Process Engineering Control & Manufacturing Issue 38 2019

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PECM

Global Success Through Innovation Issue 38 2019 £3.95 www.pecm.co.uk

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Engineering Inside Issue 38

Editors Choice Automechanika Show Preview Automotive Engineering Subcon Show Preview Advanced Manufacturing show preview Safety & Health Show Preview Utility Week Live Show Preview Air, Gas, & Odour Boilers & Maintenance Control & Automation Electrical & Electronics Facilities Management Fluid Handling Gears, Drives & Motors Health & Safety Machining & Machinery Measurement & Monitoring News & Events Packaging Process Technologies Product News Software & Systems Storage, Handling & Distribution Training & Recruitment Valves & Flow Control

8 48 54 60 60 72 78 81 84 87 100 108 114 120 128 134 142 155 160 164 173 182 192 198 206

ANTICORROSION FILMS PLANT LAUNCHES NEW BROCHURE!

AUTOMECHANIKA BIRMINGHAM 2019

Brand new brochure on EcoCortec®, first Croatian bioplastics and anticorrosion films plant has been launched.

Automechanika Birmingham has announced that “Innovation” will be the leading theme for the 2019 event, held at Birmingham NEC on 4 to 6 June.

SAFE, RELIABLE AND SUSTAINABLE SPACE EXPLORATION Edward Arata, Brazing Engineer at Morgan Advanced Materials’ Braze Alloys Business, explains how braze alloys play their part in safe, reliable and sustainable space exploration.

SURVIVING IN A DIGITAL AGE David Lenehan of global spare parts and repairs provider Northern Industrial argues, sometimes Google is not all-knowing – especially in a complex breakdown situation.

STATE OF THE ART FACILITY Coventry University and FEV join forces to launch £50m centre for cleaner mobility.

SUBCON 2019 Subcon returns on the 4-6 June 2019 and is once again set to take place at the NEC, Birmingham.

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Issue 38 PECM

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Tiny temperature probe for fast response The The TA-series TA-series of of miniature miniature temperature temperature transmitters transmitters features features aa fast fast response response with with built-in built-in IO-Link IO-Link for for setting, setting, PT1000 PT1000 element element and and class class A A accuracy accuracy for for precise precise measurement. measurement. 44 to to 20mA 20mA output, output, available available lengths lengths from from 25 25 to to 150mm.

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Process

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

Published bimonthly, a subscription to PECM magazine is essential for Process Engineers, Chemical Engineers, Instrumentation Engineers, Mechanical Engineers, Plant Engineers, Precision Engineers, Environmental Engineers & General Engineers, Companies and Organizations in the Food, Dairy, Beverage, Brewing, Semiconductor, Pharmaceutical, Biotechnology, Chemical, Oil & Gas, as well as all UK's major manufacturing units.

Every issue of the magazine contains the latest news, in-depth features, together with product innovations and case studies showing how process engineers are implementing new technologies to reduce costs and impact on the environment.

With over 300,000 readers worldwide the publication is widely read, recognized, and well respected within the Process, Engineering & maintenance industries.

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EDITOR’S CHOICE

CORROSION PROTECTION ECOCORTEC

ANTICORROSION FILMS PLANT LAUNCHES NEW BROCHURE! We are proud to announce that brand new brochure on EcoCortec®, first Croatian bioplastics and anticorrosion films plant has been launched. Last year plant’s management finalized the big expansion project: new facility has been built and production capacity is now tripled. New brochure contains in-depth information about EcoCortec’s new equipment, manufacturing process, technologies, products, customer service, in-house laboratory and much more.

EcoCortec® specializes in manufacturing of Cortec’s innovative Vapor phase Corrosion Inhibitor (VpCI®) films.

The plant offers complete converting, extruding and printing capabilities. Located in Croatia’s Baranja region on a 10,000 square meter site, the facility is in an excellent geo-strategic location. Croatian plant manufactures films and bags according to customer specifications in terms of the product size and performance.

Together with new offices and brand new 2000 m2 facility the plant also includes state-of-the-art extrusion line E5. EcoCortec® has sideweld and bottomweld converting machines for making wide range of bags, a film rewinder and recycling machine allowing elimination of waste from the production process. Plant’s team is continually improving its technologies, services and manufacturing process to meet expectations for highest-quality films and bags delivered on time. EcoCortec® is utilizing green environmentally safe technologieswhile strongly promoting responsible approach towards the community. EcoCortec® films as well as the production process conform to highest environmental standards. The plant has pioneered two technologies of biodegradable and compostable films, Eco Film® and Eco Works®. They offer a certified biodegradable alternative to polyethylene films and bags while offering performance characteristics superior to both low and high density poly films.

As a company investing in research and development, EcoCortec® is successfully cooperating with numerous scientific institutions and universities. New product development, research papers, participation and organization of scientific and educational seminars are just part of this

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valuable, long term cooperation. Continuous research and innovation approach combined with ecological awareness are among reasons why we are a leader in corrosion protection industry.

You can acess the whole brochure at: www.ecocortec.hr/docs/brochures/ EcoCortec_brochure.pdf

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EDITOR’S CHOICE

BRITISH HUMIDIFICATION HUMIDITY SOLUTIONS

BETTER TOGETHER

exclusive distributor in the UK and to be able to add our Humidity control experience, expertise and application knowledge to the brand. Vapac being manufactured in the UK was also an important factor. Removing currency fluctuations and international delivery will allow us to ensure that the units are competitive and a great investment’.

From the beginning of April, Humidity Solutions - based in Leatherhead - will be the sole UK distributor for the West Midlands manufactured Vapac range of electrode boiler steam humidifiers.

The knowledge and expertise of both companies combine to enable Vapac humidifiers to be offered to the market with the full package of support services.

Vapac is the name for Electrode boilers and has for many years been the go-to make for this type of humidifier. Unfortunately, the manufacturing site was destroyed by fire in 2018 causing disruption to supply. Nortek Global HVAC, who has three leading brands in the UK, Reznor, ServerCool and Vapac, has dedicated itself to getting the production line up and running with improved stocks and supply reliability. Spares have been available for many months with humidifier production coming on line at the beginning of 2019.

Stocks have been established and based at Humidity Solutions Ltd allowing delivery of standard spares and humidifiers to be supplied from stock.

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

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The result: the synergy of two well established British companies to provide the UK market with humidification.

Kevin Hartshorne, Sales Manager of Vapac, stated ‘we are delighted to have Humidity Solutions to partner us in presenting Vapac back to the market after a turbulent year dealing with the disaster of the fire.

This wiped out production for a number of months but our plan has always been to come back even better and stronger with our great product, and now the extra service and support offered by Humidity Solutions.

John Barker, Humidity Solutions Managing Director, stated ‘the chance to work with what has been the name for electrode boiler humidifiers in the UK over the past 40 years was too good an opportunity to pass by. We are delighted to be the

Humidity Solutions HQ is based in Leatherhead and offers training and familiarization courses in their show room where they have the Vapac units in operation, so is an ideal course to send installers or maintenance engineers on to become fully familiar with the technology.

Training on-site or at companies’ own offices/factory can also be facilitated on request.

A full range of steam and adiabatic humidifiers plus refrigerant and desiccant dehumidifiers with associated water treatment and controls are also available from Humidity Solutions.

With well over 100 years of combined experience in the industry, the team at Humidity Solutions have considerable knowledge and expertise to be able to assess each unique application and provide exactly the right solution.

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EDITOR’S CHOICE

POWER PLANT MAINTENANCE LOBO SYSTEMS

ADVANCED PLATFORM SYSTEMS

THE PROBLEM Awkward and restricted access areas, present in all power plants, create significant hazards when working at height. Outage and preventative maintenance tasks must routinely be performed inside congested plant rooms, around pipes, flanges and exhaust vents and in tunnels where access is extremely difficult. Further complications occur when access is required inside storage tanks, silos, vessels and combustion chambers. Areas where, typically, standard working at height equipment cannot fit.

Safety management at the power plant begins with an organisation ensuring that employees have fit for purpose, work at height safety equipment, on which they have been trained to assemble, inspect and use safely.

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INCREASING SAFETY & REDUCING COST The LOBO System is a versatile work platform product that combines the flexibility and strength of traditional scaffolding with the simplicity and mobility of tower systems. The unique and patented hand adjustable clamp, when combined with the tube, allows the maintenance engineer to create a work platform, of any shape or size, without the need for any tools. The system is made from modular steel components, which are easy and quick to assemble. It flat packs for transportation and yet is incredibly strong.

Areas, previously awkward to get to, can now be accessed by your own engineers or technicians whenever required.

The LOBO System comprises of steel trestle legs that vary in size, and adjustable extensions with fixed side clamps. Steel tubes can then be passed through the clamps, which are hand tightened to form a structure to suit the application. Sway braces, toe boards, wheels, handrails, outriggers and a lifting slider beam can be added to enhance the construction.

The LOBO System can be transported around the power plant to incidents and assembled quickly and with ease, from a flat pack, into any required configuration, by your own engineers and technicians. Options include Lifting Slider beams which can be fitted to the system. And it can be stored in a LOBO Towerstore unit when not in use.

CONCLUSION The LOBO System increases safety and reduces cost and requires no tools to assemble. The system is a unique access platform and has been successfully sold to some of the largest companies in the world. It is up to 10 times faster than scaffolding.

Certified training is provided and an ongoing refresher training program is actively monitored and promoted to ensure LOBO users work as safely as possible. Since your own maintenance teams can be trained to use the system out sourced scaffolder costs can be controlled and significantly reduced. The LOBO System meets or exceeds international safety regulations.

As the LOBO System is scalable, adaptable and adjustable it meets your on-going and changing requirements.

UK & Europe and Rest of World: + 44 (0)1332 365666.

North America: 1-800-640-5492.

Email: sales@lobosystems.com www.lobosystems.com Issue 38 PECM

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EDITOR’S CHOICE

GAME CHANGER OGP UK

REAL-TIME QUALITY CONTROL CAPABILITIES INDISPENSABLE FOR AEROSPACE COMPONENT SPECIALIST An aerospace manufacturer says its partnership with multi-sensor metrology expert OGP UK has been a ‘game-changer’ for delivering right-first-time parts in a highly regulated industry.

Winbro Group, a world leader in the design and production of machines and technologies based on non-conventional processes, specialises in producing the miniature cooling holes and forms in components used in the most demanding part of aero and industrial gas turbines.

These holes are critical in allowing internal airflow to prevent overheating during engine operation and, because effective cooling improves component efficiency, this leads to reduced fuel consumption and nitrogen oxide emissions on today’s generation of lightweight, low-noise jet engines.

The Leicestershire-based firm teamed up with OGP UK eight years ago and now uses three of its SmartScope systems – a CNC 300 and two Vantage 450s.

Winbro Chief Technology Officer Andy

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first part will go into the inspection lab and in less than 10 minutes feedback is given straight to the operator to be able to control the process.

“We already get a much more quality inspection report real time, such that we are no more than one part away from an issue.”

Lawson says the solutions are key to being able to guarantee quality for customers.

He said: “As Winbro’s advanced machining division has gained more and more parts, in both aerospace and industrial gas turbines, we’ve gone back to OGP UK for turnkey solutions. We’ve bought additional programming and help for parts that we weren’t necessarily familiar with, and OGP has been very responsive in that area.

“Ultimately it’s about the speed of inspection versus production. We’re able to take parts straight off the machine and then, while the second part is being machined or drilled, the

OGP UK’s market-leading multi-sensor technologies house superior optical, laser and tactile sensors, automatically selecting the right tools for any given task in one routine and eliminating the need for multiple traditional measuring systems.

Collecting detailed data and gauging the characteristics of even the most demanding components and features, and doing so faster and more reliably than anything else around, come as standard.

Working with more accurate and real-time statistics, from a single reference point, has proved revolutionary for tighter control of production processes, as issues can be identified and remedied immediately.

“Our experience with OGP over the last eight years has been very positive. We feel as though the relationship is ongoing, as a partnership should be.”

Largely thanks to its flagship Vantage machines – which work to sub-micron precision on even the most demanding components, with unparalleled speed - OGP UK has become a key player in industries like medical, automotive and aerospace.

The intuitive ZONE3 metrology software utilised by the Vantage range offers full 3D CAD-based programming to automatically and effortlessly generate measurement routines.

Graham Shaw, Sales Manager at Derbyshirebased OGP UK, said: “More and more manufacturers are discovering that OGP systems are a must-have for ensuring the levels of precision required in their industry.

