Skids incorporate an advanced control system built to GAMP guidelines, with 21CFR part11 compliance with audit trails and user access controls by passwords. Designed to comply with ASME BPE (Bioprocessing Equipment), the international standard for the design and construction of equipment intended for use in the manufacturing of biopharmaceuticals, they include compliance with the 2D deadleg rule, full drainability, full traceability and are suitable for validation. The GMP Water Heating Skids, with capacities varied to suit a wide range of hot water supply applications, are equipped with controls and interlocking functionality to ensure water supply is constantly maintained at the required quality. HEPA sterile filters are incorporated to ensure that water quality is maintained in the system envelope.

Fully certified, the cGMP designed systems comply with all legislative and safety standards. Available in standard or bespoke versions, they are highly efficient and incorporate GAMP, ASME BPE, FDA and ATEX guidelines. Commenting on the worldwide release of the system, Suncombe director Steve Overton said, “The GMP Water Heating Skids are able to provide a comprehensive and validatable water heating, storing and distributing solution. To meet and comply with all the relevant international standards, requirements are assessed for each project

individually, making it highly accessible to all parts of the world.” Developed to incorporate “Lean Manufacturing Principles” ensuring that waste is minimised and efficiency is maximised, GMP Water Heating Skids are manufactured from 316L certified stainless steels and incorporating high quality components. The units can be fully thermally and chemical decontaminated for maintenance and the maintenance operations have been incorporated on the system display screens (HMI – Human Machine interface).

For further information, please visit www.suncombe.com

PECM Issue 59

EDITOR’S CHOICE

When managing real pressure is your job… MIPC® helps practitioner-level engineers stay on-site and on top of the latest industry developments and good practice in primary containment of hazardous substances.

MIPC® shortlisted for the Best E-learning/ Online Education Initiative memcom membership excellence awards 2020 and 2022

Using a blend of live, online classes, one-to-one sessions with expert tutors, and e-learning, enhanced by a mentor’s support and guidance, EEMUA’s Mechanical Integrity Practitioner Certificate course delivers in-depth training to engineers where they work – to give professionals the flexibility to learn on-site or on-call. Induction of 2 hours to suit your schedule from November 2022 adapts coursework to your site/s needs. Learning starts in January 2023.

Registration open now.

For more information please contact EEMUA online-learning@eemua.org +44 (0)20 7488 0801 www.eemua.org

1982 – 2022 Celebrating 40 Years of Premier Coatings Ltd Premier Coatings Ltd are proud to be celebrating 40 years of trading this year. Founded in 1982 and operating from Smarden in Kent, Premier Coatings Ltd specialise in the manufacture and supply of a wide range of corrosion prevention and chemical resistant coatings, linings, and waterproofing systems. The company supplies reliable and cost-effective products to the Oil & Gas sector, Utilities sector, and construction industry. Their Products are supplied to a variety of National, ISO, and commercial standards. The Premseal™ range of waterproofing and gasproofing products are CE and UKCA marked, and the company operates under ISO 9001:2015 and ISO 14001:2015 quality and environmental management systems. In 1997 Premier Coatings Ltd was acquired by anti-corrosion and sealing specialist Winn & Coales International, where it continued to prosper and in 2017 achieved a Queen’s Award for Enterprise: International Trade. Steve Crawley, Managing Director of Premier Coatings Ltd commented, ‘This major milestone of 40 years could not have been achieved without the support of our employees, distributors, clients and the continual development of the company and its products. We are proud of our past and look forward to an exciting and successful future together.’ The 40-year success of Premier Coatings Ltd is a story of technical expertise coupled with high-quality, long-lasting products underpinned by continued investment in new manufacturing methods and technology.

www.premiercoatings.com

PECM Issue 59

EDITOR’S CHOICE

Agreement with South Korean distributor enhances Lanemark Combustion Engineering capability Process gas burner specialist, Lanemark Combustion Engineering Ltd., is announcing a major agreement with a new distributor in South Korea. The link with Shinsung Ener-Tech Co., Ltd., based in Seoul, South Korea will create opportunities for both organisations in one of the most active markets in the region. “Shinsung is very well established in the field of HVAC and process burners which are used within a variety of applications,” says Jeff Foster, Sales Director at Nuneatonbased Lanemark. “We share a commitment to quality, efficiency and environmental optimisation so are confident that, jointly, we can bring proven performance and key benefits to the regional customer base.” The agreement with Shinsung is set to strengthen Lanemark’s own burner sales in the new distributor’s markets. The company’s (TX) tank heating burners, (FD) forced-draught oven burners, (FDB) forced-draught duct burners and its (DB) duct burners – each used extensively in processing and manufacturing operations from aluminium anodising to food processing – will, in turn, all enhance Shinsung’s own market strength.

“We are committed to building on the close relationships that we have with distributors around the world, and we are, therefore, delighted to be able to add Shinsung to this list,” concludes Jeff Foster, Sales Director

at Lanemark. “The area within which both companies have developed leading reputations is highly specialist so we are confident that the link between us will offer major gains to our respective customers.”

www.lanemark.com

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 process air heating burners.

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

• • •

Midco HMA high efficiency,

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

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Issue 59 PECM

Curtiss-Wright Surface Technologies, Everlube products & Coating Services Protection & life extension of your critical components throughout any crisis!

COATING SERVICES: l l Thermal Thermal Spray Spray && HVOF HVOF Coatings Coatings PTFE, l l Dry Dry film film lubricants lubricants -- MoS MoS22,, PTFE, Graphite, Graphite, WS WS22 l l Coatings Coatings for for corrosion, corrosion, chemical chemical && environmental environmental protection protection l l Titanium Titanium anodising anodising l l Zinc Zinc rich rich coatings coatings for for corrosion corrosion protection protection l l Impingment Impingment coating coating processes processes for for ultra ultra thin thin solid solid film film lubricants lubricants l l Nonstick/release Nonstick/release coatings coatings for for low low coefficients coefficients of of friction friction l l Primers Primers for for rubber rubber and and plastics plastics for for sound sound absorbing absorbing and and dampening dampening materials materials l l High High temperature temperature resistant resistant coatings coatings l l Rare Rare earth earth magnet magnet coatings coatings l l Coatings Coatings for for EMI/RFI EMI/RFI shielding shielding provide provide highly highly conductive conductive coatings coatings and and platings platings to to control control electromagnetic electromagnetic interference interference l l Ultra Ultra thin thin conformal conformal parylene parylene coating coating to to reduce reduce friction friction and and protect protect against against contamination contamination l l Pre-treatments Pre-treatments including including Ti Ti Anodising, Anodising, Phosphate Phosphate Conversion Conversion Coating Coating and and Chilled Chilled Iron Iron Blasting, Blasting, Aluminum Aluminum Oxide Oxide Blasting Blasting and and Vapour Vapour Degreasing Degreasing

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CONTROL & AUTOMATION

Go clean. Emerson’s solutions for dust collector and filtration systems provide real-time visibility and precise control to reduce downtime, energy consumption and emissions. Discover more:

The World’s Leading One Stop Shop for Collaborative Applications

HOW TO BUILD A PICK & PLACE APPLICATION Regardless of which process you want to improve, and which robot you prefer, the One System Solution helps you automate swiftly and seamlessly. OnRobot’s cutting-edge solutions and tools provide thousands of businesses worldwide with perfect versatility and ease of use. The possibilities are utterly limitless, but if you’re curious for examples, find the most common collaborative applications for pick and place projects below. There are more to be found when visiting OnRobots website.

GECKO

MG10

RG2

2FG7

2FGP20

EYES

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VG10

For more information visit our site at www.onrobot.com Or contact us at: north-europe@onrobot.com

Issue 59 PECM

CONTROL & AUTOMATION

THE NEW IRB 1010 ABB

ABB unveils smallest industrial robot with class-leading payload and accuracy

ABB has launched its smallest ever industrial robot, offering new possibilities for faster, more flexible and high-quality production of wearable smart devices. With its compact size, class-leading payload and unrivaled accuracy, the new IRB 1010 offers electronics manufacturers the opportunity to increase their production of devices including smart watches, earphones, sensors, and health trackers through automation. “The market for wearable smart devices is accelerating rapidly, with projections estimating double digit growth between 2022 and 2028,” said Rui Liang, Managing Director of ABB Robotics’ electronics business line. “To meet this growth, companies are demanding compact robotic solutions that are suited to narrow production spaces in electronics

PECM Issue 59

manufacturing lines and that can accurately handle the small components used in wearable devices. As the most accurate robot in its class for 1.5kg payloads, our IRB 1010 meets these demands, enabling companies to maximize output and productivity while maintaining the highest levels of product quality.” The IRB 1010 is designed to suit the narrow spaces and special purpose machines typical of electronics production environments. With a reach of 370mm and a footprint of 135mm by 250mm, the IRB 1010 is 30 percent smaller than ABB’s current smallest robot, the IRB 120. These compact dimensions increase the number of cells that can be fitted into production spaces, enabling manufacturers to boost output through higher density factory layouts.

Capable of handling loads up to 1.5kg, the IRB 1010 has the highest payload in its class, with the ability to lift up to three times more weight than comparable robots. This increased payload capacity – coupled with a larger diameter air hose that provides added power for vacuum suction – enables simultaneous handling of multiple objects, allowing more objects to be processed per hour. It also opens opportunities for new applications including film peeling, material handling, assembly, gluing and inspection.

ROBOT CONTROL MATE MAKES PROGRAMMING SIMPLE

The market for wearable smart devices is accelerating rapidly, with projections estimating double digit growth between 2022 and 2028.

Productivity is further enhanced by the inclusion of six braking systems, which allow the robot arm to remain in its position even when stopped. By eliminating the time needed for the robot to recover its position after a stop or pause, production can be resumed more quickly, enabling the IRB 1010 to do more in less time than other robots in its class.

small part assembly in applications where production cell sizes need to be minimized. The controller offers the flexibility to meet changing requirements, with built-in digital connectivity and over 1000 additional functions enabling easy scalability.

Key to the IRB 1010’s high accuracy is ABB’s OmniCore™ E10 controller, which offers class-leading position and path repeatability of 0.01mm. With its slimline design, the controller is well suited to

Consuming up to 20 percent less energy compared to ABB’s previous IRC5C controllers, the OmniCore E10 also enables manufacturers to cut their energy costs and improve energy efficiency.

Programming the IRB 1010 is made simple with ABB’s Robot Control Mate. Available as an add-in to ABB’s RobotStudio® programming software, Robot Control Mate enables users to move, teach and calibrate the IRB 1010 from their computer or mobile tablets without the need for programming skills. This simple programming, together with the small size of the IRB 1010, also opens new possibilities for educational applications. The IRB 1010’s compact design makes it suitable for installation on classroom desktops, while its ease-of-use enables both teachers and students to quickly master the skills needed for programming and operation. The addition of the IRB 1010 complements ABB’s comprehensive range of articulated industrial robots, with includes a full range of small, medium, and large options, including a growing family of collaborative robots that can be safely deployed alongside workers.

For more information, visit www.abb.com/robotics. Issue 59 PECM

CONTROL & AUTOMATION

SMARTIFICATION DFI

DFI’s “new Smart Factory” introduces automated equipment and improves production capacity by 30% DFI, the world’s leading brand in embedded motherboards and industrial computers, unveiled its new smart factory and invited the media to tour the plant in Taoyuan DFI’s new facility introduces multiple automated equipment. In addition to efficiency and precision, it features more rigorous manufacturing and inspection processes. Control of the manufacturing process has been enhanced, with output increasing by 30%, material mastery reaching 99.9%, and FPYR (First Pass Yield Rate) reaching 99.6%. The global pandemic and severe labor and material shortages have recently plagued the international supply chain. Corporate automation and smart production have become keys to increasing future competitiveness. DFI has transformed the Taoyuan plant into a highefficiency, high-quality, and high-material management smart factory by introducing new automation equipment. Michael Lee, Vice Chairman of DFI, stated, “a wave of new infrastructure and IoT has swept the global industry in recent years. DFI has accumulated great expertise in the embedded field. We can help customers accelerate their integration of IT and OT to improve the deployment of smart functions to respond to the rapidly changing industrial environment. We will actively face the various impacts of the postpandemic era and economic changes.” Alexander Su, President of DFI, further shared the company’s management approach. “With the trend of corporate digital transformations, DFI will implement comprehensive production and quality management through the three operating strategies of ‘smart new factory,’ ‘AIoT product lines,’ and ‘flexible and stable supply chain deployment.’ We will provide integrated solutions and realize exceptional product performance and stable supply services to create maximum customer value.”

The New Taoyuan Plant is the Face of Smartification

Creating ultra-small products and high flexibility, high stability supply chains

• Efficiency: DFI has expanded SMT production to 6 lines and has integrated high-efficiency AS/RS unmanned vehicles with an automated smart warehouse system. Results include improved material turnover efficiency by 20% and output by 30%. • Accuracy: An automated X-ray component counter was introduced to accurately count and calculate the number of parts after mounting. The smart feeder provides two pathways of smart confirmation. A production traceability system provides complete material and product traceability, increasing mastery of materials and parts to 99.9%. • Product quality: The correctness of finished parts and production quality is ensured by 2D & 3D automated optical inspection (Pre-reflow AOI/Post-reflow AOI) and X-ray inspection. A wide temperature burn-in chamber conducts aging testing according to customer needs. It can satisfy the tolerability required by various key applications, with an FPYR of 99.6%.

