PECM - Issue 60 2023

BAUER - 6

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

Out of the Box

Such is our confidence in this technology we offer an unparalleled 5 year full warranty on all models

MANUFACTURING Engineering Process Control &

BURKERT

The ways in which manufacturers of process control equipment are making life easier for the plant operators and maintenance technicians

BRANDAUER

Former Birmingham apprentice is named as one of the top 20 manufacturing professionals in the UK

V-EX

Why your Exhibition stand needs a digital twin…

SOUTHERN MANUFACTURING SHOW

Thousands of visitors will be heading to the Farnborough International Exhibition and Conference Centre

BROANMAIN PLASTICS

Broanmain paves the way for sustainable mass-manufacturing at SM&E

Cover photo: Sulzer

FANUC

Fanuc support helps samey robotics to revolutionise fresh fish supply chain

MITSUBISHI ELECTRIC

Making productivity sustainable

INTERTRONICS

Dispensing robots: What’s the risk?

WSCAD

E-CAD integration reduces time to market by 80% for automation control specialist

TOBERMORE

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

WEG

Halifax fans and WEG motors help ventilate the world’s first full-scale liquid air energy storage facility

The leading source for innovators in Technology, Manufacturing and Maintenance within the Engineering & Processing industry worldwide.

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MANUFACTURING Engineering Process Control &

The Team

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EDITOR

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EDITOR’S

LARGE SCALE RETROFIT

BAUER

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

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

While the operating life of a motor can exceed 10 years, eventually plant managers will need to upgrade to a new efficiency standard or replace faulty units. However, the footprint and interfaces of new

equipment will almost never match up to the original, which can make retrofitting a modern motor problematic. Complex mechanical adaptations to fit the new unit can be very time consuming. With demand and prices for steel and alloy through the roof, any extended downtime for a retrofit project at a steel mill must be avoided.

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

out a motor retrofit project – which would require extensive mechanical adaptation for each unit - was unacceptable.

Consequently, Aperam approached Bauer Gear Motor, a leading brand of Altra Industrial Motion Corp., to provide a plug and play motor retrofit solution.

Bauer Gear Motor is a world leader in geared motor technologies, with a proven track record in providing highly robust and reliable drives for use in challenging metal industry applications. Focused on delivering motors that attain the highest efficiency standards, Bauer also offers operators in the metal industry a plug and play retrofit solution for drives operating on roller table conveyors.

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

The Bauer retrofit solution features two key elements. A standardised shaft connection using either a flange or coupling ensures increased ease and speed of installation. This is matched by a foot adaptor plate, which allows a one-to-one changeover between the old and new motor. A plug and play design eliminates the need for any costly, time consuming mechanical adaptations. Consequently, retrofitting new motors can be done with minimal downtime.

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

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

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

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

For further information, please visit www.bauergears.com

What was key for the Aperam project was that we could offer a plug and play solution as a complete package, which was particularly important to engineers at the facility

The motor retrofit solution features a standardised shaft connection and foot adaptor plate, unlocking plug and play motor replacement.

Roller table conveyors are used to move hot, heavy slabs of metal, with each roller powered by a dedicated motor.

Custom Inline

You design, we create

Helapet knows that no single filter can be suitable for the varied filtration applications that are used across industries. Our new online design tool provides customers with a simple-to-use design wizard, combined with enhanced information to guide customers through the 100’s of available filter combinations.

The High Performance Workhorse for High Pressures & High Temperatures

Meet the high performance doubleeccentric butterfly valves, GEMÜ R470 series, perfectly suited for applications with high pressures and temperatures. Available in nominal sizes from DN 50 to DN 600, this robust workhorse can take pressures up to 40 bar or temperatures up to 230 °C. The double-eccentric construction directly separates the disc from the seat (gasket), which reduces friction making the valves remarkably more durable and therefore increasing service life. Another features of the GEMÜ R470 is the continuous shaft with temperature resistant graphite bearing providing additional safety measures as well as the PTFE gland packing that can be adjusted in operation to minimize leakage, even at low pressures. This significantly reduces the maintenance requirements after installation. Antistatic fixtures are available as optional for use in an ATEX environment. Thanks to the optimized disc design in spherical form, the GEMÜ R470 offers excellent sealing and guaranteed mechanical functionality even at the highest pressures and temperatures. Made from PTFE TFMTM, the sealing ring is robust and versatile, ensuring excellent reliability for use in most process applications.

For more information, click here. Check out our video tutorial on how to modify a Butterfly Valve to a pneumatic, single-acting Normally Open or Normally Closed (NO/NC) actuator.

Tel: 01925 824044

Email: enquiries@gemu.co.uk Web: www.gemu.co.uk

Prokem is one of the nation’s leading acid resistant and epoxy flooring contractors

Formed in 1998 by industry specialists, Prokem is one of the nation’s leading acid resistant and epoxy flooring contractors. We have over 40 years’ experience in laying floors for a range of business requirements in locations across the UK and worldwide.

Epoxy flooring for a range of industries

As expert epoxy flooring contractors we can identify the needs of our customers and offer them the correct flooring solution for their business needs. We’ve supplied industrial flooring solutions to a wide variety of businesses across the UK. The industries that we’ve covered include: –

• Petrochemical

• Chemical Processing

• Steel

• Power Generating

• Water

• Fertilizer

• Pulp and Paper

• Food-Processing

• Beverage

• Engineering

You can arrange a quote and speak to our customer services team by calling 07713856433 or emailing info@prokem.co.uk. We will offer you honest and tailored advice on your industrial requirements and find you the industrial flooring solution that meets your needs.

ULTRAMAX BATTERIES

UK’s Largest Independent Distributor and Manufacturer of Batteries

UltraMax is the manufacturing division of the UK’s largest independent distributor and manufacturer of batteries, supplying over 150 million cells per year globally. We specialise in the manufacture of lithium and custom-built battery packs for OEMs with production sites in the Far East and the UK. We design and manufacture for various industries such as energy storage, industrial, automotive, garden and power tools, medical equipment, defense, robotics, and security. We have a wide range of expertise in managing mechanical equipment, specialist battery engineering, distribution, and storage of lithium batteries.

STOCKS

As well as bespoke battery packs, we also keep a wide range of generic lithium batteries, such as 100Ah-12V, at our north London depot for next-day nationwide delivery. We also keep stocks in Europe at our Dutch facility.

CUSTOM DESIGN AND BUILD

Our objective is to gain a detailed understanding of your requirements and then design and build a bespoke battery pack. Once this is achieved, we will efficiently scale up our manufacturing processes to meet your delivery requirement. Our experience and wealth of expertise enable us to demonstrate a proven track record of delivering projects on time and on budget.

TECHNICAL SUPPORT WHEN NEEDED

We provide technical support throughout the life cycle of our products, from initial design through qualification, manufacturing, managing distribution and transportation, and if requested, disposal. Every step requires in-depth experience and compliance with relevant regulations to ensure total reliability, safety, and environmental protection.

With UltraMax, you can be confident of a highly experienced, competent, and relentless focus on quality service and control, using the most advanced methodology and continuous innovations.

BATTERY PRODUCTS

We offer all battery chemistries and specialise in lithium rechargeable and lithium primary battery packs. We provide both direct lead acid battery replacement and custom-built battery packs, portable power and energy storage solutions complete with electronic control.

Our power solutions offer outstanding energy density and power output over a wide range of conditions. This is made possible by our use of innovative designs and advanced cell chemistry.

If you have a battery pack requirement, do not hesitate to contact us on +44 (0) 208 803 8899 or email sales@ultramax.co.uk.

For more information on our battery solutions, visit www.ultramax.co.uk.

With UltraMax, you can be confident of a highly experienced, competent, and relentless focus on quality service and control.

C M Y CM MY CY CMY K

NEW TEAM, NEW TECHNOLOGY

THORITE

Company to attend Southern Manufacturing & Electronics show

Compressed air and fluid power specialist Thorite will launch its new dedicated Electronic Automation (EA) Team at the Southern Manufacturing & Electronics show in February.

The Bradford based company will also be unveiling new products and technology at the event, to be held at the Farnborough International Exhibition and Conference Centre in Hampshire from February 7th to 9th.

Visitors to the show will be able to meet EA Technical Development Manager Mik Rhodes who will be on-hand to explain how Thorite can help original equipment manufacturers (OEMs) unlock the potential of electronic automation to develop equipment that delivers faster changeovers and improved productivity.

The team will employ demo units to explain the best uses for pneumatic and electronic automation, as well as electric pick and place grippers demonstrating the range of motion available with the latest technology.

Tom Simpson, Marketing Co-Ordinator for the EA Team, said: “Electronic automation is increasingly being recognised by OEMs as a more efficient alternative to pneumatic power on some machinery.

excited to be sharing it at the Southern Manufacturing & Electronics show, which is a highlight of the engineering events calendar.”

Thorite’s Systems Team will be available to discuss everything from panels and valve islands to compressor and OEM subassemblies.

Thorite will also use the event to introduce the newly launched Ultima range of oilfree compressors from Gardner Denver, which are 37% smaller and 13% more efficient than comparable compressors and have no need for ducting thanks to their internal heat exchangers.

Thorite’s in-house pump expert will provide hands-on demonstrations using a cut-away unit of Graco’s new gamechanging EODD pump, QUANTM, that requires zero compressed air and deliver up to 80% reduction in energy consumption, whilst maintaining the proven AODD benefits.

The Southern Manufacturing and Electronics show boasts a diverse range of suppliers which attracts manufacturers ranging from major players to SMEs, from across the UK and continental Europe.

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

“We have expanded our expertise over the years in line with this shift and we’re

Thorite’s Systems Team will be available to discuss everything from panels and valve islands to compressor and OEM sub-assemblies.

design and commissioning of bespoke systems solutions ranging from small assemblies through to fully

design and commissioning of bespoke systems solutions ranging from small assemblies through to fully

Thorite service are on hand 365 days a year to help your business. Offering a range of aftermarket services to ensure consistent operating performance while prolonging the life of your equipment, saving you time and money.

Thorite service are on hand 365 days a year to help your business. Offering a range of aftermarket services to ensure consistent operating performance while prolonging the life of your equipment, saving you time and money.

NEW CUSTOMER SOLUTIONS

EXPROMET

Consolidation following the acquisition of NC Precision

Metaltech Precision, part of the Expromet Technologies Group, is pleased to announce that, through the acquisition of NC Precision which took place in May, it has expanded its sliding head machining capacity at its Somerset facility and now boasts a wider range of equipment and capabilities to cater for the most complex of parts.

WIDER RANGE OF PLANT AND EQUIPMENT

Following the recent acquisition of NC Precision, a leading manufacturer of precision components, equipment and employees have now been transferred to the Metaltech premises. The seven sliding head machining centres have found a new home alongside Metaltech’s existing sliding head machines in a dedicated sliding head cell and are providing a welcome boost to production capacity. The new L32 which was already on order, was delivered and

installed ahead of the move.

IMPROVED FACILITIES FOR MICRO MACHINING

Metaltech has taken this opportunity also to set up a dedicated cleaning, deburring and inspection cell, providing specialist facilities which extend our capability to offer micro machining of miniature components.

EXPERIENCED OPERATIVES

We are delighted to welcome the highlyexperienced team from NC Precision to Metaltech to help us continue to deliver and expand upon the precision engineered solutions we offer our diverse customer base at the highest levels of quality and service.

HELPING OUR CUSTOMERS TO GROW IN 2023

We are working closely with existing and new customers to understand how we can

further strengthen relationships and offer them additional support in preparation for their growth during 2023.

EXPROMET TECHNOLOGIES GROUP

Expromet Technologies Group is a privately-owned precision engineering group. In addition to Metaltech Precision and NC Precision, the group also includes Investacast, a leading global supplier of investment castings, pressure die castings and forgings with a manufacturing base in Ilfracombe, Devon; and Haworth Castings, a specialist in manufacturing fully-tested, machined and finished sand and gravity die castings located in Romsey and Basingstoke, Hampshire.

If you would like to talk to Expromet about our extended capacity for CNC Turning and Milling, please get in touch on + 44 (0) 1271 866200 or email enquiry@expromet.com.

For further information, please visit www.expromet.com

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.

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

EQUIPMENT QUALITY

• 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.

• 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.

UNPARALLELED AFTER SALES SUPPORT

CUSTOMER CONFIDENCE

• 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

• We provide a dedicated technical support line which you can call for any technical support queries

• 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

• 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

BE VIGILANT WHEN PURCHASING EQUIPMENT WITH EXTENDED WARRANTY

WITH JASIC 5 MEANS 5

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 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

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

Available in the UK from Labtex, Vacuubrand manufactures a comprehensive range of laboratory and instrumentation vacuum pumps, gauges and controllers for both coarse and fine vacuums. Vacuubrand’s first priority is to offer sophisticated equipment which meets the highest quality, professional standards expected of a modern laboratory. For example, ‘intelligent pumps’ make lab work more efficient, allowing chemists and technicians to focus their attention on other tasks.

The versatile Vaccubrand chemistry pumping unit, PC 3001 VARIO select

• Unsurpassed performance

• Uncompromising chemical resistance

• Fully automatic evaporations

• Minimal operating and maintenance costs

• Whisper quiet

• Environmentally friendly, without oil and water consumption

• The Vacuubrand Chemical Resistance Chart

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

www.labtex.co.uk

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

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

The Vacuubrand chemistry diaphragm pump MZ 2C NT

• Contamination-free conveying and evacuation

• Outstanding chemical resistance

• Whisper quiet

• High pumping speed close to ultimate vacuum

• Long diaphragm life, maintenance-free drive system

• Extra low vibration

The Vacuubrand Chemical Resistance Chart

Chemical resistance is essential when working with aggressive gases and vapors. You will find detailed information on chemical resistance for our chemistry diaphragm pumps on at labtex.co.uk

www.labtex.co.uk

Vacuubrand’s high-quality and reliable range of chemistry diaphragm pumps, are designed for working with aggressive gases and vapors!

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

SPRINGWORLD 2022

ALLOY WIRE INTERNATIONAL

Technical expertise and short lead time prove a major attraction for AWI at CASMI

Alloy Wire International’s technical knowledge was in big demand when it returned to SpringWorld 2022 (CASMI) recently.

Hundreds of delegates from USA, Canada and Mexico visited the UK’s leading manufacturer of round, flat and profile wire to discuss the firm’s new INCONEL alloy 686 and to tap into its technical knowledge.

Spring manufacturers were keen to discuss exciting projects destined for the aerospace, automotive, chemical and petrochemical processing, oil and gas extraction and marine environments.

There was a common thread throughout

the conversations, which focused on the need for earlier development support and having availability of material in short lead times, something AWI currently has access to due to its unprecedented investment in maintaining 400 tonnes of stock at any one time.

“It was excellent to meet so many existing and potential new customers face-to-face and CASMI certainly didn’t disappoint in terms of footfall and the quality of visitors,” explained Stephen Olley, Sales Executive at AWI.

“Our clients require material that can work in all types of demanding applications from intense heat and sub-zero temperatures to highly corrosive environments. That is why

we were so pleased to launch INCONEL alloy 686 after months of trials and testing.

“This single-phase, austenitic alloy delivers excellent resistance to general and stress corrosion cracking that can occur in aggressive liquids and gases and, judging by the conversations we were having, there appears to be a lot of opportunities for us to supply this material.”

He continued: “It was also great having Andrew Du Plessis there to talk in-depth about technical requirements. This included finer details of our nickel alloys, such as heat treatments to achieve a certain tensile strength after ageing and which alloys are better suited to working in different, corrosive environments.”

Alloy Wire International provides more than 62 exotic alloys to more than 7500 customers across the world, with material available in sizes ranging from .001” (0.025mm) to .197” (5.00mm) and lead times often within 3 weeks of the order being placed.

The company, which celebrated 75 years in business in 2021, recently promoted Tom Mander to Managing Director, with previous MD Mark Venables moving upstairs to the position of Chairman.

This is an exciting next step in the AWI journey and will accelerate its ambition to increase sales from its current £13m level to £15m by the end of the year, with most orders now coming from clients overseas.

For further information, please visit www.alloywire.com or follow @alloywire on twitter

It was excellent to meet so many existing and potential new customers face-to-face and CASMI certainly didn’t disappoint in terms of footfall and the quality of visitors

HEATSENSE CABLES

CABLE INNOVATION

CABLE INNOVATION

CABLE INNOVATION

HEATSENSE CABLES

HEATSENSE CABLES

Specialist High-Performance thermocouple and signal cable manufacturer continues to broaden its manufacturing capabilities

Specialist High-Performance thermocouple and signal cable manufacturer continues to broaden manufacturing capabilities

Specialist

High-Performance thermocouple and signal cable manufacturer continues to broaden its manufacturing capabilities

CAPABILITIES

BACKGROUND

CAPABILITIES

Heatsense Cables is the UK’s leading specialist high performance thermocouple and signal cable manufacturer. The company is highly customer focussed and offers a bespoke technical design and manufacturing service, rapid response times, short lead times, low MOQ’s and competitive pricing. The company is a technology leader in fluoropolymer extrusion, high performance taping and cable wrapping. Related processes include cover sintering, colouring, etching and the application of various specialist coatings. The range covers cables that operate in extreme environments; cables resistant to flame, oils & chemicals and which operate in ultra-high vacuum, cryogenic and high radiation environments.

Heatsense Cables is the UK’s leading specialist high performance thermocouple and signal cable manufacturer. The company is highly customer focussed and offers a bespoke technical design and manufacturing service, rapid response times, short lead times, low MOQ’s and competitive pricing. The company is a technology leader in fluoropolymer extrusion, high performance taping and cable wrapping. Related processes include cover sintering, colouring, etching and the application of various specialist coatings. The range covers cables that operate in extreme environments; cables resistant to flame, oils & chemicals and which operate in ultra-high vacuum, cryogenic and high radiation environments.

Heatsense Cables, www.heatsensecables. co.uk , established in 1984, is regarded as the UK’s leading specialist high-performance thermocouple and signal cable manufacturer. Its manufacturing capabilities cover a broad range of specialist cables that operate in extreme (harsh) environments. The company is a technology leader in fluoropolymer extrusion, high-performance taping and cable wrapping. Related processes include cover sintering, colouring, etching and the application of various specialist coatings. The range covers cables that are resistant to flame, oils & chemicals and which operate in ultra-high vacuum, cryogenic and high radiation environments.

INSULATION & BRAIDING EXPERTS

INSULATION & BRAIDING EXPERTS

The company offers a bespoke advanced technical design and manufacturing service and undertakes development work on new cable designs and materials.

Insulation materials include; PFA, FEP, PTFE, ETFE, EFGLAS, SILICONE, PE, PU, PVC, Taped & Sintered PTFE, Polyimide, Aramid, PTFE impregnated yarns and Mica.

Insulation materials include; PFA, FEP, PTFE, ETFE, EFGLAS, SILICONE, PE, PU, PVC, Taped & Sintered PTFE, Polyimide, Aramid, PTFE impregnated yarns and Mica.

INSULATION & BRAIDING EXPERTS

PFA, FEP, PTFE, ETFE, EFGLAS, SILICONE, PE, PU, PVC, Taped & Sintered PTFE, Polyimide & Aramid Yarns, PTFE impregnated yarns and Mica.

Braiding materials include glass, quartz, ceramic fibre and other specialist yarns and various metals.

Braiding materials include glass, quartz, ceramic fibre and other specialist yarns and various metals.

PRODUCTS

Braiding materials include glass, quartz & ceramic fibres, other specialist yarns and various metals.

PRODUCTS

The company manufactures a broad range of cables including; thermocouple cables, RTD cables & PRT wires, sensor wires & cables, cryogenic cables, glass, quartz, ceramic fibre and pure nickel cables, the INTEMP® Range (250°C - 1250°C), radiation resistant cables, equipment wires & cables, high voltage cables, multicore cables, micro wires & cables, micro-coaxial cables, high-flex braided cables and PTFE yarns & threads. To support these activities Heatsense has its own specialist thermocouple calibration facilities and cable testing laboratory.

The company manufactures a broad range of cables including; thermocouple cables, RTD cables & PRT wires, sensor wires & cables, cryogenic cables, glass, quartz, ceramic fibre and pure nickel cables, the INTEMP® Range (250°C - 1250°C), radiation resistant cables, equipment wires & cables, high voltage cables, multicore cables, micro wires & cables, micro-coaxial cables, high-flex braided cables and PTFE yarns & threads. To support these activities Heatsense has its own specialist thermocouple calibration facilities and cable testing laboratory.

PRODUCTS

The high-performance cable range includes thermocouple cables, RTD cables & PRT wires, sensor wires & cables, micro-wire & miniature cables, cryogenic cables, heat resistant cables & wires – the INTEMP™ range of cables, glass fibre, quartz, ceramic & pure nickel cables, radiation resistant wires & cables, equipment wires, UHV & low outgassing cables, high-voltage wires & cables, micro-coaxial cables, bespoke cables, multicore cables, high flex braided cables, PTFE yarns and PTFE cable tapes & cords.

INDUSTRY4.0

EXPANSION

Heatsense has fully embraced LEAN manufacturing techniques and has made substantial progress on its continuous improvement journey. The company is currently working on Industry 4.0 technology, utilising digital processes on individual production lines to further improve efficiencies, quality and throughput rates.

Markets include, aerospace, nuclear, automotive,, medical, R&D, oil & gas and general industry. The company offers a range of approvals which meet internationally recognised specifications.