Fewer rejects, minimal rework and faster product-to-market times are just some of the benefits.

Mr Lawson added: “OGP offered a full turnkey system, so we were able to give one or two of the components we had just won with our customers and work with OGP for them to develop the software and programmes, such that those programmes were fully verified with the equipment.

“During the development of the new parts, you often have hiccups. What we found was that OGP was very responsive – we were able to work together to get through technical problems and solutions, and I think that for me was a game-changer.

“It’s more than just buying the hardware and equipment – it’s really how you utilise and get the most out of it.

“Our solutions provide live, accurate, consistent and holistic data in the heart of the production environment, giving businesses total peace of mind that their parts will always be of the necessary standard and therefore leading to significantly increased throughput.”

www.carfulan.com/ Issue 38 PECM

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EDITOR’S CHOICE

BESPOKE FACILITY 3D PRINT

3D PRINTING CUTS END-OF-ARM TOOLING COSTS If you thought 3D printing, or additive manufacturing, was only suitable for prototyping or short-run production then maybe it’s time to think again, as PECM found out from 3DPRINTUK Director, Nick Allen.

End of arm tooling (EOAT) is about as bespoke as you get it in a production facility.

But tooling can be expensive, even if you have the facilities in-house. So could they be made cheaper with additive manufacturing (AM) and in particular selective laser sintering (SLS)? If so, will the material stand up to the task? And even if you have your own in-house CNC facility, could it be better to outsource the job to a 3D printing bureau?

In many cases, the answer to all these questions is yes, and there are many reasons why AM is a viable option when it comes to EOAT. The first area is cost. The cost to produce end of arm parts can be surprisingly low, and at 3DPRINTUK we have created them on behalf of clients for as little as £25+vat. Yes, they can range up to around £1,000 for much larger and more complex items; however the majority of parts that we produce sit in the sub £100 area.

• Pneumatic and hydraulic channels – these can also be incorporated into the print rather than needing external and additional piping. This is particularly useful for pneumatic picking systems that use a vacuum to sort parts. Hydraulic channels will need to be vacuum impregnated to make them completely watertight.

The competitiveness of the method is demonstrated by the fact that a number of our customers have in-house equipment to manufacture parts, yet still choose to outsource to us.

Of course, strength is another consideration.

While not being as strong as a part CNC’d from aluminium, the strength properties of SLS nylon make it very effective. With a tensile strength of 48MPa, it is suitable for a large number of applications in low and medium harshness environments.

It’s when you look at the design freedom the AM method offers when things get a little more interesting. Restrictions on the more traditional methods of manufacture mean that the ideal design for an application may not be achievable in one part, and often, may not be possible at all. With SLS, you have far fewer limitations, allowing for greater freedom of design.

These design aspects include: • Multi-part in one – previously, complex designs would have to be made up from

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An excellent example of the benefits AM offers is Brushtec. The world-class manufacturer and designer of innovative brush ware use our SLS prints to produce precise, robust jigs and high quality machine parts for their brush production systems. multiple parts which were then assembled to make a finished piece. By using SLS, you can more often than not, manufacture the part in one.

• Internal geometry – the geometry needed to hold items in place such as wires, sensors, mechanical parts etc, can all be designed internally without issue – you only need to make sure that you can get the parts in there once the item is printed.

• Weight saving – a lighter weight ‘end’ can reduce strain on a robotic arm and increase the longevity of the device.

Brushtec uses SLS over machined aluminium because it can design complex SLS parts and not be restricted by the limitation of standard machining. Plus the cost of SLS printing its EOAT is considerably cheaper than machining aluminium inhouse once it factors in the raw material purchase and delivery, machining centre setup, machining centre programming, purchase of milling cutters, overheads, and wages. www.3dprint-uk.co.uk

we make plastic parts in low volume 1-10,000 UNITS no tooling cost what do you need?

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SLS 3D printing service. Low volume production and one off prints.

Fixtures & fittings, PCB enclosures, machine parts, jigs & clamps, end of arm tooling. Upload your part now for an instant quote!

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

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EDITOR’S CHOICE

FORGING CLOSER LINKS AEROSPACE ALLIANCE

MIDLANDS AEROSPACE ALLIANCE JOINS MAKE UK

Midlands Aerospace Alliance which supports the aerospace sector across the region has signed up as an affiliate partner of Make UK. Make UK CEO Stephen Phipson spoke at the Midland’s Aerospace Alliance Conference in Birmingham, forging closer links between our two member organisations.

Dr Andrew Mair, Chief Executive, Midlands Aerospace Alliance said: “We are pleased to announce this partnership as it brings with it access to Make UK’s traditional expertise relating to skills and people which will be of great benefit to our members.

“Most of our member companies work in aerospace but also across other sectors, so this partnership is a good fit given Make UK’s broader engineering coverage.

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“Working together in this way will ensure that the Midlands Aerospace Alliance’s voice is heard at the highest level in Government when it comes to policy discussions about manufacturing.

“Collaborating with NDI will be a great opportunity for us as most of our companies work in civil aerospace and this new partnership will give us access to complementary defence industry supply chain expertise.”

Stephen Phipson, CEO of Make UK, the manufacturers’ organisation added: “We are delighted to welcome Midlands Aerospace Alliance as an affiliate member of Make UK and look forward to working ever more closely together in the coming months at this challenging time for our sector in the current political climate.”

EDITOR’S CHOICE

THE INTELLIGENCE OF THE PUMP PUMP MONITOR Pump Monitor turns the progressive cavity pump into an intelligent field device.  Performance analysis to optimize the pump and process

 Process protection through continuous monitoring

 Alarm notification

 Transparent pump performance  Optimized operating costs SEEPEX UK Ltd. sales.uk@seepex.com www.seepex.com

ELMERIDGE CABLES LIMITED PRODUCTS & CAPABILITIES Elmeridge Cables Limited (ECL) have been a market leader in the production and distribution of custom-made cables for over 30 years, designing and supplying a wide range of stock and specialist cables to a growing worldwide market.

Our expertise and technical knowledge have helped companies within the following industry sectors: - Underwater marine and offshore - Pumps and sensors - Oil and gas - Pipes and drain inspection - Cranes and ports - Diving, fish farming and fisheries - Medical - Railways and signalling …and many other unique applications.

to 140mm and with up to five layers of steel wire armour. The cable comes in lengths of up to 8000 metres, fully pressure tested to 6000 metres.

Added to this list are our three compounds for termite-proof cables, along with a rodent-proof cable for the rail industry.

ECL also supply seismic cables, deepsea mining cables (including 3.5kV, 4.5kV and 6kV), ‘hairy fairing’ cables, bladed fairing (which can be supplied pre-terminated), ROV cables, tether cables, deep trenching cables and many others.

Depending on the product and quantity, our lead-times vary but we advise 6-8 weeks from order to delivery.

We are proud to have developed some highly successful products, including our very own compound for the subsea industry known as ‘Supreme Polyurethane’. This compound is hydrolysis resistant, UV and abrasion resistant, and is incredibly tough whilst still remaining flexible.

At ECL, we have an excellent understanding of what our customers require and we continue to help until it is achieved.

Our reputation is built on quality and value - Think Cable, Think Quality, Think Elmeridge. www.elmeridge.com info@elmeridge.com +44 (0)1273 391810

Our product range and capabilities are ever growing. We have recently added cables with an outside diameter of up

Issue 38 PECM

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EDITOR’S CHOICE

EFFECTIVE VENTILATION AXAIR FANS

POLYPROPYLENE VS. STAINLESS STEEL AND GRP IN WASTEWATER TREATMENT VENTILATION Wastewater treatment plants face a number of challenges in terms of ensuring safe and effective ventilation. The chemicals used during the wastewater treatment process pass through metering equipment in a dosing system. In the system, the solution is at its strongest and the chemicals and their gases are often corrosive and can be flammable. Such chemicals and gases include methane, ammonia, phosphorous, pesticides and carbon dioxide.

Consequently, wastewater treatment plants are, by nature, one of the harshest engineering environments.

To ventilate wastewater treatment plants, engineers have a choice of materials for the fans and systems. Typically, these materials are stainless steel, glass reinforced plastic and polypropylene. The range of corrosive gases present in the plants is so vast that it is essential to select ventilation equipment resistant to the largest array of chemicals possible. The benefits and drawbacks of each material is discussed below.

STAINLESS STEEL FANS Benefits: Stainless steel is a highly durable material that can withstand some harsh environments.

Drawbacks: Often, a special finish, for example, marine grade powder coating is required to make stainless steel corrosion resistant in environments where highly corrosive chemicals and vapours are present. Therefore, there is an added cost implication to what can be a relatively expensive material.

Stainless steel is also the heaviest of the three options, meaning there is an extra challenge when designing the ventilation system.

GLASS REINFORCED PLASTIC (GRP) FANS Benefits: GRP, as the name suggests, is plastic reinforced with fibreglass. It can be manufactured in a way that makes it more resistant to corrosion and lighter than stainless steel.

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Drawbacks: The cost of making GRP corrosion resistant can cause it to have a considerably greater manufacturing cost that material counterparts like polypropylene.

Furthermore, the corrosion resistance achieved with GRP is often not as effective as stainless steel or polypropylene according to the HVAC and Chemical Resistance Handbook for the Engineer and Architect: ‘GRP equipment resisted only 29% of 109 chemicals in a satisfactory manner, thus affecting its durability. That same rating was higher for stainless steel (52%), and even higher for Polypropylene (79%).’

Moreover, GRP can be subject to fibre shedding due to the nature of the material.

This can cause problems with longevity and overall durability.

POLYPROPYLENE FANS Benefits: Polypropylene is thermoplastic and many of its properties are similar to polyethylene.

However, it offers several additional benefits over GRP and stainless steel.

Firstly, it can be up to 30% less expensive than other materials used for ventilation in environment with harsh gases and chemicals. As previously mentioned, it usually offers more durability than most other materials used in wastewater

treatment plants and resists the largest number of chemicals. It is also the lightest of the three options, making polypropylene ideal in terms of ease of installation.

In certain circumstances, there may be other variables to consider when selecting the material of the ventilation system but the polypropylene option is ideally suited to the wastewater treatment environment due to its lightweight, durable, affordable, corrosion resistant properties.

Axair fan’s range of polypropylene fans have scrolls which are moulded into a single piece, meaning that there are no welding joins. This improves the durability of the fan at it eliminates the risk of welded joins parting and needing to be repaired.

For more information, contact our team by calling 01782 349 430, emailing sales@axair-fans.co.uk or visiting www.axair-fans.co.uk.

EDITOR’S CHOICE

corrosion resistant fume extraction Corrosion resistant polypropylene ATEX certified Suitable for handling chemical vapours Short lead times Call to order your

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

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

NEW: ADVANCED VIDEO MICROSCOPE OPTION FOR IGASORP DVS ANALYZER Hiden Isochema’s IGAsorp dynamic vapor sorption (DVS) analyzer is now available with a colour video microscope for high resolution in situ image capture between 5 and 350 °C. • Simultaneous high resolution image collection with vapor sorption and TGA measurements • Compatible with both water and organic vapors • All-new software interface including time lapse video presentation mode.

Tel: 0208 339 7370 462 Ewell Road, Surbiton, Surrey KT6 7EL, England

Fax: 0208 339 7371

Email: sales@blackfast.com Web: www.blackfast.com

Web: hidenisochema.com Email: info@hidenisochema.com Issue 38 PECM

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EDITOR’S CHOICE

Power Electronics, Machines and Drives experts wanted!

Bring your latest research to over 450 experts in Power Electronics, Machines and Drives at #PEMD2020. PEMD delivers the very latest in practical innovations, technical developments and new theoretical research across the breadth of power electronics, machines and drives.

Authors also benefit from: • Indexing on IET Inspec – with 17 million records and over 3 million searches annually • Submission to IEEE Xplore – publisher of nearly a third of the world’s technical literature • Indexing on Ei Compendex –used by 72% of the top 50 Universities worldwide • Plus a discounted rate to attend the conference Key conference themes are power electronics, machines, drives and control, transportation, energy systems and advanced manufacturing. Submit your paper by 13 September at www.theiet.org/pemd

RRC International Since its establishment in 1928, RRC International has helped millions of individuals all over the world achieve professional, educational and vocational qualifications. RRC are well established within the HSE training industry and have been attending the SHExpo for the last 15 years. This year on stand SH1660 we have Gary, Kevin, Nick and Emma to assist with any training or consultancy needs.