In recent years, DFI has actively invested in the research and development of ultrasmall motherboards and fully invested in developing Edge AI related products. We have expanded the deployment of vertical applications, such as industrial automation, Internet of Vehicles, and medical solutions. The supply of highquality products requires a firm yet flexible supply chain for support. DFI has created a stable supply chain by enhancing smart production management capabilities.

For more information, please visit: www.dfi.com

PECM Issue 59

DFI’s Taoyuan smart factory has successfully integrated the IT and OT systems. The production line’s efficiency, accuracy, and quality have been enhanced. Hybrid cloud architecture has been established, and the connectivity and correctness of the information system has been improved. Sufficient production capacity and strong performance will drive the company’s implementation of OT smart transformations.

Breaking Down Automation Barriers The World’s Leading - One Stop Shop for Collaborative Applications

Where to start your journey in Automation?

OnRobot’s solutions help small

and mid-sized manufacturers optimize their processes and grow their businesses with greater flexibility, higher output and improved quality. Regardless of the robot brand, OnRobot provides compatibility and versatility beyond compare. It’s everything manufacturers need from one supplier, providing even more value from the automation investment. OnRobot is an application provider for Cobots, which makes production more efficient and cost-effectively. When the first robot applications appeared, the advantages were quickly recognized. This made collaborative applications the fastest-growing segment of the robot market. Collaborative application solutions are fast, easy and affordable for efficient and productive processes. What does automation do other than being a productivity tool? One key advantage is that it gives the manufacturers flexibility, and this help ensure the wellbeing of the workers.

Collaborative automation keeps production running while skilled workers focus on jobs where their unique capabilities provide the most value. Automating with the use of collaborative pplications present manufacturers with new opportunities to build resilience and adaptability in productivity, competitiveness, and workforce.

The OnRobot Palletizer: The beginning of breaking down automation barriers!

It is installed with the OnRobot 2FGP20 palletizing gripper, which offers a wide stroke and customizable arms to handle heavy or open boxes, shelf-ready products, and other containers that can’t be handled with traditional vacuum grippers. The OnRobot Palletizer also contains a Pallet Station, which is a durable, floor-mounted pallet fixture that ensures consistent positioning and includes a built-in sensor for detecting pallet presence. To find out more contact us diretly of download your free eBook below. Contact OnRobot to find out more about our palletizing solutions. north-europe@onrobot.com Or visit our Learningsite on Collaborative applications know-how to all learn.onrobot.com/en

The OnRobot Palletizing, intuitive software designed to ensure fast set up, regardless of the end user’s prior robotics deployment experience. The Palletizer has a high-payload elevator with minimal deflection that ensures precise positioning of boxes, even at high speeds. Outof-the-box integration with the OnRobot palletizing solution shortens deployment time, and offers futureproof flexibility.

Be ready for the future as something big is going to happen soon!

BREAKING DOWN AUTOMATION BARRIERS ONE SYSTEM, ZERO COMPLEXITY

www.onrobot.com

Get your FREE Palletizer eBook

CONTROL & AUTOMATION

AUTOMATION SUCCESS BRILLOPAK

David Jahn, sales director at Brillopak explains why automation should not be feared and that proper planning can prevent myriad issues, while delivering significant performance increases Your investment in end-of-line automation in food packing is no longer a medium-term aspiration, it is now a short-term business imperative. And with an optimum combination of class-leading technology and a partner that understands every facet of the

evolutionary process, you can quickly reap the throughput rewards and avoid all the planning, architectural and logistical pitfalls. This push to automate is being driven by your end users; the proliferation of digital

supply chains, which thrive on end-toend operational data; labour market shortages, evolution and migration; and efficiency, agility & speed of response becoming ever-more essential metrics for your customers.

Modern packing halls require a specialist automation architect to create floor and installation plans for the packing hall to run efficiently and smoothly

PECM Issue 59

Brillopak’s automation architecture service specialises in presenting factory floor plans and equipment installation in phases for a smoother transition to creating a modern packing hall But we know that deploying automation is a big step as it can be very different to manual operations. There is also an element of perceived risk. Indeed, we’ve heard from many food processors and packers who are not fully utilising their new automation equipment, often for simple reasons that were overlooked at the planning stage. These can include simply not asking “why are we automating?”, a failure to create forwardlooking requirements plans, engineers and operators being reluctant to use more complex technology, failure to consider future business when planning and failure to involve all stakeholders. To prevent these issues, we highly recommend you partner with a manufacturer that can act as an expert guide, as you prepare and transition into automation - from planning through design, deployment, evaluation and enhancement, and onto carefully phased and fully scaled operations. There’s a lot to consider. By taking a holistic view of your requirements, your facilities, your business plan, your customers’ needs and your plant capabilities, Brillopak can help you create an automation action plan that delivers your desired improvements in operations efficiency and a quick payback. We’ve created a multi-stage agenda that captures all plant, project and business requirements and addresses many of the issues before they can even appear. These steps help users to much better understand our process. Step one is a full plant audit and

We’ve created a multistage agenda that captures all plant, project and business requirements and addresses many of the issues before they can even appear. requirements capture, where we ask the questions ‘why are you automating?’ and ‘what are your business goals, drivers and needs?’ In step 2 we look at the plant architecture to assess space, utilities, flow and potential. We then look at your packaging, in terms of the product, the package types, the primary materials and the desired throughput. We need to look at this to define the robotic systems. End-of-line packaging machine design is next, where we examine any unique product/plant/customer factors that could influence design/operation? At this and every stage the devil is always in the detail. We mustn’t forget your people. Here we will look at workforce preparation, especially at skill and staffing levels. Following this we look a little to the future and discuss what you will need in terms of maintenance and service. Once this has all been finalised we can examine the installation, test and

commissioning of your new automation solutions, where we will minimise downtime and ensure your engineering team is part of the process as early as possible. The final step is to study your future requirements and how a phased approach can take you onto the next evolutionary steps. We can look at how we can help you to enhance and grow your initial installation. Maybe add a second packer and additional conveyors and then copy this three-machine format and co-locate. At each phase we will examine the lessons learnt to define best practice for the next stage. You can grow and expand at your own pace and set operational and financial stage gates to suit your precise needs. Our award-winning robotic case-loading systems include single-system solutions and everything for end-to-end packing lines, including pack-management conveyor systems, robotic product loaders, crate de-stackers, bale arm closers and palletisers. Our team has installed over 200 systems, helping transform manual packing halls into semi or fully automated operations. Ultimately you don’t know what you don’t know. Our systems are designed with the flexibility to handle multiple product types now and into the future, to ensure that your investment today is still generating payback in 10 years’ time. If you’d like to discuss a project, please contact us at technicalsales@brillopak. co.uk or phone us a 01622 872 907 for a free consultation.

For further information, please visit www.brillopak.co.uk Issue 59 PECM

CONTROL & AUTOMATION

ROBOTIC SOLUTIONS FANUC

VW Group shows faith in FANUC with order for 1,300 robots

FANUC robots working at the Audi plant in Györ, Hungary; one of four VW sites that will benefit from the order of 1,300 new FANUC robots (Photo ©Audi)

The Volkswagen Group has placed an order with FANUC for 1,300 robots, demonstrating the strength of its relationship with the leading industrial automation specialist. Throughout 2022 and 2023, FANUC will supply four VW plants across Europe with a variety of robotic solutions to support production of both Audi and VW models. The majority of the robots will be installed at Volkswagen’s manufacturing facility in Bratislava, Slovakia. “We are delighted that we can now extend our longstanding and trusted cooperation with Volkswagen to the Bratislava plant,” says Ralf Winkelmann, Managing Director of FANUC Deutschland GmbH. As well as the Bratislava facility, the main VW plant in Wolfsburg will also receive a significant percentage of the 1,300 newly ordered robots. Volkswagen’s all-electric

Further contributing to the expansion of e-mobility, the new FANUC robots will also be installed at Audi’s battery assembly plant in Ingolstadt. ID.3 is due to roll off the Wolfsburg production line from 2023, and FANUC robots will be integral in assisting with body construction. Further contributing to the expansion of e-mobility, the new FANUC robots will also

be installed at Audi’s battery assembly plant in Ingolstadt. The fourth facility benefitting from the contract is the Audi plant in Györ, Hungary. With a 40-year history of automating production lines, a portfolio comprising over 100 models, and a monthly production capacity of around 10,000 robots, FANUC is ideally placed to supply major automotive projects on time and on budget, despite the ongoing global supply chain crisis. The company’s offering includes SCARA robots, which are in high demand for electric vehicle battery production due to their payload and proven reliability, as well as a newly launched model capable of handling loads of up to 1,000 kg, making FANUC the go-to automation partner for automotive manufacturers.

For further information, please visit www.fanuc.eu/uk/en

PECM Issue 59

ELECTRICAL & ELECTRONICS

Exponential growth at Electro-Wind Established in 1979 Electro-Wind have been designing and manufacturing single and three phase transformer products for customers in the UK, Europe, and Global Markets over the past 40 years. As a secondgeneration family owned and operated company, over the past couple of years Electro-Wind has seen exponential growth, both standard and custom-built products have proved to be in demand. With a very low staff turnover, many of the long-established team members have worked for the company for over 20 years, however the business has expanded

Jack Colclough mechanical work placement before joining Electro-Wind Alister Holmes experience came from working in Bespoke Lighting dramatically over the past few years with the addition of many new recruits. Jeff Roberts background in the electrical distribution and wholesale markets Justyna Rokita electrical assembly work and winding small to medium sized coils.

Matt Gould electrical background as a qualified Electrician Chris Ball worked in construction whilst working on an engineering qualification.

https://electro-wind.co.uk

Issue 59 PECM

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ELECTRICAL & ELECTRONICS

Confident in your changeover? Addition of an appliance inlet is the latest in our changeover switch range . Meeting the requirements of IEC60309 it allows many sockets to plug-in, making a practical & economic solution. The appliance inlet (IP67) is wired 10-2400 A to the changeover switch with tri-rated

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ELECTRICAL & ELECTRONICS

Upgraded 6 Amp Relay satisfies need for high power in miniature format 4PDT with full terminal compatibility with industry standard sockets. Exhibiting versatility, the HF18FH is available with coil voltages of 6, 12, 24 VDC, 6, 12, 24, 110 and 230VAC.

Hongfa’ s HF18FH, part of Hongfa Plug in relay range, is a 6 Amp 4 Pole miniature high power relay operating from an AC or DC supplies. Hongfa have improved the HF18FH from the industry standard 5 Amp 250VAC/30VDC to an improved 6 Amp 250VAC/30VDC. This relay enables manufacturers and end users to use a small, high-power relay where a greater switching current is needed or preferred.

The high-performance relay features a 1500V dielectric strength (between coils and contacts) and a coil power of 1W & 1.5VA.

Alongside the improved 6 Amp rated contacts, the relay boasts built in LED, Lockable Test Button and Mechanical Flag Indicator. Hongfa have also taken the opportunity to change the colour of the relay case, from a translucent smoked brown colour to a more aesthetically pleasing clear transparent case. This enables the operator to clearly see the Relays switching contact and the internal LED and Mechanical flag indicator. The forementioned LED has also been improved, Hongfa have moved away from a polarity sensitive LED to an LED which will operate on both the positive and negative terminals. Previously the relay needed to be wired with the correct terminal arrangement for the LED to operate. With the new relay either terminal can be used allowing greater flexibility to the installer.

The LED along with the Mechanical test button is colour coded, Red LED with Orange Test Button for AC Coils and a Green LED with Blue Test Button for DC Coils. Aimed at OEMs, CEMs, panel builders and equipment manufacturers, the HF18HF is suitable for a diverse range of applications such as control panels, pumping applications, lift manufacturers, stair lifts and vending machines. The relay measures just 37.0 x 21.5 x 28mm, and three versions of the relay are available: a 7A 2 Pole DPDT, a 7A 3 Pole 3PDT, and a 6A 4 Pole

To compliment the range there are three styles of socket available. The 18FF-4Z-C7, 18FF-4Z-C4 and the 18FF-4Z-C5 sockets which have available accessories including ejector &/or retaining clip and Marking Tag. Also available is an eight-way jumper link, LED & suppression modules, and PCB sockets. Approved to UL/CSA and TUV, CE & UKCA the fully RoHS compliant HF18FH relay joins the Hongfa family of industrial relays to complete and complement the range The ongoing process of improving products is part of Hongfa’s core beliefs, Hongfa have drawn on its considerable expertise in relay manufacturing to develop the improved HF18FH power relay. All versions of the Hongfa HF18FH are available ex stock from Switchtec.

www.switchtec.com

Pre Assembled and Modular Light Towers Multifunction Light and Acoustic Options 36mm, 50mm & 70mm Ø, Round & Elliptical Super bright LED Technology LED Beacons - Rotating, Flashing & Steady Light Output Multi Tone Sounders IP65/66 Ingress Rating UL, UKCA & CE Approved

Celebrating 40 years in the supply & distribution of high quality Control & Automation Products.