Markets include, aerospace, nuclear, automotive,, medical, R&D, oil & gas and general industry. The company offers a range of approvals which meet internationally recognised specifications.

See our online catalogue https://www.heatsensecables.co.uk/products/ heatsense-cables-product-catalogue

EXPANSION

Heatsense remained extremely active during the COVID lockdown period. Over the course of the last twelve months Heatsense acquired plant & equipment, including 16 additional high speed yarn braiders, a PTFE Paste Extrusion Line, a horizontal twin headed taping line, an additional corona etcher and refurbished and upgraded a number of manufacturing lines. The company also upgraded its internal manufacturing systems and ‘went live’ on a new fully integrated ERP system.

Heatsense remained extremely active during the COVID lockdown period. Over the course of the last twelve months Heatsense acquired plant & equipment, including 16 additional high speed yarn braiders, a PTFE Paste Extrusion Line, a horizontal twin headed taping line, an additional corona etcher and refurbished and upgraded a number of manufacturing lines. The company also upgraded its internal manufacturing systems and ‘went live’ on a new fully integrated ERP system.

EXPANSION

The company continually strives to broaden its manufacturing capabilities

The company continually strives to broaden its manufacturing capabilities

Heatsense continues to add specialist plant &equipment and over the last twelve months has installed a PTFE paste extrusion line, 26 additional high-speed braiders, a horizontal dual headed taping line, an additional corona etcher and refurbished and upgraded several

and improve efficiencies. The company continues to develop its digital strategy encompassing shopfloor data capture, ERP, CRM and machine automation.

and improve efficiencies. The company continues to develop its digital strategy encompassing shopfloor data capture, ERP, CRM and machine automation.

upgraded its internal manufacturing systems and went live on a new fully integrated ERP system. Heatsense has recently acquired the Cords & Lacing Tapes business from Carlisle Interconnect Blackburn.

This acquisition will present additional opportunities in the aerospace market.

MARKETS & ACCREDITATIONS

Heatsense is ISO9001:2015 and ISO14001:2015 Accredited and has F4N Status (Fit for Nuclear), awarded by the Nuclear Advanced Manufacturing Research Centre. The company is in the process of working towards AS9100D:2016 Accreditation and expects to be accredited by the end of this year.

Heatsense is ISO9001:2015 and ISO14001:2015 Accredited and has F4N Status (Fit for Nuclear), awarded by the Nuclear Advanced Manufacturing Research Centre. The company is in the process of working towards AS9100D:2016 Accreditation and expects to be accredited by the end of this year.

Markets include aerospace, nuclear, automotive, medical, R&D, oil & gas and general industry.

T: +44 (0) 1706 767070 W: www.heatsensecables.co.uk

T: +44 (0) 1706 767070 W: www.heatsensecables.co.uk

Heatsense is EN9100:2018, ISO14001:2015 Accredited, has F4N (Fit for Nuclear) Status and is Cyber Essentials Plus Certified.

For further information please visit www.heatsensecables.co.uk and/or contact sales@heatsensecables.co.uk

For further information please visit www.heatsensecables.co.uk and/or contact sales@heatsensecables.co.uk

For further information please visit www.heatsensecables.co.uk and/or contact sales@heatsensecables.co.uk

MIPC® shortlisted for the Best

Online Education Initiative memcom membership excellence awards 2020

Smaller, lighter and without time-consuming lens changes. The ImageIR® 6300 Z is predestined for demanding applications in research and development as well as for stationary or airborne inspection and monitoring tasks. Further applications can be found in quality assurance, materials testing or in a wide range of OEM integration solutions.

Smaller, lighter and without time-consuming lens changes. The ImageIR® 6300 Z is predestined for demanding applications in research and development as well as for stationary or airborne inspection and monitoring tasks. Further applications can be found in quality assurance, materials testing or in a wide range of OEM integration solutions.

Features:

Features:

■ Cooled focal plane array photon detector operating in snapshot mode with (640 × 512) IR pixels

■ Cooled focal plane array photon detector operating in snapshot mode with (640 × 512) IR pixels

■ Standard built-in 7.5x zoom lens with motor focus

■ Standard built-in 7.5x zoom lens with motor focus

■ Focal length of (15 ... 115) mm or (25 ... 170) mm

■ Focal length of (15 ... 115) mm or (25 ... 170) mm

■ Operation via smartphone or tablet with integrated web interface

■ Operation via smartphone or tablet with integrated web interface

■ Compact size and low weight for space-saving system integration

■ Compact size and low weight for space-saving system integration

■ Storage of large amounts of data on the integrated SSD

■ Storage of large amounts of data on the integrated SSD

InfraTec distributor in the UK and Ireland:

InfraTec distributor in the UK and Ireland:

Quantum Design UK and Ireland Ltd,

Quantum Design UK and Ireland Ltd,

1 Mole Business Park, Leatherhead, Surrey KT22 7BA Tel: +44 (0)1372 378822 | Email: info@qd-uki.co.uk

1 Mole Business Park, Leatherhead, Surrey KT22 7BA Tel: +44 (0)1372 378822 | Email: info@qd-uki.co.uk

RELIABLE TEST CHAMBERS

Achieving Stability and Minimising Fluctuation

JTS is a leading UK manufacturer of environmental test chambers. Our mission is to design and build robust environmental test chambers, working closely with our customers to provide innovative solutions for their own product development and quality assurance.

An issue faced by many customers is how to achieve the most test capacity without impacting on chamber performance. Putting the maximum test load in and still achieving even distribution and stability is a challenge when building bespoke equipment. Airflow is key and having a good understanding of how a customer will load their product ensures the best results are achieved.

For one JTS customer who’s test cycle lasts several months, incorporating steady slow ramps and long dwells, humidity distribution is critical. For them the distribution accuracy is so paramount the chamber is regularly calibrated using the 9 point mapping system. One probe in each corner just away for the chamber wall and one in the centre, the allowable tolerance in this scenario is 2% rh. During tests if the humidity fluctuates out of specification in any area of the chamber, the test is aborted.

Bespoke racking can help resolve distribution issues and the rack on this recent project was built to ensure good even air flow and ensure stability. With a temperature range of -20°C to +80°C and a humidity range of 20 to 98% the chamber spends a lot of time testing at high temperature and high humidity, over 95%. These conditions are harsh, so the test frame was built of stainless steel and to enable easy product loading, sliding compartments were incorporated in the design. Fully loaded this racking weighs around 600kg, so a reinforced chamber floor was essential.

Reliability of chambers that do long term testing is essential, down time causes testing backlogs and unwanted stress. Time spent understanding what is required of a chamber and how it is going to be

used, ensures JTS get the design and build correct. This in turn enables us to keep to our mission, to design and build robust, innovative solutions for our customers - something to rely on.

For further information, please visit www.jts-test-chambers.co.uk

Bespoke racking can help resolve distribution issues and the rack on this recent project was built to ensure good even air flow and ensure stability.

PROCESS IMPROVEMENTS

NORTHRIDGE PUMPS

Improving Marine Fuel Pump Unloading Performance

Unloading pumps are designed to unload a vessels or oil tankers liquid cargo in the shortest possible amount of time when receiving bulk deliveries of fuel. Oil cargos are typically transported via vessel as it is the most economical form of transportation for bulk cargo transfer and is only surpassed if fuel oils can be transferred via a pipeline eliminating double handling.

An overseas electricity provider contacted us who were having issues unloading light fuel oil (LFO) from their barge. The port would regularly receive shipments of oil cargo by vessel which docked over 50M away from the pump. The unit would operate for approximately 16 hours a day, unloading marine fuel for transfer to an oil storage tank located nearly 300M away, which was 10M high.

The customer was experiencing issues with their existing pump which was undersized, noisy and they wanted explore whether a better solution was available to improve marine fuel pump performance and reduce the amount of time vessels were kept moored at port and underutilised whilst discharging cargo.

UNDERSIZED FUEL TRANSFER PUMP

The customer was experiencing several tell tale signs that their pump was undersized. Their screw pump which technology is normally very quiet was producing high levels of noise, there seemed to aeration of the pumped fluid which was detected by their Coriolis Flow Meter, flow rate was less than what the unit was designed for and flow was turbulent meaning there was the potential for inconsistent metering of unloaded fuel as some designs of flowmeters rely on a steady flow of fluid- all symptoms of what happens when a pump is undersized. Furthermore, when the vessel used a pump located on the vessel to boost flow, the aforementioned issues disappeared.

UNLOADING PUMP DESIGN

Unloading pumps are usually designed to produce high flows at low to medium pressures, are self-priming to ensure they

can completely empty a vessels cargo, have a wide viscosity handling to ensure they handle a variety of marine fuel oil derivatives from light distillate, to medium, and heavy fuel oils. Also known as stripping pumps, they enable the complete discharging of fluid from tanks without manual intervention or residue remaining in holds.

They are usually ATEX rated to remove any source of ignition and may have a motor suitable for inverter operation to enable operators to control oil transfer rates in particular when oil viscosity changes. Units can be heat traced as a way of maintaining a fluids viscosity and flow rate or to prevent solidification within the pump head. Similar pumps are also used in fuel bunkering and debunkering operations.

OUR SOLUTION

The client wanted a flow rate of 100M³H to 150M³H when pumping oil derivatives, be able to draw fluid from the barge and completely strip without manual intervention, whilst varying flow as required

Although pumps can typically only prime a maximum of 9.8M (based on water), and even though the suction pipework extended to over 50M away, in this particular application it was well within the capability of the design.

That is because most of the pipework runs horizontally, rather than vertically but care still needs to be taken to ensure that with the fluids viscosity, pipework diameter, and any vertical pipework sections do not amount to a pressure loss high enough to stop the unit functioning as it should.

The marine fuel transfer pump will produce varying flow up to 116M³H, be controlled via a Variable Frequency Drive and deliver pressures up to 8 Bar. Coupled to a 45KW ATEX WEG Motor suitable for operation via VFD the unit was assembled with 6” inlet and Outlet matching the clients existing pipework.

The new unit will speed up tanker offloading, will enable users to have increased control of tanker unloading and enable the unit to function without any of the issues experienced by the current installation.

If you are experiencing low flows, slow tanker offloading / loading or simply have a unit approaching the end of its useful life and want to see if process improvements can be made - speak to us to see how we can help.

The new unit will speed up tanker offloading and will enable users to have increased control of tanker unloading.

North Ridge specified and selected our NRPZ Self Priming Horizontal Triple Screw Pump complete with ATEX rated Motor suitable for operation via Variable Frequency Drive (VFD).

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 stator wear

Clogging

Changes to fluid consistency

Flow Reduction

consistency

Inconsistency in finished product

Inaccurate transfer of chemicals

Leakage | Liquid separation

Product Wastage

Seal wear or failure

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

EXPERT GUIDANCE:

Our expert engineers understand your process and guide you through the options, so you can confidently select the most suitable chemically resistant pump. Want to optimise performance sooner? Speak to one of our specialists.

Valve Blockage or unintended Opening

Cybertools Limited

If you are looking for a UK based toolmaker, then you need look no further than Cybertools. Cybertools are specialists in the design and manufacture of plastic injection mould tools. We have a fully equipped Toolmaking facility here in the UK and have over 25 years of toolmaking experience. We have quality standard ISO 9001 and ISO 14001 accreditation.

We are currently working towards ISO 13485 accreditation which is the medical industry’s optimal medical device standard.

We have a range of plastic injection moulding machines on site from 35 tonnes to 300 tonnes including two precision all electric machines used for tool trial and T1 first-off sampling as well as Factory Acceptance Test (FAT) and initial batch runs. We will work with you from initial concept and design through to production and assembly. All projects are designed, specified and guaranteed by our UK team with manufacturing optimised across our UK and Chinese facility according to your projects technical, budget and

delivery requirements. All mould tools are supplied warrantied and production ready. Cybertools provide a fast-response service for urgent repairs, with engineers available to visit your site to endeavour to minimise machine and tool downtime to protect your manufacturing schedules.

We always work through a thorough Design for Manufacture (DFM) process and mould flow analysis prior to producing a full General Assemble (GA) drawing for customer approval. This is done before we start work on manufacturing your injection mould tool. Once we start work on the tool a T1 date will be set and weekly updates will be supplied in the form of a Gannt timing plan and images of the engineering progression.

To further protect and maintain a tool throughout its life cycle, we always recommend customers take advantage of our Preventative Maintenance Contracts.

www.cybertoolsltd.co.uk

Dirty Parts Cleaning at the Lowest Cost

Rozone’s bioremediating ROwasher range outperforms every parts washer on the market and beats our previous machine’s running costs by 54.5% and uses 30%-37% less consumables.* The ROwasher is the first innovation in parts washing for decades. It is UKdesigned and manufactured, together with the bioremediating filter mat and the ROwash degreaser.

Contaminants such as oils and grease are always present in engineering and workshop environments. Current legislation makes us improve our sustainability, environmentally friendly, and health and safety credentials.

The ROwasher reduces toxic solvent use, cuts any toxic waste, and improves the technicians’ working environment, whilst reducing operating costs.

Discover

QUICK AND ABLE MANUFACTURING

AMAZON FILTERS LIMITED

Amazon

Filters strengthens in-house component manufacture

Process filter maker Amazon Filters has begun the latest stage of a £1 million investment programme designed to support industries worldwide that rely on process filtration.

Having opened a new production hall and storage space at its Surrey factory, the 37-year-old firm has now added fresh capacity to its housing component manufacturing with two semi-automated CNC mills going live.

The new machines will strengthen Amazon Filters’ policy of ‘vertical integration’ in which production activity is increasingly done in-house with less reliance on third parties or subcontractors.

The aim is to support ‘quick and able’ manufacturing, the fast, accurate capacity to turn round customer orders, including complex and bespoke projects, whatever their size and wherever they originate.

Adrian Price, Lead Fabricator, said: “As the global market expands, the ability to do things in-house becomes more important so we have taken the opportunity to grasp the nettle and improve our processes.

“Our work is very diverse and we relish the challenge of the one-off, for example if you have an oil and gas customer saying they need specific equipment to go that bit deeper in the oceans, it’s great to be able to say we can do it.”

The new CNC equipment complements a doubling of staff numbers in housing component manufacture from six operatives three years ago to 12 now and with a further appointment due in 2023.

Component manufacture involves the processing of raw, hardcore metal bars, blocks, sheets and tubes into parts ready for welding and final housing assembly.

Tube lengths tend to be three or six metres, weighing up to 130kg and with diameters of 12 or 16 inches.

Stored on huge racks, the raw material parts are moved into position for cutting, folding, drilling, marking and other processes using lifting aids including a motorised platform.

Most metal is stainless steel but, for some applications, the nickel alloy Hastelloy is the base material.

At any given time, hundreds of flat discs or plates are in the process of being turned into lids, top ends or end caps and with different-sized holes drilled to suit.

The team operate five distinct cells: sheet metal; de-burring and degreasing (the removal of very fine coats of oil); press; fabrication; and, most recently, machining.

Amazon Filters’ capital spend complements recent team appointments on the sales side, including territory managers for the Americas and Asian-Pacific regions.

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

As the global market expands, the ability to do things in-house becomes more important so we have taken the opportunity to grasp the nettle and improve our processes.

Amazon Filters colleagues Troy Procter, right, Housings Production Support Technician, and Josh Booth, Housing Component Manufacturing Operator, in the firm’s dedicated production hub.

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.

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.

LAUNCH YOUR DESIGN DREAMS

TMS CAD CENTRE

TMS CADCentre is a SOLIDWORKS Reseller based in Scotland. We are proud to support early-stage Start-ups (and Scale-ups) through the SOLIDWORKS Start Up Program. This is a three-year program providing entrepreneurs and start-ups free SOLIDWORKS software, training, and expert support to help them succeed.

In 2019 Freedom One Life joined the SOLIDWORKS Start Up Program with TMS CADCentre. Freedom One Life are disrupting the powered wheelchair market with the launch of the Series 5.

Freedom One Life was founded by Alex Papanikolaou, a powered wheelchair user. His frustrations with products on the market which constantly let him down and restricted his life due to limited range, breakdowns, and constant fear of being stranded made him question if powered wheelchairs could be designed differently. It turns out Alex wasn’t alone and met other people who were also fed up having to plan their lives around their powered wheelchairs. And so, Freedom One Life was born with the mission to enable users to live the life they choose.

The journey designing the Series 5 required the use of SOLIDWORKS to create concepts, validate designs and finally design parts and assemblies for manufacture.

Designing a powered wheelchair is not an easy task. There are a huge number of factors which need considered for every component and as all the parts connect together to form a complex assembly.

With SOLIDWORKS you can design, test using FEA (Finite Element Analysis), and visualise using the rendering package. Prototyping was difficult initially due to the size and cost of certain components. FEA contributed to the design process significantly and helped mitigate as much risk as possible before committing to expensive functional prototypes.

This not only saved Freedom One Life

CADCentre

invest in start-ups. The first year is always difficult and to have access to SOLIDWORKS makes a real difference. I’ve told everyone I know and work with about the SOLIDWORKS Startups Program and how good the benefits are.

Savage, Technical Director.

money, but it also helped them have confidence going into medical device testing because they’d tested everything using SOLIDWORKS Simulation first. They also used SOLIDWORKS Composer to design the illustrations and layout of the product manual.

Now after years of development, refinement,

and continuous improvement of the Series 5, they are now ready to begin fulfilling orders.

To apply for the SOLIDWORKS Start Up Program please get in touch.

Tel: 01324 550760

Email: solidworks@tms-scotland.com Website: tms-scotland.com/solidworks

For further information, please visit tms-scotland.com/solidworks

Freedom One Life are disrupting the powered wheelchair market with the launch of the Series 5

I would absolutely recommend SOLIDWORKS Startups Program to other entrepreneurs. It’s great the support you can get from both SOLIDWORKS and TMS

and it’s a really good way to

Scott

LOCAL PROCESS DIAGNOSTICS

BURKERT

Process automation has delivered huge benefits for manufacturers in many industries. In everyday use, plant operators are far from being made redundant, they still need to make regular inspections of the process, among other things, looking for leaks and making sure the control valves remain in good operation condition. These activities are made easier by local diagnostics indicators, which are used on valves and local control distributions.

Greg Wainhouse, UK Field Segment Manager for Bürkert, looks at the ways in which manufacturers of process control equipment are making life easier for the plant operators and maintenance technicians.

Process control infrastructures will predominantly use programmable logic controllers (PLCs) as the main hub for instructions, process monitoring and diagnostics. In many cases, these will be connected to human-machine interfaces (HMIs) to enable an easier way to interrogate the PLC without the need for a laptop computer.

DECENTRALISED SIMPLICITY

However, all of this equipment is usually located away from the process itself as part of a decentralised control network. As such, it doesn’t help the plant technician as he makes regular inspections of the process to immediately see any issues with components such as the control valves. What is needed is a simple and easily assessed signal or display that highlights any issues locally.

Local, at-a-glance diagnostics can take several forms. The most obvious is the use of coloured LEDs that are located in the control heads of each process valve. With normal operation indicated by a green display, it is very easy to spot any out-of-specification operation, which is clearly denoted by amber or red indicators.

For a decentralised control architecture, local valve control islands predominantly offer very little in terms of diagnostic information. This is a typical situation where plant operators

would need to interrogate the PLC before they could gain any insight into any faults in the system. However, there is an alternative that can improve this situation.

OPTIMIZING OPERATOR PERFORMANCE

The use of coloured indicators according to NAMUR NE107 is common practice in process control applications. Bürkert and many other manufacturers have used this standard across many product lines to improve the effectiveness and efficiency of plant operators. However, improving awareness of an issue is just the first step –rectifying the situation quickly is where the most significant savings can be made.

For applications that use decentralised control, the pneumatic valve islands provide the local process management, but any diagnostics would need to be carried out at the PLC. This can extend the time to resolve any problems or complete a maintenance task.

Bürkert has taken the concept of local diagnostics to the next level with its Type 8647 and Type 8652 pneumatic valve islands by providing on-board diagnostics and messages via an LCD screen which is located on each channel. This means, for example, that a blue indicator light, which highlights a maintenance issue, can be

quickly identified and resolved by reviewing the additional information provided by the LCS screen.

LOCAL INFORMATION

This additional information is also very useful during installation and commissioning work. The ability to access diagnostic information locally can significantly reduce the time required to complete an installation. An overreliance on the HMI to provide all the system information means that installers and plant operators need more time to identify issues and find the root cause.

To compound the situation, the PLC will only pass on warnings or alerts about circuits or problems that it has been programmed for. Normally, this would be done during the commissioning process, but there are opportunities for some warnings to be overlooked or new equipment may not be fully integrated.

Furthermore, unless all of the codes from the control valves and sensors have been correctly interpreted in the PLC, this information may be missing or misidentified. Rather than interrogating the PLC or repeatedly going back to the HMI to read the messages, the best solution is to use local diagnostics as a quicker route to identifying any issues and getting them resolved.

For further information, please visit www.burkert.com/en

The ways in which manufacturers of process control equipment are making life easier for the plant operators and maintenance technicians

Bürkert has taken the concept of local diagnostics to the next level with its Type 8647 and Type 8652 pneumatic valve islands by providing on-board diagnostics and messages via an LCD screen which is located on each channel

Compressing air in a compressed air system requires a lot of power and results in continuous pressure losses during transport from the point of generation to the point of consumption - This makes compressed air one of the most expensive forms of energy of its kind. For this reason, Micronel‘s powerful compact blowers are becoming increasingly utilized in the market for pressure and vacuum applications.