Visitors can look forward to a prize draw for your chance of winning a £1,000 training voucher every day of the Expo! There is an additional £1,000 voucher to be won, for those who sign up to our virtual expo on the RRC website.

Runners up can win RRC Law guides which are a great resource for students and practitioners across the industry. We will also be offering a show discount of 20% off all of our Classroom and Online courses, and textbooks until 31st July 2019.

Visit us at stand SH1660 www.rrc.co.uk

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The advantages of IoT monitoring technology are fully detailed on linkthru.com

Aerospace manufacturer fuels further growth through sevenfigure machinery investment

Cistermiser’s website dedicated to IoT water temperature and flow monitoring www.linkthru. com provides full details on the many practical advantages delivered by this innovative use of technology.

Middlesex Aerospace has committed to a sevenfigure investment with long-term machine tool partner, Yamazaki Mazak, to support the continued expansion of the company following an extended period of success. Middlesex Aerospace is one of Britain’s leading tier-one suppliers of critical components and assemblies to major OEMs throughout the global aerospace market. The Basingstoke-based business currently employs 150 staff, including five apprentices, and the new investment will lead to the creation of further roles within Middlesex Aerospace’s machining and assembly department.

Linkthru.com outlines the benefits of installing LinkThru TMUs (Temperature Monitoring Units) at sentinel points across a building’s water system, to capture and access 24/7 remote monitoring data on water temperatures and flow events via a secure cloud-based portal.

“LinkThru TMU helps to ensure Building Owner compliance with HSG274 and reduce risk of Legionella,” says Cistermiser’s Marketing Manager, Mark Schlotel. “Linkthru.com is the digital home for this exciting technology with videos, guides, downloads and everything you need to know stored in one place.” www.linkthru.com

Published today – ‘Brexit: The Seven Major Risks To The Continuity Of Your Production Line That You Haven’t Considered’ With it estimated that 53% of all UK imports in 2017 came from the EU, UK-based manufacturing businesses should be planning right now on how to pre-empt increased costs, delays and spare parts shortages affecting production line continuity, both in the lead up to, and following, Brexit. And yet, according to the British Chamber of Commerce, nearly two-thirds of UK companies have still not carried out a risk assessment on the impact of a ‘No Deal’ (Hard) Brexit. Consequentially, large parts of the British economy are simply not prepared to minimise impact and maintain production output levels to satisfy customer demands.

To read more on these potential threats and use the Brammer Buck & Hickman diagnostic tool to highlight areas where you can help make your business ready ahead of Brexit, visit www.brammerbuckandhickman.com/pdfs/ brexit.pdf

For more information on Middlesex Aerospace, please visit: www.middlesexaerospace.com.

For more information on Yamazaki Mazak’s range of machining solutions please visit: www.mazakeu.co.uk/aerospace. sales@middlesexaerospace.com

CORTIME - Explore Optimal Designs For engineers working to optimize and validate their design, CORTIME is an automated Design Exploration and Data Analysis-tool that provides engineers with the easiest way to gain unprecedented insight with the help of intelligently generated design variations. Compared to conventional optimization processes, which are typically time consuming and inefficient in their manual approach to trial and error processes, CORTIME’s advanced optimization technology enables engineers to make better design decisions – thereby: 1) Reducing the risk of product failures 2) Minimizing cost price 3) Improving the reliability of the design.

Get in touch with us at contact@cortime. com or visit www.cortime.com to learn more, start a free trial or book a CORTIME live demo with our application engineer.

EDITOR’S CHOICE GF Piping Systems

Measurement

 Flow

Accurate measurement is the basis for reliable process control

Sensors and instruments for mechanical, magnetic, sonic or visual measurement of flow.

 pH/ORP Sensors and instruments for measurement of pH/ORP also for aggressive media and removal without process shutdown.

 Chlorine

 Level

Chlorine analysing systems designed to accurately measure free chlorine, in applications with varying pH levels.

Sensors and instruments for measurement of level using ultrasonic and hydrostatic pressure.

www.gfps.com/uk @gfps_uk

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

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

www.mcs-corporate.com

01926 512475

gjw@mcs-corporate.com Issue 38 PECM

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EDITOR’S CHOICE

A BRAZE NEW WORLD MORGAN ADVANCED MATERIALS

SAFE, RELIABLE AND SUSTAINABLE SPACE EXPLORATION

The space industry is growing fast and is predicted to be worth over a trillion dollars by 2040. Edward Arata, Brazing Engineer at Morgan Advanced Materials’ Braze Alloys Business, explains how braze alloys play their part in safe, reliable and sustainable space exploration.

The saying goes “one small step for man, one giant leap for mankind”. This famous phrase, uttered by Neil Armstrong, is the perfect advertisement for space exploration and its importance to the future.

Less than a century old, space exploration has come on leaps and bounds since the first artificial satellite, Sputnik 1, was propelled into space in 1957. Since then, the world has witnessed marvels such as landing on the moon, the space shuttle programme of the 1970s, and the launch of the International Space Station.

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The importance of these missions and their subsequent value is immeasurable. While many might not realise on a day-to-day basis, space exploration has improved lives and the global economy no end. This includes simple weather forecasting, broadcasting TV and radio, predicting natural disasters, monitoring for fertile land, forecasting sea level patterns, and even aiding research in muscular atrophy.

external opinion though, there are internal operational challenges. Namely, space exploration needs to become safer and more sustainable.

A huge part of solving this challenge is in brazing alloys.

A BRIEF HISTORY ON BRAZING IN SPACE

It’s little wonder then, that this industry has significant value. The space industry was reportedly worth $384 million USD in 2017, growing at a rate of 7.4 per cent. According to Morgan Stanley, it sees the industry growing to be worth $1.1 trillion USD by 2040.

In simple terms, brazing joins two metals by heating and melting a filler (alloy) that bonds to the two pieces of metal and joins them.

The filler must have a melting temperature below that of the metal pieces.

However, there are challenges. Many believe that the millions of dollars and resources used to explore space could be better used on immediate threats to society like clean water, famine, poverty and more. Outside of

The use of braze alloys in space equipment is mission critical, as they allow sensors to be mounted as close as possible to engines to measure and monitor output and feed data back to operators.

Indeed, they’ve already aided successful missions. Two of Morgan Advanced Materials’ braze alloys, RI-46 and RI-49, were specifically engineered and used by NASA on the Space Shuttle Main Engine, also known as the RS25.

RI-46 specifically was developed as a replacement for the existing Nioro braze alloy, which is comprised of 82/18 Au/Ni (gold/nickel). RI-46 contains much less gold, adding in copper and manganese instead.

This helped make the braze alloy significantly less dense and provided crucial weight savings, but also still operable from a wide range of temperatures, between -240°C to 700°C (-400°F to 1292°F).

These alloys have not only been critical for past space missions, but also for future missions. RI-46 and RI-49 have been adopted for NASA’s Space Launch System (SLS), a vehicle that is planned to take a crewed mission to Mars.

As alluded to already, developing new braze alloys is as much about performance as well as sustainability.

THE NEED FOR NON-PRECIOUS ALLOYS It needs no mention that space exploration is a costly exercise. According to NASA, the average cost to launch a Space Shuttle is $450 million per mission. The Space Shuttle Endeavour, the orbiter built to replace the Space Shuttle Challenger, cost an eyewatering $1.7 billion USD. Bringing costs down is clearly required to keep space missions feasible. One key part of cost reduction is in reducing the use of precious metal braze alloys.

Precious metals like gold and palladium are becoming increasingly scarce. Of course, the cost of producing alloys from these precious metals is also increasing as a result.

However, there can be a reluctance to come away from using precious metal alloys. Years of research, development and data means these alloys are tested and reliable. When dealing with missions and equipment that run into the hundreds of millions of dollars and, more importantly, the lives of crew

members, reliability becomes an overarching objective, and failures must be prevented.

To solve this issue, Morgan’s Braze Alloys business has been researching and developing non-precious metal alloys over many years. As seen from the RI-46 and RI-49 alloys, these solutions are just as strong as their equivalent high precious-metal counterparts, but at a fraction of the cost.

Non-precious metal alloys can be made from metals like nickel, chromium, and cobalt.

Their success has already been seen in the aerospace sector, and now research is being pioneered into making them fit for going into orbit and beyond.

SPACE, FOR ALL TO ENJOY Space travel is not just for highly trained astronauts and public benefit, there is also a growing commercial aspect. Satellite TV and radio has already been mentioned, but billionaire entrepreneurs such as Richard Branson and Elon Musk have also been pioneering private space travel. The hope is that civilians might one day be able to enjoy outer space as well, albeit for potentially high prices.

Achieving this dream is of course hinged on safety and reliability, given that lives will be

at stake. The key to improving these factors is being able to place sensors as close as possible to the spacecraft’s engine.

By enabling sensors to be placed as close as possible to the spacecraft’s engine, mission control and crew can then accurately read and measure data and output. This includes fuel efficiency, temperature, gas flow and monitoring for fire detection or abnormalities. If these sensors are placed too far away from the engines, then data readings become inaccurate and missions can be compromised.

Recent news highlights why sensor technologies are critical, as a two-man space crew had to abort their flight to the ISS after a post-rocket launch failure. The Soyuz spacecraft started to experience failure 119 seconds into the flight, and seemingly, problems were reported by the crew first, not by mission control. The crew described feelings of weightlessness, an indication of a problem during that stage of the flight.

Luckily, they aborted, ejected their capsule from the rocket, and returned safely to Earth.

While the cause is of the failure is still to be identified at time of writing, clearly, such a situation should not be happening.

Any problems should be picked up by mission control, and not be reliant on crew judgement.

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The challenge though is that some sensors are made from ceramic, due to the need to resist corrosion and high temperatures, typically up to 950°C (1742°F). However, these ceramic sensors then need to be joined to metallic parts of the engine.

This is where ‘active alloys’ come in.

Unlike regular braze alloys that join metal to metal, these alloys can join metal to ceramic, or even ceramic to ceramic.

Industry standard active alloys like Incusil®ABA and Ticusil® from Morgan’s range, were developed up to 40 years ago but are still in use today. New alloys are also currently in development to withstand much higher temperatures.

A NEVER-ENDING JOURNEY Much like how there is still so much to learn and explore about space, so too is Morgan’s journey with braze alloys. Morgan Advanced Materials is not just committed to making the space industry more sustainable and safer, but it is helping with applications across all industries.

A key pillar of this is through Morgan’s highly specialised Metals and Joining Centre of Excellence (CoE), based in Hayward, California, as well as Morgan’s Brazing Department.

With highly trained researchers and scientists, Morgan’s Braze Alloys business can custom cater alloys to specific applications, run trials to test materials, braze cycles and fixturing. The whole operation, from powder atomization, to preform fabrication and brazing trials, can be looked after from start to finish.

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One of the latest developments being pioneered at the Metals and Joining CoE is Flexicore®. This new technology transforms traditionally brittle alloys (such as AMS4777) into a flexible wire form.

In many cases, this will be far superior to pastes in terms of repeatability and ease of use. Along with the operational benefits, Flexicore® will also allow for the use of nickel-based alloys to replace precious-metal alloys. Again, this will help to bring costs down for operators and manufacturers.

WATCH THIS SPACE Space travel, as Richard Branson predicts for his own Virgin Galactic programme, is only

two or three flights away. We’re truly not far away from entering a new world, and brazing alloys will have their say on how the space industry turns out.

Morgan’s Braze Alloy solutions, like RI-46 and RI-49, as well as others like Palniro-1 and Palniro-7, can already be found across the various programmes and spacecraft. Through more research and development, who knows where this important industry could lead us to.

For more about Morgan Advanced Materials and its Braze Alloys Services, please visit www.morganbrazealloys.com/

THINK lowest cost per pick We manufacture the widest range of computer controlled storage and retrieval systems for bar, tube, profile, sheet and other materials.

Systems may be interlinked with saws, including ours, other machine tools, robotic sorting systems, MRP and ERP systems, and more.

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Horizontal and vertical bandsaws including block and tube saws, circular saws and hack saws are included in our range.

Whatever the application, from job shop to mass production with robotic sorting, we have a solution to suit your needs.

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EDITOR’S CHOICE

CABLE INNOVATION HEATSENSE CABLES

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

CAPABILITIES Heatsense’s manufacturing capabilities cover a broad range of specialist high-performance thermocouple and signal cables that operate in extreme environments. The company is regarded as a technology leader in fluoropolymer extrusion.