Audible & Visual Alarms

t: 01785 818600 f: 01785 811900 e: sales@switchtec.com

www.switchtec.com

Issue 59 PECM

ELECTRICAL & ELECTRONICS

ON CLOSER INSPECTION INSPEKTO

Challenges manufacturers can face in PCB inspection The ever-increasing development pace and diversity of electronic appliances means increasing production challenges in printed circuit board assembly (PCBA), a complex process that involves numerous component suppliers, sophisticated assembly machines and manual labour. In addition, the miniaturisation and growing complexity of printed circuit boards (PCBs) and the derived assembly work add to the complexity of this phase. This makes quality assurance (QA) of the PCBA an invaluable, yet challenging step of the manufacturing process. Here Ofer Nir, VP of Products & Marketing at autonomous visual inspection specialist Inspekto, explores the challenges faced in PCB inspections. To quote Leonardo da Vinci, “Details make perfection, and perfection is not a detail.” This is certainly true for the manufacturing and quality inspection of PCBs, the basic assembly unit of any electronic device, where a slight deviation in assembly can produce a significant performance problem in the final product. Growing demand for consumer electronics and smart connected devices in industry 4.0 is leading to considerable growth in the global PCB market, which is expected to reach USD 86.17 billion by 2026. The market has also become more demanding, requiring boards with higher accuracy and precision during the manufacturing process. The quality and reliability of PCBA directly impacts the efficiency and cost

The quality and reliability of PCBA directly impacts the efficiency and cost of production, as well as the functionality and reliability of end devices.

of production, as well as the functionality and reliability of end devices. In the highly competitive consumer electronics sector, production margins are key for survival; any variation in production efficiency and cost has significant implications for the manufacturers. Reliability and performance are especially important in safety-critical sectors such as aerospace, automotive, defence and med-tech. For example, PCBs are a key component in producing cochlear implants, pacemakers and medical imaging equipment — where precision could be a matter of life or death. Over the past decades, PCB manufacturers have also striven to produce smaller, increasingly complex boards. The higherdensity placement of smaller components makes the design, manufacturing and assembly processes even more challenging. For these reasons, quality assurance (QA) is essential to ensuring that the transition from PCB design to manufacturing is mistake-free.

THE NEED FOR INSPECTION RELIABILITY AND AGILITY Because of the high complexity of modern PCBs, which incorporate a huge number of hardly-visible elements, manual inspection is not a reliable nor scalable QA method. Defects on tiny sub-components are difficult to see and can become almost impossible to spot after an eight-hour shift. Moreover, even if inspectors manage to keep their focus unaltered throughout an entire shift, the amount of time needed to examine a PCB makes this method unviable. For these reasons, automated visual quality inspection has long been sought-after to inspect PCBs. Machine vision (MV) solutions have mitigated the core challenges of human inspectors — they are accurate, do not tire, and analyse huge amounts of small details. MV seems ideal for detecting common defects such as soldering errors, a warped board, surface finishing mistakes and more. However, traditional MV solutions struggle to keep up with a PCB manufacturer’s need for flexible yet accurate QA. These conventional solutions generally involve

the commissioning, design and integration of a customised project that relies on the constant services of a systems integrator or MV expert. The whole process can be expensive and time-consuming, and the final solution will be fit to inspect only a specific type of PCB. At best, these solutions can be a good fit for highly engineered, rigid assembly lines with large production batches. Moreover, another common attribute of PCBA lines is the constant change of the assembled module. In the current global supply-chain reality, component suppliers constantly change, also inevitably changing the appearance of the PCBA. Given the dynamicity of the PCBA market — and its need for customisation, smallbatch manufacturing and how frequently PCBs change — it’s easy to see why the fixity of traditional MV discourages many manufacturers from transitioning to automated QA. However, to compete on a global scale, PCB manufacturers need to aim for nothing less than perfection. Autonomous QA can give manufacturers the competitive edge they need and ensure that PCBs leave their facilities mistake-free — after all, as Leonardo da Vinci said, “Details make perfection.” For more information on automating your QA or to book a free, personalised demo of the INSPEKTO S70, contact Inspekto at www.inspekto.com.

For further information, please visit www.inspekto.com

PECM Issue 59

FACILITIES MANAGEMENT

THE SMART NETWORKED FACTORY INFOR

By Anwen Robinson, Infor GM and SVP for UK and Ireland Judging by the headlines, continuous global logistics issues, continued pandemic restrictions, and rising prices for raw materials mean that manufacturers have their work cut out for the rest of 2022. In addition, the drive towards sustainability is adding pressure to readjust the manufacturing footprint. Most manufacturers are still stuck with a geographic footprint, which was driven by labor arbitrage around the globe, rather than by factors such as proximity to customers or ecological concerns. To increase efficiency, many producers have started to implement Industry 4.0 technologies. Industry 4.0 came with the promise of a smart factory being profitable at the production lot size of one unit. The concept was introduced at the brink of the millennium change with the introduction of cyber-physical systems to share, analyse and guide intelligent actions for various processes in the industry to make the machines smarter and to lower downtime. Analytics can also be used for other aspects like logistics, demand forecasts, production scheduling and quality control, capacity utilisation and efficiency boosting. But we still stand at the beginning for leveraging the true potential of Industry 4.0. Smart technologies offer no less than the possibility to redesign the global manufacturing footprint, to position factories closer to markets, reduce logistics nightmares and increase visibility of the ecosystem partners, including suppliers and customers.

costs, as well as the drive toward a more sustainable production and the imperative to reduce the distance to the physical endconsumer lead organisations to redesign the manufacturing footprint, with the support of leading-edge technologies, to build smaller, smart factories closer to the customer. Smart decisions require end-to end visibility. This requires a consolidated view across the manufacturing business, including the commercial, the procurement and the operational sides.

So, what are the most important ingredients for a strategy to create the future-proof smart factory?

A tightly linked view and streamlined processes across the order system, shop floor operations, and the supply chain optimise capacity and requirement management and failover alternatives across the entire system.

Customers increasingly demand highly personalised products as well as an enhanced customer experience. Manufacturing companies adopt highly agile cloud-based solutions to gain the ability to increase individualisation, service additions, and serve higher flexibility requirements.

A global view and command structure to react quickly to supply chain challenges. A connected supply chain operating with a single view of orders, shipments and inventory, and shared digital processes provides the visibility needed to improve velocity and the agility to respond to disruptions in a timely and efficient manner.

The need to reduce delays and transport

More intelligent automation, using AI-driven

insights, can lead to assembly lines that are adjusting automatically. Smart technologies allow smaller manufacturing sites to be situated close to the customers. But how can producers reach fundamental business decisions as to how to relocate manufacturing sites? The most important ingredient needed is good intelligence. True, manufacturing organisations leverage plenty of data across the operation. But is the data linked up, consistent and treated to enable insightful business decisions? A smart factory is a highly digitised, connected production facility that uses technologies such as artificial intelligence (AI), Internet of Things (IoT) and robotics to help companies manufacture products, create new business value, unlock datadriven insights, and automate or eliminate business processes. These technologies enable people to do their jobs in a more productive and efficient manner while improving quality and overall safety. At the same time, the technologies enable smart factories to self-adapt and autonomously optimise manufacturing operations, helping organisations to compete better amid the many global challenges they face.

For further information, please visit https://www.infor.com/en-gb

PECM Issue 59

FLUID HANDLING / FOOD PROCESSING

Fluid Carrying

Swivel Joints Solutions Rotaflow FV Ltd was recently contacted by Ronez, the Channel Islands based manufacturer and supplier of construction materials, they needed a swivel joint for their cement processing system. We are specialist designers and manufactures of Swivel Joints. Swivel Joints allow fluids to be transferred across rotating interfaces and enable flow without leakage on moving machinery. We reviewed Ronez’s needs and offered up our 1” Female threaded 316L SS FS Series at 90 degrees. This swivel allowed the required water connection to be attached to a rotating shaft. Ronez advised they have been happy with the swivel and supplied the photo of it in use. Standard Rotaflow SK Swivels come with a grease nipple to enable easy greasing for longer life and less downtime. This swivel if offered in various seal material to suit your application, including hygienic.

Flexibility We are specialists in taking your bespoke requirements and being able to design a solution that can fit your budget, dimensions, materials, FAT/witness testing; hygienic and pressurised environments. We regularly test to Hyperbaric, Seal Life and conduct Temperature/ Pressure/Load Cycle Testing. We are ISO 9001:2015 certified.

Articulated Torsion Pipework In Hoses Rotating Cylinders

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.

To find out more please visit our website and/or give us a call. Tel: +44(0)1663 735003 sales@rotaflow.com

www.rotaflow.com

Swivel Joints

Tel:

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

+44(0)1663 735003

E-mail:

DSEAR 3 DAY - Risk Assessment Training Course (11th - 13th October) Our “Three Day” DSEAR course is aimed at those who responsible for conducting DSEAR assessments, but are not necessarily fully confident with the process. They may work in a flammable environment, inaddition to being responsible for managing the area, day to day. The course content: • Legal foundations • How sources of danger arise. • What is the difference between flashpoint, fire point, boiling point and Auto Ignition? • The fundamentals on the origin of Explosions, Deflagrations and Fires • Risks resulting from improper storage or handling of these substances • The meaning of the danger triangle and pentagon. An overview of the regulations, understanding solvents and their physical properties, explosive dusts, ATEX classifications, gas groups, temperature ratings and BS 60079-10 Ex Zone determination, all giving

PECM Issue 59

a greater understanding of how ATEX fits into the DSEAR equation when establishing hazardous zones. Reference is made to the theoretical understanding of flammable vapours with examples of how the L.E.L can be converted into a meaningful quantity of chemical per cubic metre. Supported by a full and detailed 200-page, training manual to assist with their learning.

sales@dsc-ltd.co.uk www.dsc-ltd.co.uk

GEARS, DRIVES & MOTORS

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 ◊ Blacking Drilling & Tapping ◊ Marking 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 www.CrossMorse.com

Introducing QualCoil H Preformed Windings are very pleased to announce the launch of ‘QualCoil H’, the first resin rich diamond coils suitable for class H motors and generators. QualCoil H has successfully passed 1,000 hours on VE test. Preformed Windings are a high-quality supplier

of high voltage diamond with customers including ABB, Siemens and GE who say: “Preformed Windings have supplied many sets of high voltage coils to GE Renewables over the years. The quality of product and service is exceptional, and they are a trusted partner

in our supply chain. We enjoy collaborative and cutting-edge research and development with Preformed Windings, which positions both organisations as thought leaders in the hydro industry. Their products offer significant benefits such as very low partial discharge and a long service life”

coilshop@preformedwindings.com | www.preformedwindings.com Issue 59 PECM

HEALTH & SAFETY

PREVENTION TECHNOLOGY GRECON

Your Fire Prevention and Measuring Technology partner for over 30 years! GreCon Limited makes people and places safer and enables the ‘smart factory’ as the leading provider of innovative industrial fire prevention and process measurement solutions. GreCon Limited is located near Newcastle upon Tyne and is a member of the Fagus-GreCon Group. With a wealth of experience as a global market leader, GreCon demonstrates a strong understanding of customer needs and provides turnkey solutions for many industries, including recycling, manufacturing, biomass, pharmaceutical, food, and hygiene.

YOUR STRATEGIC PARTNER

GreCon IEM

The company focuses on developing sustainable customer relationships as a strategic partner. Customers depend on GreCon for consultative and problemsolving sales engagement and firstclass customer service. In addition, a fast response is possible due to comprehensive local stock-holding and a strong engineering team with national coverage.

Technology IDT® provides optimal detection performance for all ignition sources in any environment and enables the detector to distinguish between dangerous sparks and harmless ambient light.

FIRE PREVENTION TO ENABLE UNINTERRUPTED PRODUCTION

GreCon’s fire prevention technology protects industrial premises, processes and people, detecting and extinguishing ignition sources in mechanical and pneumatic conveying systems, filters, dryers, silos and other production areas, making workplaces safer and enabling uninterrupted production.

ENABLING THE SMART FACTORY

A comprehensive range of industrial process measurement solutions equips the ‘smart factory’, helping customers improve product quality in their production processes, using proven German engineering to reduce raw material and energy costs, ultimately maximising operational efficiency.

A STRONGER TEAM

Recently, two experienced leaders joined the GreCon team. Jonathan Marley heads a new Service & Operations Department

GreCon DLD 1/9 ensuring we continue to deliver against our reputation for excellent customer service. Ben Rosby took up the Head of Sales role, bringing considerable experience in industrial solution selling. Both Jonathan and Ben are keen to discuss customer challenges.

A TRACK RECORD IN INNOVATION

GreCon focuses on anticipating customer requirements in a technology roadmap, with a proven track record of bringing innovative products to market.