Compressing air in a compressed air system requires a lot of power and results in continuous pressure losses during transport from the point of generation to the point of consumption - This makes compressed air one of the most expensive forms of energy of its kind. For this reason, Micronel‘s powerful compact blowers are becoming increasingly utilized in the market for pressure and vacuum applications.

• Compact design and flexible positioning at point of use

• Compact design and flexible positioning at point of use

• Extremely small sizes – Typically 50 mm diameter up to 100 mm x 100 mm square

• Extremely small sizes – Typically 50 mm diameter up to 100 mm x 100 mm square

• Lower operating costs with higher efficiency

• Lower operating costs with higher efficiency

• Work independently of existing compressed air systems

• Work independently of existing compressed air systems

• Robust aluminum housing for harsh industry conditions

• Robust aluminum housing for harsh industry conditions

• Maintenance free and long lifetime

• Maintenance free and long lifetime

• Quiet operation with optional silencer and accessories

• Quiet operation with optional silencer and accessories

Micronel UK Ltd. Unit 53, The Arches Industrial Estate Alma Road, Windsor, Berkshire SL4 3HY United Kingdom

Micronel UK Ltd. Unit 53, The Arches Industrial Estate Alma Road, Windsor, Berkshire SL4 3HY United Kingdom

Phone +44 1753 641 412 info@micronel.co.uk www.micronel.com

Phone +44 1753 641 412 info@micronel.co.uk www.micronel.com

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 from Litre Meter, call 01296 670200, now.

www.litremeter.com

Measuring Immunoglobulin without Sample Degradation

ODIN is a new, compact, and reliable deep UV resonant Raman instrument developed by IS-Instruments (IS-I) and TOPTICA for measurement of biopharma products.

ODIN is a new, compact, and reliable deep UV resonant Raman instrument developed by IS-Instruments (ISI) and TOPTICA for measurement of biopharma products. TOPTICA’s Industrial CW Laser TopWave 229 enables new Deep UV Raman Spectrometer ODIN.

The system combines the newly developed solid state diode laser TopWave 229 and a spatial heterodyne spectrometer integrated into a single instrument with a unique all-reflective backscatter Raman collection probe. Sample damage caused by extended laser exposure has been mitigated via the introductiwww. toptica.comon of a dynamic sample positioning stage.

www.toptica.com

Winn & Coales International Ltd. Celebrate 140 Years’ Service to Industry: 1883 - 2023

Winn

First established as an import/export house in London in 1883, the company has earned an enviable reputation for supplying high-quality, effective, long-term solutions for its customers problems. It’s well-known brands such as Denso™, Premier™, Archco™, Protal™, Premier Shrink Sleeves™, Steelcoat™, SeaShield™ and Sylglas™ provide effective protection for buried, submerged, or exposed steel and concrete pipes, tanks, and structures. A vast number of industries benefit from the tailor-made solutions Winn & Coales provide, with the company demonstrating a clear commitment to continual improvement of its product offering through innovative research and development, and product acquisitions – a notable example of which being Viscotaq™ visco-elastic coatings in 2021.

Today, Winn & Coales International Ltd. comprises seven subsidiary companies – two in the UK, and one each in the USA, Canada, South Africa, Australia, and New Zealand – with multiple regional offices, and a network of global agents and distributors. The shared knowledge and experience across the group of companies ensures its extensive range of corrosion and chemical resistant coatings and linings are available almost anywhere in the world.

Winn & Coales International Group Chairman, Chris Winn says, “It is with great pride that we celebrate this remarkable milestone for the company. As we reflect on the last 140 years, we also look forward to the future with tremendous excitement as our continued programme of investment and growth brings new technologies to our customers.”

www.denso.net

& Coales International Ltd., leading manufacturer and supplier of corrosion prevention, waterproofing and sealing products, are celebrating their 140th Anniversary.

A UNIQUE SERVICE

STAR FASTENERS

Providing technical knowledge and support

As a distributor in today’s market, it is not enough to simply supply a product, you need to be able to offer something unique. Thanks to their technical knowledge and flexibility, Star Fasteners have the ability to work alongside project designers and mechanical engineers from a diverse range of industries, ensuring that customers are offered the most appropriate and costeffective technology for their application.

GLOBAL HUCK® FASTENER DISTRIBUTOR

The Huck® fastener range is used where high structural strength is required. Offering a clean and safe alternative to welding and a more efficient fastening method than standard nuts and bolts, Huck Fasteners offer benefits which other fastening methods cannot. These include quick and easy installation, elimination of re-checking / replacement and ultimately cost reductions. Each Huck fastener has its own unique characteristics ensuring that there is a product for every application. The business Lou Huck founded over 60 years ago and the fasteners he designed are still solving the problem of coping with extreme stress and vibration, providing strength and facilitating lighter, stronger, more durable structures. Today the product range based on his original design has evolved to include a diverse range of LockBolts® and structural blind fasteners.

Huck Fasteners are used in a wide range of markets including truck, trailer, horseboxes, automotive, air conditioning, bus / coach, portable buildings, doors and door gear, agricultural machinery, green energy, rail; in fact, anywhere that needs a dependable fastening solution.

INTRODUCING SWAGED HUCK® LOCKBOLTS®

For years, welding was seen as the only way to ensure the integrity of joints in demanding load-bearing or high-vibration structures. Companies manufacturing heavy-duty equipment or fabricating large, metal structures employed the universally accepted process of welding joints together. However, today there are alternatives to welding, one of the foremost being directtension installed, swaged LockBolts.

Bobtail installation sequence

The pin is inserted into the prepared hole, and the collar is spun onto the pin.

The installation tool is applied to the annular pull grooves. When the tool is activated, a puller in the nose assembly draws the pin into the tool, causing the swaging anvil to press on the collar, drawing up any sheet gap.

HuckBolts® (or Huck LockBolts) are precision engineered two-piece fasteners that, once installed, no matter how vibration-intensive the environment, do not come loose. HuckBolts provide direct metal-to-metal contact when installed, which eliminates the transverse vibration often found in conventional nuts and bolts. Engineered for a wide range of applications, HuckBolts deliver superior joining, shear, and tensile strength for an unmatched fastening solution.

HuckBolts can be used with virtually any metal; dissimilar metals, coefficients of thermal expansion, present no problems. Varying material thicknesses in a joint are readily accommodated, and surface finishes are not damaged. Most importantly, HuckBolts have proven to hold up over years of service in demanding, high-stress, high-vibration environments.

HOW LOCKBOLTS ARE INSTALLED

The pin of a LockBolts is simply inserted into the pre-prepared hole and the collar can either be placed straight onto the pin, or where project pre-assembly is required, can be pre-installed, spun by hand onto the

At a predetermined force, the anvil begins to swage the collar into the pin’s lockgrooves. Continued swaging elongates the collar and pin, developing precis* clamp.

When swaging of the collar into pin lockgrooves is complete, the tool ejects the fastener and releases the puller to complete the sequence.

pin (*depending on the product used). When the installation tool is applied and the tool is activated, the action of the puller engaging onto the pin, together with the anvil swaging the collar, completes the installation. The swage and eject sequence are programmed to complete the cycle without any additional installer input. The process ensures excellent gap closing capability.

Manufacturers of heavy equipment are now using direct-tension LockBolts in their assembly process. Even taking into consideration the need to prepare a hole to take the fastener, installing a LockBolts is significantly faster than welding a joint. Once installed, a quick visual inspection is all that is required to confirm the accuracy and quality of the installation. Operators require minimal training in order to be proficient in the fastener’s installation.

These unique engineered fasteners, proven in demanding applications such as truck suspensions and chassis, railroad track crossings, and heavy defence vehicles, are now being used in a wide range of of products and structures where welding was once the only option.

Based on a typical installation of 5/8" grade 8 fastener

HIGH PERFORMANCE HUCK® LOCKBOLTS

Compared to conventional nut and bolt installations which can loosen in highvibration environments, HuckBolt® have proven to be impervious to the effect of vibration in a number of very demanding applications. The secret to this performance difference can be found in the unique HuckBolt design, in which the collar is fully swaged into the locking grooves of the pin.

Huck® LockBolt brand names include, BobTail®, Magna-Grip®, C6L®, C50L®, C120L® and Hucktainer®; each differing in design, diameter, grip range material, plating and purpose.

HUCK BOBTAIL® - A LOCKBOLT WITHOUT A PIN-BREAK

Huck BobTail fasteners are available in a wide range of sizes (up to 1-3/8 inch). The two-part fastening system consists of a pin and a collar. These advanced fasteners are installed using a direct tension technique, in which the pin is pulled and the collar is simultaneously swaged into the locking grooves of the pin, deforming the collar into the grooves.

Declared by DIBt as “maintenance free”, the 12mm, 14mm, 16mm, 20mm and 1 inch diameter BobTail is approved to be used in both static and dynamic civil engineering applications (smaller and larger diameters are available by request).

The DIBt test confirmed that a BobTail is maintenance-free during the lifetime of the joint it is fastening, which is not the case when using traditional nut and bolt products. As a result, it can be integrated into a range of applications with complete confidence by civil engineering designers.

Through its advanced fastener design the BobTail system offers a strong connection. One key advantage of this fastener over conventional LockBolting systems is that

HuckBolts® (or Huck LockBolts) are precision engineered two-piece fasteners that, once installed, no matter how vibration-intensive the environment, do not come loose.

it doesn’t have a pintail to break off. As a result, there is no waste material to collect and dispose of post-installation. The added benefit of this is that the tools are lighter and smaller as they do not need the force to break the pintail off, as traditional Lockbolt tools do.

The BobTail is installed using a quiet, jolt-free swaging action, eliminating the potential for repetitive stress syndrome issues. It has significantly reduced noise levels, typically less than 70dB. The elimination of the shock load and reduced noise can offer real and significant health and safety benefits.

Using the Huck BobTail in key joining applications helps remove housekeeping and safety issues that are integral to the welding process. There are no sparks to start fires or cause explosions, nor any debris on the floor that can lead to slips and falls.

INTRODUCING HUCK STRUCTURAL BLIND FASTENERS

When only one side of the joint material is accessible, performance-engineered Huck structural blind fasteners have a solution. Each designed and engineered with a unique set of features and delivering

solutions to common manufacturing challenges; hole-filling, water-resistance, wide grip ranges, welding replacement, to self-grounding fastening solutions, all offering high-speed assembly. Huck structural blind fasteners are engineered with a unique locking design, an internal ‘lock’ is created during installation that virtually eliminates pin push-out by mechanically ‘locking’ the pin to the sleeve. Simple, visual inspections ensure joint integrity.

Huck® structural blind fastener brand names include, Auto-Bulb®, BOM®, FloorTight®, Hucklok®, Magna-Bulb®, Magna-Lok®, Magna-Tite®, and Penta-Lok™. Again, each differ in design, diameter, grip range, material, plating and purpose. In applications where vibration resistance, reliability, and strong-hold are critical, no fastening system is more dependable than Huck.

In-house and on-site tool repair and servicing, makes sure that customers production lines are kept rolling and fasteners are installed correctly. The inhouse powder coating facility also means that fasteners can be pre-coloured to customers specifications.

Star Fasteners have a close relationship with their suppliers’ and are proactive in designing products and developing new ideas. Technology is always evolving; customers often require fasteners with specific design requirements and want to develop projects beyond the norm or to push the limits of current fastening technology. Being hands-on and keeping up with new developments is core to Star Fasteners success; any new developments are seamlessly integrated into the existing product range. Star Fasteners are definitely not just a fastener distributor, but a company that is proactive and one that offers something different; a solutions provider.

Email: sales@starfasteners.co.uk Tel: +44(0)115 9324939

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

HuckLok Structural

Blind Huck Fastener

Huck Range Force Battery Tool

Huck BobTail LockBolt

LATEST NEWS FROM BRANDAUER

A Birmingham-based apprentice turned Manufacturing Director has been named as one of industry’s Top 100 professionals.

Stuart Berry, who joined metal stamping and tooling specialist Brandauer 15 years ago, was recognised by The Manufacturer as an Exemplar in the Innovation, Inspiring Leader and Young Pioneer categories.

The passionate advocate of engineering impressed judges with how he has used vocational learning to progress to the very top of his profession, securing a ‘First Class’ BEng Honours degree in Management of Manufacturing Systems in the process.

Judges at the high-profile event in Liverpool also praised his role in helping the company diversify into new markets, combining a strong production methodology with a commitment to the latest technology, delivering a host of product introductions for a male grooming product, nose clips for face masks and wafer-thin laminations for electric vehicles.

Stuart commented: “There are some things in life that take you completely by surprise and this is one of them. To be named in The Top 100 manufacturing professionals in the UK is a massive honour, to be named an Exemplar in that prestigious field is mindblowing.

“From the minute I stepped on the shopfloor at Brandauer, I knew I wanted to learn as much as I could and progress in industry. Sometimes it’s about finding the right company that gets you and you get them, that’s what happened here and we’ve both benefitted.”

More than 250 people gathered at The Exhibition Centre in Liverpool last night to recognise the best talent in UK manufacturing.

Stuart, who was joined on stage by Make UK’s Stephen Phipson and Donna Bruce of Northern Lights, has recently played a key role in the development of the UK’s first

From

£1m Precision Tooling Academy in the West Midlands.

A joint project between Brandauer and In-Comm, the purpose-built commercial toolroom will produce complex tooling, as well as acting as a professional training ground for the toolmakers and designers of the future.

This is a vital move for domestic industry, with the sector being held back by a severe lack of toolmakers and the very real possibility of losing these essential skills forever as older workers choose to retire.

The Precision Tooling Academy aims to reverse this trend by offering companies access to professional toolmaking courses, upskilling opportunities for qualified engineers looking to diversify their skills and a Level 6 Tool Process Design Apprenticeship to develop the next generation of talent.

Training will be unlike anything currently on the market, with up to 35 individuals in the first twelve months able to learn on live tooling projects that will be producing hundreds of thousands of parts every week and, under Stuart’s guidance, will give Brandauer and other tooling experts the opportunity to reshore more manufacturing projects from Asia, the EU and the US.

Stuart concluded: “Embarking on an apprenticeship has been so good for me and that’s something I want to get across to the next generation…this Top 100 title will definitely help me to do that.”

The Manufacturer Top 100 are the most dynamic leaders and innovators in manufacturing, as nominated by a 265k-strong audience, the wider industrial community, and judged by an esteemed panel featuring leaders of industry, academic institutions and manufacturing associations.

For further information, please visit www.brandauer.co.uk or follow @cbrandauer on twitter.

Former Birmingham apprentice is named as one of the top 20 manufacturing professionals in the UK

BRANDAUER

the minute I stepped on the shopfloor at Brandauer, I knew I wanted to learn as much as I could and progress in industry.

T&D

Compact,

THE RTR500B SERIES

robust, wireless data acquisition solutions

The Wireless Data Logging System RTR500B series from T&D is the ideal solution for measuring and storing physical data. Designed to record and measure data such as temperature and humidity, the RTR500B series includes data loggers and a range of base stations to ensure the safe, wireless collection and storage of data.

The system uses T&D’s proven short-range wireless communication for logger to base transmission, and the RTR-500B series is also compatible with HTTPS – an encrypted communication feature that ensures superior security. Furthermore, users can register devices and adjust settings not only from a PC, but also a smartphone or via the cloud for greater flexibility and convenience.

The wireless communication range between base and remote units, if unobstructed and direct, is about 150 metres (500ft). However, repeaters can be easily added for an even greater range across a variety of environments. And when used in conjunction with RTR-500BC repeaters, the base unit will automatically select the best route for stable, wireless communication.

The wireless communication range between base and remote units, if unobstructed and direct, is about 150 metres (500ft).

By adding the base unit to the free, cloudbased T&D WebStorage facility, recorded data can be automatically uploaded, managed and accessed anytime, anywhere. Automated data collection

is carried out using a robust wireless communications protocol.

The devices in the new RTR500B Series are compatible with the earlier RTR-500 series, but also have additional Bluetooth capability. This means mobile devices can be used for data logger and base station registration, and to adjust settings.

The base units in the new series comprise: RTR500BW, for transferring data to the cloud or server via a wireless

and wired LAN connection, RTR500BC, for downloading data to a PC connected with a USB cable, and also with repeater functionality, and RTR500BM for transferring data via 4G mobile connectivity. This impressive line-

up of RTR505B data loggers meets multifunctional measurement needs including temperature (Pt 100, Pt 1000, TC type K, J, T, S), voltage (4-20mA) and pulse count.

T&D’s RTR-500 series offers the RTR-574 for monitoring illuminance, UV intensity, temperature and humidity. The RTR-576 can even measure CO2 concentration, and the RTR-500DC as a wireless portable data collector can be used in conjunction with the RTR-500B series.

Warnings for upper and lower limits can be made via the settings. Users can also be alerted to sensor faults, low battery or communication errors, and notified

by email or SMS. In addition, an external alarm output is built into the base units.

Finally, recorded data can be effectively managed and analysed using free T&D Graph – high-performance software that can also be used in conjunction with the T&D WebStorage cloud service.

For further information, please visit: www.tandd.com | www.webstorage-service.com

V-EX DIGITAL TWIN

Why your Exhibition stand needs a digital twin…

Physical events and exhibitions are finally back in full swing around the world allowing people to meet and see products for real again. Successful virtual events run over the last two years have also proven popular, with the convenience of online accessibility delivering large global audiences.

Click the video link to learn more about V-Ex Digital Twin

Now we can have the best of both worlds, using a service such as V-Ex Digital Twin it is an easy step to create a low-cost digital copy of a physical exhibition stand to maximise the visitor numbers from any popular exhibition or trade show.

There are other considerations, a ‘Digital Twin’ of any physical exhibition stand, product launch venue or showroom can increase accessibility for your audience and promote diversity while also greatly improving sustainability.

A perfect online duplicate of your exhibition stand or venue will utilise all the design, content and marketing collateral you’ve already produced to create an always-on digital presence with marginal additional outlay (The cost of a digital twin exhibition stand is usually around 10% of that invested in the physical version). During an exhibition or event it can be used to offer a simultaneous ‘hybrid’ experience where remote visitors can engage with

As an exhibitor, a digital twin of an exhibition stand provides a great opportunity to extend the engagement period of the event.

your live content and speak to your sales representatives.

As an exhibitor, a digital twin of an exhibition stand provides a great opportunity to extend the engagement period of the event. Many pre-registered visitors for a live event are often not able to attend on the day, most B2B trade shows for example have a 50 –60% attendance rate compared to pre-show registration numbers. Working with the show organiser to help promote your digital twin to registered visitors who did not attend allows you to reach verified leads long after the doors have closed to the physical event.

The V-Ex virtual platform incorporates visitor registration, live stats and user analysis and incorporates a simple Content Management System (CMS) which allows you to update your digital twin throughout the year.

Companies such as V-Ex have been building purely virtual exhibition stands and digital twins of physical designs for over ten years now, and have constructed 1,000’s of them, so the process of ordering one and having it built is both easy and convenient.

Having built the digital twin, you can embed it into your website or host it on a standalone webpage. Visitors can access it from any current web browser with no need to download any software.

For further information, please visit www.v-ex.com

Digital twin example for Mitsubishi Electric

Digital twin example for Burkert Fluid Control Systems

Work

INNOVATIVE SPECIALISTS

LTI METALTECH

Pressure Vessels: High Integrity Fabrication &

LTi Metaltech is a dynamic, innovative, and ambitious production company, with solid foundations in regulated precision fabrication and welding. We work with global companies and OEM’s to deliver advanced high-performance vessels and structures using Stainless Steel, Copper and high purity Aluminium. Based at Milton Park, Oxfordshire’s international business and science park, LTi is a recognised expert in high integrity welded structures capable of withstanding extreme pressure, vacuum, and temperature differentials.

LTi manufactures over 4,000 pressure & vacuum vessels per year, used to encapsulate liquid Helium that cools superconducting electromagnets to 4 Kelvin (-269 degrees Celsius). With a history of being part of a leading blue-chip organisation, LTi is a Tier 1 supplier that has invested in the latest equipment, technology and working practices to manufacture products to strict industry standards, with lifetime records and traceability for all materials and components.

Welding Experts

To ensure the integrity of these components, the company performs very high levels of quality control and testing throughout the production and fabrication process, from visual welding inspection through to X-Ray and High Vacuum testing. The business is comprised of core volume business and an increasing project and consultancy service.

We employ around 100 people, including one of the largest groups of coded welders in the South East of England, working to AD Merkblatt 2000 and PD 5500 pressure containment standards. We continuously strive to push the boundaries investing in the latest technologies, techniques, and processes to help exceed our customers’ expectations.

We have been a Tier 1 supplier to Siemens Healthcare for well over a decade, manufacturing in excess of 15,000 cryogenic pressure vessel sets for use in their Magnetic Resonance Imaging (MRI) scanners, exported for installation in hospitals and medical facilities around the globe.

LTi recently completed the acquisition of Vessco Engineering which will bolster our capabilities and facilitate access into several key sectors, including nuclear energy, oil and gas, utilities, and food processing, having itself completed several prestigious projects including specialist fabrication assignments with Tokamak Energy & Reaction Engines.

Founded in 2006, Vessco Engineering Ltd is a Tier 2 supplier to the turbine hall at Hinkley Point C, supplying large pressure vessels for GE Power Systems. The company, which employs 40 people on the Bridgend Industrial Estate, also has experience in oil & gas, power generation as well as water supply.