The company manufactures thermocouple cables and extensions wires, equipment wires, coaxial cables, multicore cables, micro cables and fine wires.

Insulation materials include PFA, FEP, PTFE, ETFE, PEEK, EFGLAS, PE, PU, PVC, Taped & Sintered PTFE, Mica, Silicone, Polyimide & Aramid Yarns. Braiding materials include glass & ceramic fibres, other specialist yarns and various metals.

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

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

Highly customer focused, Heatsense offers a bespoke advanced technical design and manufacturing service, rapid response times, short lead times, low MOQ’s and competitive pricing.

Current management acquired the business in 2014, relocated it to Greater Manchester and made significant investment in plant and equipment, broadening the company’s manufacturing capabilities. Throughout 2018, the company saw significant growth; acquiring new equipment and significantly expanding its workforce.

Heatsense has achieved both ISO9001:2015 and ISO14001:2015 Accreditations since 2014 and is currently working closely with the NAMRC (Nuclear Advanced Manufacturing Research Centre) on the F4N (Fit for Nuclear) Approval Scheme.

The company is also working towards AS9100:2016 and aims to be accredited in 2019.

Call: (+44) 01706 767070 www.heatsensecables.co.uk

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

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

MARKET SPECIALISTS

Automotive

Aerospace

Nuclear

Medical

Industrial

Research

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

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

*Registered *Registered owner owner of of the the world-renowned world-renowned INTEMP INTEMP trademark trademark

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

EDITOR’S CHOICE

JAMES TECHNICAL SERVICES JTS LTD

HIGH-PERFORMING TEST CHAMBERS

Since 1995, JTS Ltd has been designing and building reliable, high-performing environmental test chambers for a wide variety of industries. The company is an independent specialist UK manufacturer, with design and build undertaken inhouse by a team of skilled engineers and technicians.

Environmental testing is an essential process in the research and development of new products, and the maintenance of quality and reliability of established product lines. Using the right environmental test chamber to simulate given conditions, such as heat, cold, humidity, dust, vibration and pressure, ensures products meet industry standards, improving quality and minimising failures.

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JTS Ltd specialises in designing and building systems for temperature, humidity, rain, dust and vibration testing, with units ranging from small bench-top chambers to walk-in rooms, and air conditioning units to supply independent test rigs.

Operating from a modern purpose-built factory unit in Mid-Wales, JTS engineers will work with you, from initial enquiry through quote, design and delivery to training and after sales support and service. Backed by 40 years of experience in the design and manufacture of test chambers, our aim is to ensure that the system you order is right for your project.

One such project, currently, is for Swansea University’s Centre for Automotive and Power Systems Engineering (CAPSE).

The team there are working with major companies to test new battery technologies, not only for the automotive industry but for National Grid and renewable energies too.

JTS has converted eight 30 ft shipping containers into specialist self-contained ‘test cells’ for temperature and humidity testing

jts-test-chambers.co.uk

at CAPSE’s Pontypridd site. Battery testing can be highly volatile and to minimise risk in this case, JTS engineers designed an innovative CO2 cascade system, capable of achieving a range of +80 / -40c at high rates of temperature change. As an inert gas, CO2 has a major advantage in this application over alternative refrigerants which are either highly flammable, less efficient or have a far higher GWP (Global Warming Potential).

Working closely with clients ensures the best outcomes for individual test needs, whether the requirement is for standard or bespoke chambers, containerised systems, or walk-in rooms. With experience across a wide range of industries, and a client base including manufacturers such as Dyson, BAE Systems, TRW Automotive and Red Bull, we are ready to help you achieve the best environmental test solutions for your products.

01874 711209 Issue 38 PECM

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EDITOR’S CHOICE

SURVIVING IN A DIGITAL AGE NORTHERN INDUSTRIAL

WE NEED TO TALK… ABOUT SPARES

In this digital age, dialling a number and putting a phone to your ear can seem antiquated. Why talk, when the internet has all the answers, right? But, David Lenehan of global spare parts and repairs provider Northern Industrial argues, sometimes Google is not all-knowing – especially in a complex breakdown situation.

When you’ve had a breakdown, chances are you’re super stressed. The downtime money clock is ticking. You think you’ve worked out the spare part that you need, but you don’t have one in stock. Worse still your kit has been declared obsolete by the OEM. You type the part number into Google and cross your fingers. The dots spin on the screen.

You wait a few more painful milliseconds.

Google says “no”. And the world stops. This isn’t how it’s supposed to be.

Alternatively, Google says “yes”. But also reveals that everyone else on the planet who owns the same machine as you has already been onto Google about this self-same part.

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Meaning it has effectively become gold dust. The downtime money clock keeps ticking. You weigh up your single option.

Click. Buy. Ouch.

Somewhere in the multiverse, another version of you has the exact same problem.

In his universe though, there is no Google.

So he picks up the phone and calls a trusted spare parts supplier. They talk briefly about the weather and the stresses of downtime.

Then the supplier asks him a few questions back.

Can you describe the fault? What is the machine? What is the issue? What make and model of PLC or drive is showing the fault?

The multiverse you does not mutter about wasted time and demand an engineer be despatched immediately because every second of downtime is costing him money.

He patiently goes away to find the details, in the full understanding that finding this information now means the engineer can come to site with the correct equipment, the correct manuals, the correct laptop if necessary, with the correct software and cables, perhaps a replacement unit if it is appropriate. Spending five minutes getting accurate information now could save hours of downtime through driving back and forth or unnecessary fault finding.

The multi-universe you also takes the same attitude to purchasing spare parts. With no Google to consult, he has learnt not only to call with his requirements, but also not just to ‘check stock on an item’. Instead he explains what machine he needs to keep running. He may have an item in mind, but he is open to options. He has found

taking five minutes to have a chat about the problem, or potential problem, can save a huge amount of time, and money, when problems strike.

The supplier explains to him that, with over 30 years’ experience finding solutions to breakdown problems, there is not much they haven’t seen. And, although their website can suggest replacement products for obsolete equipment, it is no substitute for talking a problem through to find the solution.

Inverter faulty? He says. We may not have the exact model number but maybe we have a higher kw rating in the same frame size. PLC problem? Maybe we have the exact CPU or maybe we have one with more memory. Maybe we have your exact HMI but it is under a different part number because it has a different colour bezel or has a plain membrane instead of a branded one.

All of these are drop-in solutions, not complicated retrofits. They are all things they come across on a regular basis, and they are all things a website cannot tell you, because the scenario planning would just to be too vast to make it functional. It is easy to rely on the speed at which technology can give us an absolute answer, but from time to time, having a conversation with someone who knows a guy who knows a guy can be the quickest or even the only way to solve a problem.

So, even in a Google universe, breaking the norm and picking up the phone and taking a few minutes to talk, will actually get the job done faster.

www.nicontrols.com Issue 38 PECM

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EDITOR’S CHOICE

GoatThroat Pumps The SCP Pump Series for class 1 and 2 flammable liquids are durable, drip-proof, engineering controls to safely transfer flammable liquids from barrels and pails at the point of use. Created for the most demanding safety programs, the line is designed to minimize hazards associated with transferring flammable or combustible chemicals such as Acetone, MEK, alcohols, solvents and other volatile hydrocarbons.

As a sealed system, the SCP Line of Pumps provide spill-free, environmentally safe transfer with no chance for vapors and VOCs to escape the container. This significantly reduces the chance of an ignition event. By eliminating VOCs, drips and spills, these systems also reduce waste and improve safety for both employees and the environment.

Available through Acota Specialty Materials www.acota.co.uk/products/other-specialtymaterials/goatthroat-pumps/ +44 (0)1743 466200

Molds like plastic / CNC precision / stronger than titanium Liquidmetal’s amorphous alloys allow engineers to design parts with the most demanding requirements. The one-step injection molding process eliminates crystalline grain boundaries that create weak regions in your component. The parts are net-shape from the mold and require little post mold processing, unlike other metal molding or die casting processes.

Parts molded with Liquidmetal hold tolerances of +/- 0.02mm per linear 25mm, with 1524 mPa and 53HRC. Amorphous molding produces parts with excellent corrosion resistance and pass ISO10933 Biocompatibility tests for the medical industry.

We’re the experts at amorphous alloys. Contact us today to start designing parts that were previously not possible. www.liquidmetal.com

Process, engineering and manufacturing PHOENIX County Metals are specialists in the recovery of Gold, Silver, Platinum, Palladium & Rhodium.

Our own in house laboratory has a full range of analytical instrumentation that allows us to analyze your material promptly. Our key principle is that when possible, we sample and analyze prior to processing, agreeing expectations and charges with you before recovery begins.

Malema Sensors expands its lineup of SumoFlo® CPFM-8100-Series Single-Use Flow Meters, a family of advanced flow meters for the biopharma industry with unmatched accuracy and measurement based on the Coriolis principle. SumoFlo® flow meters are capable of measuring flow rates from 0.5 g/min up to 100 kg/min with an accuracy within 1% of reading.

New members of the product family include flow sensors enabling accurate measurement of extremely low flow rates – as low as 0.5 g/min.

New electronics packages permit transmission of four simultaneous analog signals for mass flow rate, density, volumetric flow rate, and temperature.

We would be pleased to discuss the material that you have and the various recovery options.

Learn more at www.malema.com or email malema@malema.com.

Whatever your manufacturing process, if the waste produced (solid, liquid or sludge) contains precious metals, it can be reclaimed, turning your waste into profit.

Telephone@ 01327 260581 www.pcm-ltd.co.uk

Ongoing Investment for SIC Ltd UK electronic manufacturing powerhouse SIC Ltd is expanding its precision manufacturing capabilities with a portfolio of new state of the art printing and fully-automated wire processing machines. The electronic components manufacturer – one of the largest and longest established privately owned manufacturing businesses in the UK serves thousands of customers with bespoke harnesses, control panels and box builds.

With specialist production facilities for a wide range of markets including medical, catering, automotive and industrial, SIC’s distinct brand of precision engineering which results in cost and time savings for its domestic and international customer base. SIC’s 50-year ethos of manufacturing excellence is underpinned by robust investment in infrastructure and equipment which delivers innovative manufacturing solutions for even the most demanding industry. If you’re interested in hearing more, please visit Stand F24 at Subcon 2019 or email enquiries@sicltd.com Sales: 01792957009 | www.sicltd.com

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PECM Issue 38

Malema Sensors expands its lineup of SumoFlo® CPFM-8100Series Single-Use Flow Meters

NSK bearings help bakery save €9400 per annum A large bakery has replaced the type of bearings used in its cake-cutting machines after experiencing repeat failures on the integral blade saw pulleys. The switch to NSK Molded-Oil bearings immediately reduced maintenance costs and increased productivity, leading to total savings of approximately €9400 a year.

NSK´s Molded-Oil bearings (stainless steel variant) are ideal for applications in food and beverage plants. Not only do they prevent the ingress of contaminants such as water and particulates, but no lubricant can escape the bearing and enter other parts of the machine, where it could conceivably contact food. Molded-Oil bearings are equipped with a proprietary oil-impregnated material that consists of lubricating oil and a polyolefin resin with an affinity for oil. This carrier material releases the lubricant continuously over a long period.

For more information, visit www.nskeurope.com

EDITOR’S CHOICE

we

WHEN THE GOING GETS TOUGH…

Litre Meter now distribute the Lake Monitors range of VA meters for a variety of applications including bidirectional flow, high temperature and high pressure.

x

The Basic unit is rated to 116°C and 240 bar in brass. High temperature versions rated to 315°C and high pressure versions to 410

bar are in stainless steel.

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

Engineering Services Fabrication Welding Machining Painting Assembly NDE

Marine Loading Arms Precision Engineering Swivels Spare Parts Global Life Cycle Support

Installation Inspection

For more information contact:

sales@woodfieldsystemsltd.com

www.woodfieldsystemsltd.com Woodfield Systems Ltd, Tyler Way, Whitstable, Kent CT5 2RS United Kingdom

Issue 38 PECM

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EDITOR’S CHOICE

THE MERITS OF PAPERLESS EPICOR

GETTING FIT FOR GROWTH BY SAYING GOODBYE TO PAPER The manufacturing industry has been debating the merits of paperless for the last two decades, but few have actually adopted entirely paper-free operations. In today’s manufacturing landscape, where digital transformation is widely considered as essential to business growth and survival, and where Industry 4.0 and smart factories are proliferating, there’s no longer a place for paper.