Demonstrations have also begun of the GreCon IEM, the Intelligent Extinguishing Module, as an exciting addition to an intelligent fire prevention solutions portfolio. Critical benefits include more rapid extinguishing of sparks and harmful ignition sources. In addition, integrated intelligent extinguishing technology (IET®) enables highly precise extinguishing process monitoring and predictive maintenance control.

CALL GRECON TODAY

Today customers all over the world rely on GreCon. Please get in touch to discuss how we can help: Email: sales@grecon.co.uk T: 0191 414 7200

Customers are particularly interested in the DLD 1/9, a highly sensitive spark, ember and hot particle detector for protection against fire and explosion in industrial processes. Intelligent Detection

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

PECM Issue 59

HEALTH & SAFETY

01202 875657 sales@laserprofiles.co.uk

Laser Cutting (Flat Profiles)

Sheet & Plate – Up to 25mm thick

Laser Cutting (Rotary)

Tube, Round, Oval & Box section

Waterjet Cutting

Sheet & Plate – Up to 200mm thick

Fabrication

Bending/Folding, Countersinking, Tapping, Drilling

Welding

MIG & TIG

Aluminium - Stainless Steel - Galvanised Steel – Steel – Copper – Brass – Titanium Carbon Fibre – Acrylic – Polycarbonate and more… The majority of materials listed are in stock and all are fully traceable.

Fast-Track Service Saving your business time, turning weeks into days and days into hours! Standard Industry Lead Time Laser Cutting 3 days Fabrication 6 weeks

Laser Profiles (Fast-Track) Lead Time 3 hours 6 days

Offering one of the fastest turnarounds in the UK for laser cutting and low volume fabricated components, this fast-track service has previously been sold to the F1 Automotive industry only; we are now able to offer it to all industries.

PECM Issue 59

MACHINING & MACHINERY

Starrag Heckert’s DBF integrated facing head delivers one-hit savings With a multi-tasking DBF radial (U-axis) facing head, Starrag’s Heckert DBF horizontal machining centres are unrivalled for single set-up, multiface, multi-faceting machining – including conical and contour turning – slashing processing times on, for example, oil & gas sector valves and fluid ends, in one case from 20 hours to just 4.5 and achieving 95% reductions in overall processing times and 77% cuts in cycle times. Compared to machines that may offer, say, facing head tooling via a toolchanger, the universal DBF spindle with face plate has an integrated 45 kW, 3,500 revs/min and 1,700 Nm torque spindle, and accommodates HSK 100 and Capto toolholders. The result is that with DBF, the tool tip is much closer to the workpiece – 200 mm-275 mm rather than the conventional 335 mm-410 mm – and this leads to much more stable and therefore highly accurate machining. KOSO KentIntrol is one of Starrag UK’s customers who realise the benefits of DBF machining, not least because the machine has eliminated the need for two separate machines, and all the associated re-setting and queuing times, to produce finished valve bodies. “The elimination of multiple set-ups on a lathe, plus the lack of queuing and set-up times for drilling, has produced dramatic time savings,” says the company. The Heckert DBF was purchased to increase capacity of the machining of valve and globe bodies in the 1-6 inches range (flange outlet bore size) and from a variety of materials, from carbon steels through to super duplex and Inconel. It enables the production of complete body machining in one or two operations, depending on casting type and size.

The DBF strategy – for angle bodies in one-hit and for globe bodies in two operations of set-up for machining the plug-way (including drilling) then set-up and machine the flanges (including drilling) - has replaced a comparatively longer and laborious process of: • Load to lathe • Set-up and machine first flange • Set-up and machine second flange • Set-up and machine the plug-way • Move body to drilling cell • Set-up and drill.

www.starrag.com

Engineering precisely what you value — Heckert

For those who aim for more.

35%

shorter machining time due to milling, turning and drilling operations in one clamping position

www.starrag.com

Issue 59 PECM

MACHINING & MACHINERY

FORTRESS DOUGH CHECKWEIGHER FORTRESS TECHNOLOGY

Harvesting savings on baked goods lines Rising wheat and energy prices could put bread and baked goods supply chains at risk cautioned CEO of the Federation of Bakers recently. To help curb these escalating macroeconomic costs, food inspection specialist Fortress Technology unveils how automated technologies can be deployed by industrial bakeries to reduce giveaway and false rejects and boost productivity. Before the Ukraine conflict, bakers were already digging in and preparing for a bumpy ride, with rising commodity and import prices adding an extra 4.5 pence to the production costs of an 800 gram bread loaf. In the last six months, production costs have more than doubled again, claims the Federation of Bakers. Naturally, the cost of flour contributes to these hikes. However, it’s the higher energy consumption figures from running machinery, ovens and keeping the production lights on that impacts the final costs more. Making it even more imperative to uncover the causes of upstream losses and counteract batches of baked goods being wasted because they were out of tolerance before reaching the ovens.

Dough that is 0.5 grams over or under weight is automatically rejected beneath the system for reworking communicates back to the dough divider in real time to adjust the position of the blade for the next batch. For optimum processing flexibility, Fortress can pre-programme up to 500 different product codes, ranging from 150 grams to six kilograms.

Automated weight monitoring Checking the weight of baked goods before the proving phase is pertinent. As is maintaining consistent processing and checkweighing speeds. The reason, explains Fortress Technology’s Commercial Manager Jodie Curry, is to factor in processing variables and ensure products aren’t out of tolerance before baking. “Leaving until the final stage of the process could result in an entire batch being over or underweight. Potentially costing a bakery over four hours of lost production time and thousands of wasted product being binned,” cautions Jodie Additionally, a bread loaf may weigh 800 grams when baked, but in its raw state is 917 grams. If it is out of tolerance by just a few grams, dough can overspill and potentially spoil other loaves during baking. Plus, if one is overweight there will definitely be an underweight loaf in the batch. Guaranteeing uniform portion weights, the

PECM Issue 59

Fortress Technology’s unique unclippable and ‘no-tool’ conveyor optimises Clean In Place (CIP) standards Fortress Hestia Dough Checkweigher - used for all sorts of baked goods applications - from pizza to baps, French sticks to cakes and crumpets to traditional loaves - inspects up to 12,000 dough pieces per hour. Connected to an automated upstream dough dividing line, if a piece of dough is under or overweight by as little as 0.5 grams, the Dough Checkweigher automatically rejects it. Simultaneously, the machine’s advanced fibre optic controlled software

“Every big bakery started off performing these dough dividing and weight check tasks by hand. Not only is this labour intensive, but also leads to variations in product quality. For commercial as well as artisan bakers, automated dough checkweighing allows for individual pieces that are off target weight to be removed and reworked, as well as providing corrective feedback to the dough divider,” emphasises Jodie. Data gathered via the management control system can also help to track uptime and address line inefficiencies. Using the swipe touchscreen, baking operatives can select the statistical parameters most relevant to their operation. The easy to use graphical display automatically logs and reports Reject Integrity compliance tests. This intuitive digital interface also helps to significantly reduce set up time between each batch.

The Hestia Dough Checkweigher measures just 200cm in length and 90cm wide, with a slide out reject box tucked neatly beneath the conveyor. For enhanced traceability, reports configured by time, date or product code - can be downloaded and easily converted to common management reporting and software applications. Secure remote and authorised access levels enable bakers to troubleshoot, diagnose and resolve equipment issues on the spot to minimise system downtime and avoid production bottlenecks. Small energy footprint To help bakeries address gas price rises, which have risen five-fold from £45 per therm just 12 months ago, this Dough Checkweigher features an energy-efficient electric servo drive instead of compressed air. The result is a more compact system to accurately and automatically reject over or under weight dough faster and more sustainably. Measuring just 200cm in length and 90cm wide, one of the key advantages of this electric drive is the reject unit can be

Every big bakery started off performing these dough dividing and weight check tasks by hand. Not only is this labour intensive, but also leads to variations in product quality located beneath the hygienic, unclippable conveyor within the body of the machine, highlights Jodie. “In an automated inspection cell like the Hestia, servo drives are proven to be extremely energy efficient. But these drives also help our

engineers to maintain compact and slimline unit. Especially when compared to systems that typically have the reject bin protruding to the side.” Adapting to these market forces, producers of baked goods remain under constant pressure from all sides to optimise energy efficiency and workforce productivity while simultaneously reducing waste and giveaway. Jodie concludes: “Bakery rejects not only waste raw ingredients and affect yield, it also wastes all the labour that went into producing every batch. Add in the energy consumed by ovens, mixers and other automated equipment on the line, and inefficient start-ups and shut downs, all these interconnected factors contribute to the economic and ecological performance in today’s commercial bakeries.” Dependent on production volumes, switching from manual weight checks to automated upstream checkweighing can save industrial bakers up to £1,000 a day.

For further information, please visit www.fortresstechnology.co.uk Issue 59 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 +44(0)1527 520 580 sales@threadtools.com www.threadtools.com

For further information, please visit www.threadtools.com

PECM Issue 59

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 +44(0)1527 520 580 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!

MACHINING & MACHINERY

DEEP HOLE DRILLING AIDS UNISIG

By Anthony Fettig – CEO, UNISIG Deep Hole Drilling Systems The future of the auto industry is interesting but uncertain. No one knows how quickly electric vehicles are going to replace gasoline- and diesel-powered vehicles, how completely it will happen, and when it will occur in passenger cars as opposed to SUVs and heavy trucks. However, we do know that fuel economy standards continue to progress and drive vehicle design toward smaller displacement, higher-technology engines. As a result, technology that was developed years ago for high-performance vehicles is now becoming mainstream. For example, sodium filled valves, which formerly were used in only extremely high-performance engines to manage heat in the valve train, are becoming more common. The same goes with hollow camshafts, which reduce energyconsuming rotational inertia and provide opportunities for engine management. Within vehicle drivetrains, today’s automatic transmissions now have as many as eight or even 10 speeds instead of five or six. This wide selection of gear ratios enables smaller displacement engines to provide better fuel economy and deliver higher performance. These kinds of technological upgrades for higher performance and economy are not new, but previously were considered too costly for general use. Now, advanced manufacturing and materials technology make common application of these upgrades viable.

ENABLING COST-EFFECTIVE PRODUCTION Deep hole drilling is one advanced manufacturing technology that allows for the cost-effective production of key features of those performance-boosting parts. Sodiumfilled valves, for example, have holes drilled the length of the valve stem in which liquid sodium circulates and draws heat from the valve head. Precise deep hole drilling methods enable hollow and more energyefficient camshafts to be manufactured. Complex multi-speed transmissions feature shafts with multiple off-center holes of varying depths for lubrication or hydraulic sequencing. The holes in the shafts are too deep to produce effectively on machining

centers, so deep hole drilling machines are critical in those instances.

BALANCING VOLUME OUTPUT WITH FLEXIBILITY

Increase challenges your mold manufacturing versatility Other manufacturing in automotive LIGHTER YET STRONGER production can also benefit from today’s using the power of gundrilling with the In addition to production benefits, a future advanced machine tool technology. For opportunity for automotive manufacturers leaders in deep UNISIG. Oﬀering decades, the automotive industryhole focuseddrilling, that involves deep hole drilling technology nearly exclusively on volume production. The complete solutions for everything fromparts lighter yet still is in making vehicle emphasis was on making as many parts at the maintaining or evenUNISIG increasing their stiffness lowestsimple cost possible. was merely a components, toFlexibility complex mold and strength. Deep hole drilling can produce minor consideration. machines help moldmakers improve thin-wall parts such as axles and power transmission shafts, for example, that provide Marketeﬃciency, changes have made balancing volume throughput and significantly precision with higher mechanical integrity and output with flexibility a major issue. If volume better improved energy outstanding versatility at economy. an drops on a vehicle program,part-processing there remains a

need to produce the vehicle cost-effectively. exceptional value. For instance, drilling a 20-mm axial hole Expanded product mixes created to meet through a heavy 30-mm diameter shaft makes customer desires for different powertrains the shaft much lighter while maintaining its and other options demand high efficiency This lighter shaft has less rotational regardless of volume. TAKE YOUR MOLDMAKINGstiffness. OPERATIONS inertia which, in turn, reduces energy consumption. Designers continually search FURTHER UNISIG Consequently, flexibilityWITH and spindle utilizationTODAY. for such small gains in efficiency and will have become the main drivers of deep hole seek ways to enhance lightness and stiffness drilling machine design. Instead of having a throughout the automobile. gang of four spindles pounding out parts, a two-spindle machine with a rotary table and Find out more at www.UNISIG.com As machine tool manufacturers, our job is X-Y positioning system can provide extremely to listen to our customers, understand what high spindle utilization along with flexibility. they need, and develop those needs into a Technology such as automated setup through solution that is viable from a cost and reliability servo motion to reduce changeover time standpoint. With ongoing advancements is also considered in the early concept in engineering technology, machine development of the machines. These systems manufacturing, and service, what might have allow manufacturers to plan and implement been very expensive to do only three or small, agile cells to replace large, old-school, four years ago is now viable. Concepts that high-volume systems. once seemed a bit far-fetched are now quite common.