The acquisition will enable LTi to accelerate its expansionary programme as it diversifies its portfolio whilst underpinning existing capabilities in medical technology.

Further information about LTi and Vessco Engineering’s precision fabrication expertise is available at:

www.lti-metaltech.com www.vesscoengineering.co.uK

For any enquiries, please get in touch: enquiries@lti-metaltech.com

We continuously strive to push the boundaries investing in the latest technologies, techniques, and processes to help exceed our customers’ expectations.

SAVE SPACE, ENERGY & MONEY

Micronel reduce operating costs with decentralised compact dc blower solutions

Micronel dc blowers save space, energy and money compared to other air sources such as bulky side channel blowers and compressed air systems.

Saving energy not only conserves resources but is also good for the balance sheet. That is why machine and plant manufacturers as well as production companies rely on Micronel high-performance blowers in process control and automation applications. The reliable high-tech solutions enable new and more efficient application possibilities and promote independence in comparison with previous compressed air systems.

Thanks to their very small compact sizes, Micronel blowers are suitable for decentralised installations and can be placed adjacent to the relevant process reducing pressure losses incurred in long air supply lines and allows flexible installation without the need to install or relocate air lines. Dynamic blower control allows air supply to be called up as on demand as required, increasing the efficiency of the application.

Here is a simple example: compared to a conventional Air-Knife compressed air application, with an annual consumption of 60000 m³ air volume, a Micronel Radial Blower U100H4 (pressure 165 hPa, flow volume 820 l/min) with a power consumption of 100 watts pays for itself in energy savings after only half a year.

The compact U100 dc blower family features a tough full aluminium IP67 housing, efficient brushless dc motor with integrated electronic driver for plug n run capability

and ease of use, M16 connector and has G¾ inch pipe threads for 32mm tight hose connections. The housing complies with protection class IP67 with connected suction and discharge ports.

The 2 stage U100H4 can generate over 165 mBar (16,500 pascals) of pressure and achieve free blowing air flow over 900 litres per minute (54 metres cubed per hour) all from a very compact small size package of 107mm x 107mm x 118mm. With typical power consumption of 100 – 180 watts depending on working point they can pay for themselves in energy savings after only a few months.

The performance and cost savings of the blowers is particularly evident in applications such as drying and cleaning processes, where high pressure and a considerable volume of air are constantly required.

Micronel blowers are also extremely advantageous in suction and extraction processes, such as pick & place processes or vacuum holding or conveying technology. A full range of accessories are also available including air knives, filters, and anti-vibration mountings.

Micronel specialise in High Performance Blowers and Fans, their fan and blower products meet the needs of industries with special performance characteristics – Medical, Electronics Cooling, Personal Protection, Packaging, Gas Analysis, Laboratory, Transportation, Process Control and many more applications. Micronel offer customers the widest choice of standard ultra-slim fans, axial fans and high performance high pressure radial blowers from UK stock and provide technical design support for modified products and client specific designs.

World Leaders in Selective Soldering

Pillarhouse International Southern Manufacturing 2023 Stand G125

JADE MKII

Elementary, exible, single point selective soldering system

World’s Best-Selling Entry-Level Selective Soldering System • Universally Adjustable Tooling Carrier • Maximum 457mm x 508mm PCB Handling Size • Drop-Jet Fluxer • Ultrasonic Fluxing capability * • Flux Monitoring/Control capability * • Top and Bottom Side I.R. Pre-Heat * • Closed-Loop Pyrometer Top Side Pre-Heat Control * • Real-Time Laser PCB Warp Correction * • Low Maintenance Solder Bath and Pump Mechanism • Flexible AP (all purpose) Nozzle Technology • Revolutionary Patented 1.5mm Micro Nozzle capability * • PillarGEN Nitrogen Generator * • * Optional Features

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 International Ltd.

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

TWO DISCIPLINES, ONE SHOW

SOUTHERN MANUFACTURING & ELECTRONICS 2023

Thousands of visitors will be heading to the Farnborough International Exhibition and Conference Centre

Southern Manufacturing & Electronics 2023 is taking place from 7th to 9th February and excitement is building now that it is so close. Many thousands of visitors will be heading to the Farnborough International Exhibition and Conference Centre to see what more than 600 companies have to offer in two distinct areas - mechanical engineering and electronics. The show is devoted roughly half and half to the two disciplines. Technology trails group together firms with similar expertise to guide visitors around the stands, making it the ideal place to source multiple products and services, identify business opportunities and discover new ideas, all under one roof.

One of the most important engineering shows in the UK calendar and the largest

annual event in the sector, it started out 25 years ago as a gathering of local engineering companies, but now attracts exhibitors and visitors from throughout Britain, Ireland, continental Europe, the Americas and Asia. A large proportion of exhibitors have supported the show since the very beginning and the percentage of returning firms is high.

Visitors can expect to see a vast array of automated equipment for electronics production and assembly, PCBs, connectors, sensors, mechanical systems, hydraulic, pneumatic and other components, drives, encoders, fasteners, pressings, wireforms, springs, plastic and rubber mouldings, gaskets and more. There will be suppliers of machine tools and tooling, workholding equipment, automated handling solutions,

metrology machines and software, test and inspection systems, finishing machines, laser cutting and marking equipment, additive manufacturing machines and consumables, industrial hardware, production and planning aids, and software for both engineering and business.

Industry 4.0 solutions will be promoted alongside controls, displays, HMIs, data acquisition systems, virtual reality, robot and cobot machine tending and other automation solutions. Other diverse and no less essential products and services on offer will encompass oil and coolant supply, workshop equipment, dust and fume extraction, humidity control, workplace storage, bespoke case and foam manufacture, plastic packaging, injection moulding, hand tools, adhesives,

industrial flooring, waste removal and recycling, training and finance.

Providers of subcontracting services specialising in the manufacture of sheet metal components, as well as metal and plastic rotational and prismatic parts produced either subtractively or additively, will be there to explain what they can offer. So too will firms providing electrical engineering services, electronics assembly, finishing, test and inspection. Experienced staff on the stands will explain how they can help industrial companies maintain momentum and profitability throughout 2023, despite the well-publicised headwinds they are encountering.

A stand that will be interesting to visit is Leybold UK, which designs and manufactures vacuum pumps, components and systems for use in the production of semiconductors, data carriers, displays and solar cells as well as across a vast range of processes in the refinement of steel and the production and packaging of food. Servo

Components & Systems will exhibit a range of motion products including linear electric actuators and motors, servo drives, brushless motors and gearheads. They may be assembled into simple pick & place, XYZ gantry, push/pull or stacking systems for entry-level robotics and automation.

Top Hex produces electronic controls for process machinery, industrial applications, laboratories and retail environments. Canadian firm VKS offers

work instruction software to digitalise, standardise and optimise processes, without the need for paper. Of interest also will be Process Parameters, a UK manufacturer of industrial temperature sensors including thermocouples and platinum resistance thermometers. It is also a distributor for infrared sensors and thermal cameras for non-contact temperature measurement. Eurotherm is known for its advanced control systems and high integrity data recording. It is a preferred partner for small to medium size automation projects that improve process efficiency, maximise availability and assure regulatory compliance.

Heidenhain will show its CNC systems, DROs, encoders, touch probes, camera systems, length gauges, signal converters and inspection devices, as well as software solutions for the shop floor that empower end users to digitalise their manufacturing. In the field of enterprise resource planning, E-MAX Systems, Medatech UK and MIE Solutions UK will all explain the merits of their different software solutions.

A large proportion of exhibitors have supported the show since the very beginning and the percentage of returning firms is high.

Southern Manufacturing & Electronics 2023 will co-locate with AutoAero, a specialist theme within the exhibition devoted to aerospace and automotive engineering.

Alongside the exhibition and demonstration areas, over the three days there will be an extensive seminar programme. It will give visitors and exhibitors alike valuable learning opportunities, with a particular focus on the technical, managerial and environmental issues facing manufacturers today. Presentations will span lean continuous improvement, design for test, marketing, team motivation, additive manufacturing, business succession planning, management techniques, CE and UKCA marking, the role of IP in commerce, social media for lead generation and other marketing strategies, commercialisation of ideas, and testing.

Southern Manufacturing & Electronics 2023 will co-locate with AutoAero, a specialist theme within the exhibition devoted to aerospace and automotive engineering. There is a free, regular bus service between Farnborough’s train stations and the show. Admission and parking are also free.

Over 600 national and international suppliers come together to exhibit at Farnborough International Exhibition and Conference Centre this February for Southern Manufacturing and Electronics (inc AutoAero) 2023. Meet the power behind UK manufacturing industry and see live demonstrations and new product launches of machine tools & tooling, electronics, factory & process automation, packaging & handling, labelling & marking, 3D print technology, test & measurement, materials, composites & adhesives, rapid prototyping, ICT, drives & controls and laboratory equipment.

Free industry seminar programme online @ www.industrysouth.co.uk

The exhibition is free to attend, free to park and easy to get to. Doors open at 9.30am on Tuesday 7th February.

www.industrysouth.co.uk

Protecting Your Plant

Rotech Motion Sensor’s can be used whenever information or monitoring of shaft rotation, position, direction, speed, slip etc is required!

Rotech Motion Sensor’s can be used for indication, control, interlocking, protection, sequencing, alarm initiations and many more functions!

Rotech Motion Sensor’s can be used wherever materials are transported or processed By conveyors, elevators, screws, mixers, etc!

UK’S widest range of springs

European Springs & Pressings are leading experts in spring manufacturing and high-speed press technology, providing a full design and manufacturing service.

We understand that no two jobs are the same; similar products often require different materials, treatments, variable tolerances or specific heat resistance. This is why we invest in the latest technology and qualified toolmakers to ensure we design and produce the very best bespoke stampings, springs and wire forms.

A custom-tailored manufacturing process and in-house design service – with CAD/CAM software and systems – means we can help you realise a range of prototype ideas, individually cut using precision lasers for R&D testing or put into full production. Our fully-equipped tool room can design and build any production tooling needed, assuring you of competitive pricing, consistent quality and dependable supply.

Phone: +44 (0)208 663 1800

Email: info.bec@europeansprings.com

MASS-PRODUCTION EFFICIENCY

BROANMAIN PLASTICS

Broanmain paves the way for sustainable mass-manufacturing at SM&E

Aligned to industry and customer-driven sustainability principles, UK technical moulder Broanmain Plastics will unveil how it is navigating the energy and cost of living curveballs. Including a number of production and energy efficient enhancements it has taken to assist domestic OEMs meet sustainability KPIs, reduce supply chain risks, manage stock holdings, spur UK engineering innovation, increase value and maintain production continuity.

On Stand C195 at Southern Manufacturing & Electronics 2023, Broanmain Plastics will showcase the continual improvement steps implemented at its Dorking factory to get ahead of the spiraling energy crisis costs and reduce its mass manufacturing production carbon footprint.

From capturing live dashboard data to further machinery investments, relocating to one production site and the introduction of overlapping double injection moulding shifts to reduce machine shut-offs and restarts, Broanmain will highlight to visitors how its new approach continues to embody mass-production efficiency and reduce overproduction to minimise utilities consumption.

A number of process and site improvements are already delivering tangible savings, including approximately £17,000 p/a in compressed air power consumption. Additionally, the company’s investment in all-electric moulding clean-tech has increased its production capacity and mass repeatability, while reducing energy use by over 70 percent compared to hybrid and hydraulic machines. Broanmain is also benchmarking the savings and reduction in curing time of upgrading to variable speed drives on its other moulding machines. Balancing the ‘rightshoring’ benefits In today’s cost of living and energy crisis, shipping heavier and bulkier weighted components across continents can incur large costs and is not carbon neutral. Adding a 500-ton machine to the company’s Dorking fleet, means customers can now rationalise their supply chain and have all their precision components - from 0.1mm-sized micro components right up to polymer parts with shot weights of up to

3kg - moulded, finished, assembled and despatched from Broanmain.

Managing Director Jo Davis comments: “Supply chains in the plastic industry are highly sensitive. Evidenced during the pandemic. Now, for UK OEMs seeking bespoke moulded and fabricated parts all managed through one vendor, Broanmain offers the flexibility, tools, production and assembly resources to undertake manufacturing projects of all volumes. We also project manage tooling commissions. This expertise helps to de-risk projects, supports real-time production, provides customers with supply-chain assurance and enhances quality control.”

Cucumber Lighting Controls is the latest British business to select Broanmain as its preferred mass-component manufacturer. As well as overseeing the initial development of 14 mould tools designs, Cucumber was adamant that they wanted to partner with a British moulder with the capacity and flexibility to mass-manufacture estimated

significantly high volumes in an everchanging market sector.

Cucumber Product Manager John Mercer comments: “The logistical benefits of appointing a British company that has the capacity to mass mould and store components for us, combined with a skilled and collaborative team that can oversee the design and production of technical tools, are multiple. The advanced samples have been extremely impressive. We feel confident to have selected a responsive and dependable partner that is aligned to our sustainability KPIs and mature market knowledge, who will equally challenge us on all aspects of getting our innovative products ready for market in early 2023.”

Whatever your design challenge or sustainable plastic moulding question, the Broanmain production experts have a solution. Test their knowledge at Southern Manufacturing & Electronics, Stand C195, Farnborough, 7-9 February 2023.

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

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.

www.lanemark.com

Gas Process Burners

Lanemark

FD

•Speci

•High

•High

•Heat

TX

•High ef ciency (80%+) heating of all types of spray and dip process tanks

•Compact high ef ciency 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 red, high ef ciency 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 ring rates to suit alternative temperature rise and air velocity system requirements

•DbCalc system design software Lanemark

“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.”

BESPOKE AUTOMATION

FANUC

Fanuc support helps samey robotics to revolutionise fresh fish supply chain

A 22-year partnership with leading industrial robot manufacturer FANUC has been hailed as a key factor in Icelandic firm Samey Robotics’ role in revolutionising the international supply chain for fresh fish. Specialising in the design, manufacture and installation of bespoke automation for the food processing industry, Samey Robotics has delivered over 150 projects across 10 countries including Iceland, Norway, the Faroe Islands and the UK. At the heart of many of its tailored solutions is FANUC’s M-410 series of industrial palletising robots, renowned for its ability to handle heavy items, such as pallets of fresh produce. With over 100 FANUC M-410 robots already purchased by Samey Robotics (including 25 in 2021 alone), the company currently has a further 25 on order.

“We know we can trust FANUC products to deliver time and time again in harsh operating environments while handling delicate and high-margin fresh produce,” says Kristjan Karl Adalsteinsson, Samey Robotics’ Chief Sales & Marketing Officer.

JUST-IN-TIME SUPPLY CHAIN

Samey Robotics was founded 32 years ago, just south of Reykjavik in Iceland; a country renowned for its seafood. During this time, the company has built a reputation for delivering robust robotic systems that promote the safe, efficient and fast handling of fresh fish.

The M-410 series is renowned for its ability to handle heavy items, such as pallets of fresh produce, allowing fish to land, be processed and shipped to a customer within just 24 hours

Blazing a trail for other food sectors to follow, Samey Robotics has revolutionised the fresh fish supply chain, with distribution handled by automated centres supported by robotics. In many cases, fish may be landed, processed and shipped to the customer within just 24 hours, meaning every second counts.

“An order can be placed in London, logged onto one of our customers’ operating systems in Iceland or another coastal country, and a robot will automatically

start feeding the raw produce into the production cell,” explains Kristjan. “In less than an hour, it will be palletised and on its way to being shipped, without anyone having to send an email, take a phone call or make a decision as to when to start or stop the system. The whole process, from order to delivery, is fully automated.”

As well as the ability to gently and rapidly handle large quantities of fresh produce, it is imperative that any robotic solutions specified by Samey Robotics are also robust and reliable. “Given the nature of our clients’ supply chain, the fish will spoil if production stops for any length of time,” states Kristjan. “Some of our customers handle up to 500 tonnes of fresh produce per day, so unexpected downtime is simply not an option. The reliability of FANUC robots has been a huge factor in our joint success.”

A CHANGING MARKET

With over 100 FANUC M-410 robots already purchased by Samey Robotics (including 25 in 2021 alone), the company currently has a further 25 on order

A perfect storm of rising labour costs, post-Covid digital transformation and affordable automation has helped drive a surge in industrial robot installations throughout the food and beverage processing industry. In fact, the number of industrial robots installed in European food processing applications is set to double in the 10 years from 2015 to 2025,

and Samey Robotics is experiencing this growth first hand: “Demand is increasing every year, especially with regard to high-throughput cells that can operate within stringent hygiene parameters,” says Kristjan. “The market is seeing the benefits that automation can bring from both a productivity and profitability point of view.”

TRUST AND TRANSPARENCY

For Oliver Selby, Robotics Business Development Manager for FANUC UK, supporting Samey Robotics’ innovative and forward-thinking approach to automating the fresh fish supply chain is testament to the power of a strong supplier-client relationship: “We have a number of longstanding client relationships, but to go from strength to strength like we have with Samey Robotics is especially rewarding. Key to our partnership is transparency. It’s a trait which runs throughout our business, right from the very top at our headquarters in Japan down to our delivery drivers meeting clients on the ground. This builds trust and gives our customers confidence that they can rely on us to deliver what we’ve promised.”

SETTING THE STANDARD

Also key to the partnership’s success is a focus on innovation. “For a number of years now, Samey Robotics has been leading supply chain development in the

European fish sector, with their automated approach to distribution serving as an example for other food sectors to follow. Going forward, Samey Robotics’ customer base is changing as the company embarks on a growth initiative through acquisition. Moving beyond Europe, it is now opening up to a global audience. At the forefront of this strategy is of course robotics and automation, and Samey Robotics is keen to spread its commitment to automated supply chains into regions that are not necessarily renowned for automation. We are excited to continue supporting them in this exciting phase of their journey, derisking their future

business to ensure that Samey Robotics continues to be renowned for implementing solutions that facilitate the fast, safe and efficient handling of fresh fish, right across the world.”

DIVERSE OFFERING

To this end, FANUC has recently begun supplying Samey Robotics with an alternative to the M-410, providing the company with a different robotic solution to improve end product handling even further: the M-2000. On the inbound supply chain direct from the boat, fresh fish is loaded directly from 460 kg totes into the fish processing equipment by the M-2000; the strongest 6-axis robot on the market, boasting a handling capacity of up to 2.3 tonnes and a maximum reach of up to 4.7m. This robotic solution changes the way food producers need to think about their onsite logistics, removing the need for specialist forklift trucks and drivers, and representing the ideal choice for gentle handling of what is a delicate food item.

For Samey Robotics, a commitment to innovation, transparency and reliability ensures that FANUC remains a key partner in its ongoing global success. Kristjan concludes: “We are proud to have enjoyed such a longstanding relationship with FANUC. For us, and our customers, the reliability of their robots is priceless.”

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

We know we can trust FANUC products to deliver time and time again in harsh operating environments while handling delicate and high-margin fresh produce

FANUC and Samey Robotics’ 22-year partnership has revolutionised the international supply chain for fresh fish using FANUC’s M-410 series of industrial palletising robots

THE MK GUF-P 2000 SERIES

MK PROFILE SYSTEMS

High load-bearing capacity and a torsion-resistant structure

Belt conveyors of the mk GUF-P 2000 series are true all-rounders, with a large selection of drives, tails, stands and belt types for outstanding variability. They are based on the mk 2000 profile, which provides high load-bearing capacity and a torsion-resistant structure.

In addition to its low height of 50mm and a compact ø53mm drive roller – which can be coated with rubber according to the application – the conveyor also offers a wide range of different belt types. As with all mk belt conveyor systems, the crowned design of the driving and idler rollers make belt adjustment significantly easier. The system is available with an optional stationary or rolling knife edge.

System slots running along both sides (10 mm slot width in accordance with our profile technology) allow you to easily integrate the conveyors into existing machine frames or to attach stands, side rails, sensors and other accessories. In addition to our wide selection of side rails and stands, we also offer a standard range of end stops and electrical accessories. A further quality feature of this conveyor system is the stainless steel sheet installed below where the belt runs, which ensures long-term wear resistance of the belt.

Here we can see an example of an mk GUF-P 2000 belt conveyor being used in an application for sorted feeding and item collection for a mail order business.

The mail order business required a belt conveyor for picking items of clothing for order processing. The items from the individual orders, together with the shipping documents, needed to be fed to a manual workstation on a belt conveyor. The conveyor is loaded using a pocket sorting system, from which the items are discharged through a slide onto the belt conveyor. The shipping documents needed to be assigned to the corresponding delivery directly from the printer ensuring that the individual orders did not get mixed up.

mk used its GUF-P 2000 belt conveyor

to provide the perfect solution for this task. Thanks to its high degree of standardisation and modular design, the belt conveyor is ideally suited for flexible use in the packaging industry. A belt with transverse cleats welded on was chosen for this particular application. As a result, a separate compartment was formed on the belt conveyor for each order, and the corresponding items were discharged into the compartment through the slide. The orders could no longer be mixed up. The delivery note for the order was printed out directly to the appropriate compartment, which ensures the documents were always matched to the correct order. The ready-

picked orders were sent to a manual workstation, where they were checked again and then transferred to the packaging machine.

mk’s solution used standard mk components compatible with the GUF-P 2000 conveyor to ensure delivery with inline delivery note printing for each order, and that items were collected order by order.