Now, it’s time to stop talking about it—and start adapting. Changes in legislations, advances in technology, and the rapidly evolving marketplace, will amplify the need for adoption in 2019. With regulatory and compliance authorities increasingly demanding the automated generation of digital records, the move to go paperless is fast becoming crucial. For UK manufacturers, minimising unnecessary checks and preventing disruption to supply chains postBrexit will be heavily dependent on their ability to participate in paperless customs procedures.

Investing in the right software will help keep businesses agile, and able respond quickly to any market changes, but these systems are driven by data. Data should therefore be stored electronically so that it can be used and accessed, across an organisation, by anyone, at any time.

The multiple benefits of paperless manufacturing are widely recognised— increased accuracy, seamless electronic record-keeping, and easily-shared data, to name a few. By not digitising and automating their operations, businesses run the risk of being unable to navigate today’s turbulent economic and political landscape—let alone capitalise on growth opportunities.

THE BUSINESS CASE FOR PAPERLESS For the manufacturing community, compliancy is king. For instance, breaching GDPR guidelines could cost firms an eye watering four percent of annual turnover.

Accuracy and transparency is becoming imperative—and paper leads to multitudes of inaccuracies, which also costs the industry millions of pounds each year.

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PECM Issue 38

For food and beverage manufacturing particularly, accuracy has never been more crucial. The frequency of high-profile, large-scale food recalls has become too commonplace for comfort. You only have to look at the Food Standards Agency UK government website to see that the volume of food and allergen-related recalls shows no sign of reducing—in 2018, 189 recalls were issued. Businesses that have been forced to recall large amounts of product over safety, hygiene, or labelling concerns can incur catastrophic damage, both in monetary and reputational terms.

This reinforces the need for optimal levels of traceability, quality, and regulatory compliance to minimise damaging product recalls, as well as risks to consumers.

For UK manufacturers, navigating the regulatory and recall processes is only set to become harder as Brexit approaches.

Paperless manufacturing will be crucial in the wake of the UK leaving the EU—as British businesses could face an increase in administration, which will be an extra hindrance for firms that haven’t fully automated their business processes.

By Mark Hughes, regional vice president, UK and Ireland, Epicor Software

BREAKING DOWN THE BARRIERS The benefits might seem obvious, yet decades on from initial predictions, manufacturers still have yet to completely remove paper from the factory floor. Despite various technological advancements in the industry, manufacturers are struggling to break down the barriers standing in their way to an entirely paperless environment.

The transition from pen and paper to the Industry 4.0 technologies of today can prove daunting to manufacturers. However, digitalisation doesn’t necessarily mean complicated, and the move to paperless can often begin with a single process—rather than a complete system overhaul.

Another barrier standing in the way of digital adoption is concern that the current workforce lacks the skills needed to adapt to this digital transition—and the technologies that power it. With new technologies invariably requiring extensive training, the worry may be that a firm’s existing workforce is not equipped for these changes.

However, manufacturers should be aware that the new workforce demographic is keen to work with digital innovations. According to research[i], 41 percent of young people overall want the opportunity to work with the latest innovations, including voiceactivated technologies that connect them with resources on-demand or automate tasks. Indeed, 33 percent of millennials say they want to be at the cutting edge of new developments and to interact with new technologies in ways that boost their productivity in the workplace.

The way we interact with machines, robots, and the world around us continues to evolve, speeding up every day actions and making these easier. Switching to a paperless environment, bolstered by software and tools, will help deliver a more seamless user experience for employees on the factory

floor and in other areas of a manufacturing business.

Goodbye paper, hello technology Staying still is not an option. Businesses that refuse to say goodbye to paper run the risk of being left behind in today’s increasingly digital landscape. Even long-established companies are overhauling their day-to-day business operations—WD-40, a globally renowned manufacturer of household products, has completely automated its order processing, shipping and invoicing. In doing so, the firm streamlined its business processes into one system, which has helped free up employee time and enabled better inter-office communications between the company’s multiple dispersed sites.

Southco, a manufacturer of engineered access hardware solutions that include entry door latches and locks, began its global digital transformation journey over 10 years ago with the implementation of a variety of automated processes across its factories— integrated and managed by an effective enterprise management solution. Moving away from paper and connecting software with processes enabled the firm to transform its facilities into smart factories that have reduced product defects, downtime and waste.

Another firm extolling paperless manufacturing is BV Dairy, a dairy producer that went paperless with Epicor DocStar— an enterprise content management (ECM) solution. DocStar began to yield benefits

shortly after implementation, freeing up time in the accounts department and releasing staff to perform more complex tasks and help fuel corporate growth. The system also removed employees’ daily need to manually sort through over a hundred delivery notes, saving ten hours per week.

Under the new system, delivery notes are now scanned in, cross-referenced, marked as received, and stored in both DocStar and Epicor ERP to permit cross-referencing and searching from each. The new system has increased the producer’s accuracy, efficiency, traceability, and flexibility—and helped streamline processes.

The multiple benefits of going paperless are clear—but manufacturing firms need the right IT infrastructure in place to ease the path to growth. Enterprise resource planning (ERP) solutions can help organisations manage and simplify their business processes by tying everything together under a single database and interface., while manufacturing execution software (MES) can help eliminate inefficiencies and support better business decisions with accurate, easy-to-access, real-time information.

Not only are these technologies key to supporting the move to a paperless environment—they also provide manufacturers with the visibility they need to manage new industry 4.0 innovations.

www.epicor.com/en-uk Issue 38 PECM

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E/M Coating Services www.emcoatingsuk.co.uk COMPANY PROFILE At the forefront of the latest designs, materials and technologies, E/M Coating Services pride themselves on offering high quality coating applications and processes to improve performance and extend the life of critical components and fabrications of all shapes and sizes for a wide range of industrial sectors. With specialised facilities we are able to design and manufacture bespoke coating systems and have in-house NACE Level 3 trained Inspectors.

Quality is at the heart of our business and we operate under the highest quality control procedures including AS9100 Rev C, NADCAP, ISO9001/9008 and NACE.

New Anti-Corrosion Coating for Rare Earth Magnets Neodymium Iron Boron magnets are utilised in a wide number of industries, including the highly demanding wind turbine industry.

A multitude of these magnets are bonded together to increase the overall level of magnetism. This process leads to two potential issues: Firstly, any adhesive or coating between the magnets acts as an air gap and thus reduces the level of magnetism and secondly NdFeB magnets corrode extremely aggressively. This corrosion issue is exacerbated by the environmental conditions that the wind turbines face.

The corrosion mechanism for NdFeB magnets is detailed in Figure 1. This shows that when exposed to water or humid conditions, the Neodymium rich layers at the grain boundaries react to form Neodymium Hydroxide. The effect of this conversion from Nd to Nd(OH)3, is a large

volume increase along the grain boundaries, leading to cracking and degradation of magnet properties.

Curtiss-Wright Surface Technologies (CWST) has been working on a solution to these issues. This involved developing a high grade anti-corrosion coating with minimal coat thickness (effective air gap).

The current market leader for corrosion protection is CWST’s own Everlube 6155 providing 500 hours protection in the ASTM B117 salt spray test.

After extensive studies and trials, CWST is pleased to announce they have successfully developed a coating system which will provide 1,000 hours salt spray resistance for NdFeB magnets at a coating thickness of just 25um. This NEW coating system – Everlube 1155 is environmentally friendly, easy to apply and a cost effective solution to this critical problem. Please call on +44 (0)1386 421444 for further details.

Nd rich phase

Exposure to humidity or salt spray

Nd2Fe14B

Thick Grain Boundaries

E/M Coating Services are a business unit of Surface Technologies, a Division of Curtiss-Wright, who are global specialists in surface treatments to improve the life and performance of critical components and preventing premature failures through their network of over 75 facilities worldwide. www.cwst.co.uk

Thin Grain Boundaries

Figure 1: Shows the corrosion mechanism for NdFeB rare earth magnets.

Nd(OH)3

Exposure to humidity or salt spray

E/M Coating Services Curtiss-Wright, Enterprise Way, Vale Industrial Park, Evesham, Worcestershire WR11 1GX, UK l Tel: +44 (0)1386 421444

For more information on all our services and full worldwide contact details: www.cwst.co.uk

EDITOR’S CHOICE

EASY SPRAY FORMULA CORTEC

CORTEC’S 329 D ES IN EASY SPRAY FORMULA: POWERFULL, LONG-TERM CORROSION PROTECTION OF YOUR ASSETS! VpCI®-329 D ES is a ready to use spray providing strong rust prevention for metals in indoor and outdoor sheltered conditions.

The product can be easily applied/sprayed from a handheld trigger spray bottle. It offers a convenient way to protect gears, spindles, coils, or any other metal parts that require a light coat of oil for further processing and shipment. VpCI®-329 D ES contains innovative Vapor phase Corrosion Inhibitors (VpCI®) technology and its carrier is a combination of bio-based oil and mineral spirit. By spraying VpCI® 329 D ES, the corrosion is attacked on two fronts. Its oil-soluble corrosion inhibitors first create a tenacious film that clings to metal surfaces, providing excellent contact corrosion protection.

VpCI’s release into the air and attach electrochemically to the metal surface.

The coating provides universal corrosion protection to ferrous and non-ferrous metals and performs effectively even under the adverse conditions of 100% relative humidity as well as the presence of corrosive species such as chlorides, hydrogen sulfide, or other sulfur compounds. The product does not contain any hazardous chromates, nitrites, or phosphate inhibitors.

It is thermally stable, providing longlasting contact and vapor phase corrosion protection for a wider variety of applications.

SUCCESSFUL CORROSION PROTECTION OF SPEED REDUCERS WITH VPCI® 329 D ES Merger is a leading world manufacturer of power transmission gears. Their teams have been working to bring power transmission solutions to manufacturing companies for more than 70 years. The sensitivity of their reduction gears requires them to be protected against corrosion during shipment, storage and in between manufacturing processes. Because of this Merger relied on Cortec’s expertise and highly advanced corrosion protection solutions. VpCI®-329 was used at a low concentration to protect the internal areas of speed reducers and gears. The product was poured into the bottom of the gear

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PECM Issue 38

case lubricant reservoir at only 0.3% of total volume. The oil-based solution provided double action against corrosion. VpCI®-329 works in the contact phase for protection of immersed metal surfaces, while vapor phase action allows the inhibitors to migrate effectively to non-immersed and remote areas where they adsorb and form a protective layer. For exterior protection, external surfaces were sprayed with Cortec’s CorShield® VpCI®-369, a temporary coating that leaves a moisture-displacing protective film, providing superior protection against aggressive environments.

VpCI®-329 will protect against corrosion for up to four years. Stephane Morel, a sales

manager at MERGER, commented that the company now uses VpCI®-329 on all their strategic speed reducers designed for lifting in the manufacturing sector. The efficiency of using VpCI®-329 at low concentration has resulted in cost savings and increased shipping safety. There is no more need to fill the entire case with lubricating oils, and the company has even been able to save on freight that is no longer considered hazardous.

www.cortecvci.com

EDITOR’S CHOICE

GET SMART SEEPEX

THE PUMPING OPERATIONS ENJOYING A DIGITAL MAKEOVER The digital revolution is moving forwards at an impressive rate, with many firms actively investing in connected technology to improve their processes and increase their productivity. Here are some of the smart developments from SEEPEX improving progressive cavity (PC) pump performance and maintenance…

PUMP AND PROCESS CONTROL

Pumps are becoming more intelligent, with increased integral sensors and connectivity.

SEEPEX’s smart dosing pumps comprise a PC pump with drive and control software, as well as flow rate sensors and optional safety functions. Constant real-time feedback compares data from sensors with parameters determined for the process, and automatically adjusts the pump speed as process conditions change, reducing maintenance and increasing cost-efficiency.

CONDITION AND PROCESS MONITORING

Specialised devices are available to turn pumps into intelligent field devices that continuously self-monitor. Pump monitoring systems from SEEPEX observe operational information such as flow rate, temperature and pressure in real time, recording the operating conditions and pump efficiency. This provides users with trends for performance analysis and process optimisation. Deviations from set values trigger alarms, reducing standard inspection tours and providing greater safeguards for critical production processes.

CONNECTED SERVICES

By connecting pump monitors and automation equipment, data can be transferred to cloud-based online services and retrieved by the user anytime, anywhere.