BENEFITS OF MACHINE AND FIXTURE DESIGN

A recent customer experienced significant benefits with UNISIG’s machine and fixture design. Previously, the customer was processing a challenging family of parts on a system that involved nearly 20 fixtures. Each part required multiple holes with varying depths and diameters. A bulky, dedicated machine created an unnecessary expense and bottleneck in their production. UNISIG provided a machine that allowed the company to manage deep hole drilling of these parts with just two pallet-changeout www.unisig.com

PECM Issue 59

type fixtures, and requiring only the selection of a new part program. By eliminating fixturing, setup, and programming time, the company experiences significant savings every time the machine runs.

Because of that, we design our machines to provide both flexibility and utilization that will enable our customers to successfully face the expected—but not yet fully known—major changes in the automotive manufacturing industry. Further information on all machines and the complete UNISIG machine program is available on our website or follow the company on LinkedIn and Twitter (@UNISIG). You will also meet us at the EMO 2023 show in Hannover, Germany from 18.–23 September 2023.

UNISIG.COM

UNISIG TAKES YOUR GUNDRILLING PRODUCTION FURTHER

Gundrilling and BTA deep hole drilling for highly productive shops. Whether your shop needs on-center or oﬀ-center holes, specialized job shop work or fully automated production, UNISIG has a deep hole drilling solution with the accuracy and performance you need. Take your shop’s production further - learn more at UNISIG.COM.

Machines • Tools • Automation UNISIG machines, engineered and manufactured in the USA

MACHINING & MACHINERY

FLOWER POWER FANUC

Solar powered roboshot sets bloom-in-box on road to net zero Following its investment in an energysaving FANUC ROBOSHOT injection moulding machine, eco-conscious plastic products manufacturer Bloom-in-Box is well on the way to becoming car-bon neutral. Thanks to superior servo technology and intelligent power regeneration capabili-ties, the energy-efficient ROBOSHOT S150iA installed at Bloom-in-Box’s Burscough facility uses just 3kW per hour, permitting it to be powered exclusively by renewable solar energy. “Our goal at Bloom-in-Box is to become carbon neutral over the next 12-18 months. We have been working with all-electric machines for the last 20 years to reduce power consumption and emissions. Solar installations and our new FANUC ROBOSHOT were the next steps to achieving this. Thanks to these latest investments, our current carbon emissions as a business are estimat-ed to be less than 10 tonnes of CO2 per year, with our ultimate goal to achieve net zero,” says Tom Reardon, production coordinator and robotics engineer at Bloom-in-Box.

BORN AGAIN PLASTICS Bloom-in-Box is a third-generation, family-run plastic injection moulding business grounded in an ethos of responsible consumption and production. A commitment to creating products with more than one life drives the company’s design and manufacturing activities and in 2018 earned Bloom-in-Box a place in the final of Best Recycled Plastic Product of the Year for its Bloomie floristry box. The Bloomie is made from 99% recycled material and is 100% recyclable. Any boxes that mould incorrectly are chopped up, passed through a grinder and made into se-curity spikes. Other products made by the business include laundry pegs, scoops and measures. Bloom-in-Box has been involved in injection moulding for more than 20 years and has always been an advocate of electric moulding machines on the basis that they use up to 80% less en-ergy than their hydraulic counterparts. When significant growth meant the company had reached maximum production capacity last year, it took the decision to invest in a

PECM Issue 59

Bloom-in-Box is a family-run plastic injection moulding business grounded in an ethos of respon-sible consumption and production. new electric machine that would enable it to increase capacity by 25-40%. “We had reached a plateau. Our older machines were slower, causing production bottlenecks, and lacked the precise temperature control needed for working with biodegradable plastics,” recalls David Reardon, director of Bloom-in-Box.

CARBON NEUTRAL AMBITIONS At the same time, the company had embarked on a roadmap to become carbon neutral, start-ing with an assessment of its carbon footprint. This revealed that electricity was its biggest source of carbon emissions, accounting for 95% of its total emissions. To address

this situation, in November 2021, Bloomin-Box installed a 40kWp solar system that feeds directly into the factory. During daylight hours this generates on average 10kW per hour, with the potential to produce even more electrical energy during the summer months. Therefore, when it came to deciding which injection moulding machine to invest in, energy efficiency was a top consideration, alongside production speed, quality, CNC reliability and repeatability. Bloom-in-Box wanted this machine purchase to support its carbon emission reduc-tion ambitions and to be powered exclusively by the new solar panels.

The Bloomie living vases, injection moulded using recycled material by Bloom-in-Box

In our opinion, FANUC machines are at the top of the league table for energy efficiency in injection moulding. This search led Bloom-in-Box to FANUC’s ROBOSHOT range, which the company claims are the most energy-efficient injection moulding machines available today. “In our opinion, FANUC machines are at the top of the league table for energy efficiency in injection moulding,” says Tom Reardon. It is well known that all-electric injection moulding machines use up to 80% less electricity than a hydraulic machine of a comparable size. FANUC’s ROBOSHOT goes even further than this; the company claims it consumes 10-15% less energy than the average all-electric machine.

ENERGY EFFICIENT DESIGN The ROBOSHOT’s best-in-category energy efficiency can largely be attributed to a combination of FANUC’s proprietary servo technology and smart energy recovery. “Rather than buying them in from a thirdparty manufacturer, we build our own servo

drives, meaning they are as energy efficient as is physically possible. This also enables us to specify ser-vo drives that are the perfect match for each machine’s target performance, ensuring they de-liver exactly the amount of power to the motor that it needs,” explains David Raine, ROBOSHOT sales manager UK and Ireland. In addition, the ROBOSHOT’s advanced power regeneration feature enables intelligent energy recovery: when an axis decelerates, energy returns to the power source, adding to the overall savings. “When the equipment starts to decelerate and the motor is no longer required to drive a pro-cess, it automatically switches to being a generator, feeding the electricity that is generated back through the system

to another location on the machine where it is needed,” says Raine. The 150T clamp force ROBOSHOT S150iA in operation at Bloom-in-Box runs at 2.9-3kW per hour for a six-second cycle (the longer the cycle the less energy consumed), reducing energy con-sumption by 20% versus previous generation electric machines in the plastic processor’s fleet. “This represents a huge saving both in terms of CO2 emissions and energy bills,” says David Reardon. As well as being well on track to becoming carbon neutral, Bloom-in-Box is well-placed to ex-pand its garden, scoops and measures ranges and to develop new medical and PPE products.

The energy-efficient ROBOSHOT S150iA installed at Bloom-in-Box’s Burscough facility uses just 3kW per hour, permitting it to be powered exclusively by renewable solar energy For further information, please visit www.fanuc.eu/uk/en Issue 59 PECM

MACHINING & MACHINERY

FROM FARM TO FORK SMB BEARINGS

The role of bearings in the food and beverage supply chain From the London Beer Flood of 1814 to the Tapioca Tanker Disaster of 1972, there has been a host of high-profile food and beverage disasters at all stages of the food processing chain. While innovative new technologies have been vital in continuing to improve safety and of modern operations, one small mechanical component is indispensable across the whole food and beverage supply chain. Here Chris Johnson, managing director at food grade bearing supplier, SMB Bearings investigates the role that bearings play in the food and beverage industry. Despite consistent challenges over the past two years, the food processing industry is projected to reach USD 235.67 billion by 2028, demonstrating healthy growth from its USD 143.51 billion market size in 2020. Ball bearings are used in countless precision agriculture applications, as well as in conveyors, mixers and picking and weighing machinery. In fact, if any piece of food processing machinery rotates, it will use bearings to ensure smooth travel. So, let’s take a closer look at the importance of choosing the right bearings at three key stages of the food processing supply chain.

BEARINGS IN AGRICULTURE

The food cycle begins at the production stage. In the face of greater demand, farmers are increasingly employing automation to augment their operations. In this setting, bearings are used in a range of machinery such as agricultural scanners, combine harvesters, balers and seeders. Due to the severe mechanical strain and abrasive particles in this environment, bearings for agriculture must be durable and reliable, with a long service life. Heavy duty bearings are a popular choice when choosing bearings for precision farming technology as they are often subjected to heavy loads in addition to shock loads and vibration. Due to the high risk of contamination, bearings fitted with labyrinth contact seals are often specified along with extreme pressure (EP) greases. Many agricultural bearings have a “hex bore” and are designed to fit on to a hexagonal shaft for easy assembly.

MANUFACTURING CHALLENGES

Next, the product passes to the manufacturing stage. From continuous high speeds to extreme temperature, excessive moisture and chemical exposure — bearings in food processing lines face numerous challenges. Bearings used in these settings must meet a range of non-standard criteria. The first consideration is the need for continuous high speeds. Contamination is also a concern in many forms. For the highly regulated food and beverage sector, contamination can lead to costly production loss. Excessive moisture due to washdown cycles can also result in lubricants being flushed out of the component. Similarly, chemical exposure from detergents and sanitisers can cause corrosion and accelerate component wear. Acetal resin bearings offer a low cost, corrosion resistant option. Suitable for low load and low speed use. For greater corrosion resistance and extreme temperatures, alternative ring or cage materials can be used such as polyether ether ketone (PEEK), polytetrafluoroethylene (PTFE) or polyvinylidene fluoride (PVDF). For processes such as heating, boiling and baking, bearings must be suited to extreme temperatures. Stainless steel ball bearings can be supplied with non-toxic lubricants approved to NSF H1 or H2 standards. Bearings with a choice of food grade lubricants can withstand the ingress of water or cleaning chemicals, as well as coping with regular steam cleaning.

PACKAGING CONSIDERATIONS AND BEYOND

Following production, the product passes to the packaging stage. By investing in a high-speed robotic pick and place cell, operational efficiency can be increased substantially. For robotics applications, thin section bearings deliver high speeds, improve efficiency and offer design flexibility. Due to the little difference in size between the internal and external ring, these bearings also reduce the weight on the application and the space requirements. However, because they are so thin, you have to pay particular attention to the roundness of the ring itself. As a result, the manufacturing process must be extremely precise to ensure the highest possible degree of roundness in both rings, as well as good noise levels in the bearing itself. This will normally call for fine grinding and machining, complemented by a very high level of quality in both the process and the raw materials. If the rings are not perfectly formed, even a minute discrepancy will stop the bearing running as smoothly, producing excess noise and disrupting the food packaging line. In efforts to enhance supply chain efficiency, even the smallest components can make a big difference. It’s important that food and beverage plant managers consider component suitability at all stages of the food cycle to ensure they can meet the production needs of tomorrow. For further information about food grade bearings and lubricants, visit the SMB Bearings’ website or contact a specialist today by emailing sales@smbbearings.com.

For further information, please visit www.smbbearings.com

PECM Issue 59

MACHINING & MACHINERY

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Issue 59 PECM

MACHINING & MACHINERY

THE ROTOR RETURNS

PRE

5 most co

SULZER

Sulzer identifies faulty OEM replacement compressor rotors ensuring an optimum repair Ever ordered something online, only to discover on delivery it’s not right and needs to be sent back? While this is annoying for personal items, when it’s a rotor for your chlorine compressor, it can potentially have significant consequences for production. Thankfully for Nobian Industrial Chemicals B.V., Sulzer’s Venlo Service Center was there to spot and solve the problem before things could go spinning out of control. As a global leader in the production of specialty chemicals, Nobian manufactures and moves large quantities of chlorine. To allow delivery to customers, this key ingredient for many industrial and chemical processes is often liquefied. An important enabler of this process at Nobian’s Rotterdam plant is a 4-stage chlorine compressor and its back-up spare. This means that when the main compressor needs attention from the maintenance team after prolonged service with this materially corrosive element, it is swapped out for repairs and the spare takes its place. To make sure it had its spare ready, Nobian contacted Sulzer in the Netherlands to perform a complete overhaul. With its turnkey service for the maintenance and upgrade of compressors and other rotating equipment, the local team was ready to take this on.

A comprehensive compressor overhaul The results of the compressor inspection showed that the casing could be re-used. This would be achieved by welding some erosion marks and machining the entire split line to remove corrosion, with the entire casing to be re-bored afterwards. Furthermore, the new diaphragms from the compressor OEM did not meet Nobian’s specifications, but the used items were found to be in reasonable condition. Considering this, the final project scope encompassed machining the casing, the reuse of the existing diaphragms and the replacement of all other internals. These included the rotor and impellers, internal labyrinth seals, bearings, oil seals, the

variable inlet guide vanes (VIGV) assembly and stuffing boxes. Consequently, Sulzer in the Netherlands subcontracted the compressor casing machining, installed the used diaphragms and replaced all other internals with new items supplied by Nobian. However, during a trial fit of the rotor from the OEM, it appeared that its balance drum was wrongly installed, being twisted at 180°. Consequently, the rotor was shipped by Nobian back to the OEM, with final reassembly put on hold.

Identifying more rotor issues

Collaborating on a customer problem Sulzer invited Nobian to the Venlo Service Center so that they could share their unwelcome discoveries regarding the rotor. The team presented its inspection results and comprehensive 3D scans of the compressor casing and rotor, conforming that there was a positional offset between the center line of the casing and rotor shaft. Because of that, the internals would need to be machined to compensate for this offset. Representatives from both businesses sat down to review the measurements and Nobian agreed with Sulzer’s diagnosis.