To find out more about the mk conveyor range please visit www.mkprofiles.co.uk, call (01949) 823751 or email info@mkprofiles.co.uk.

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

As with all mk belt conveyor systems, the crowned design of the driving and idler rollers make belt adjustment significantly easier.

Many

Many variants for light weight & medium weight

Suitable for bulk product, loose piece goods & boxes

Suitable for bulk product, loose piece goods & boxes

Wide range of different drives, tails, belt types, stands & side rails

Wide range of different drives, tails, belt types, stands & side rails

Built with the mk 2000 profile for high load capacity and a torsion-resistant structure

Built with the mk 2000 profile for high load capacity and a torsion-resistant structure

mk Profile Systems Limited a company of the mk Technology Group www.mkprofiles.co.uk

mk Profile Systems Limited a company of the mk Technology Group www.mkprofiles.co.uk

Knight Optical

Knight Optical, a leading provider of optical components for over three decades, has been serving the robotics and automation industry for just as long. Our range of available optics, either from our stock catalogue or as custom optics, is expansive.

Our typical optics include:

• Infrared components manufactured from substrates such as germanium, zinc selenide, silicon, and many more materials that work in the UV to IR wavelengths.

• Filters include interference bandpass filters available from UV to IR wavelengths, dichroic filters, colour glass, and neutral

density.

• Mirrors – our stock coatings include UV-enhanced aluminium to protected gold, which works to the far IR.

• Polarisers

• Lenses

• Windows, including optical domes

• Beamsplitters

• Optical flats

• Prisms.

We pride ourselves on our custom capabilities, so if our stock options do not meet your requirements, do not hesitate to contact our technical account managers with your enquiry. www.knightoptical.com

Benefit from our experience to increase your success!

The valve technology by Schubert & Salzer Control Systems offers you the perfect solution for your individual control applications. www.schubert-salzer.com

Visit us at PPMA 27th - 29th September 2022 NEC, Birmingham, UK Stand: G30

An Obvious Need

OnRobot believes deploying robotic applications on the manufacturing floor has been too complex and time-consuming for far too long. Therefore OnRobot has been working hard to break down these complexities and enable easier deployment from just one unified, automated platform.

With the advantage of OnRobot´s applications working with over 14 collaborative robots, OnRobot has achieved zero complexity and one-stop-shop. However, deploying/redeploying is still a time consumer.

The revolutionary approach with D:PLOY will simplify the installation process even more, allowing the end user to focus on what truly matters in their production line and business.

D:PLOY will be the first automated, application-centric software platform for making cobots talk to each other. While the adoption of intelligent robots is growing, the installation and programming of these systems remains a time-consuming and complicated process.

The D:PLOY platform will enable the automated deployment of these collaborative applications to create, run, monitor and redeploy individual cobots from a single online environment. Configuration times can then be reduced by up to 90%.

Sign up to learn more about this revolutionary platform

Contact details www.onrobot.com

Contact OnRobot to find out more about what we can offer you: north-europe@onrobot.com

Or visit our Learningsite on Collaborative applications know-how to all learn.onrobot.com/en

Danish company OnRobot is making automation easier and faster.

PHARMA 4.0

MITSUBISHI ELECTRIC

Making productivity sustainable

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

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

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

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

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

PHARMA 4.0 IS GREEN

Well-designed automation solutions can optimise resource utilisation, reducing both waste and rework. Mitsubishi Electric’s specialist teams have supported a multitude

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

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

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

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

To learn more about how industrial automation can help pharmaceutical manufacturers improve their environmental footprint and operations, download Mitsubishi Electric’s latest white paper ‘Advancing pharmaceutical manufacturing now – Key automation technologies, applications and real-world benefits’: https://gb.mitsubishielectric.com/fa/lp/whitepaper-robots-in-pharma-technology-guide

For further information, please visit https://gb.mitsubishielectric.com

DISPENSING ROBOTS

INTERTRONICS

What’s the risk?

The application of adhesives, potting compounds, encapsulants or other liquids, fluids or pastes, is something that can often be readily automated with a dispensing robot. However, manufacturers that are still performing these processes manually may be concerned about the potential risks of transforming their processes with automation. On the other hand, the potential rewards are great — including improved consistency, speed, and accuracy that lead to gains in productivity. Here Peter Swanson, Managing Director of adhesives and dispensing equipment specialist Intertronics, assesses the risk versus reward of investing in dispensing automation.

According to the International Federation of Robotics 2021 World Robot Report, the UK ranks below the global average of 126 robots per 10,000 employees, placing it 24th in the world in terms of robot density. Europe’s most automated country, Germany, has 371 robots per 10,000 employees, while the UK has just 101 per 10,000 employees. This trend, of increased robot use in mainland Europe contrasted with a downward trend in the UK, looks set to continue. In 2021, robot installations across Europe were up 24% to 4,302 units — a new peak — but down by 7% to 2,054 units in the UK.

Britain’s lack of investment in robots has its roots in the financial crisis of 2008. This is due, in part, to the culture of British industry. If you attend a manufacturing facility in Germany, for instance, the team might proudly point out their newest technology investments. In the UK, the plant manager is more likely to point to a trusted, reliable machine that has been in use for more than 20 years.

Britain has fallen behind the global average investment in robots. As the rest of Europe invests heavily in automation to drive productivity, the UK’s ability to remain competitive will be dependent on breaking the barriers to automation.

AUTOMATION: RISK OR REWARD?

One of the historic barriers to automation is the perceived risk of investing in new equipment. After all, if a manual process is working well then why upset the applecart? Nevertheless, recent events like Covid, the war in Ukraine, and Brexit have impacted how we do business, and how industry perceives risk.

Supply chain challenges are making it more difficult to source components, and the risks associated with long global supply chains mean that many manufacturers are reshoring their manufacturing operations. Businesses are also increasing their local supplier base. According to a survey by Make UK, three quarters of companies have increased the number of British suppliers they are using.

The success of these reshoring programmes depends on the availability of labour and, at present, the UK is facing a high number of job vacancies. If manufacturers are unable to recruit the people they need to reshore manual processes, then alternative methods of production become more attractive.

Following the events of the last few years, manufacturers are now more likely to see the opportunities of robots, rather than the risks. As Henry Ford once said, “If you need a machine and don’t buy it, you pay for it without getting it.”

With these factors in mind, the application of adhesives and other materials is a prime candidate for automation. A dispensing robot can apply materials with positional accuracy and precise quantities, and repeat that all day long. The output is often faster than a manual process and, sometimes, robots can achieve results that are not possible for a human. For example, applying an even bead of gasketing around a complex profile is not manually feasible.

INVESTING IN DISPENSING ROBOTS: WHAT WILL I NEED?

For manufacturers looking to invest in dispensing automation, there are four main components to the system. They are, first, the robot used to position and actuate the dispenser and, second, the dispenser (valve, pump, syringe or cartridge as well as the required controller and material reservoir) that is chosen to distribute the material. The third component is the tooling used to hold the parts in place and, fourth, the enclosure — an important consideration for health and safety.

The specification and choice of the dispensing methodology (valve, pump, syringe, cartridge, etc) is quite complex and material dependent. By working with a reliable supplier that understands the

intricacies of both the chemistry and the dispensing technology, manufacturers are more likely to invest in an optimal combination of technologies for their application — and get better results. Your supplier should also be able to integrate the dispenser with the robot and configure and customise the system with holding tools and fixtures, benches, and safety enclosures. The last piece of the puzzle is installation and training, to ensure that you are up and running right away, and that your team understands how to operate the equipment to get the best from it.

REDUCING THE RISK

To help de-risk the investment further, check that the supplier has been validated by a third party. Do they have a number of case studies that show successful robot installations? At Intertronics, we also offer customers the opportunity to visit our Technology Centre in Kidlington, Oxfordshire, where we can support with trials and tests to establish how the equipment will perform in your application.

In many cases, the upfront cost of dispensing robots is not as high as some manufacturers

think — it might even be less than the Managing Director’s new car! At Intertronics, we often see our customers achieve a payback period of six months-to-a year, although it may take up-to two years in some applications.

With the UK lagging in its robot uptake, it’s time we focus on the rewards of robots: improved productivity, efficiency, output, quality, and flexibility. In applications like dispensing, which lend themselves so well to automation, manufacturers have a lot to gain and very little to lose.

For further information, please visit www.intertronics.co.uk/2022/08/dispensing-automation-an-roi-story.

ELECTRICAL & ELECTRONICS

Cyntech confirm Vitalconn Partnership

Cyntech are pleased to announce their new Partnership with interface I/O manufacturer Vitalconn who are located in Dongguan and Foshan in China. Cyntech Director Dave Mellor said - ‘we are very pleased and excited to have Vitalconn amongst our connector offering. Connectors are a vital part of any system and Vitalconn can be key to the design in process. They are a ISO9001 company with excellent quality and pricing. Their great support team enables us to quote quickly and efficiently’

The Vitalconn range includes;

• Modular Jack RJ11/45

• Ethernet connector modules (ICM R45)

• SFP/SFP+ cages for Fiber Optics,

• Ethernet Transformer Modules

• HDMI connectors

• USB

• DC Jacks

Enquire today at sales@cyntech. co.uk or 01908 373927

www.vitalconn.com/product.html

since 1907 Trusted brand since 1907 We have built up our strong reputation by consistently producing products that are universally recognised for their quality and workmanship. KRAUSNAIMER.COM 01635 26 26 26 sales-uk@krausnaimer.com visit our website to see more

PCB-MOTION CONTROLLERS

INMOCO

Build or buy a three-axis motion controller?

Three-axis embedded PCB motion controllers are integral for applications such as robotic arm control. While high volume and specific development needs might drive towards an in-house build, minimising development time and lowering cost for smaller volumes is an advantage of buying-in a controller. Comparing these approaches, a hybrid option can also offer the best of both worlds.

Gerard Bush of motion specialist INMOCO compares the build versus buy approach for PCB-motion controllers.

Printed Circuit Board (PCB)-based motion controllers are frequently integrated within applications such as laboratory automation, mobile robotics, test equipment, packaging machines, and robot arm control. Typically controlling three axes of brushless DC and/ or stepper motors up to around 350W, the increasing trend is to embed a microchipbased controller within the machine itself. The close proximity this provides enables faster response times, less noise, and a more compact footprint, plus a reduced cabling.

Balancing specification requirements with cost, an OEM faces the decision of procuring an established controller or developing their own. Assuming an off-the-shelf controller can meet needs, development volume that impacts the total procurement cost might be the deciding factor. Alternatively, an exacting specification might drive internal development. While examining the pros and cons of both approaches, a hybrid option can combine the best of both worlds.

BUILDING A CONTROLLER

The advantages of developing in-house are two-fold. Firstly, this approach gives a controller that is entirely tailored to the application in terms of connectors and form factor, as well as dedicated functionality.

Unique design can also be a selling point, providing it includes features that the market is willing to pay for. The other main advantage is cost. Assuming the production run is high enough, talking in the region of 1,000 units or more, a custom designed controller might be a more costeffective procurement option.

The clear requirement, however, is the need for expertise and time in development.

While cost can be saved compared to highvolume procurement, the design effort for developing a three-axis motion controller PCB is significant.

Selecting connectors and the wiring scheme is a preliminary step, and this stage can take up to three months. Next, a pivotal decision is the approach to the motor amplifier. A designed-from-the-ground up amplifier offers the greatest flexibility in specification and control. However, with design considerations such as electromagnetic interference and current control, this process is likely to take

at least three months or more. Instead, an off-the-shelf PCB-mounted amplifier can be integrated, still providing advanced features such as safety controls, while saving development time.

The other primary component decision is the motion control chip itself. Using a separate micoprocessor gives the freedom to write a customised motion engine code. This affords complete flexibility over motion functions, but development would add at least 12 months to the project. To enable communication with the host network and coordinate motion

sequences, microprocessor system software code development is also required, taking up to six months.

Like the approach to the amplifier, alternatively an off-the-shelf motion control chip can be integrated into a customdesigned PCB controller to save time. This would give the OEM control over attributes including the PCB’s form factor, while still providing motion capabilities such as profile generation and field oriented control.

Progressing to the PCB schematic, this stage requires research, selection, and testing of components to achieve the circuit. Integrating the control chip and amplifier, the latter would also require a dedicated circuit. In total, at least 12 months should be allowed for PCB schematic development.

The final aspect of the software development process is application and motion parameter development. The timespan depends on previous application development experience but can take from 12 to 16 months. However, whether the motion controller is an in-house build, a buy-in, or a hybrid design, this stage of motion control

development is a prerequisite.

With an estimated total of 34-58 months’ work, divided into a threeperson team this project could take up to 18 months or more. Notwithstanding the design effort, for some OEMs, the long-term advantages may be worth it.

BUYING-IN A MOTION CONTROLLER

All of these steps, except for the application and motion parameter development, can instead be removed by using a ready-

to-go PCBbased motion controller. This effectively reduces development time to a little over a year and doesn’t necessarily mean a sacrifice in motion control features. As well as functionality such as profile and servo position control, integrating user downloadable code written with C language libraries also extends their control flexibility.

An advantage of buying-in an off-the-shelf motion controller is that it can also be more cost-effective if a lower volume is required. Perhaps up to approximately 1,000 units, integrating a pre-developed controller could be the less expensive option. If your organisation doesn’t have the existing development know-how in house, this approach could also save significant cost in hiring the required expertise.

Quicker development also means faster time to market. Demands of end users and the competitive landscape, might make this the preferable approach, even for higher volume projects.

HYBRID PCB-MOTION CONTROL DEVELOPMENT

Now, it’s possible for OEMs to use a hybrid approach that features PCBmounted motion control modules. These single-axis modules can handle up to 1kW and can execute user-written application software, extending control flexibility.

Just like an off-the-shelf controller, these modules include advanced motion functions such as profiling, field oriented control, and safety. The advantage though is the ease and speed of integration. Mounted on a user designed, application-specific interconnect board, these modules require much simplified wiring, needing just connectors and capacitors.

Like the buy-in option, the engineering resources required are significantly lower. Following simplified hardware integration, engineers can move directly to application development. This approach however still lets the OEM create a controller within their own form factor. Given the right volume, procurement cost of the hybrid approach can also return a lower rate than the buy-in option.

MAKING THE CHOICE

To navigate priorities in design, INMOCO’s engineers can interface with OEM development teams, providing insights to clarify the right approach. INMOCO works alongside Performance Motion Devices, a motion control manufacturer that has innovated the embedded PCB motion control concept. Whether the application requires a build-from-scratch, buy-in, or hybrid approach, INMOCO and Performance Motion Devices can provide the optimal control solution. For further information, please visit https://inmoco.co.uk

Balancing specification requirements with cost, an OEM faces the decision of procuring an established controller or developing their own.

SUITE X

WSCAD

integration

control specialist

The time to market for automation system design and development has decreased by up to 80% for a control technology specialist following the introduction of a comprehensive electrical system design package. WSCAD’s E-CAD software platform Suite X has delivered the result for automation system builder Bruckmann Steuerungstechnik GmbH (BSG), based in Uedem north of Düsseldorf, Germany. BSG needed a solution that would interface with its own in-house developed configuration software and an established ERP system to deliver an intuitive, easy to use design and specification tool.

BSG is a control technology integrator, automating systems for process and manufacturing industries from single machines to full production lines. Author of its own software suite, the capability of BSG’s ONEsystems platform includes machine automation and control, data acquisition and vision across the automated operation, as well as software integration between ERP-level IT and real machine data. BSG demanded a CAD package which could manage the design of its automation integration projects, and crucially, it also had to integrate with ONEsystems and be fully interoperable. Aware of the track record in deploying time-saving CAD packages for industrial automation solutions, BSG engaged with WSCAD with the aim of developing a partnership to create optimum automation design and streamline the design and development process.

The key challenge for BSG is time to market. Whether a new project or retrofit, BSG’s customers demand quick project delivery in order to optimise productivity. Integration with ONEsystems’ ERP system would be vital in order to reduce time on data transfer, management and accuracy. ERP integration would also increase efficiency of the project planning and procurement processes.

A further aspect to achieve reduced time to market is consistent product standardisation and the re-use of pre-developed, effective solutions. Crucial to reducing project time at BSG is electrical engineering design, from the development of individual machines and

circuit diagrams with wiring and distribution components, through to complete production plants and switchgear. As a result, the re-use and automation of electrical design would be a key factor in achieving rapid time to market.

WSCAD was able to fulfil BSG’s requirements through deployment of its electrical CAD system Suite X. “It was important for us that the interface from the E-CAD supplier would be able to directly integrate with our ERP system, as well as enabling project

replication to speed-up future projects,” says Leendert van Straalen, Operations Manager at BSG.

“WSCAD was able to provide the features we needed to design individual machines through to complete greenfield site project development – and be able to re-use these effective designs again. With the Project Wizard within WSCAD Suite X we received exactly the interface with which we could dock our self-developed solution to our ERP system.”

WSCAD Suite X’s integration with BSG’s ERP system means that projects which can be transferred directly are 80 to 90% faster to plan, according to BSG. Even projects which deviate from the standard design can be up to a third quicker in the planning stage. Based on the customer’s specification, the bill of materials is placed with the ERP system and all relevant component data is then transferred from BSG’s ONEsystem software to WSCAD’s Suite X, ready for design. Integration includes the transfer of part numbers and technical data between the ERP system and WSCAD Suite X, speeding the design process.

E-CAD

reduces time to market by 80% for automation

WSCAD Suite X’s integration with BSG’s

ERP system means that projects which can be transferred directly are 80 to 90% faster to plan, according to BSG.

Thanks to WSCAD’s basis of open integration, it can also communicate directly with other third-party ERP-related software, such as material suppliers. BSG uses WSCAD Suite X to communicate data to a supplier for the procurement of larger wire sets and bundles, making the process faster, more efficient, and more accurate. WSCAD Suite X’s Project Wizard stores macros for various function requirements, such as circuit diagrams and cabinet wiring, and automates their use, able to follow pre-set specifications on deployment. It also generates electrical engineering documentation in a structured format, making service and maintenance faster and easier for BSG’s customers.

“The Project Wizard puts everything together automatically. Once planned and saved in sets, the Project Wizard follows all company specifications when arranging the macros and their variants,” says Leendert van Straalen, Operations Manager at BSG.

Using ERP-generated data combined with WSCAD’s Cabinet Engineering Expert module, which is inclusive within the suite, BSG’s designers can also quickly create cabinet wiring diagrams. Component selection is generated within BSG’s software, then once transferred to WSCAD Suite X, detailed design adjustments can be made accordingly.

BSG’s control programming is based on a Siemens platform, with control data also integrated with the WSCAD Suite. Programming configurations are recorded within the CAD software and any changes are automatically updated. WSCAD Suite X can also reciprocally communicate any changes made within its designs back to the Siemens portal.

Similarly, WSCAD Suite X’s integrated approach means that replacement of a component in one plan is automatically updated across associated plans. This also ensures consistency of engineering data, especially important for large-scale projects such as the design of a process plant. This capability has also resolved BSG’s requirement to re-use plans, meaning that once a design has been created, regardless of project size, it can form the basis of a new project with only specific adaptions required. BSG has also reduced project time

by relying on WSCAD’s library, comprising over 1.4 million parts and including over 300 manufacturers, with 3D STEP drawings available.

Speed of development also means a CAD platform which is intuitive to use. The interface has been developed in conjunction with the experiences of designers within industry, including only occasional E-CAD users, making it usable with a limited number of settings. It’s also joined by the WSCAD Augmented Reality App, aimed at maintenance engineers, which visually identifies cabinet components and displays the relevant schematics and data, giving the engineers the data they need to quickly resolve any challenges.

“What we particularly like about WSCAD is the openness of the system and its logical structure. Handling the application is simple and easy to learn. Once understood, you can explore and use the many functions without further guidance. This is much more difficult with other systems,” says Leendert.

WSCAD Suite X increases the speed of time to market with its integration capabilities and intuitive design functionality. It also further reduces total cost with additional modules included as standard and retails at a price point significantly lower than comparable solutions.

HEATING USING A LOOP PROFILE

STEGO

Enclosure

heaters with an innovative heating body

The thermal management specialist STEGO presents its enclosure heaters with an innovative, loop-style heating body. The company is offering a total of five heater series ranging in power from 10 to 150 W for thermal management applications. Certified safety when exposed to shocks and vibrations enables the heaters to be used for a wider range of applications, while pressure clamps help to reduce installation time.

LOOP HEATERS TO PREVENT CONDENSATION INSIDE YOUR CONTROL CABINET

Enclosure heaters are the tool of choice for preventing condensation in control cabinets. Heating the air inside the cabinet avoids temperature fluctuations and keeps relative humidity constant, thus protecting electric and electronic components against harmful humidity as it condenses and preventing short circuits.

STEGO, a pioneer in enclosure heaters, will be showcasing its enclosure heater with a completely new heating body: the loop heater. No fewer than five series featuring the new body are being launched on the market: the LPS 164 and LTS 064 series are based on the compact loop profile and deliver a heating power of between 10 and 50 W, while the larger loop profile in the LT 065, LTF 065 and LP 165 series gives them a heating capacity of 50 to 150 W.

THE LOOP: A BRAND-NEW DESIGN FOR THE HEATING BODY

The most striking product and design feature of the compact convection heaters is the

innovative aluminium profile strip that forms part of its heating body and, in fact, gives it its name – the loop – based on its shape with similarities to a figure-of-eight and thus also the symbol for infinity.