This connectivity is the basis for Industry 4.0 and provides the information needed to improve equipment and process performance. SEEPEX connected services compare the data received from pump monitors with previously defined operational specifications to determine deviations from optimum performance, enabling corrections to be made. The use of API (application programming interface) software can also interlink equipment from different suppliers to produce a general process overview and enable whole process optimisation.

PREDICTIVE MAINTENANCE AND SERVICE DIGITALISATION

Data collected by pump monitors using bluetooth, wifi or SCADA systems can identify when maintenance is needed – predictive rather than scheduled maintenance.

The SEEPEX ERP (enterprise resource planning) system then ensures the correct parts are available, even arranging shipment to site, providing a fully automated diagnostics and spare parts ordering system for customers. Service apps can provide technicians with virtual reality instructions for pump maintenance and provide access to service and instruction manuals, spare parts lists, chat service lines and ordering systems. In addition, SEEPEX pumps have QR codes which, when scanned with a smart phone camera, uniquely identify the pump and generate a spare parts list and O&M manual if needed.

Using the app, spare parts quotations can also be requested. Apps of this kind offer on-site digital solutions to provide instant operational information and simplify the supply chain.

About SEEPEX SEEPEX UK Ltd is the UK subsidiary of SEEPEX, a leading global specialist in pump technology. Established in 1972, SEEPEX has more than 700 employees serving customers in over 70 countries worldwide, across a variety of industries including water and waste water, food and beverage, oil and pharmaceutical, chemical and many more. SEEPEX provides a comprehensive sales and support service for its products, ensuring that customers enjoy the best technical and commercial pumping solutions. www.seepex.com Issue 38 PECM

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EDITOR’S CHOICE

THE MATERIAL DIFFERENCE M&I MATERIALS

MOVING FROM DEVELOPMENT TO COMMERCIALISATION IN DEMANDING APPLICATIONS

By Giles Salt, CEO of M&I Materials Thousands of new materials are developed each year, many of which could be gamechanging. But even with the concept proven there is still a long way to go. How do you commercialise materials for use in demanding applications?

START WITH A DOUBLE TAKE In the excitement of having developed an innovative, new material it’s easy to get carried away. It’s important to start by taking two things: a breath, and a step back.

The hard work is not over. Now is the time to invest in developing a deeper understanding of the material’s potential customers, markets and applications.

radiation shielding on the other. The two applications aren’t closely related so finding these commercial opportunities depended on judicious and comprehensive research.

The business model for demanding, niche applications is often likely to be one of high value, low volume; so understanding each potential customer and their specific needs is doubly important.

MARKET MAKING Not all suitable markets already exist.

Sometimes it’s not as simple as saying: “I’ve got a great material, what do you think” - it’s about creating the market.

Working specifically in demanding applications can be a blessing and a curse; competition may be less fierce but higher specificity means more effort is required to understand precisely where commercial opportunity lies.

This could involve working with companies who are developing new technologies so that the materials become integral to the design. For our MIDEL transformer fluids, we work closely with transformer manufacturers as they looked to design new models; our product helps to push their design in terms of performance.

One of our brands, Wolfmet, produces a tungsten heavy alloy that found its niche in providing fine balance to Formula 1 cars and Boeing 737s on the one hand and

These sorts of opportunities don’t occur by themselves. It involves going out and collaborating to create the market providing benefits for all.

COMMERCIAL SKILLS Developing a new material and its early use cases calls for very specific types of technical expertise. Commercialising it requires a different set of skills. Chief among these are patience and tenacity.

For materials designed for specialist, demanding applications it can feel like forever getting the first customer, signing the contracts and putting the supply chains in place. Engineers can be risk averse, preferring to stick to what’s tried and tested; tenacity is required at every step to bring them around.

But it can also go the other way. Certain applications, such as Formula 1, are always looking for something that can give them an edge, making them more receptive to innovation.

PICK YOUR PARTNERS Frequently manufacturers need to seek out organisations with complementary expertise to bring a new product to market.

This might take the form of research from universities or private laboratories, collaboration with potential customers, or even other private companies.

There are also a host of agencies that exist purely to help promising, young technologies scale by providing tailormade, commercial support.

KEEP INNOVATING Perhaps the most important thing to do is to never stand still. New applications may still be developed for successfully commercialised products. At M&I Materials, we’ve been making Apiezon, a range of high vacuum greases, sealants and lubricants, for over 80 years. Yet we recently created a new grease to work at a wider range of temperatures replacing several products.

Commercialising a material for demanding applications is a complex process with no set formula, the key is to remembering that the material itself is only ever the start.

For further information visit www.mimaterials.com

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hygienic furniture & equipment

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

Easy to clean design inside and out

Intelligently designed sloping shelves prevent sitting water

Add additional shelving to suit your needs

No ledges or crevices for dirt to hide

Easy clean underneath with drainage holes

For more information get in touch today Quality

Value

Service

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

EDITOR’S CHOICE

SUBMERSIBLE SOLUTION ALTRA

SUBMERSIBLE GEARED MOTORS SOLUTION FOR STATEOF-THE-ART WASTEWATER TREATMENT PLANT Conducting an effective and up-to-date wastewater treatment service is challenging.

When a plant in the Netherlands needed to renovate its systems in one of its postsedimentation tanks, it chose Bauer Gear Motor to provide a durable, submersible solution.

The Hague, Netherlands. One of the plants, located in Houtrust, covers 5 hectares and, on average, can treat nearly 79,000 cubic metres of waste water a day.

Delfluent Services BV is a consortium of specialised companies working on wastewater treatment facilities in The Hague, Netherlands. One of the plants, located in Houtrust, covers 5 hectares and, on average, can treat nearly 79,000 cubic metres of waste water a day.

The treatment process at Houtrust begins with the removal of large, solid material.

Subsequently, the wastewater goes through pre-sedimentation tanks, activated sludge, biological treatment and post-sedimentation tanks.

The wastewater treatment plant was originally built in 1967 and needed to be refurbished to be in line with current environmental regulations. Included in the maintenance project was the replacement of a gear unit that was used to drive the chainwheel in one of the sedimentation tanks. The original equipment gear had always required a high degree of maintenance, demanding the tank’s basin be emptied twice a year to carry out regular services. This level of ongoing maintenance resulted in production losses and high maintenance costs. Delfluent chose to use the refurbishment as an opportunity to upgrade the system to a solution that could be easily maintained.

The original supplier had designed a solution which employed a single stage bevel gearbox fully submerged in the water. A connection tube was used to connect the gearbox to the rest of the power train, positioned above the water level. The tube connected to a prestage gearbox and an overload coupling, with a 0.55 kW motor driving the application.

In order to replace the existing motors and gears, Delfluent contacted Bauer Gear Motor, worldwide supplier of high quality, reliable geared motors, and part of Altra Industrial Motion Corporation.

Bauer has a proven track record of developing geared motors for challenging conditions and was particularly suited to help design a

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Below, Specific advantages of the BK series include: simple and cost-effective installation together with submersible options in compliance with IP68. replacement to the original equipment. In particular, Bauer produces IP68-rated versions of its motors, which are fully submersible and impervious to water and dust ingress.

To provide the optimal service, Bauer conducted the replacement operations with its strategy partner Vos Gekas & Boot (VGB), expert in rotating equipment, including pumps – a supplier familiar to the wastewater treatment facility where the activity took place.

The solution provided by Bauer consisted of a drive belonging to the BK series of bevel geared motors (type BK70G20X82W/DHEU09SA4/SP) that can operate continuously underwater. This motor series is available with power ratings between 0.03 kW-75 kW and operates at 110-690 V and 50/60 Hz. From two one-stage gears, Bauer moved to a multi-stage geared motor. The bevel gearbox range can withstand torque of 80 Nm up to 18,500 Nm and gear ratios of 3.67-108.60 for two-stage gears or 7.29-441.3 for threestage gears. In this way, the equipment was simplified, making future maintenance easier.

In addition, by removing the gear, the tube and the coupling, Bauer reduced the oscillations in the system and provided a more energy efficient solution.

Specific advantages of the BK series, besides IP protection against dust and water, include simple and cost-effective installation, high energy efficiency, robustness and durability,

low maintenance requirements and low running costs.

This particular application runs at a set speed and so there was no need for a variable speed drive that might prove advantageous in other situations. Using a lower power-rated 0,37kW IE2 direct on line (DOL) motor offered the most energy efficient and cost-effective solution for this application.

Ferry Spaans, Project Leader, Innovation Projects at Delfluent Services BV, commented: “Our main goal at Delfluent is to develop, refurbish and manage wastewater treatment plants in The Hague. The wastewater treatment plant in Houtrust has been operating for 50 years and has been renovated three times since then. Now, thanks to Bauer, we can continue providing an optimal service, treating the waste water flow from the homes and companies in The Hague with an innovative solution.”

For further information visit www.altramotion.com

EDITOR’S CHOICE

• Vibration Sensors (IEPE + 4-20mA) • Test & Measurement Sensors • Hazardous Area Vibration Sensors • Seismic Sensors • Hydrophones • Vector Sensors • Proximity Probes • Vibration Switches

Bespoke Badge Manufacturers We supply a wide range of domed badges for all industries which can be customised to include your own design, logo and details. We offer a full print and dome service for manufacturers wishing to enhance their products.

We can print directly from your supplied vector artwork or hi-res PDFs. All our products are tailor made to your requirements and ideally suited for all control panel and product marketing, even in harsh environments. For a cost effective and professional way to brand and personalise your products for your market or application contact us by phone or email with your requirements.

Certifications Including FM, CSA, ATEX and IECEx Offer Compliance to Customers Worldwide • Cable Assemblies • Enclosures • Vibration Transmitters • Supportive Instrumentation

Small Production Runs Here at Dash Dynamics, unlike many of our competitors, we specialise in small production runs. So if you just need a series of machine panels for a new prototype or low production run, then simply send us your artwork and we’ll get on with it.

All at a realistic price.

Turnaround time is fast! In most cases, if you order before 11.00am, the order will be produced the same day and after overnight curing it will be sent the following day via first class post or carrier depending on size.

New Inclinometer range!

Visit our website for more information

International orders are accepted too.

www.dashdynamics.co.uk

info@dashdynamics.co.uk

01995 606 158

WORLD-CLASS SENSORS FOR INDUSTRY +44 (0)1767 651058

www.kdpes.co.uk

Issue 38 PECM

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EDITOR’S CHOICE

SHOCK PROTECTION DOEPKE

BS7671 18TH EDITION REVISED RCD REQUIREMENTS If you are involved in the safety specification and or installation of electrical equipment, take note of changes that will come into force in BS7671 January 2019 (18th Edition).

There are a number of recommendations directly linked to improving the security and safety of electrical installations protected by RCDs.

Why is BS7671 relevant to most industrial sites?

The Electricity at Work Regulations and the HSE refer to BS7671 as a “Code of Practice” for electrical installation”. Circuits may rely on additional protection provide by RCDs, to reduce deaths from electrocution and or fire. Installations using Type AC RCDs may not provide the level of protection required, when supplying modern equipment containing switch mode power supplies and inverters. The 18th Edition Regs specify the Type of RCD required, based on the types of residual current generated by the equipment connected to the supply see 531.3.3 and Annex A53 Fig A53. This is a general requirement and applies to all installations. Particular requirements see Part 7.

531.3.3 Types of RCD The type of RCD installed must be capable of providing the required level of protection based on the residual currents that may be generated under possible fault conditions: “Different types of RCD exist, depending on their behaviour in the presence of DC components and frequencies. The appropriate RCD shall be selected from the following”, this clause goes on to list the various types of RCD namely A, F, B and their suitability for different types of residual current.

Type AC RCDs are only listed for general purpose applications such as electric kettles, emersion heaters, filament lamps. Many modern appliances contain semiconductors, and are not suitable for connection to Type AC RCDs e.g.

The internal topology of a Single phase VFD/ VSD will determine the residual current characteristics (Type A, F or B) and therefore the type of RCDs that can be installed safely upstream. 3 phase VFD/VSD must only be connected to Type B RCDs, irrespective of the application or location.

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PECM Issue 38

Two examples of possible fault currents in circuits containing semiconductor devices (PECS): see BS7671 Annex A53 Fig A53.1 Circuit with fault location

Normal load current IL

L

~

IL

IL 50Hz

RCD Type

Earth fault current IF

IF t

t

"A"

IF

N PE

Example 1. Phase control: IF frequency is the same as the supply current IL @ 50Hz IF1

IL

L IL

~

M

50Hz

N

PE

t

t

IF2

=

IF1

"F, B" t

IF2

Example 2. Inverter control: IF2 frequency is a function of the Inverter / Motor design>>50Hz

doepke cla 07/17

Annex A53.1 gives details of typical faults currents associated with circuits containing semiconductors and the required RCD type (see example 1 and 2).