As this was the spare compressor, Nobian opted to wait for this rotor to be repaired. When it did finally appear, Sulzer’s Venlo Service Center resumed the project to finish the compressor overhaul. However, the refurbished rotor was delivered with some minor nonconformities such as rust and broken, incorrectly secured labyrinth seals.

Both parties confirmed that the replacement rotor sent by the original equipment manufacturer (OEM) had to be returned again, so the project was put on hold for a second time until it was repaired. Nobian was invited to return to Sulzer for the unboxing and inspection of the rotor when it arrived.

As a consolation, the balance drum was now in the correct position and in terms of dimensions at least, the rotor was fit for purpose. Sulzer commenced with machining the shims to the correct thickness to achieve the right axial clearances for the rotor. Since the labyrinth seals might be replaced by the OEM, it was decided to not machine the stuffing box to the required internal diameter until the refurbished rotor was inspected and the outer diameter of the labyrinth seals were measured again. Despite this progress, the faulty rotor still presented positioning problems.

Getting the right rotor

Why rotor position is important The positioning of the rotor is absolutely vital in any compressor. As the split line of casing had been machined to remove the corrosion, the internal packaging of the unit had changed. To compensate for this, the internal bores of the casing had been modified to ensure that the central shaft would be properly aligned. However, the faulty rotor could potentially make contact with other elements in the compressor such as the labyrinth seals or stuffing boxes regardless of the other modifications.

Better late than never, the refurbished rotor arrived at the Venlo Service Center to be welcomed by experts from both businesses. Thankfully for everyone involved, it was a case of third time lucky. A close inspection and a 3D scan confirmed the rotor was finally fit for purpose and would sit in the right position. To complete the overhaul, the last stuffing box was machined within tolerances. The rotor was installed and the entire unit reassembled, all witnessed by Nobian. Using its engineering expertise and identifying the nonconformities on the refurbished rotor, the team at the Venlo Service Center had ensured that the spare compressor was brought back to optimum condition. Plant operators at Nobian could breathe a sigh of relief.

Sulzer secures compressor availability With the compressor now fixed, Nobian has access to a spare that can step up when required. As a result, compressor availability is assured, protecting process uptime, profitability and chlorine production.

For further information, please visit www.sulzer.com

PECM Issue 59

1. Lack o progra 2. Lubric than p 3. Lack o 4. The CM based 5. Lubric

Source; las audits

fai

PRECISIO We have question

VISUALIS Colour co coded gr colour co machines

If kept ac impact on site and i a “grease

MACHINING & MACHINERY

LUBRICATION MANAGEMENT

ECISION LUBRICATION IS CRITICAL FOR RELIABLE PLANT Rogues' IS Gallery PRECISION LUBRICATION CRITICAL FOR RELIABLE PLANT

ommon reasons for poor lubrication.

of ownership ofLUBEAPP the site lubrication am 5 most common reasons for poor lubrication. cants are selected on price rather performance 1. Lack of ownership of the site lubrication of specific lubrication training 5 program most common reasons for poor lubrication. 5support most common reasons for poor MMS does not precision2. Lubricants are selected on price rather lubrication. d lubrication than performance

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Rogues’ Gallery

Rogues' Gallery

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60% of bearing

Source; last 3 years CBM Partners site lubrication audits 4.The CMMS does not support precision-

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>60% of bearing poor lubrication Source; last lubrication 3 years CBM Partners site poor failures lubrication auditsare

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At least one person on site should be VISUALISATION KPI'S & &METRICS PERSONNEL ON LUBRICATION SUCCESS FACTORS KPI'S METRICS PERSONNEL PRECISION LUBRICATION SUCCESS FACTORS poor lubrication trained & certified in machine lubrication; all Colour code charts in the storage area, Schedulesshould should be down to to Any personnel in lubrication should Wescores have summarised scores 140personnel Schedules beestablished established down involved involved in lubrication should summarised against our 140against ourAny personnel involved in lubrication should be colour guns and top-up lubricationpoint point level, level, not just machine. TaskTask have theircoded lubrication and responsibilities question assessment survey; lubrication not just machine. have their lubrication rolegrease androle responsibilities assessment survey; trained. containers, colour coded grease nipples completion should enable KPI data & reporting. clearly described in their Job description. KPI'S & METRICS PERSONNEL PRECISION LUBRICATION SUCCESSclearly FACTORS completion should enable KPI data & reporting. described in their Job description. VISUALISATION and by machines. Schedule compliance (incl. % overdue). Schedules should be established down to Any signs personnel involved in lubrication should We have summarised against our 140 60%in the ofscores bearing SATION Schedule compliance % overdue). Back-up personnel &(incl. processes should be Colour code charts storage area, colour At have least their one person on site be trained & lubrication point level, not just machine. Task lubrication roleshould and responsibilities question assessment survey; ode charts coded in thegrease storage area, colour At least onecertified person on site should be trained & in place in case offrequency need forof lubrication tasks. guns and top-up containers, Amount, type and lubricant per machine lubrication; allhas personnel Ifclearly kept in accurate, visualisation a very completion should enable KPI data & reporting. described in their Job description. failures are due to rease guns colour and top-up containers, coded grease nipples and signs by typecompliance and frequency lubricant per certified in machine lubrication; allway personnel point. Ideally including machine criticality to aid involved lubrication should be trained. VISUALISATION Schedule (incl. %of overdue). positiveinimpact on the that lubrication Amount, oded greasemachines. nipples and signs KPI’S & METRICS focus. Colour code charts inby the storage area, colour in lubrication Ideally including machine criticality to aid involved should trained. least on onesite person on site should befactor trained & point. poor lubrication. isAtseen and be is an important Back-up personnel should betoin coded grease guns and top-up containers, s. Amount, type andbe frequency of lubricant in machine lubrication; all personnel incertified changing from&aprocesses “grease monkey” focus. Schedules should established down per If kept accurate, visualisation has a very place in case of need for should lubrication tasks. colour coded grease nipples and signspositive by point. Ideally including machine criticality to aid involved in lubrication be trained. “tribologist” mindset. to lubrication point level, not just machine. Back-up personnel & processes should be in TASK MANAGEMENT impact on the way that lubrication is seen on machines. focus. Task completion should enable KPI data ccurate, visualisation has a very positive Visual observations should be easily recorded place of need for lubrication tasks. site and is an important factor in changing fromin case Back-up personnel & processes should be in TASK PRECISION LUBRICATION SUCCESS MANAGEMENT & reporting. compliance PERSONNEL and assigned Schedule to maintenance teams. (incl. % n the way that lubrication on has a “grease monkey”isvisualisation toseen “tribologist” mindset If kept accurate, a very positive place in case of need for lubrication tasks. FACTORS overdue). Visual observations should be easily recorded TASK MANAGEMENT Any personnel involved in lubrication is an important factor in changing from is seen on impact on the way that lubrication MANAGEMENT Weand have summarised scores Visual observations should beteams. easily recorded andPROGRAM assigned to maintenance should have their lubrication role and is an important in against changingour from e monkey” to site “tribologist” mindset factor “health check” of lubrication standards Amount, type and frequency of lubricant per and assigned to maintenance teams. question assessment survey; responsibilities clearly described in their job Regular a140 “grease monkey” to “tribologist” mindset including product quality & effectiveness. point. Ideally including machine criticality to description. PROGRAM MANAGEMENT MANAGEMENT aidPROGRAM focus. Regular “health check” of lubrication standards Continuous improvement “moving into Regular “health check” ofprojects lubrication standards including product quality & effectiveness. the best practice zone”. including product quality & effectiveness. TASK MANAGEMENT Visual observations should be easily recorded Continuous improvementprojects projects “moving into Continuous improvement “moving into and assigned to maintenance teams. the best practice zone”. the best practice zone”.

PROGRAM MANAGEMENT Regular “health check” of lubrication THE LUBRICATION MANAGEMENT TOOL standards including product quality & effectiveness. Continuous improvement projects “moving THE LUBRICATION MANAGEMENT TOOL into the best practice zone”. THE LUBRICATION MANAGEMENT TOOL

THE LUBRICATION MANAGEMENT TOOL

For further information, please visit www.cmbpartners.com/lubeapp/ Issue 59 PECM

MEASUREMENT & MONITORING

Fiber Optic Temperature Measurement Solution for Medical and General Lab Applications Advanced Energy’s Luxtron® m924 fiber optic temperature sensor for medical and general research applications offers temperature ranges of -100 to 330ºC Various medical systems and research applications require the most reliable and highly accurate monitoring of a wide range of temperatures. Fiber optic temperature sensors (FOT) are particularly useful in providing such monitoring in applications and environments such as magnetic resonance imaging (MRI) and radio frequency (RF) implantable medical device testing where it may not be possible to deploy more conventional electronic measurement methods. Designed for systems that need precise and repeatable in-situ temperature measurements for control of processes involving RF, EMI, magnetic fields and high voltages, the Luxtron® m924 module uses FluorOptic® technology, based on a temperature-sensitive phosphorescent sensor attached to the end of an optical fiber. The complete m924 OEM solution consists of the electronics module assembly, Luxtron® probes and accessories. The small and rugged non-metallic and electrically non-conductive FOT probes are immune to EMI and voltages that adversely affect conventional sensors, such as thermocouples, RTDs and thermistors. By using material of minimal thermal conductance, these probes measure temperature on minute samples without perturbing or heat sinking the sample. Check out the m924 module at Advanced Energy’s booth S19 in Hall 8A of the MEDICA/Compamed show in Düsseldorf, which takes place November 14-17. Discover Advanced Energy’s broad medical power portfolio for standard and configurable products, including custom probes that meet specific lab and OEM requirements.

Four-channel FOT Module

m924 FOT Module -board

www.advancedenergy.com

Visilume’s range of Sight Glasses Visilume present our tried and tested range of sight glass assemblies and spares, suitable for a wide variety of process applications. Available in a range of materials, our sight glass and process vision solutions will be sure to cater for your needs. Typically used to visually verify stages of a process, inspect process media, and to observe liquid levels.

sales@visilume.com | +44 (0) 1457 865700 www.visilume.com

PECM Issue 59

Niton XRF Analysers MARKET LEADING PORTABLE ANALYSIS

Goods in Ensure raw materials are to specification.

Quality Control Check the right Alloy is in the right place.

Non-destructive final quality assurance on finished goods.

Maximise your scrap metal value.

01256 397 860 sales@nitonuk.co.uk www.nitonuk.co.uk

MEASUREMENT & MONITORING

The UK’s Laboratory Equipment Experts

THINK YOU KNOW LABTEX? THINK AGAIN. Labtex scale-up equipment, sourced from European and US manufacturers, is amongst the highest quality available.

Aerospace Bio-manufacturing Pharmaceutical Automotive Defence Chemical manufacturing

• Filtration • Fluid transfer • Process automation • Reaction vessel systems • Vacuum pumps and networks • Temperature Control -125oC to +425oC

For innovative process and control equipment, contact Labtex!

01484 600 200

info@labtex.co.uk

labtex.co.uk

The best Lubrication Management Software dedicated to the 5 "Rights" of Lubrication! Schedule all lubrication points including frequency, lubricant type and quantity Assign detailed lubrication and inspection task per point. Attach key documents like MSDS and COSHH Assign images to tasks and assets Raise and email "on the spot" action notes View due and overdue tasks Insert oil analysis, vibration and ultrasound readings Manage KPI's and produce reports, specific to precision lubrication Works on ALL mobile devices and computers!

info@lubeapp.com 01908 229641 80

PECM Issue 59

https://www.cbmpartners.com/lubeapp/

BS40: ULTRASONIC BROADBAND SENSOR

For Bearing Inspection & Acoustic Lubrication MADE IN GERMANY

Find out more

Preventive Maintenance

MEASUREMENT & MONITORING

VEGA UNVEIL NEW UK HQ VEGA

VEGA officially open their new building After a ‘slightly COVID delayed’ build and hand-over, it meant the official opening had to be slightly delayed too. Fortunately this also coincided with the 40th anniversary of the founding of VEGA UK, so a celebration was well overdue! On May the 25th 2022, guests from all over the UK, Ireland and Germany were welcomed to the new UK headquarters, with the event beginning with a welcome reception in the new training and demonstration areas. The building, named Metior House, was officially declared open and the ribbon cut by Isabel Grieshaber the CEO of VEGA Grieshaber KG and Ray Tregale the UK Managing Director. After an enjoyable lunch and music in the new cafe, guests toured the building, sampling products, as well as learning about the varied industries that VEGA are engaged in. It was then followed by an evening gala dinner with music and entertainment.

Isabel Grieshaber VEGA CEO and Ray Tregale UK MD cutting the ribbon to declare the building open

Managing Director Ray Tregale said, “Along with our exciting product portfolio, this high quality building is our vision and investment for the long term. We have carefully designed a spacious office, service centre, flexible training and seminar facility for generations to come.” He added, “It demonstrates our ongoing commitment to support our colleagues, product users and engineers from all industries.” Metior House is located in a beautiful area of East Sussex countryside, yet within easy

Along with our exciting product portfolio, this high quality building is our vision and investment for the long term. range of Gatwick airport, the M25 and railway connections to London. For motorists there is plenty of parking and EV charging available on site. This award-winning, carbon-neutral building features ample working space to provide support and service for everyone. “We’re already busy hosting seminars and training courses for all types businesses, the feedback has been excellent, we’re looking forward to welcoming many more people here.” Ray concluded.