This profile is extremely efficient at absorbing the heat from the PTC heating elements, meaning that users benefit from improved, uniform heat transmission inside their control cabinet.

SAFE AND USER-FRIENDLY

All loop heaters come with a clip so that they can be attached quickly to their 35 mm DIN rail. Pressure clamp connection reduce installation time for the user by up to 50%. Cables with rigid wire and ferrules can be connected quickly and without any tools. The clamps exert constant pressure on the cables, which provides added security when transporting pre-assembled control cabinets, for example. You therefore need not worry about the connecting cables ever coming loose during operation. The LTF 065 loop heater series with integrated tamper-proof thermostat offers additional potential for

savings as there is no need to have a separate thermostat for control purposes. The LTS 064, LT 065 and LTF 065 series are designed to be touch-safe. Their light-grey, insulated plastic housings keep the surface temperature under 80°C, thus protecting maintenance and operating personnel from burns in the event of accidental contact. STEGO products are approved and safety certified independently by globally recognised testing institutes such as VDE, UL and EAC.

SHOCK- AND VIBRATION-PROOF

The loop heaters are shock- and vibrationproof and have the approvals to prove it. The innovative loop profile allows the heater to be assembled in a completely new way: rather than being pressed together, the heating body and heating element are firmly interlocked by the spring action exerted by the loop profile. The elastic property of the aluminium profile is leveraged to maintain a strong force on the heating elements at all times, even in the event of temperature cycles during operation, and to ensure constant heating power throughout the heater’s service life. The effort that went into this design has been well worth it: all touch-safe loop heaters, i.e. the LT 065, LTF 065 and LTS 064 series, have been successfully tested for shock and vibration resistance in accordance with the standards DIN EN 60068-2-27:2010-02 and DIN EN 60068-2-64:2009-04 in relation to the standard DIN EN IEC 61373:2011-04, cat. 1 B. This also makes them demonstrably suitable for situations exposed to a strong vibration impact in environments such as rail and mobile applications or wind power.

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

Enclosure heaters are the tool of choice for preventing condensation in control cabinets

SUSTAINABLE LIGHTING

TOBERMORE

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

Tobermore

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

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

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

According to The Climate Group, lighting accounts for nearly 5% of global CO2 emissions. It has been projected that a global switch to LED lighting could save over 1,400 million tonnes of CO2 and avoid the construction of 1,250 power stations.

David Henderson, Managing Director of Tobermore, commented:

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

LED lighting

Rolling out £34k of LED lighting within our production facilities was a no brainer. The energy-efficient lighting will reduce our CO2 emissions while saving money on our energy bills. LED lighting is a win-win for businesses and households alike, I would encourage more people to make the switch.”

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

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

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

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

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

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

For more information on Tobermore’s sustainability journey please visit tobermore.co.uk/about-us/sustainability

With soaring energy prices and global emissions rising at unprecedented levels, companies and households alike are transitioning to energyefficient LED lighting.

Tobermore factories and quarry feature energy-efficient

Growing from strength to strength since the 1950’s to an award winning multi-discipline Design and Installation specialist

rowing from strength to rength since the 1950’s to an ward winning multi-discipline esign and Installation specialist

rowing from strength to strength since the 1950’s to an ward winning multi-discipline esign and Installation specialist

to strength since the 1950’s to an award winning multi-discipline Design and Installation specialist

A&B Engineering is a privately owned company based in Liverpool and provides design and installation of mechanical, electrical and plumbing services throughout the northwest.

A&B Engineering is a privately owned company based in Liverpool and provides design and installation of mechanical, electrical and plumbing services throughout the northwest.

A&B Engineering is a privately owned company based in Liverpool and provides design and installation of mechanical, electrical and plumbing services throughout the northwest.

The company started life back in the 1950 s and has developed over recent years to be one of the la gest in its sector and this ear the turnover is ca £50 Million.

The company started life back in the 1950’s and has developed over recent years to be one of the gest in its sec or and his year the turnover is circa £50 Million.

MECHANICAL ECTRICAL UMBING DESIGN

MECHANICAL ELECTRICAL PLUMBING

DESIGN

MECHANICAL ELECTRICAL PLUMBING DESIGN

A&B Engineering Limited ol L13 6QA www.abeng.co.uk

Proud to support the Jan Fairclough Ball in aid of The Walton Centre Charity.

A&B Engineering Limited 9-17 Derby Lane, Liverpool L13 6QA www.abeng.co.uk

A&B Engineering Limited 9-17 Derby Lane, Liverpool L13 6QA www.abeng.co.uk

Proud to support the Jan Fairclough Ball in aid of The Walton Centre Charity.

23/10/2019 13:28

Proud to support the Jan Fairclough Ball in aid of The Walton Centre Charity.

Growing from strength Specialist Maintenance Chemicals that deliver GAME CHANGING PERFORMANCE. with a major focus on sustainability!

23/10/2019 13:28

23/10/2019 13:28

0118 930

Swivel joint solutions for all sectors of engineering

Rotaflow swivels are regularly utilised in the following engineering sectors with tailored or stock designs for specific needs: Brewery, Chemical, Dairy & Farming, Food & Drink, Nuclear, Process & Plant, Drilling & Mining, Oil & Gas, Subsea, Water & Waste.

Through design and in-house manufacture our swivel joints allow one or more different flows through a single unit, enabling the pipework to rotate 360 degrees whilst carrying fluids (including hydraulic and pneumatic) of different pressures without cross-contamination or leakage.

There are many different forms of Swivel Joint… from very straight forward designs of our F and FS series, Compact swivels, or Heavy Duty to Articulated Pipework configurations, Floating Suction Arms, Jacketed, High pressure. A Swivel Joint reduces costs by reducing the risk of leakage with its associated downtime.

By fitting a quality designed swivel, you are improving your production capacity.

Rotaflow have built up a reputation for providing reliable and quality designed products that resolve your engineering needs and we are proud to say many customers request our services over and over again.

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

Whippendell

Whippendell specialises in providing electrical solutions for harsh environments such as the Rail, Naval and Commercial Marine Industrial Sectors. This includes design, manufacture, in-service support and maintenance.

For example, the company has been supporting the Royal Navy since the 1930s, with equipment on all current surface ships and submarines.

We offer a range of electrical panels, motor starters, control systems, power conversion equipment and aircraft ground power support systems.

Many of our solutions arise from a reverse engineering task to replace obsolete systems with modern alternatives. Typical applications include high pressure air control systems, pumps, steering gear, stabilisers, lifts, winches, mechanical handling equipment and HVAC systems. Solutions can be designed around Whippendell components or to customer preferred requirements and components – use of COTS and PLC technology is standard.

www.whippendell-marine.co.uk

Since 1984

NEW LAES FACILITY

air energy storage facility

A new 5MW Liquid Air Energy Storage (LAES) facility, designed by Highview Power Storage will soon be operational thanks, in part to some slightly less space age, but still very efficient 175kW WEG W22 IE3 electric motors and efficient EU327 Compliant centrifugal fan systems from Halifax Fan.

Large power stations using coal and nuclear fuel are also slow to ‘turn-down’ if demand drops and usually very, very expensive to get going again if you have to turn them off completely.

SO WHAT IS AN LAES FACILITY?

An LAES or Liquid Air Energy Storage facility is a new way of storing electrical energy, like a battery, but on a grid-scale power plant platform. A lot of electrical energy is created when the daily demand cycle from the grid isn’t high enough to receive it – good examples are renewables like wind, solar and tidal power that are generated based on the weather, not demand.

An ideal solution then would be to be able to store electrical energy for a few hours when demand is low and release it again quickly when demand (and in some instances – the price) is higher. An LAES facility uses a large gas compressor to turn air to a liquid then store it in insulated, pressurised tanks, which keeps it as a liquid. In order to generate power the air is heated and allowed to expand again, the pressure then pushes a gas turbine around to generate power. The only emission created is air…

After having built and tested a successful pilot plant, Highview and project partner Viridor were awarded government funding by the Department of Energy and Climate Change (DECC) to build a pre-commercial scale 5MW Liquid Air Energy Storage technology demonstrator. That LAES plant is now currently undergoing final commissioning in Bury Lancashire.

SO HOW EXACTLY DOES AN LAES WORK?

Air turns to liquid when refrigerated to -196°C, which is usually achieved by a cycle

The components of Highview’s processes were chosen purposefully from large OEMs so they could be readily adapted and have proven operating life times and performances.

of compression, cooling and expansion, it can then be stored inconventionally insulated, ambient pressure vessels at very large scale. Exposure to ambient temperatures causes rapid re-gasification and a 700-fold expansion in volume, which is used to drive a turbine and create electricity.

Highview’s technology draws from established processes from the turbomachinery, power generation and industrial gas sectors.

Stuart Nelmes Head of Engineering at Highview, ‘The beauty of this system is that each component part of the process is built using tried and tested technology, which we know works and has established performance parameters. The centrifugal fans sourced from Halifax Fan, one of the

UK’s leading suppliers, driven by WEG motors, one of the worlds most recognised brands, therefore fitted our remit very closely.

‘The LAES system comprises of three primary processes: a charging system, an energy store and a power recovery stage. The energy efficiency of each stage is crucial to the economic viability of the project. Because we have to power the system with the electricity we generate or buy it from the grid the energy efficiency of each component is very important.

Halifax has developed its centrifugal range to maximise energy efficiency and WEG offers a very energy efficient IE3 motor as standard so this also influenced our decision. Every little helps in this situation.

‘There is a big temperature change as the gas is converted to a liquid and back again. It is the same principle used to make your kitchen fridge cold but more akin in scale to the effect you see freezing moisture in the air creating slabs of ice that crack off the surface of a space rocket as the fuel tanks empty. We needed a very reliable, wellproven blown air solution to regulate the temperature and airflow around some of the key components in the system and so the Halifax Fan / WEG combination was a good one for us.

WEG is the main supplier of motors to Halifax Fan, the WEG Regional Sales Manager Russell Auty comments,

‘We have a great long standing relationship with Halifax Fan based on a highly efficient and extensive product range, one that is available next-day off-the-shelf in the UK from fractional kW ratings up to 500kW. It is this mix of range, quality and availability that makes the difference to our customers. That and the fact that we supply an IE3 spec motor with up to 98% electrical energy efficiency as standard.’

GREEN MACHINES

The green credentials for the LAES technology are off the scale compared to other large-scale energy storage

Halifax fans and WEG motors help ventilate the world’s first full-scale liquid

The centrifugal fans employ 175kW WEG W22 Premium Efficiency IP55 IE3 3~ electric motors. They are foot mounted to a skid and connected using a torque limiting anti-vibration coupling to the fan drive shaft.

methods; once constructed the commercial installations will be close to environmentally neutral, output is simply air, (or in the case of this test unit inert Nitrogen supplied by BOC, which makes up 78% of the air anyway). Commercial installations are likely to be used as temporary energy banks for larger power stations, which are both slow and expensive to turn down, or turn off.

The solution would also be very effective for storing energy from renewable sources such as wind turbines when there is a grid surplus and then fed back into the grid when demand peaks. The project will operate for at least one year and is intended to demonstrate how LAES can provide a number of electricity grid balancing services, including Short Term Operating Reserve (STOR), Triad avoidance (supporting the grid during the winter peaks) and testing for the US regulation market. Construction on the project began in February 2015 and it is expected to be operational during 2016. Highview’s LAES technology can be scaled up from around 5MW output and 15MWh of storage capacity to more than 200MW output and 1.2GWh of capacity. It can be considered as being comparable to medium scale pumped hydro-electricity storage, but without the geographical restrictions of mountains and reservoirs. When scaling up LAES technology, the system will be modular

For further information, please visit www.weg.net

and benefit from scale and convenience, an advantage when locating it to different regions and applications.

The Pros and Cons of LAES technology:

Why Liquid Air Energy Storage?

• No geographical constraints

• Close to environmentally neutral in operation

• Competitive capital cost

• Long lifetime 25+ years

• Scalable to 200MW/1GWh

• Components available from a global supply chain

• Integration of industrial low-grade waste heat and waste cold

• Uses no scarce or toxic materials

The beauty of this system is that each component part of the process is built using tried and tested technology.

Fast, effective peak-lopping is an extremely desirable function from an energy grid management point of view and this is one reason why government funding has been provided. It is also a reason for considerable global commercial interest in the project.

THE CO.PILOT

Explosion prevention in new spheres

The topic of “explosion safety” is omnipresent for plant operators and OEM´s when it comes to handling or transporting combustible dusts. Despite the widespread assumption that an increased risk of explosion only exists for gases, enormous forces can also be released by explosive dust- / air mixtures.

To help minimise the risk of explosions when handing combustible dusts, it is important to understand the requirements for an explosion and the respective dust safety characteristics, which are described below. The following picture shows the fire triangle and the explosion pentagon which must be taken into account.

The following conditions must exist for an explosion to occur within a production facility or machine:

If any one of the afore mentioned prerequisites is eliminated, explosion prevention has intrinsically been practised. However, if this is not possible at all times and in all operating states, explosion hazards will still be present. In this case, it is necessary to divide any potentially explosive atmospheres into zones and systematically apply safety measures.

Drying processes in particular are used in many industries to produce material, for easier storage, more efficient transport and a longer shelf life. However, the combination of moisture extraction and high temperatures creates an increased risk of both, fires and explosions.

If fires and/or explosions occur in drying plants, which are usually very large, the situation is not only extremely dangerous for the machines and the business, but especially for the employees on site.

Operators of spray dryers must combat a particular type of ignition source –namely smouldering nests that can lead to spontaneous combustion if the material undergoes excessive caking. Caking occurs due to sub-optimal drying of the material and its initially high moisture content. The caked material is then insulated against

the surrounding air by a build-up of moist material. The high temperatures ensure that the caked material is continuously heated until a biological reaction takes place involving protein, carbohydrate and water –known as the Maillard reaction. The Maillard reaction generates additional heat that cannot be dissipated due to the insulating layer of caked material. This process continues to accelerate until spontaneous combustion finally occurs.

Caking of this kind can build up both on the nozzles and the inner wall of the spray dryers. If the nozzle malfunctions, droplets may fall down into the fluid bed and cause further clumping. If a smouldering nest is able to form, this can ignite the explosive atmosphere inside the dryer or the downstream machinery.

HOW CAN SUCH CONDITIONS, WHICH ARE FREQUENTLY ENCOUNTERED IN PRACTICE, BE PREVENTED?

Everything starts with the human factor, i.e. properly trained personnel for the respective processes. Optimal process control is also required to avoid caking. But without precise and reliable information/ measurements, this is virtually impossible, even for specialists. Nowadays, humidity and one of the by-products of spontaneous combustion at early stages – carbon monoxide (CO) – are used as indicators to ensure a smooth and thus safe process. However, the fact that combined measurement systems cannot clearly distinguish between these two indicators is problematic and can result in inaccurate measurements.

The REMBE CO.Pilot makes exactly this symbiosis possible!

Via a permanent comparison of recorded data with a database of stored reference gases that serve as “fingerprints” of the selected gases, it is possible to perform a one-time check in real time and thus permanently verify the measurement accuracy. At the same time, the realtime fingerprint analysis eliminates the cross-sensitivity to other gases in the

measurement spectrum that is common in commercial gas analysers.

To ensure a reliable measurement of the operating status, samples are sucked in from all of the dryer’s relevant supply and exhaust air ducts under very high vacuum. REMBE calculates the delta CO value on the basis of the absolute values measured at the individual measuring points. This value is the mathematical difference between the CO content of the extract air and the CO content of the supply air. Thus, only events that actually occur in the respective process are detected. External factors that may disturb the process can thus be ignored.

A proprietary evaluation algorithm (RFA REMBE Flow Algorithm) enables the measured supply and exhaust air values to be compared in real time. As a result, the REMBE CO.Pilot is the first system on the market that makes it possible to adjust the individual alarm limits and gas run times for the individual measuring points in the dryer’s various air throughputs without any delays. The ratios of the different supply air channels and the flexible operating hours are balanced via the software and calculated accordingly in the PLC.

Thus, if an increased carbon monoxide concentration is detected due to spontaneous combustion during the process, countermeasures can be initiated immediately.

BUT WHAT DOES THIS MEAN IN DETAIL?

This special sampling process eliminates the need for costly and error-prone gas treatment, thus ensuring that the CO.Pilot is less susceptible to faults and requires less maintenance. Furthermore, this measurement method can make recurring calibrations unnecessary. Due to the precise measurement technology and the reproducible results, false alarms and downtimes can also be avoided. And in combination with moisture measurements, the entire drying process can be optimally controlled, significantly increasing the energy efficiency of the system.

For further information, please visit www.rembe.com

HEALTH & SAFETY

PREVENTION TECHNOLOGY

GRECON LIMITED

Your Fire Prevention and Measuring Technology partner for over 30

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 FagusGreCon 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

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

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.

FIRE PREVENTION OR FIRE PROTECTION?

The adage, ‘prevention is better than cure, ‘ rings true. GreCon believes that early detection of ignition sources is critically important. Once a fire starts, the results can be catastrophic. When companies are unaware of GreCon’s technologies, they rely on more conventional fire protection systems, which do not always provide the best defence.

ENABLING THE SMART FACTORY

A comprehensive range of industrial process measurement solutions equips the ‘smart

GreCon DLD 1/9

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 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.

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 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.

Demonstrations started in 2022 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 www.grecon.co.uk

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

THREE TIMES THE PERFORMANCE

DONGHUA LIMITED

Deluxe Chain making a mark in the UK

A new chain called X3 which was introduced to the UK market last year has already made its mark in the timber, waste & recycling and mining & quarrying industries

Designed and manufactured by the Hangzhou Donghua Chain Group which manufactures over 40 million metres of chain per year, the new chain has been well received by UK distributors thanks to its exceptional performance.

Bob Wellsbury, managing director of Donghua Limited, explains: “Our X3 Chain delivers three times the performance for wear resistance, fatigue resistance and high speed performance of comparable Roller Chain. It’s designed for high demand drives and we’ve had very positive feedback from our Product Partners and Stockists across the UK - some are even replacing all their standard Roller Chain and only offering X3!”

Its superior quality, durability and outstanding wear and fatigue resistance are realised by the new hardened, shot-blasted plate shape, calibrated pin and bushing holes, special heat-treated and surface coated pins, seamless rollers and bushings and high performance pre-lubrication.

It is manufactured on its own purpose-built production line which encompasses new production techniques and new surface treatments, and is designed with a unique

pin coating, optimised plate geometry and high precision stamping.

Supplied pre-loaded and pre-lubricated as standard, X3 is available in British Standard 06B to 24B in simplex and duplex, ex-stock from Donghua’s 25,000 sq ft warehouse in the West Midlands.

X3 is part of the Premium Range offering customers a deluxe solution to problems with chain wear, chain fatigue, corrosion, high speed, lubrication, chain length accuracy and chain strength with specific build features designed to enhance durability and withstand a range of arduous environments.

Donghua also supplies roller chain in Standard and Solution ranges.

Wear Life

The Standard Range features a variety of standard Roller Chain manufactured with precision to suit simple drives with large diameter sprockets or complex drives with multiple sprockets and high load bearings.

The Solution Range offers customers a genuine solution to problems with chain wear, chain fatigue, high speed, lubrication, chain length accuracy and chain strength offering optimum performance in extreme conditions.

Chains within this range include: chromized pin (CP) chain, heavy duty chain, selflubricated roller chain and EXL chain which incorporates their unique ‘Easy Break Technology’ enabling the chain to be cut in the field using Donghua’s Plate Extractor tools.

To download our X3 catalogue visit: https://www.donghua.co.uk/X3-chain

TECHNICAL INNOVATION

NOVACAST

How working closely with a modern foundry can enable innovation

NovaCast are specialists in the casting of high-quality metal components used in pumps and valves throughout the process industries. The introduction of sophisticated technology, an emphasis on design engineering, and a willingness to work closely with its customers’ design teams, has resulted in many technical innovations that have reduced costs and lead times, while improving component performance and giving its customers a competitive edge.

A good example is the venturi orifice steam trap solution used in a wide variety of process engineering applications within the food manufacture, sports and recreation, laundry, chemical and biomechanical markets.

NovaCast’s customer developed a venturi orifice trap design that featured a cast stainless steel body with a unique reamoveable orifice insert allowing for easy maintenance without the need to remove the trap from the steam line. To meet the demands of the European market, the central casting required the welding of stainless steel flanges at both ends. In addition to adding cost and time to the production process, the specialist welds needed to be machined, checked and certified because the steam traps operate in high pressure environments.

The success of the innovative venturi design, which has largely replaced mechanical steam traps, encouraged NovaCast’s customer to seek ways of reducing production costs and simplifying the manufacturing process.

While the existing unit met its functional design and performance requirements, it was expensive and time-consuming to produce. So, every aspect of the product design and manufacturing process was reassessed with the objective of evolving an already successful design into one which delivered a significant competitive advantage.

A key objective of the re-design was to incorporate the welded flanges into the

main casting. This would deliver several benefits including a simplification of the production process by eliminating the need for any welding, a reduction in the amount of machining required, a lowering of the manufacturing cost and the opportunity to benefit from economies of scale.

It was critical that the quality of the stainless steel casting was high to ensure the integrity of the steam trap when working at high temperatures and pressures. This would also reduce the amount of machining required to achieve both operational performance and the required surface finish.