These recommendations along with other changes are directly linked to reducing the risks associated with electrical faults, namely fire and electrocution.

For additional information on RCDs refer to www.doepke.co.uk/ download/Techpub-16

EDITOR’S CHOICE CAS ADVANCED DOCUMENT MANAGEMENT SERVICES

CAS have been keeping clients’ documents safe and secure for over 20 years. We pride ourselves on providing an efficient and cost-effective archive storage system. Our document scanning services save you time and money when it comes to information processing and management. Documents can be scanned and converted into searchable and editable electronic documents that are stored on the CAS Cloud, providing access 24/7 for authorised personnel.

When your documents are ready for disposal, we provide a confidential shredding process and safe disposal of IT data and equipment.

We have an excellent track record of working with organisations

whose document management arrangements are complex and demanding, this includes GP surgeries, NHS Trusts, financial services providers, and corporate and private clients.

We are proud of our client retention rate and have an impressive array of industry accreditations that prove our compliance with the strictest national and international regulations. They also demonstrate our commitment to provide innovative systems on security, confidentiality and quality control; always keeping your files safe and well managed.

For a free, no-obligation quote, please contact our specialist team.

Call: 0845 50 50 003 Email: info@cas.ltd Web: www.cas.ltd

RMIG is the world's largest manufacturer and supplier of perforated metal and its related products.

We know our customers’ requirements for price and quality and meet their demands with uncompromising service.

Not only do we offer standard and bespoke perforated metal sheets, we are able to offer you a range of secondary operations as detailed below.

Complete solutions With a continued investment in the latest equipment and a network of professional partners we are able to produce prime quality products and solutions – from a simple perforated sheet to the fully formed and coated custom made part.

RESPOL INDUSTRIAL & COMMERCIAL FLOORING SOLUTIONS

Technically advanced commercial and industrial flooring solutions, designed and guaranteed to perform to the highest standards and provide years of cost-effective service in the most diverse and demanding environments.

Twice FERFA ‘Flooring Contractors of the Year Award’ winners, RESPOL’s flooring service and systems are accredited to ISO9001:2008 which is testament to their commitment to quality standards and peace of mind for their customers, nationwide.

Epoxy resin, polyurethane, pumped polymers, flooring screeds and coatings - cost effective solutions installed by highly skilled and fully trained personnel.

All work carried out by Respol is guaranteed by a single source warranty covering workmanship and materials.

From dust proofing contracts for industrial warehouses to the most sophisticated multi-layer performance floors for hightech enterprises, RESPOL offer a complete service, guaranteed to exceed all expectations.

For free of charge, no obligation survey and recommendations, contact Respol on 01952 740400 or visit: www.respol.co.uk

Levelling For some applications a high degree of flatness is required, we have processes in place to ensure our perforated coils and sheets meet with your most demanding requirements.

Rolling and forming We can roll, bend and form perforated sheets to match your design.

Aesthetic finishes and protective coating We can offer powder coating and hot dip galvanizing solutions to meet your specifications.

For more information please contact us www.rmig.com email: info.uk@rmig.com Tel: 01925 839610

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

Issue 38 PECM

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AUTOMECHANIKA SHOW PREVIEW

NEW INITIATIVES AUTOMECHANIKA

INNOVATION KEY THEME OF AUTOMECHANIKA BIRMINGHAM 2019

Automechanika Birmingham has announced that “Innovation” will be the leading theme for the 2019 event, held at Birmingham NEC on 4 to 6 June.

Aftermarket Power Network and ‘The Big UK Garage Event’, as well as the Future Mobility & Innovation Hub, all designed to deliver an enhanced visitor experience.

Following extensive Automechanika Birmingham research, “new technology and innovation” were key reasons to attend the event for visitors and so Automechanika is looking to build on this by highlighting all innovation from within the automotive industry.

“2019 is the last year before the show goes biennial, so there has been a surge in the number of space bookings to ensure the latest products, services and technology are showcased to the market before 2021.”

This is all in addition to the automotive industry’s largest seminar programme, which will feature seminars across Aftermarket and Vehicle Production sectors, comprising both business and technical advice and information.

In addition, the visitor campaign is off to a record start with pre-registrations up thanks to the new features and initiatives, designed to offer the very best visitor and exhibitor experience.

This year’s event will see the launch of many new points of interest covering all aspects of the automotive industry, including: A new Bodyshop Zone, Aftermarket Innovation Showcase, Remanufacturing Showcase,

Jack Halliday, Event Director of Automechanika Birmingham, explains: “We’ve experienced a high demand from companies wanting to exhibit that will really boost the appeal for visitors coming along this year.

With the number of registrations having already exceeded targets, there are currently over 2,000 visitors who have signed up to attend the event, including more motor factors and garages, an increase of 21% compared to this time last year.

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PECM Issue 38

The news comes as a major confidence boost for the automotive trade and UK economy as the event, which has been running at Birmingham NEC since 2016, continues to attract the highest profile names from within the global automotive industry.

Jack continued: “We’ve seen an increase in registrations from across the industry and this, combined with our close collaboration with exhibitors, means that a visit to Automechanika Birmingham is a must visit for anybody working in the automotive industry.

“The feedback we are getting is reflected in the fact that so far we have seen 30% of new registrations for 2019, that is, 30% of whom who haven’t registered or attended the event before.

“With record investment levels into the event, we’re sending out a clear message to the automotive trade that Automechanika Birmingham 2019 is the prime event to do business and network. It’s even more important that we share a vision with exhibitors and visitors to celebrate all that is good in the automotive industry and that Automechanika Birmingham demonstrates a sector that is not only thriving but evolving to meet the challenges of tomorrow.

“With so many new initiatives planned, this year’s event is going to be the most engaging yet and will cement Automechanika Birmingham’s position as the meeting place for the UK’s automotive industry.”

The event will also occupy a larger area of the NEC as more exhibitors take more stand space. The show has also attracted new exhibitors from countries such as Czech Republic and welcomed back exhibitors from Denmark & Korea, adding to the show’s growing international appeal.

With over 10,200 automotive industry personnel attending the highly successful 2018 event, alongside 500 exhibitors from over 120 companies spanning 26 countries, 2019 promises to see the return of leading

suppliers. More than 100 suppliers so far have signed up to exhibit, including Schaeffler, ZF, DENSO, MAHLE Aftermarket, Delphi Technologies, Valeo, Bosch, Hella, Bilstein Group, MANN + HUMMEL, NGK and Yuasa.

Visitors can register to attend the event by booking their free ticket here: automechanikabirmingham-2019.reg.buzz.

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The UK’s leading exhibition for the vehicle production sector

4-6 June 2019, NEC

Discover the best of the UK automotive industry » Meet over 500+ suppliers » Discover cutting-edge innovation » Network with your industry

4 events. 1 registration, Designed for engineers.

In association with

Register for your free ticket at www.automechanika-birmingham.com

AUTOMECHANIKA SHOW PREVIEW

NEW RANGES OF STAINLESS AND SPRING STEEL FASTENERS SD Products Ltd is a third generation family owned business with over 40 years of experience as a stockist distributor of specialist fasteners, we supply product across all industries. The corner stones of our business are Quality Products at Competitive prices with Service and Supply requirements tailored to our customers’ needs. As our business continues to grow we constantly aim to expand our extensive product catalogue.

A brand new range of 12-150mm safety clips is now available from SD Products website.

These fasteners are manufactured from high grade spring steel, offering excellent stress and corrosion resistance, as well as ability to withstand considerable forces without any distortion. High yield strength of spring steel in our safety clips allows them to return to their original shape, even after substantial deflection, twisting or compression, without suffering any significant deformation. Safety clips are well suited for both domestic and industrial applications and can be easily installed or removed by hand.

Several new lines of stainless steel connector bolts and nuts have been added to our furniture fastener range. Connector bolts are designed to be used with connector caps nuts - nut applying an axial clamping force and the

shank of the bolt acting as a dowel, pinning the joint against sideways shear forces. Our connector bolts are suitable for a variety of furniture applications, flat low profile bolt heads allowing for a decorative finish.

We have increased our range of mild steel slab base t-nuts and added a new range of stainless steel 4 pronged t-nuts.

T-nuts have a wide range uses – ideal for automotive, domestic, furniture and industrial applications. Durable, reliable and low in

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

Come and visit us at Stand L156 www.sdproducts.co.uk

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AUTOMECHANIKA SHOW PREVIEW

INDUSTRY SPECIALIST TR FASTENINGS

TR FASTENINGS IS EXHIBITING AT AUTOMECHANIKA BIRMINGHAM FOR THE 4TH TIME! TR Fastenings (TR) will be exhibiting at Automechanika Birmingham from 4th-6th June 2019, when the successful exhibition for the automotive supply chain returns to the NEC for its fourth year.

TR is part of Trifast plc and is a global specialist in the design, engineering, manufacture and distribution of high quality industrial and Cat C fastenings principally to major global assembly industries. TR has 31 business locations within the UK, Asia, Europe and the USA including eight high volume, high-quality and cost-effective manufacturing sites.

TR will be exhibiting at Automechanika Birmingham on Stand F92, having enjoyed success at the previous three events. TR sees the event as “the place to be seen” and it is an important part of its annual calendar of events and promotions.

As a Full Service Provider (FSP) to Tier 1 and Tier 2 businesses supporting global OEMs in the automotive industry, TR delivers comprehensive support to its customers giving an end2end service.

A key focus this year will be on components for Electric Vehicle (EV) charging units and EV batteries (EVBs) as the EV market gathers considerable pace. The products required for these areas are already within TR’s portfolio and we will be able to support and advise on applications.

Glenda Roberts, Trifast’s Global Sales Director, comments: “The growth of the EV market and the electric highways being created has led TR into new areas of development, in particular with battery production, the fixings that are required and the finishes. Our strength as a manufacturer and distributor is further enhanced by the design and technical support that we are providing to our customers as part of the FSP service. We have heavily invested in recruiting fastener engineers over the last few years and this is proving to be a much-needed support that we can offer to our customers, from the initial design right though to VA/VE initiatives on mature products.”

TR’s qualified engineers and Product Managers will be on hand at

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Automechanika to advise designers, production and purchasing teams, encouraging them to bring their fastener application issues to us so we can offer solutions and demonstrate our knowledge.

TR is a member of the Society of Motor Manufacturers and Traders (SMMT) and the North East Automotive Association (NEAA) and has benefitted greatly from its association with these organisations.

Attending Automechanika Birmingham over the last three years has enabled TR to further cement its position within the automotive industry, allowing it to access and converse with wider audiences, from design through to aftermarket.

NEC, 4-6 June, Stand F92 trfastenings.com/

Come and visit us on F92 TR Fastenings, international specialist in the design, engineering, manufacture and distribution of high quality industrial and Cat C fastenings principally to major global assembly industries.

Seating Seating

Interior Interior Trim Trim

Lighting Lighting Clusters Clusters

Chassis Chassis & & BIW BIW

Braking Braking & & Steering Steering Systems Systems

Safety Safety Systems Systems

Powertrain Powertrain

TR is a major component supplier to the automotive sector. Our aim is to be seen as the vendor of choice for the Tier 1’s who support global OEM’s, with our comprehensive product offering: Special Parts | Marriage Bolts | Airbag Fasteners | Spring Steel Clips | Washers | Rubber Bumpstops | Damper Grommets | Bushings | Spring Staples | Hog Rings | Plastic Clips & Rivets | Plastic Components

Manufacturing

Electric Vehicle Charging

88 manufacturing manufacturing facilities facilities with with an an annual annual output output of of over over 88 billion billion components. components.

Working Working with with organisations organisations involved involved in in the the design, design, manufacture manufacture and and development development of of Electric Electric Vehicles Vehicles (EVs), (EVs), Battery Battery Pack Pack Modules Modules (EVB) (EVB) and and EV EV Charging Charging Units Units for for both both commercial commercial and and residential residential use. use.

Design & Engineering

Logistics

As As aa Full Full Service Service Provider Provider (FSP), (FSP), we we offer offer early early design design and and technical technical involvement, involvement, VA/VE VA/VE engineering, engineering, global global sourcing sourcing and and logistical logistical solutions. solutions.