For further information, please visit www.vega.com/uk, email info.uk@vega.com or call 01444 870055

PECM Issue 59

We bring colour into view! Compact pressure sensors and switches with 360° custom-colour status display

256 colours Individually Individually selectable: selectable: Measurement Measurement in in progress progress Sensor Sensor switching switching Process Process malfunction malfunction

15 cm

Compact Compact design design

Hygienic Hygienic adapter adapter system system

Adjustment Adjustment via via smartphone smartphone

STAND STAND NUMBER NUMBER

C52

www.vega.com/vegabar

MEASUREMENT & MONITORING

Tinytag data loggers monitor heat curing cycles during the production of custom made ocular prostheses Tinytag Ultra 2 thermocouple data loggers are used to record temperature data during the heat curing of medical grade acrylic at Manchester Royal Eye Hospital. NHS ocularists working in the Department of Ocular Prosthetics at Manchester Royal Eye Hospital are responsible for fabricating and fitting custom ocular prostheses, cosmetic shells and facial prostheses. Part of the fabrication process is the heat curing cycle, in which the medical grade acrylic which the prosthetic eyes are made out of is exposed to high temperatures so that it hardens and is suitable for wear. The ocularists use Tinytag Ultra 2 thermocouple data loggers to monitor temperatures during the heat curing cycle to ascertain that the acrylic has been cured at the optimum temperature (a temperature range of 200 C to 130 0 C for the correct amount of time). To monitor the heat curing cycle, the data logger’s thermocouple probe measures the temperature within the heat curing tank, while the data logger itself remains outside the tank recording the readings taken by the probe.

The data from each cycle is downloaded, viewed and analysed using Tinytag Explorer software. If the temperatures are found to have fallen outside the desired parameters, indicating that the acrylic may have not cured properly, the cycle is repeated to ensure that the prosthesis is properly cured.

Tinytag Ultra 2 Thermocouple data loggers are compatible with K, J, T and N thermocouple sensors and can measure from -200°C to +1370°C, offering fast response monitoring in high temperature applications.

www.geminidataloggers.com

Tinytag Data Loggers:

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Radio and LAN loggers

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Automatic data collection Bundles – 3 loggers/receiver/ software from £1000 +VAT

For sites requiring remote data access, Tinytag Radio and LAN loggers gather data automatically for viewing on a PC, across a LAN, or remotely across the internet. temperature

humidity

Gemini Data Loggers (UK) Ltd Scientific House, Terminus Road, Chichester, West Sussex, PO19 8UJ, England

PECM Issue 59

power usage

Telephone: +44 (0)1243 813000 email: info@tinytag.info www.geminidataloggers.com www.tinytag.info

co2

count

Indoor temperature & RH From £69 +VAT

voltage

current

PROCESS TECHNOLOGIES

New SEPURA™ app makes product selection even easier Global filtration specialist Bowman Stor, has announced the launch of a new SEPURA Technologies app for its extensive oil/water separator range. With a growing number of customers wanting genuine SEPURA™-branded units, the UKbased company has developed a unique mobile application. The new app allows users to access a handy OEM Comparison Tool to find the most suitable product for their needs - all by simply searching for their current manufacturer. Available on both Android and Apple platforms, the application also includes an easy-to-use oil/water calculator which helps establish the right size of filtration unit for the customer’s compressor system. Bowman Stor’s Managing Director, Richard Potts said: “The free SEPURA™ app makes life even easier for distributors, resellers and endusers in every industry. We believe this is the first app of its kind in the filtration industry and users can now source the best separator products for their needs from any location.” Only genuine SEPURA-branded products contain the groundbreaking SILEXA™ media - a revolutionary patented media developed through years of research in Bowman Stor’s

own laboratories. The SILEXA material has major environmental benefits, achieving outlet quality discharges as low as 5ppm. With SEPURA’s comprehensive range of oil/ water separator units and third party service kits covering low, medium and high capacity requirements for multiple industries, the app is the perfect way to find the ideal product for each specific use and send enquiries direct to the distributor.

To download the app Go to your App Store and search “Sepura Technologies”. To place an order or for further information on SEPURA’s unique range of filtration products contact: Multi Factor Europe Ltd., t: 01978 855995 e: sales@mfeuk.co.uk or visit our website.

Sepura App Advert 132x180L.qxp 15/03/2022 14:25 www.sepura-technologies.com Page 1

scan the code to go to the download page

Make life easier

Get the free App We have developed a mobile App that will make it easy to identify the right SEPURA™ product to fit your current oil/water filtration system. Not only that, we have also built in a calculator so you will know straight away which product from our comprehensive range is the correct one for you.

Our unique SILEXA™ filtration media is made from recycled materials and is more effective than any other filtration media currently available. Many users are now switching to our products over their existing OEM suppliers to meet their environmental commitments. SEPURA™ is part of the Bowman Group

www.sepura-technologies.com

t: e:

+44 (0)1543 379212 sales@sepura-technologies.com

Issue 59 PECM

PROCESS TECHNOLOGIES

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Surface Technologies CWST have developed a Post Additive Manufacturing process to: l Improve surface finish and surface characterisation l Improve component cleanliness l Remove support structures l Remove sintered surface l Surface compression and densification l Management of residual stresses l Improve fatigue life

www.cwst.co.uk | eurosales@cwst.com | 01635 279621 86

PECM Issue 59

PUMPS

Selwood and Borger create new pump partnership As it continues to invest record amounts in its fleet, Selwood, the UK leader in pump rental solutions, has agreed a new partnership with Borger. The arrangement commences with Selwood’s purchase of 15 custom-designed, positive displacement process-critical pumps to complement its existing stock of 5,000 pumps for rental; primarily in water and wastewater applications. Selwood and Borger have worked together for several years on a number of key sites, with this first official order being for Borger to provide its proven BLUEline Maintenance-InPlace pumps in three sizes; from 7.5kW up to 30kW; protected in stackable crash-frames. Mark Bebbington, Group Technical Solutions Director at Selwood, said: “As the UK’s leader in pump rental solutions and pump manufacture, we are committed to continual investment in our fleet. Over the years, we’ve seen how Borger’s macerators and rotary lobe pumps can complement our own stock; supporting our reputation for providing customers with exceptional products and service. Borger’s reliability, easy servicing and backup we receive from their teams are also important factors”.

“This new agreement support’s Selwood’s ability to provide the best possible solutions for our customers, including major water authorities across the UK”. David Brown, Managing Director of Borger UK, added: “Our companies work very well together, with a similar ethos. We look forward to strengthening what is already a very strong collaboration”. The 15 new Borger pumps (five of each size), have been designed and supplied to WIMES specification. Fitted with dry run, discharge pressure and suction monitoring, they are all compatible with Selwood Pumps’ in-house designed telemetry site monitoring system, SelWatch.

www.boerger.com

FLOW OPTIMIZATION SECOND TO NONE

THE NEW BLUELINE NOVA ROTARY LOBE PUMP The BLUEline Nova sets new standards in pump technology. With or completely without casing protection – the BLUEline Nova achieves unrivaled volumetric efficiencies. Made for one another – the newly developed DIUS rotors in combination with the flow-optimized pump chamber ensure perfectly smooth running at pressures of up to 12 bar.

EXCELLENCE – MADE TO LAST

BLUEline

NOVA www.newblueline.com

Börger UK Limited • East Wing • Watling St. Gailey • Staffordshire • +44 1902 798977 • uk@boerger.com • www.boerger.com 220318 ANZ UK NOVA 180 x132 mm_RZ.indd 1

18.03.2022 08:02:17

Issue 59 PECM

PUMPS

MAXIMISING THP PRODUCTION SEEPEX

Maximise Thermal Hydrolysis Production with Correct Pump According to government sources, there are 7,078 sewage treatment works (STW) in England and Wales, and 10,814 STW in Scotland and Northern Ireland. Pumping and storing sludge cake during the wastewater treatment process can be costly, driving water companies to technologies that reduce their volume to minimise such costs.

ANGLIAN WATER’S COTTON VALLEY

This can be achieved through conventional Anaerobic Digestion (AD) or through Advanced Anaerobic Digestion (ADD) processes, such as Thermal Hydrolysis Process (THP). ADD can reduce the volume of solids and increase the yield of biogas used to power engines. This can make plants energy self-sufficient or generate income by exporting power to the National Grid.

Their inability to transfer no more than 3.5m3/h (bottleneck and limiting biogas production) meant the site was not able to meet the design criteria limiting the amount of imported raw cake being handled to only 120 tonnes per day. Additionally, before pump maintenance could be carried out, the silo had to be emptied. This also meant cake imports from satellite sites had to be diverted, which resulted in substantial logistical costs.

PECM Issue 59

At Cotton Valley Sludge Treatment Centre (STC), one of Anglian Water’s ten main STCs, competitor’s progressive cavity pumps were installed to back mix the dewatered sludge and pump it into the THP. The two pumps were costing overall circa £100K per annum due to rotor and stator changes every 3-6 months.

SEEPEX supplied and installed two custom-made open hopper pumps with a dimensionally identical hopper to fit within the same footprint of the original pumps whilst delivering over 55% increased throughput capacity from 3.5m3/hr to 5.5m3/hr. Prior to the installation of the new pumps, Anglian Water was processing approx. 120 tonnes per day of imported sludge cake with both pumps running. With the new pumps installed, the customer is now able to exceed this by 50% (from 120 tonnes up to 180 tonnes) whilst maintaining the same footprint and motor size. “Due to the reliability and performance of the new SEEPEX pumps there is an increase in uptime of the cake import

Zero downtime and no drop off in performance with SEEPEX PC pumps and Digital Solutions facility at Cotton Valley,” explains Luke Fish, Production Manager at Anglian Water. “This has not only allowed us to increase the sludge throughput on site and therefore generate more biogas but has also given us significant savings in logistics and raw cake storage costs.” AT A MAJOR ADVANCED DIGESTION PLANT IN THE UK Existing competitor’s progressive cavity (PC) pumps at a large AD plant were unreliable, causing downtime to the thermal hydrolysis streams. When the THP feed pumps were offline, this affected production and biogas generation. To address this, SEEPEX delivered a custom-made open hopper PC pump fitted with Maintain-In-Place technology to replace the original pump, incorporating condition monitoring and digital solutions. SEEPEX Maintain-In-Place technology includes Rotor Joint Access (RJA) and Drive Joint Access (DJA) which simplifies maintenance and improves availability of equipment. To complement these features, the pump’s baseplate is manufactured in three pieces (on wheels) which enables individual sections of the pump to be removed for maintenance or major overhaul.

Due to the reliability and performance of the new SEEPEX pumps there is an increase in uptime of the cake import facility at Cotton Valley. SEEPEX Digital Solutions facilitate preventative maintenance, equipment availability and process optimisation, which has a direct impact on reactive costs and biogas production – contributing to net zero objectives and increased sustainability. Since installation, there has been zero downtime and no drop off in performance, and the sludge handling process has gained resilience. AT ANOTHER MAJOR UK THERMAL HYDROLYSIS PLANT SEEPEX open hopper pumps were used to replace unreliable chain conveyor systems. These pumps are used in two applications.

Firstly, to transport the imported dewatered sludge from the imported belt facilities at a capacity of up to 75 m3/h with dry solids up to 32% to either of the two pre-THP silos, enabling a 20-minute turnaround time for the trucks to unload and prevent backlog of vehicles. Secondly, to transport the indigenous dewatered sludge from the four decanting centrifuges to a third pre-THP silo. Pump maintenance is carried out at ground level, improving health and safety issues associated with working at height with the previous conveyor installation. In addition, with the new SEEPEX pumps, the site now benefits from increased availability of their THP streams with subsequent improvements in gas yield. THE KEY: RELIABILITY AND RIGHT FEEDSTOCK To achieve the full benefits of advanced digestion by thermal hydrolysis requires reliable and efficient delivery of feedstock to the process. SEEPEX solutions combine back mixing expertise with open hopper PC pump technology to both transfer and blend imported and indigenous dewatered sludges to the precise DS % content. This ensures optimum digestion and maximises biogas production, reducing carbon footprint.