NovaCast was selected for the redevelopment due to its extensive experience of converting fabrications into castings combined with its ability to deliver stainless steel castings of the highest quality at highly competitive prices due to its partnering relationships with several ferrous foundries in the far east.

NovaCast’s design team developed and refined the casting geometry using 3D modelling and casting simulation software. A 3D printed prototype was then produced prior to commissioning full stainless steel production samples. The combination of advanced computer modelling and 3D printing eased the process of developing, testing, and refining the casting geometry and saved both time and cost.

The new steam trap body, including the flanges, was investment cast in one piece using CF8 stainless steel giving it consistent strength, resilience, and dimensional accuracy. The new body was totally homogenous making it physically stronger and safer as all welding had been eliminated. This also simplified certification, speeded up production and ensured repeatable, high quality.

From a commercial perspective, the new steam trap delivered the same technically advanced solution as its predecessor but in a fully integrated flanged form that exactly met market requirements. The streamlined manufacturing process enabled by the new design also lowered the costs to end users.

Richard Phillips, Managing Director at NovaCast is delighted with the result: “We have been encouraging customers to look for opportunities to replace expensive and time-consuming fabrications with single castings for a long time now. It is very rewarding when a customer takes our advice on board and is prepared to re-assess their manufacturing processes to realise the benefits that high quality, complex castings can deliver.”

To discuss your requirements, call a member of NovaCast’s team on +44 (0) 1225 707466, or email sales@novacast.co.uk.

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

WISEMAN THREADING TOOLS LTD

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

HSS DIES & DIE NUTS

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

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!

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

FAST, STABLE MEASURING

MICRO-EPSILON

Autonetics, a specialist in custom measurement solutions that are used in a wide range of industries, has chosen to use noncontact laser micrometers and non-contact laser triangulation sensors from Micro-Epsilon on its Vertical Gauging Unit (VGU), a measuring tool for the precise measurement of shafts and axes.

The VGU is equipped with a tailstock and servo drive, linear drives with rack, and a precision turntable. In addition, four optoCONTROL 2600 laser micrometers and an optoNCDT 2300 laser triangulation distance sensor from Micro-Epsilon are integrated into the VGU. All components together measure axial lengths, diameters, concentricity and splines, achieving cycle times and accuracies that cannot be achieved using manual measurement techniques. Not only do the sensors enable fast, non-contact measurement of shafts and splines, they also ensure stable measurements to sub-micrometer accuracy, even on metal surfaces. Comprehensive software enables evaluation of measurement data, recording of key values and data output to a PLC. The measurement data is automatically sent to the CNC controller so that tool adjustments can be made automatically in real time to compensate for tool wear.

MEASURING TRACTOR AXLE SHAFTS

The VGU is used, for example, in an automated machining centre for tractor axle shafts. The shafts are guided into the VGU by a robot and clamped into position. The measuring station moves along the shaft and uses the four integrated optoCONTROL 2600 optical micrometers to determine the diameters. The four micrometers individually have a 40 mm measurement range but are arranged in pairs and offset in order to detect a range of shaft diameters from 58 mm up to 178 mm. In addition, the optoNCDT 2300 laser triangulation sensor, in combination with the rotary stage, is used to measure the splines of the shaft.

The optoCONTROL 2600 is an optical measuring system (sensor unit and controller) with integrated high resolution CCD camera. The sensor has been developed with solid state (non-rotating) optics and so the measurement accuracy does not drift over time. Using a special lens arrangement, an LED light source produces a parallel light curtain (visible red light), which is imaged on the CCD camera via a telecentric lens. If an object to be measured is placed in the light curtain, the shadow it creates is detected by the CCD array – even transparent targets can be measured. The measured data is output via analogue and digital interfaces, enabling easy integration for both OEMs and end users. The system is insensitive to high external light conditions, as well as dirt and moisture. The optoCONTROL 2600 has a measuring range of 40mm, resolution of 0.1µm and measuring rate of 2.3 kHz.

The optoNCDT 2300 is the high performance model of MicroEpsilon’s laser triangulation sensor range, with an adjustable measuring rate up to 49.14 kHz and a resolution of 0.03µm. The entire electronics is integrated in a compact sensor housing. The laser sensor is particularly suitable for high speed applications such as measurements on challenging surfaces, including diffuse reflective surfaces, glass and transparent plastics. The A-RTSC (Advanced Real Time Surface Compensation) feature enables more precise real time surface compensation during the measurement process. A range of interfaces are available including analogue, RS422, Ethernet, EtherCAT, Profinet and Ethernet/IP.

For more information on the optoCONTROL range of optical micrometers or the optoNCDT range of laser triangulation sensors from Micro-Epsilon, please visit www.micro-epsilon.co.uk or call the Micro-Epsilon sales department on +44 (0)151 355 6070 or email mailto:info@micro-epsilon.co.uk

For further information, please visit www.micro-epsilon.co.uk

Autonetics chooses non-contact optical micrometers and laser triangulation sensors from Micro-Epsilon to measure shaft diameters and splines

Improve energy performance and make cost savings

For higher consumers of electricity, such as those in the manufacturing sector, power usage monitoring and energy efficiency measures are of particular importance. Regular power usage monitoring in industrial facilities can also perform an important role in ongoing energy efficiency schemes.

The Tinytag Energy Data Logger is a portable data recorder which can be used to monitor electricity consumption in individual pieces of equipment to help identify where potential energy usage savings can be made, improving energy performance and cost savings.

Celab, based in Hampshire, designs and manufactures high reliability power supplies for military and commercial applications. With 2000m2 of manufacturing space housing a variety of equipment and processes, Celab are a relatively high user of electricity, typically 55,000-70,000kWh/month. The Quality Manager at Celab purchased a Tinytag Energy Logger to better understand the power usage of individual pieces of equipment and the results allowed the team to identify where energy usage savings can be made, particularly when equipment is in idle mode.

Regular monitoring with the Tinytag Energy Logger has also proved effective for European Freeze Dry, a leading multiproduct freeze drying facility and provider of speciality freeze drying services. As part of its overall energy efficiency scheme, European Freeze Dry monitors the energy consumption of all plant and equipment at its site. The energy logger is used in 24-hour

www.geminidataloggers.com

periods on equipment such as vacuum pumps, vacuum boosters, air compressors and pumps. The recorded data is analyzed to identify areas where the usage or loading of equipment can be reduced. Where modifications to systems or practices are implemented, the equipment will be monitored again to quantify savings and efficiencies.

Sight

Visilume present our tried and tested UK manufactured sight flow indicators.

Our standard range, with a choice of stainless steel and carbon steel castings can be supplied with a flap or spinner to offer additional visual indication.

We have vast experience with custom requirements, whether that be special materials, overall lengths or pressure ratings.

IMPROVED CYCLE TIMES

200-year-old manufacturer turns to smart technology to drive efficiency FOURJAW

A Midlands-based manufacturer that can trace its roots back more than 200 years is using Industry 4.0 machine monitoring software from FourJaw to drive efficiency.

Cast-nylon and plastic components manufacturer Westley Plastics has improved cycle times and achieved more consistent and efficient 24/7 production after adopting smart technology, which has given the company greater visibility of its manufacturing process.

Westley Plastics is a family-run business that specialises in taking engineering plastic products from concept and design to final manufacture, utilising its on-site design, casting and CNC machining facilities. It works across several heavy industrial sectors including construction, defence, automotive, rail and steel.

The company operates 24 hours a day, but it wasn’t evident whether machine utilisation and productivity were consistent throughout any 24-hour period. It was agreed that greater visibility of the shop floor through machine monitoring would enable them to identify capacity and cycle times and help to focus the workforce on the processes that required and benefited most from their skills.

FourJaw’s manufacturing analytics platform, which works on machines of all types and ages, enabled the business to identify machine downtimes and understand the reasons behind the stoppages. Machine monitoring has also identified and improved cycle times. The team had previously discussed running two machines at the same time but didn’t think it could be done. However, the data from FourJaw revealed which machines could be run together –improving efficiency, productivity and job profitability.

Tom Westley, Operations Director said: “The information that the FourJaw platform provides has resulted in some very positive changes for the business, including the introduction of new production processes, improvements to the factory layout, and

Westley Plastics’ smart factory strategy will include installing FourJaw machine monitoring to every machine that it adds to its manufacturing operations as it grows.

improved cycle times by creating new jigs, reducing on-job operations of big jobs by 50%.

“We now have a clear and informed picture of the factory floor including accurate cycle times and utilisation by shift. The factory is now more efficient and productive with its resources which is evidenced by the increased utilisation of machines running 24 hours during the week, which has improved so much that fewer shifts need to run over

the weekend, saving the business money on staffing, energy and other operating costs.”

Westley Plastics’ smart factory strategy will include installing FourJaw machine monitoring to every machine that it adds to its manufacturing operations as it grows.

Oliver Pogmore, Head of Business Development at FourJaw, said: “Our MachineLink IIoT device can be easily and quickly self-installed on any manufacturing machine, regardless of brand, type or age, which makes it perfect for small and medium-sized businesses who’d prefer a low-cost, no-fuss ‘plug-and-play’ solution.

By monitoring and analysing machine data, FourJaw enables manufacturers to make machines run productively and profitably. This is certainly the case for Westley Plastics.

“It’s always been important to get the most from your assets, but we are seeing a big uplift in manufacturers turning to smart technologies to ensure their machines are as productive and efficient as possible. Enabling them to offset some of the economic and inflationary pressures faced”

For further information, please visit www.fourjaw.com

Treatt is a natural extracts and ingredients manufacturer with sites across the UK, US and China. Whilst focusing on sustainability, they use groundbreaking technology to create extracts and flavourings for the global beverage, flavour, fragrance and consumer goods markets.

Over the years, AWM has provided Treatt with products and support for their UK headquarters. This particular solution controls the batching of liquid via a peristaltic pump controlled via a 4-20mA output. With each batch, a label is produced to adhere to the container.

The solution consists of a Cardinal 825 weight indicator with batching and labelling software, a P311T label printer and DAC card for milliamp control.

The system stores product data with associated target total values and variable speeds. Once selected and batch information is input, the display shows live weight readings. Once the desired product is selected, a summary of the values is displayed. It’s crucial to check these values prior to batching as the cost of the material is high, meaning wastage needs to be minimised. The selectable data includes;

• Target weight

• Percentage of target weight to run at full speed

• Percentage of the maximum pump speed that corresponds to full speed

• Percentage of the maximum pump speed that corresponds to fine speed

• Free fall compensation – accounting for material in the tubing that cannot be stopped from flowing out after the target is reached. This is minimised by reversing the pump near the end of the fill

www.awmltd.com

FOAMplus® perfect protective packaging solution from Storopack

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

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

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

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

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

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

The benefits for customers are numerous. As well as an ideal solution for protecting awkward and valuable products, customers with product

design changes and new product line additions are able to quickly adapt the packaging without the need to carry a large range of bespoke cartons or fabricated packaging.

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

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

www.storopack.co.uk

SUSTAINABLE SOLUTIONS

MEDMIX

Professional filling service for sustainable packaging system ecopaCC from medmix by CTA GmbH in Ludwigsburg, Germany

medmix is providing customers with sustainable packaging solutions for adhesives & sealants used for industrial applications. Supporting this, CTA is offering its customers full contract filling services for the MIXPACTM ecopaCCTM, a collapsible, foil based, high performance packaging. The ecopaCC significantly reduces plastic waste by 75% compared to a conventional solid cartridge with equivalent volume, while also saving transportation costs and waste volume.

medmix, a leading provider of high-precision liquid application and mixing technologies, has developed the ecopaCC sustainable packaging system. CTA, a large filling service provider based in Ludwigsburg, Germany, is already successfully supplying its customers with this innovative solution.

CTA provides development, production, filling, packaging, assembling and logistics services for chemical-technical products. The company regularly supplies solutions used for applications in various industries such as wind energy, automotive, transportation, aerospace, electronics, chemistry and many more. CTA belongs to the largest contract manufacturers for two component cartridge filling in Europe. CTA’s service offering for the ecopaCC packaging system ensures that medmix customers can specify a proven sustainable cartridge to support environmental strategies and reduce emissions.

In addition to remarkable CO2 emission saving during its manufacturing process by its unique design, using a significantly reduced amount of plastic combined with production processes, powered by renewable energy, the ecopaCC requires four times less space for shipping. This results in reduced logistics requirements and emissions during transportation. The collapsible design also means that empty ecopaCC cartridges can be stored requiring 4 times less space compared to the solid cartridge design, which reduces the storage cost of empty cartridges significantly. The cartridge uses a support sleeve, which can be re-used up to 1000 times. The packaging design

ecopaCC used for construction applications

Abive, ecopaCC filled. Right, ecopaCC when fully compressed - minimal waste

labeling to meet various industry or customer based branding requirements, enabling the production of fully finished products. Our long-standing relationship with medmix since 2006, high technical expertise, a strong logistics network as well as in-house capabilities reflects a complete service offering for the outstanding and sustainable packaging system ecopaCC.”

ensures exceptional mechanical and barrier properties, while offering full compatibility with standard dispensers. So, customers can order professionally filled ecopaCC cartridges in any quantity from CTA.

Franco Menchetti, Sales Manager at CTA, further adds: “Using dedicated machines developed ourselves, we may offer tailored ecopaCC filling services for low to high viscosity products. Our inherent flexibility as a contract manufacturer ensures we can provide everything from samples to full production runs - delivered anywhere in the world. We also carry out custom

CTA ensures the highest quality with its rigorous testing and inspection processes in place which includes extrusion and application tests as well as X-ray inspection of filled cartridges for enhanced quality purposes for customers. Quality inspection for each production run can be tailored to customer specific requirements or industrial standards. As a result, customers are ensured to get cartridges filled at the highest quality levels, which enhances performance. “We are seeing market pressure in the industrial sector towards more sustainable cartridge and packaging products,” says Christian Majoleth, Product Manager at medmix Switzerland. “This is due to customers wanting to reduce the environmental impact of their business and tightening regulations around the world regarding emissions and plastic waste reduction. By adopting the ecopaCC, customers can take an important step to achieve their sustainability targets and hence towards an improved CO2 footprint overall.”

For further information, please visit www.medmix.swiss

Using dedicated machines developed ourselves, we may offer tailored ecopaCC filling services for low to high viscosity products.

SEPURA™ Quality Filters Through

For filtration specialist, Bowman Stor, its homegrown SEPURA™ range of oil/water separators is only part of the story; the industry-leading firm also manufactures and supplies high performance replacement service kits for all brands of condensate filtration units, producing a comprehensive range from its UK headquarters and distributing them via a global network of partner organisations. Essentially, this means that any business using compressed air systems can benefit from the advantages of SEPURA’s innovative filtration technology.

It was in Bowman’s own laboratories that the company developed its revolutionary SILEXA™ media - a key ingredient in the success of the whole SEPURA range. Manufactured from recycled glass, SILEXA has been proven to be lighter, 20% more absorbent per weight, and cleaner compared to other OEM products. The SILEXA material has major environmental benefits, achieving outlet quality discharges as low as 5ppm.

Only genuine SEPURA-branded products contain the groundbreaking SILEXA™ media but Bowman Stor has created a dedicated app to make it even easier for every user to find the right SEPURA filter

kit for their specific filtration unit - quickly and efficiently - 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

www.sepura-technologies.com

helps establish the right size of filtration unit for the customer’s compressor system.

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.

Bowman Stor’s managing director, Richard Potts says; “At SEPURA we are committed to creating a greener future for everyone. A key part of this ethos is ensuring that, whatever equipment they use, our customers can achieve SEPURA’s unparalleled levels of performance, long service life and cleaner condensate. And that’s better for industry, better for the environment.

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

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.

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.

www.boerger.com

PUMPS MODERNISATION PROJECT

SULZER

Sulzer inaugurates highly automated and digitized pump production line and logistics center in Kotka, Finland

Sulzer has successfully finalized an extensive modernization project in the Karhula pump factory. Automation and digitization of the processes will take production to a completely new level, cutting throughput time by 93%. World-class measurement accuracy and digitized quality inspection will guarantee the highest product quality.

Sulzer has been manufacturing pumps in Kotka for 130 years. Now the company is entering a new era with the new, state-ofthe-art pump production line that meets the highest industry standards, alongside excellent ergonomics and safety. The production throughput time of the cuttingedge and energy-efficient equipment will be reduced by 93%. This will translate into far more favorable delivery times for our customers.

The automated facilities have been designed to deliver fast and efficient workflows, incorporating digital and lean principles to ensure effective production. A brand-new logistics center provides materials and component handling, streamlining material operations, and contributing to shorter lead times. The increased output from the Karhula pump factory will strengthen Sulzer’s entire global supply chain.

Sulzer’s factory in Kotka is one of the key providers of configured process pumps, agitators and high-speed turbocompressors for the global market. The facility also comprises industry- scale test beds and research facilities. The factory serves process industry customers in markets such as pulp, paper and board,

“The new production line represents the most advanced technology in the field, and we are excited about the possibilities it offers our customers when it comes to quality and delivery times. Moreover, given that the materials used in our highefficiency pumps are 99% recyclable, the new facility reflects not only our dedication to quality, but is also a significant step in building a sustainable future that our customers value and our employees can take pride in,” says Veli-Pekka Tiittanen, Head of the Industry Business Unit at Sulzer.

For further information, please visit www.sulzer.com/en

new wood-based processes, biofuels, sugar and starch, metals and mining, fertilizers, chemical processing, and water treatment.

ATEX Application for Water Re-injection

Cat Pumps (U.K.) were contacted by an onshore wellsite based in the South of England, looking for a complete pump and motor unit that was able to deliver the pressure and flowrate required for their water injection “downhole re-injection” system. Following an online search, they discovered via the Cat Pumps (U.K.) website that Cat Pumps offer ATEX Pumps and Pump Motor Units that were a suitable solution for their application.

Our customer drills, appraises and develops any hydrocarbons found at an onshore wellsite in the Weald Basin in the South of England. During this process our customer wanted produced water from oil and gas fields to be reinjected into the formation to stimulate hydrocarbon production in aging wells. This is known as water injection or water flooding. Produced water is very expensive to dispose of, so it is cost effective to re-inject into designated wells, back into compatible ground formations.

Water injection into oil wells involves the following steps:

• Injection wells are first drilled close to the producing well. An injection well is a well that is designed to channel water into the surrounding formation in proximity of a producing well to stimulate hydrocarbon production or for fluid disposal purposes.

• Produced water or treated water is pumped into the formation under high pressure. Tests may be carried out to ensure that the produced water to be injected is compatible with the formation, therefore the water may be treated to remove fine particles that might clog the well and oxygen that encourages the growth of bacteria.

• The pressurised fluid exerts a sweeping force that collects existing hydrocarbon from hard-to-reach areas in the formation, driving the products toward a nearby producing well for collection.

Cat Pumps has provided high-pressure pumps, pump systems and components to the well drilling industry for over 30 years. Due to the field-proven dependability and superior suction capabilities, our pumps have become the industry standard for water injection applications worldwide.

With field-proven dependability in applications around the globe, Cat Pumps provides the best value for water injection systems.

Our customer advised: “Cat Pumps had a very good understanding of our requirements. Their Technical support, after-purchase correspondence and ease of delivery to our location, made it a pleasure to do business. Any further requirements, we will contact Cat Pumps as our preferred supplier.”

At its core Sapman v12  is a sophisticated Manufacturing, Warehousing and Stock Control solution. This modular product provides extensive facilities for Stock Control, Sales and Purchase Order Processing, Warehouse Management, Bill of Materials, Works Order Processing, Engineering Control, MRP and CRP. With the Microsoft SQL database engine at its core this product provides a leading edge business management solution.

Our highly skilled team has 20 years of experience resolving our customers’ Assembly, Manufacturing Control and ERP requirements, their Stock Control and Warehouse Management needs using our advanced, effective and efficient software solution.

Sapman v12 fully integrates with Sage’s Accounting solutions: Sage 50 and Sage 200. It also provides an upgrade path from Sage 100.

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

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

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

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

SELL IT

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

SoP : The Sales Order Processing gets underway

MAKE IT

Stock : Stock Enquiry : Check material Needs : Make to Order or Ex Stock?

If not it may generate a Purchase Order for more Stock

If the Sale item is Make To Order (MTO) then the Works Order Processing routine kicks in

v12 is suitable for Batch Manufacturing, Make to Stock, make to Order, Kanban & service works

Stock values from v12 update Sage50 Nominal Ledger

PoP Purchase Order Raised

Purchase Invoice received & Sage 50 updated for Nominal Codes, Purchase Ledger and VAT

WoP The confirmed order has to be manufactured & v12 produces the works order

BOM V12 produces the BoM  : tree-view with collapsible/expandable nodes

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

WiP With Shop Floor Data Capture SFDC v12 knows :

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

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

Stock Finished item is booked into Stock

v12 knows where it is; it covers multiple sock locations and stock with Sub Contractors

Stock values per client defined categories can be up dated to Sage50 Nominal at client defined times

SEND IT

Stock Stock records updated, Despatch note raised; Certificates of conformity produced

Sales Invoice raised & Sage 50 updated for Nominal Codes, Sales Ledger & VAT

WHAT THEY SAY

“We really like the Shop Floor Data Capture system which enables us to see the current status of any Works Order live and onscreen.”