For further information, please visit www.seepex.com Issue 59 PECM

SWITCHES & SENSORS

LIQUID DETECTION SWITCHES SST SENSING

Detecting the presence or absence of a liquid Knowing if you have a liquid at a point in your process or system can be critical to preventing expensive damage to components and ensuring optimal conditions for process performance. Checking for liquids where there shouldn’t be any or maintaining a fluid between set levels keeps cost of repair and maintenance down, ensures efficient running of systems and by consequence, lower cost of ownership for the customer. SST Sensing, a Process Sensing Technologies company, has been the leading manufacturer of low-cost optical liquid detection switches for over 18 years. Designed to detect the presence or absence of any water or oil-based liquid, SST’s range of miniature and high-pressure level switches are designed into many fluid control applications. From protecting expensive control cabinets from damage by water ingress to maintaining hydraulic and additive fluid levels in production equipment SST’s optical liquid detection switches have been the choice of system designers where reliable and lowcost switching is needed. Working in partnership with design teams has allowed SST to develop solutions for level and leak detection sensing in some of the trickiest applications where traditional float switches have been unreliable or require too much liquid to switch, or in viscous or continuously moving liquids humid environments. Solid state sensors with no moving parts to stick and designed in various fluid compatible plastics or stainless steel for the more aggressive and high-pressure environments SST’s optical liquid detection sensors only require 1mm of liquid to switch from dry to wet or wet to dry. In continuous use protecting run dry in tanks and pumps and overflow protection in industrial processes, optical liquid detection sensors have also replaced float switches in food and pharmaceutical reactors due to

their low profile, insensitivity to bubbles or foam and allowing stirrers and agitators to operate without hindrance.

SST Sensing, a Process Sensing Technologies company, has been the leading manufacturer of low-cost optical liquid detection switches for over 18 years.

SST’s in-house design and production teams work with customers to provide samples and test fluid compatibility and application specific details, offering standard or customised solutions that include cable and connector changes, hydrophobic coatings, food and pharmaceutical grade components and high vibration resistant switching. Choose liquid detection switches from SST Sensing. The leader in low-cost optical liquid control solutions.

For further information, please visit processsensing.com/level

PECM Issue 59

SOFTWARE & SYSTEMS

INNOVATIVE DIGITISATION SAB BROCKSKES

High Flexible Industrial Ethernet Cables Flexibility, efficiency and digitisation. This is industry 4.0 – the current subject of German manufacturing industry. Due to the complete linking and communication on all levels of the production process considerable amelioration with regard to productivity and flexibility may result. Today it is not quite clear how industry 4.0 in fully automated production will look like. Nevertheless, it is sure that a reliable transmission of increasing data volumes due to the steadily growing linking and communication of machine parts even under the most difficult conditions have to be ensured. As a consequence cables especially for machine construction, robotics or railway techniques are subject to extreme torsional stress and very high temperatures. These cables get in contact with different chemicals, oils or detergents. Also the subject of longevity with respect to industry 4.0 in industrial sectors are of basic importance. 70 years after its foundation, SAB Bröckskes presents itself highly innovative as answer to the mega trends of digitisation and industry 4.0 . The company presents a range of new industrial Ethernet cables 6, 6A, 7 and 7A that are not only extremely robust but also ensure a quick and efficient data transmission. SAB is not only a cable manufacturer but also offers support in automation technique for example in the range of new communication systems for drive technology. Herewith, the individual requirements of the customer and the longterm experience of SAB as manufacturer of highly flexible cables are combined in new products . The quick and flexible production of sample lengths is no problem at all. The cable manufacturer focus on two Industrial Gigabit Ethernet cables that have been especially developed for the increasing data transfer in automation technique. Besides the world innovation CATLine CAT 7A RT, a CAT 7 A cable for robot application, SAB Bröckskes is also going to present a cable chain cable with UL/ CSA approval – the CATLine CAT 7 A S.

INDUSTRIAL ETHERNET CABLES AND WIRES CATEGORY 6A AND 7A: CATLINE CAT 7 A RT – for robot application Gigabit Ethernet cable with UL/ CSA The cable CATLine CT 7 A RT for robot application is suitable for rough industrial conditions in automation technique for example at high temperatures, pollution by oil and aggressive chemicals. CATLINE CAT 7A S – FOR CABLE CHAIN APPLICATION GIGABIT ETHERNET CABLE WITH UL/ CSA

The cable chain cable CATLine CAT 7A S is suitable for rough industrial conditions in cable chains for example at high temperatures, pollution by oil and aggressive chemicals.

CATLINE CAT 6A HT – TEMPERATURE RESISTANT The temperature resistant cable CATLine CAT 6A HT is suitable for rough industrial conditions at temperatures up to fixed: -90°C/+ 180°C flexible: -55°C/ + 180°C.

CATLINE CAT 7A DR REELING CAT 7A GIGABIT ETHERNET CABLE

Our reeling CATLine CAT 7A cables have been developed for different applications whenever a considerable data volume must be transferred safely. They are for example used in stage technique of theaters, signal transmission and mobile trash rake cleaning or in high rack storage technique.

CATLINE CAT 7A R - RAIL CAT 7A

CATLine CAT 7A R acc. to DIN EN 45545-2, is especially appropriate for rail applications. The cable fulfills the requirements on no flame propagation of DIN EN 60332-3-25 + DIN EN 50305 section 9.1.1 + 9.1.2 and is flame retardant and self-extinguishing acc. to DIN EN 60332-1-2

SPECIAL SOLUTIONS FOR SPECIAL APPLICATIONS The production possibilities of SAB range from basic types and standard dimensions to special cables according to the individual requirements of our customers. New productions are already possible for small quantities – especially interesting for small and pilot productions. Cable manufacturer – SAB Bröckskes is a worldwide leading manufacturer of cables and wires, cable harnessing and temperature measuring technique. More than 60 years of experience in cable manufacturing as well as in temperature measuring technique have made out of a one man business a company with almost 500 staff members. The strength of SAB Bröckskes is not only the manufacturing of standard cables but also the construction of special items. Every year SAB manufactures more than 1500 special cables on customer´s request.

For further information, please visit www.sab-cable.com

PECM Issue 59

SOFTWARE & SYSTEMS / TOOLS

Snap-on’s Level 5 tool management system guards against FOD For engineers and technicians working in many industrial sectors FOD will always be a real and present danger. Keeping track of every tool and piece of equipment, especially when several storage cabinets are in simultaneous use, can be challenging. Snap-on Industrial’s Level 5™ automated total asset management system minimises the risk of FOD by constantly tracking every tool, detecting which tools have been removed or returned.

Powerful software enables users to review activity at all boxes in their location from one central computer, avoiding the need to inspect each box.

It also enables engineers and technicians to quickly find every tool they need, when they need it, saving time and easing stress. Engineered to track individual tools by user, without bar codes, scanners, RFID tags or other add-ons, the system works at the speed its users demand.

Major benefits of the system include:

Level 5™ boxes are network ready, using either Ethernet or wireless connection.

• • • •

No individual tool scanning required; No RFID tags to install or replace; Intuitive interface, via touch screen; Audible voice confirmation of tool removal and replacement; • Automatic locking for maximum security; • Errors announced and displayed to indicate incorrect tool position or advise when a drawer is not closed;

• Keyless access control for easy access by authorised users. Says Richard Packham, Director UK & Europe for Snap-on Industrial: “Snap-on’s automated system takes tool management to an entirely new level, giving workshop managers and other authorised users easy access to the tools they need, while protecting against foreign object damage. “The ability to monitor several boxes from one central computer offers managers a huge time saving advantage.”

For technical details visit: snapon-industrial.co.uk; call (01536) 413904 or e-mail: ukindustrialmarketing@snapon.com

PECM Issue 59

VALVES & FLOW CONTROL

Flotronic pumps Ltd Founded in 1981 in West Sussex, Flotronic Pumps is a world-leading manufacturer of air operated double diaphragm pumps (AODP). With the invention of our ground-breaking ‘One Nut’ pump design, Flotronic have revolutionised the application of diaphragm pumps throughout the industry. Over the last 30 years our ‘One Nut’ double diaphragm pump has proven its success in an incredibly diverse range of international industries including but not limited to pharmaceuticals, food & beverage, cosmetics, personal and household care and chemical manufacturing. Our global customer base can rely on our expertise in delivering the highest quality products as well as our abilities to provide engineering excellence, thus enabling them to achieve their competitive edge.

For more information please contact: +44 (0)1444 881871 or email salesteam@flotronicpumps.com

Myron L Company 900 Series™ Monitor/Controllers The innovative 900 Series Monitor/Controllers include everything you need to simplify water quality management and chemical dosing in industrial operations in one compact userintuitive instrument. Monitor 7 critical water quality parameters simultaneously from easily configured inputs: 2 Conductivity/Resistivity/TDS/ Salinity; 1 pre-amplified pH/ORP; 1 BNC pH/ORP; 1 0/4-20 mA; 1 RTD Temperature; and 1 Flow/Pulse.

% Rejection is available as a derived value. Outputs include up to 3 relays; 2 remote alarms; 1 0/4-20 mA; 1 0-10 VDC; and 1 RS-485 ASCII Serial Output. Flow Switch input can disable all relay outputs when triggered by loss of flow. Relays output to any usersupplied control equipment requiring up to 250V each and can trigger on any input parameter.

www.myronl.com Issue 59 PECM

VALVES & FLOW CONTROL

THE RSV SOLUTION DRALLIM

Drallim Rotary Selector Valve (RSV) for Critical Service Systems The RSV continues to collect new and interesting applications. It is a small bore, multiport, multibank rotary poppet valve system suitable for a variety of fluids operating from -1 +10 bar. The latest configuration has been created as the heart of a piece of equipment designed to monitor the conductivity and dissolved oxygen levels in water samples. The intention is to be able to divert the single sample stream through two different Conductivity Flow Cells and Cation Columns/Filters, but also with the capability to be able to reverse the flows to enable backflushing of the two Cation Columns/Filters while the system is in operation. The pictures show the valve in development with a complex flow diagram. At the same time, we continue to receive orders for bigger more complex systems

Our Rotary Selector Valve is used across many industries such as military, aerospace (including NASA), marine, industrial and nuclear. such as the emergency gas slam-shut system shown top right. Originally developed with ball valves which failed due to cross port leakage. The RSV solved an important safety issue and has proven to be a robust and reliable solution in this low temperature critical gas safety system.

Drallim offer full support to process equipment designers, to solve complex problems with the elegant RSV solution which is highly adaptable and available in Brass and Stainless Steel, with Fluoro Elastomer Seals and PTFE or ACETAL Resin Stems, according to service duty. The valve is used in many applications ranging from propeller pitch control, fuel change over systems, Emergency stop systems, bypass systems, and test circuits. The valve is also used in process systems such as partial stroke testing, water treatment and in override panels. Our Rotary Selector Valve is used across many industries such as military, aerospace (including NASA), marine, industrial and nuclear. Having been built since 1958, Drallim can still support fully, as well as replace using the exact same footprint all the while guaranteeing zero cross port contamination.

For further information, please visit www.drallim.com

PECM Issue 59

Permanently Open

Positive Indexing

Operative Connector

COME AND SEE US: HALL 1 | STAND E53

Base Entry

Venting Connector

Blanking Connector

VALVES & FLOW CONTROL

VALVE SOLUTIONS OLIVER VALVES LTD

Engineering ingenuity secures order for Oliver Valves Ltd

Oliver Valves Middle East distributor, GAS (Gas Arabian Services), won a half millionpound order but the sales value wasn’t the only significant highlight – it was Oliver’s Solution-Driven approach and distributor support that helped secure a second order in as many months. Oliver’s strong working relationship between the end-user and engineering consultants meant that we were able to quickly advise on using a Double Block and Bleed Valve suitable for their application, and not a traditional tubing design. When GAS received the second enquiry for 150 x Double Block and Bleed Valves, they contacted Oliver Valves and together we looked at ways to further reduce the cost to the end-user, Saudi Aramco. With state-of-the-art Research & Development facilities in the UK, our

Valve distributors across the world rely on the support, knowledge and expertise of valve manufacturers. engineering team soon jumped at the challenge. The brief to R&D was simple – save the customer money, even if it meant re-designing a DBB valve. In just 2 days, Oliver’s engineers found the perfect costsaving solution; to reduce the face-to-face dimensions of the valve by as much as 17%. This equated to saving the customer an additional 10% - hugely significant for this size of order.

The ingenuity of the Oliver engineering team and our strong sales distributor relationship with GAS led to securing both orders from Saudi Aramco. We’ve been providing valve solutions to the global energy sector for over 40 years, investing heavily in R&D, and our distributor network. Project Sales Engineer Eon Morrison, who worked with Haridas Embanath, Business Development Manager, to find the solutions, said “We’re well placed to provide world-class support to our distributors, and can react quickly to the needs of our customers with great products and the very best valve solutions”. Valve distributors across the world rely on the support, knowledge and expertise of valve manufacturers, and Oliver Valves are testament to this. For more information on distribution and valve solutions, visit our website at www.valves.co.uk.

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

PECM Issue 59

Portable Fume Extraction, Ventilation and Cooling Solutions Where fumes, smells or dust occur, our Miniveyor Air VAF series fans can move contaminated air out of a confined space or building. They effectively exhaust fumes, ventilate confined spaces, and increase the flow of fresh air. VAF-COOL evaporative coolers offer an alternative solution to conventional refrigeration systems or air conditioners. The coolers are portable so provide a highly flexible solution, and their low energy consumption means they are economical to use, kinder to the planet, and unlike air conditioners, they don’t rely on a closed environment, so can be used in more open spaces, such as warehouses, factories, event spaces, agriculture building, and sports arenas.

VAF Air Ltd Tetbury, United Kingdom sales@vaf-air.com +44 (0)330 016 0002

www.vaf-air.com

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