Alan Saitch, Managing Director, Lada Engineering Services Ltd

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

Colin Mallard, Finance Director, Lakeland Laboratories Limited

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

Mike Perkins, Managing Director, Encoders UK Ltd

For more information on Sapman v12 please visit our website at Sapmanv12.co.uk. Email us on info@sapmanv12.co.uk or please telephone us on: 0333 456 12 12.

COMPREHENSIVE ERP SYSTEM

Buying an ERP system used to be a major capital expense, potentially running to tens of thousands of pounds for an up and running system. The cost of the software purchase and associated consultancy made it a hugely considered financial outlay.

For manufacturers looking for a rapid Return On Investment – this was a major obstacle for many businesses : together with the desire to spend their CapEx budgets on modern machinery and increased manufacturing capacity rather than software!

For companies that want the software “out of the tin” - and do not require any bespoke programming – a system install and set-up, including training and data conversion would be around £2,950. Our licencing is £95-£20 per month (depending on user numbers) with no minimum contract obligation. Additional users can be added as required and, indeed, reduced.

A key market for us is Sage users. Sapphire Manufacturing Systems Ltd. The developer of Sapman v12 has been an Authorised Sage Developer for over 20 years. So most of our users run on Sage50

and Sage200, and we still have some clients on Sage Line 100 yet to upgrade.

One of the great advantages of Sapman v12 for Sage users is that users can benefit from multi depot stock and full Serial Number and Batch Traceability without the need to upgrade their accounting engine from Sage50 to Sage200. This is an additional cost saving benefit

We can demo the software remotely via Team Viewer or organise a visit to your premises or you can visit our Bristol Demo Suite: call us on 0333 456 12 12 to have a chat.

If you make stuff we’ll help you make it If you have a warehouse we’ll help you manage it If you hold stock we’ll help you control it

FIRST CLASS ELECTRICAL PLANNING

WSCAD

Germany’s largest airport expands with WSCAD

Frankfurt Airport, Germany’s largest international airport and Lufthansa’s global hub, is expanding with the assistance of WSCAD’s E-CAD software platform. Fraport Aufbau Süd GmbH, responsible for planning the new Terminal 3 including its building automation system, selected the WSCAD SUITE for its speed and flexibility in implementing 150,000 automation functions across the entire 403,000 m² structure.

Frankfurt Airport’s new Terminal 3, expected to go into operation in 2026, will eventually comprise five upper and two lower floors, hosting 25 million additional travellers each year. Planning the building automation, air conditioning, heating and ventilation is a vital requirement, managed by CANZLER GmbH on behalf of Fraport. Specifically, retail spaces need sufficient cooling capacity to deal with fluctuating passenger numbers, regardless of external climatic conditions. Fraport also required environmental sustainability features such as recycling waste heat from the baggage handling system to heat the terminal.

With function lists according to the German

standard VDI 3814, creating a unified basis to simplify planning, management and operation, and features to speed up the design process while maintaining accuracy, Fraport selected the WSCAD SUITE with its Building Automation module. The E-CAD software was also adopted by CANZLER.

“To avoid data errors and time delays, we paid special attention to the consistent planning of the building and room automation from the beginning,” says Uwe Eckardt, Planning Coordinator for Building Automation, Fraport Aufbau Süd GmbH. “BACnet object-related function lists according to VDI 3814 can be implemented perfectly with WSCAD and it was the only system with the performance features required by Fraport.”

CANZLER planned the building automation system for the terminal that involved the regulation of heating, air conditioning and cooling systems as well as the monitoring of sanitary and sprinkler systems. In total, this included approximately 1,500 rooms and the smoke control of the entire terminal. With 240 controls and components, the

system comprises around 90,000 data points and 150,000 automation functions, all of which have been designed and placed with WSCAD.

A key feature of WSCAD’s E-CAD software is the item referencing that enabled the entire air conditioning system to be designed in accordance with IEC 81346. Systematic structuring from the outset significantly accelerated and simplified the planning as well as development process. WSCAD enabled the scalability to duplicate then customise areas of design according to location and required function. For example, the drive of a ventilation system including motor, protection and control can be quickly replicated for use in the same form in another building area by drag and drop of the desired macro.

To ensure accurate and rapid referencing of duplicated areas, all stored labels are automatically inserted into the new structure. This also means that correctly structured, error-free cable or parameter lists for individual system parts can be generated very easily when required.

With around 200 ventilation systems involved in the Terminal 3 design, this was a significant advantage in time saving.

“When planning building automation projects, the automatic generation of data point keys as well as the ability to change them quickly and easily afterwards is very important,” says Heike Frommhold, CANZLER GmbH.

The system key developed for the project, including user address and data point, consists of a total of 31 digits. The automated creation of data point keys is also possible with WSCAD for projects using existing keys. When changes are made, the software automatically updates the system key across all data points. The plug-ins for building automation-specific

data point keys supplied with WSCAD’s software, as well as the extensive symbol library with article data, also increased the speed of design with no need for manual or bespoke generation.

Fraport and CANZLER also benefitted from WSCAD’s database that enables simple export of all project data, and projectspecific article databases can be easily created to bespoke standards and formats. For both design and data management, CANZLER found the software intuitive to use from the start. The next step in the development of Frankfurt’s Terminal 3 is to implement the building automation itself.

“Airports are complex and technically sophisticated buildings that require a special planning,” says Uwe Eckhardt, “and thanks to WSCAD we are on track to deliver the project to schedule.”

For further information, please visit www.wscaduniverse.com

To avoid data errors and time delays, we paid special attention to the consistent planning of the building and room automation from the beginning.

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

NETWORK COMMUNICATIONS

CLPA

Already fast becoming a reality, the e-F@ctories of the future leverage the Industrial Internet of Things (IIoT) to support smart, data-driven operations. These facilities are setups that can only work (and succeed) if backed by openness, interoperability and interconnectivity. This is why choosing the right network technology and protocols from an industry-leading organization is key.

Tom Burke, Global Strategic Advisor at the CC-Link Partner Association (CLPA), explores the key aspects of network communications for future-orientated manufacturing facilities.

e-F@ctories are all about dataflows, which generate and transfer insights on processes, equipment and other assets to drive productivity, performance and efficiency. This means that industrial communications can no longer be segmented, with parts of the enterprise completely disengaged from others. Instead, converged networks are required to fully realize the potential of digital transformation strategies.

Standard communications solutions have certainly come a long way in enabling interconnectivity. However, the current situation is still fragmented, requiring machine builders and end users to carefully consider the individual features of network technologies and the protocols available when embarking on a digitalization journey.

In effect, the market is still characterized by custom industrial Ethernet solutions, based on vendor-specific proprietary standards and with limited interoperability. Nonetheless, there are leading players in the sector that are bucking this trend, driving the development and adoption of technologies that can overcome present limitations to realize seamless connectivity.

DEFINING INTEROPERABILITY AND INTERCONNECTIVITY

The first aspect that companies should seek when looking at their communications is openness. A solution that enables open networking architectures ultimately supports

the exchange of data among hardware devices form a multitude of makers. In effect, automation vendors are able to decouple network hardware and software to develop compatible devices and interfaces.

It is precisely for these reasons that the CC-Link family of network technologies for industrial communications was developed as an open-source solution. Even more, the CLPA is committed to driving its adoption by helping device vendors to develop compatible products, certify them as well as enhance their market reach.

In addition to openness, it is recommended to favor a network or protocol that can offer interoperability or other companion specifications that support the unification of industrial communications. Thanks to this approach, end users can easily tap into the information produced by different machines or divisions within an enterprise.

When looking at this aspect, the CLPA has been driving key initiatives to deliver seamless connectivity, e.g. by incorporating MQTT and establishing valuable collaborations with other prominent organizations. These include, for example, the development of a joint specification with PROFIBUS & PROFINET International (PI) as well as the incorporation of OPC UA technology within CC-Link IE open gigabit industrial Ethernet.

IDENTIFYING FUTURE-ORIENTED FEATURES

One of the most interesting parts of interoperability is the ability to reliably leverage solutions that were previously not accessible to specific domains. One example is the application of Simple Network Management Protocol (SNMP) to the operational technology domain.

This technology has been widely used throughout information technology (IT) to help engineers gain a unique insight into the health and performance of their networks and devices, however the operational technology (OT) side has never been

able to benefit from it. Thanks to one of the industry’s most advanced network technologies, CC-Link IE TSN, this is no longer the case. Therefore, it is now possible to use SNMP to advance industrial automation and Industrial Internet of Things (IIoT) applications.

Finally, selecting a solution from a network technology provider that is committed to unified conformance testing is extremely advantageous, especially when it comes to delivering pioneering solutions. More precisely, as the market demand for Time-Sensitive Networking (TSN) grows, businesses can benefit from a standardized test plan to confirm the conformance and compatibility of products with TSN functions. This can ensure that all devices within a network can utilize the same protocols and standards.

To address this need, the CLPA is committed to the TSN Industrial Automation Conformance Collaboration (TIACC). This aims to develop and promote a single common conformance test plan to certify TSN-compatible products, in line with the IEC/IEEE 60802 TSN profile for Industrial Automation. Thus, the organization is actively engaged with other leading specialists, such as the Avnu Alliance, ODVA, OPC Foundation (OPCF) and PI, as part of this newly launched industry-wide initiative.

A SOLID PILLAR

The network of the future will be characterized by enhanced interconnectivity and openness in order to support seamless communications between a wide, ever-expanding range of devices. With a proven track record of improving and building on these core elements with every network technology released by the organization, the CLPA is well placed to address the need for easy to implement, transparent data sharing. By selecting the CC-Link family of network technologies, machine builders and end users are a step closer to achieving the unified architectures of the future.

For further information, please visit www.cc-link.org/en/

Only an open network technology will enable the transition to high productivity e-F@ctories

4-wire to 2-wire RS485 conversion and custom data conversion

The KD485-ADE-4XX-4XX from KK Systems is a DIN rail mounted interface converter with two serial ports which both support 2-wire or 4-wire RS485.

A common application is attaching new 2-wire RS485 devices to an existing 4-wire RS485 bus. The KD485 is protocol transparent and RS485 driver control is performed transparently.

Other port types available are RS232 and 20mA TTY.

User programmable versions also support data/protocol conversion.

The KD485 is powered from 7-35V DC and its 3-way isolation makes it ideal for industrial applications which require a robust unit with the full RS485 drive capability.

Custom products are also available, including C userprogrammable versions.

www.kksystems.com

Sensor Centre is a top level partner of the recently launched company, Datasensing. This new brand combines the Sensor, Safety and Machine Vision business unit of Datalogic, a world leader in the field of automatic data acquisition and M.D. Micro Detectors, the Modena-based industrial sensor producer. The creation of the new company means that Sensor Centre can now offer sensor, safety & vision solutions from more than 200 product lines as well as fixed & hand held industrial barcode readers many of which are stocked in the UK. With over 30 years of application experience in factory automation we are known throughout the industry as a leading solution provider, so if you are looking for an alternative to your current manufacturer or have new applications planned please do not hesitate to contact us.

SWITCHES & SENSORS

MAXIMIZING EFFICIENCY

PROCESS SENSING TECHNOLOGIES

Monitoring O2 Levels with Zirconia Oxygen Sensors

In many industries, there is a continuous requirement to monitor oxygen levels. In some applications it is necessary to reduce oxygen in a controlled atmosphere such as food storage and transportation. This prolongs the life of perishables. Other applications include suppressing oxygen levels in aircraft fuel tanks to eliminate the possibility of explosion or fire, reduce pollution and harmful gases in industrial plants, maximize efficiency saving fuel costs, and reduce emissions in industrial boilers. Process Sensing Technologies (PST) has a range of zirconium dioxide oxygen sensors, manufactured by one of its leading brands SST Sensing Ltd. These highly robust sensors come with different steel housing styles, cabling, and electrical connection options to meet many of these application requirements.

PST Zirconia Oxygen Sensors come standalone or with integrated electronics offering digital or analogue industry standard outputs. Unlike other technologies, their long operating life is due to the non-depleting sensor cell technology. No reference gas is required, and easy single point calibration can be performed in fresh air. Their ability to function in wide oxygen measuring ranges, operating temperatures and high-pressure environments results in a rugged, robust, and reliable sensor that is RoHS compliant. The oxygen sensors can measure over a wide oxygen range (0.1 to 100% O₂).

HOW DO ZIRCONIA SENSORS WORK?

Zirconia oxygen sensors from PST use a unique closed-loop measurement system. While the sensor continuously measures the oxygen level, a heartbeat signal is also generated, providing an immediate warning of any failure.

The sensors are constructed with a domeshaped block of Zirconium dioxide (ZrO2), coated on the inner and outer sides with a thin-porous platinum layer. The Zirconium dioxide acts as a solid electrolyte and is doped with yttrium oxide, which enhances the thermal and mechanical stability and electrical characteristics.

The platinum porous layer acts as an electrode, allowing oxygen ions to pass through into the ZrO2 electrolyte. One side of the assembly is exposed to the sample gas, whereas the other side is exposed to a reference gas (typically air).

PST can also supply an interface board that provides the necessary electronics to power and control the zirconia oxygen sensors, as well as a complete oxygen measurement system such as the PST OXY-FLEX. When choosing the most appropriate option, customers should consider the O2 measurement range required and what the output requirement is i.e., digital (RS485 Modbus or RS232) or analogue (4 – 20mA or 0 – 10VDC). Other considerations are the cable length to maintain the correct sensor heater voltage and minimize noise pickup. PST recommends keeping the cable length between the sensor and interface board as short as possible.

For more information, please visit ProcessSensing.com

Unlike other technologies, their long operating life is due to the non-depleting sensor cell technology.

Flange mounted Zirconia Sensor ZrO2 Miniature Zirconia Sensor

Zirconia Sensor Probe Series - Screw Fit Housing

TOOLS CONTINUOUS IMPROVEMENT

DK HOLDINGS LIMITED

Bespoke Diamond Tooling setting the standard

DK Holdings Limited has been a trusted partner to its global customer base for over 60 years, manufacturing off-the-shelf and bespoke Diamond Tooling solutions across the Aero, Composites, Automotive and Engineering industries from its ISOaccredited facilities in the United Kingdom.

Sales & Marketing Manager John Emptage tells us how the company continues to set the standard for bespoke Diamond Tooling solutions globally.

Our partners are as dynamic as the industries they are in. Take the Wind Turbine industry as an example, manufacturers across this sector, are continuously testing new material compositions and production processes such as incorporating natural fibres.

Our Diamond Tool range provides solutions to the most challenging applications whether you are in need of a larger than standard diameter Electroplated saw or are looking for a bespoke resin-bond grinding wheel, our dedicated sales team is here to support you.

DK Holdings continuously innovates and sets standards for Diamond Tooling solutions through the relationships we have developed with industry professionals and customers alike. Our R&D department continuously works from inception to the supply with our partners globally. Usually starting with a chat to learn more about what the requirements are and an on-site visit if needed, alongside testing of sample materials to identify the best possible Diamond Tooling solution in the most environmentally friendly and cost-effective way. This process leads to the perfect diamond tool being manufactured for the customer.

One recent example came from one of our partners in the Wind Turbine industry who was looking for a tooling solution to remove large volumes of composite material from wind turbine blades during the repair process. We worked with their team and developed a bespoke diamond electroplated grinding disc that reduced

production costs by at least 50% and minimised the environmental impact due to less wastage which was a great result for everyone.

Get in touch with us and find out how we can design, manufacture and supply a Diamond Tooling solution to elevate your production processes, the team is here to help.

Email: info@dk-holdings.co.uk | Web: www.dk-holdings.co.uk

DK Holdings sets standards through the relationships we have developed with industry professionals and customers alike.

Tel: +44(0)1580 891662 info@dk-holdings.co.uk www.dk-holdings.co.uk

Tel: +44(0)1580 891662 info@dk-holdings.co.uk www.dk-holdings.co.uk

About The Method

The Apollo Root Cause Analysis Methodology is a new way of thinking that goes far beyond the traditional root cause analysis problem solving processes It facilitates the creation of a common reality, using input from all stakeholders to produce an evidencebased understanding of the problem and ensures your solutions address proven causes and prevents recurrence.

The Apollo Root Cause Analysis Methodology is a 4 step process which facilitates a thorough incident investigation. It makes problem solving easy and gives those who have been trained the skills to solve real world problems faster, more efficiently and effectively every time.

Key Advantages Over Other Methods

TRAINING COURSES

Helping you to solve real world problems faster, more efficiently and effectively every time.

DRALLIM

VALVES SPECIALIST SOLUTIONS

Drallim is an innovative technology driven British engineering company with global presence. With experience in providing comprehensive turnkey assembly & test solutions covering electronic, electromechanical, engineering, and mechanical products. We offer our customers a total contract manufacturing service, offering design, and manufacturing solutions, providing engineering skills, manufactured equipment & custom-built systems for the Aerospace, Industrial and Utility Markets.

PRODUCT REALISATION

Prototyping and New Product Introductions; From the initial enquiry, our Business Development Team analyses the specifications and requirements of a product or project and issues a comprehensive and detailed quotation. When an order is received, a project plan is then developed; our team uses detailed documentation, engineering change and reporting control to ensure continued information integrity. An experienced project manager acts as the interface between Drallim and our customers although, at the same time, we actively encourage engineer-toengineer communication. We have had customers engineers based at our headquarters signing off drawings as they are produced to meet urgent deadlines for manufacture.

The designated project manager ensures that resources are allocated appropriately and that all tasks are tracked and recorded. The result is a controlled transition into the manufacturing process.

DESIGN SUPPORT

When it comes to product manufacturing, a substantial proportion

of the end product’s total cost is determined at the design stage. As a result, this part of the manufacturing process presents the perfect opportunity to identify improvements that will lead to cost reductions. A thorough understanding of each element will enable the product to be designed and optimised for procurement, manufacturing and test. We provide an extensive Design for Manufacture service to help our customers achieve substantial improvements, including:

• Improved manufacturing productivity

• Enhanced product quality and reliability

• Minimal/simplified maintenance

• Lower Cost

• Reduced time to market

• Increased customer satisfaction

• Manufacturing

• Precision assembly

We regularly produce complex assemblies that demand high levels of skill, precision, accuracy and consistency. The engineering and manufacturing

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

ELECTRICAL ASSEMBLY

Many of the assemblies produced require wire and cable interconnection between boards and sub-assemblies. This can be via cable forms or point to point wiring. As part of our electro-mechanical assembly service we are often called on to produce products that require critical cable routing. We also undertake electrical wiring of switch and instrument panels plus sophisticated control cabinets. We have highly trained engineering and assembly teams to assist with design and the assembly and support for all your cable and loom requirements.

• Electro-mechanical Assembly

• Pneumatic & Hydraulic Assembly

• Racks & Cabinets

• Box-Build Assembly

• PCB Assembly

• Prototype Wiring

• Cable Assembly

• Testing

So, if you are interested in British Manufacturing and looking for a Contract Manufacturer, we are sure Drallim can meet your needs.

For further information, please visit www.drallim.com

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

VALVES & FLOW CONTROL

WORLD-LEADING TECHNOLOGY

OLIVER VALVES

Oliver Valves R&D lead a valve revolution

Our Research and Development Centre based in the UK is world-leading in the technology to seal, test and innovate valves for Hydrogen, Carbon Capture and Subsea applications.

One huge part of our R&D operation is automation. As well as giving us the ability and capacity to test multiple projects simultaneously, it also allows us to replicate demanding environments to ensure that valves are qualified to meet the most robust testing criteria in the industry.

To rapidly collect, process, and analyse significant amounts of data from multiple sources, you need a powerful processing capacity with precision and accuracy. Our data processing network is custombuilt in-house and is tailored to our valve designs, ensuring that we maximise the

performance and safety of each valve we manufacture.

We have a strong mix of engineering skills within R&D which are resulting in amazing achievements, such as designing the first ball valve to be qualified by a third-party for hydrogen application. Our engineers are long-serving and have decades

of experience and are instrumental in passing on their knowledge and expertise to apprentices joining the business. This invaluable work is reciprocated by their enthusiasm for new engineering technology that’s helping drive and shape our future development projects such as automation.

Each year Oliver places significant investment in its people, processes and systems, and this was certainly evident in 2022 with the installation of new testing rigs in two factories that exceeded the cost of £1m. Yet again, an example of the confidence we have in the future of valves, especially at a time of very difficult challenges and uncertainty that surrounds the UK economy, and with the ongoing energy and cost of living crises. The future looks very positive and we’re well-placed in leading valve development within the energy industry.

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

Hydrogen & Carbon Capture Valves

• Instrumentation, Ball, Needle and DBB Valves for Hydrogen and Carbon Capture Applications • Pipeline Ball Valves upto 18” • 10K Ball Valves for Hydrogen Fuelling Stations

•

Designed to provide hot water instantaneously whatever the load conditions, up to 2100kW without the need for water storage.

Reliable, Efficient and Cost Effective

THE PREMIUM PROCESS VALVE

Reliably tight, durable and versatile triple offset valve with zero leakage, even in harsh industrial environments.

Changing from single to double isolation made easy with the small face-to-face dimensions of the ZETRIX®

ZETRIX® Double block and bleed arrangement

Contact the UK sales office on 01684 275752 or Email: marketing@ari-armaturen.co.uk

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 user-intuitive 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 RS485 ASCII Serial Output.

Flow Switch input can disable all relay outputs when triggered by loss of flow.

Relays output to any user-supplied control equipment requiring up to 250V each and can trigger on any input parameter.

Portable Fume Extraction, Ventilation and Cooling Solutions

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.