Tailored Tailored services services to to meet meet customer customer requirements requirements ensuring ensuring an an effective effective Lean Lean Supply Supply Chain Chain solution. solution.

Quality

Supplier

Meeting Meeting the the customers’ customers’ quality quality needs needs and and specifications specifications as as their their enhanced enhanced demands demands increase. increase.

AA global global network network of of AVL AVL approved approved suppliers suppliers enabling enabling an an international international source source of of supply. supply.

Contact us: +44 (0) 8454 811 800 sales@trfastenings.com | www.trfastenings.com

AUTOMOTIVE ENGINEERING

STATE OF THE ART FACILITY FEV

COVENTRY UNIVERSITY AND FEV JOIN FORCES TO LAUNCH £50M CENTRE FOR CLEANER MOBILITY

A £50m state-of-the-art facility for creating cleaner mobility has opened in Coventry, giving a major boost to the UK automotive industry.

partners keen to accelerate the creation of new propulsion systems for use across automotive, aerospace, marine and rail sectors.

The Centre for Advanced Low-Carbon Propulsion Systems (C-ALPS), an innovative collaboration between Coventry University and global engineering specialist FEV Group, is looking to harness cutting-edge academic and commercial expertise to support the development of the next generation of electric, hybrid and combustion engines.

36 new jobs will be created initially, with a number of apprentices and graduates from Coventry University already appointed.

Over 30,000 sq ft of purpose-built space on Cheetah Way will house some of the most advanced internal combustion and electrification test bed facilities currently available in the UK, creating a dedicated resource for testing current and future powertrain solutions quickly and efficiently.

The capabilities will be available to OEMs, SMEs in the supply chain and technology

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“This collaboration is very encouraging news and a welcome boost for the UK automotive industry,” explained Professor Richard Dashwood, Deputy Vice-Chancellor at Coventry University.

“We have a real opportunity for the country to lead the rest of the world when it comes to developing low carbon propulsion systems and C-ALPS has a major role to play in making this happen.”

He continued: “It’s all about bringing the best of both worlds together, using the expertise and track record of FEV Group in engineering

consultancy and combining it with the academic knowledge of our professors to create a real centre of excellence that can attract funding, build capacity in the supply chain and, importantly, offer commercial testing services to car makers.

“Automotive is naturally the first target, but the technology will also be available to support the evolution of other sectors.”

FEV UK moved into the new facility in January and this will serve as its UK Test Centre, expanding its business operation here and further increasing the local execution of projects close to its customers.

The location in the heart of the Midlands automotive industry was a major attraction and the investment will create world class test bed facilities that will prove invaluable to the sector’s move towards new powertrain solutions.

INTRODUCING THE C-ALPS CENTRE Operating within Coventry University’s Future Transport & Cities Research Institute, the C-ALPS centre has been designed by architects Broadway Malyan and built by Willmott Dixon to be the most advanced test facility of its type currently available in the UK. More than £27m of capital investment alone has been channelled into the industryleading building and in creating the infrastructure that will allow FEV’s internal combustion and electrification test beds to satisfy commercial testing requirements for current and future powertrain systems.

It houses test benches for powertrain components, including turbochargers, catalytic converters, battery systems and electric machines.

Three world class professors have also been recruited to lead the research team and they bring with them significant experience and knowledge in battery storage, power electronics and electric machines.

Professor Stefan Pischinger, President and CEO of FEV Group, added his support: “This is a major investment for our company and underlines our commitment to growing our business in the UK. “We made the decision to collaborate after the Brexit vote was taken and, despite all of the uncertainty, we see no reason to change our approach and believe the UK is amongst the most advanced in the world when it comes to developing the next generation of powertrain solutions.

“Coventry University is a fantastic partner and the expertise it brings to the table is significant and one we will undoubtedly tap into in order to commercialise new technology. It’s important to understand that whilst electrification of vehicles is critical, it is not going to happen overnight and there is a journey we must go on first.

“There is still a role to play for the combustion engine and how we integrate hybrid technologies more effectively – alongside and not instead of new developments in electric powertrains.”

Over 100 people from industry and local business groups were present today to mark the official launch of C-ALPS. In addition to keynote speeches from Coventry University, FEV Group and a guided tour of the impressive facility, delegates also heard from Ian Constance (CEO of The Advanced Propulsion Centre) and Richard Harrington, Minister for Business and Industry.

“This centre is a fantastic example of how leading international businesses are working in collaboration with the UK’s world-class universities to drive innovation,” concluded Business Minster Richard Harrington.

“This new centre will combine our heritage in automotive with our leadership in clean growth to develop advanced, cleaner propulsion systems and other transport technologies. Our modern Industrial Strategy presents the Future of Mobility and Clean Growth as global opportunities that the UK can lead in, helping create the

industries of the future and highly skilled jobs.”

For further information, please visit www.coventry.ac.uk/c-alps or contact us at admin.ftc@coventry.ac.uk Issue 38 PECM

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AUTOMOTIVE ENGINEERING

PRODUCT DATA INTELLIGENCE ACTIFY

UNLOCK OPERATIONAL EFFICIENCIES AND BUSINESS SUCCESS Future products will be smarter, more interconnected and feature complex. The challenges facing today’s Manufacturers include; labor shortages, increased global competition, economic trends, and keeping up with new technologies. As a result, this places even greater pressure on time and cost while striving to achieve raising standards in quality.

How can Actify support manufacturers bring increasingly complex, high-quality products to market within ever shorter product life cycles? We believe that interdisciplinary enterprise collaboration holds the key to unlock operational efficiencies and business success.

The enterprise is a multidisciplinary environment. In most cases, business disciplines do not cooperate and tend to carry out their work in remote and siloed business environments. Communication across various disciplines can be highly divergent because of the terminology, methodology, and unique file formats.

There are additional cultural and linguistic differences arise when collaborating with geographically dispersed teams, partners and suppliers.

Multidisciplinary collaboration involves more than just processing large volumes of enterprise data. Even more important are the different ways in which each discipline views the data and the different capabilities needed for them to perform their work.

Actify provides an enterprise solution that enables organizations to align processes, engage stakeholders and act strategically to maximize business results. The software helps companies gain a competitive edge through streamline operations and processes across the enterprise while increasing quality and productivity levels. Actify helps manufacturers collate and organize disparate program data, providing a highly systematic and structured environment for continuous improvement and optimization of today’s heterogeneous enterprise.

Actify’s enterprise solutions are designed to complement other enterprise applications and provide the core functionality needed for managing, merging and leveraging data across the enterprise. Actify’s Enterprise Collaboration Platform integrates a host of organizational disciplines and natively supports visualization, collaboration, decision making, and intellectual property protection, among other capabilities.

X CA D

Actify provides a set of business solutions designed to support the creation, management, dissemination and collaborative use of product data (i.e. product definition information including BOM structures, CAD files, specifications, requirements, manufacturing instructions, etc.).

Actify delivers powerful and affordable Product Data Intelligence solutions to the aerospace, automotive, industrial automation, and discrete manufacturing industries.

Actify’s solutions enable designers and knowledge workers alike to participate in product design and development activities, thereby lowering collaboration costs and improving manufacturing performance.

Actify is passionate about leveraging available enterprise data to make manufacturing companies smarter by harnessing the product data trapped in all their data sources.

Contact Actify for more information.

Visit: www.actify.com Email: sales@actify.com

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AUTOMOTIVE ENGINEERING

FUEL EFFICIENCY ULTRASEAL INTERNATIONAL

INCREASING DIE-CASTING PRODUCTIVITY AND REDUCING COSTS As manufacturers within the automotive industry strive to meet the challenges of a highly competitive global marketplace – particularly within the realms of fuel efficiency and environmental impact – the die casting industry is undergoing a period of change and development. Tim Butler at Ultraseal International discusses these trends and how Lubrolene water-free die-release technology can bring about significant quality, cost, productivity and environmental benefits for manufacturers.

In recent years we’ve seen a shift towards lightweighting in the automotive industry with increasing use of aluminium for powertrain components and a rapid growth in aluminium structural components such as shock towers, rails and torque boxes.

In fact, structural casting is now being adopted in higher volume, mid-sized vehicle platforms that need to be manufactured to a consistent quality in multiple global locations.

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Fundamental in delivering that functionality is the process of die-casting. Supporting manufacturers to move away from multicomponent welded assemblies for vehicle structures, high pressure vacuum diecasting technology is able to provide a complex, one-piece structural component, significantly reducing the assembly, number and weight of components in a vehicle.

In practice, substituting traditionally steel components with lightweight, one-piece structures contributes significantly to reduced vehicle weights.

That means greater efficiency, reduced fuel consumption and lower levels of CO2 emissions – all key focusses for automotive manufacturers as legislation around the world places greater emphasis on fuel efficiency, emissions and the environmental impact of vehicles.

Further to this, lightweight structures, and the weight reduction associated, are essential for the increasing adoption of

electrified vehicles. A segment of the market forecast to grow strongly in the medium term, major OEMs are investing significantly to develop the necessary technology costeffectively.

Developments in die-casting technology have facilitated the design of larger, more complex, structural components which assist the automotive industry with its weight reduction goals. This approach accommodates larger components such as door and window frames, instrument panels and cross members to be produced by diecasting, and has led to a trend toward larger die-casting machines and increasing shot weights.

However, the complexity of large onepiece components makes it difficult to design internal cooling which successfully reduces the temperature of all parts of the die uniformly. This can lead to localised hot spots and solder problems.

OVERCOMING CHALLENGES To avoid compromising quality and increasing costs in the creation of large, complex components, specifying the correct die-casting lubricant is essential to ensure an adequate release lubricant film is formed over the die surface. However, the surface temperature of the die makes this difficult with water-based lubricants. To ensure the oil film is successfully formed on the die surface some water-based lubricant will remain in the die cavities. This may cause porosity problems and water stain on the casting surface. Whilst residual water on the die surface can be dried using compressed air, this extends cycle times and is a costly consumer of electrical energy, increasing processing costs.

For an industry looking to cast larger components with higher process temperatures and also meet the challenges of maintaining product quality, improving productivity and reducing costs, Lubrolene

WFR provides the best solution. Significantly reducing the quantities of lubricant required, Lubrolene negates the need for die cooling by lubricant and delivers a high adhesion efficiency for thicker and more effective film formation. Quality is improved through better molten metal flow and reduction of the quantity of trapped gases due to no external water-cool, as well as the fact that WFR can be applied at higher temperatures than conventional water-based lubricants, meaning there is less thermal stress on dies.

The avoidance of heat cracks extends the service life of the dies significantly – the major source of savings.

With cavities increasingly present in complex pieces, Lubrolene WFR-EC – which features an electrostatic charge – ensures an effective and efficient release. Creating a wrap-around effect, the electrostatic charge delivers consistent, uniform coverage, irrespective of die complexity. Using a specially-developed electrostatic spray gun, the application of Lubrolene WFR further reduces soldering problems, providing full, unrivalled coverage.

Once the practicalities of complex, onepiece die casting are resolved through the implementation of new technologies and solutions, the benefits for automotive manufacturers begin to emerge fully.

Reduced spray time, increased die life and a low reject rate all lead to enhanced benefits and cost savings for manufacturers. Combine that with zero wastewater from the process and reduced CO2 emissions, as a result of reduced air blow, and the environmental impacts of utilising an efficient casting die release lubricant cannot be ignored.

To learn more about Lubrolene die release lubricant, or to discover more about the improvements it could have on your processes, call the Ultraseal team on 024 7625 8444 or visit www.ultrasealimpregnation.com.

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SUBCON SHOW PREVIEW

SUBCON IS BACK FOR 2019!

SUBCON

INNOVATION, PARTNERSHIP AND EXCELLENCE Subcon returns on the 4-6 June 2019 and is once again set to take place at the NEC, Birmingham. Now in its 43rd year, Subcon remains the UK’s only dedicated event to enable subcontract manufacturing buyers to source suppliers, benchmark capabilities, and form new manufacturing partnerships.

Against a backdrop of profound uncertainty and change within the engineering and manufacturing industries, Subcon 2019 will show how the industry continues to innovate and deliver maximum value, with three events in one venue.

SUPPORTING INNOVATION: THE LAUNCHPAD AND LAUNCHPAD AWARDS For 2019, Subcon has unveiled a brandnew opportunity to support engineering entrepreneurs. The Launchpad and Launchpad Awards will showcase cutting-edge innovations from across the industry with dedicated space at the event for specially selected start-ups.

The Launchpad aims to propel manufacturing and engineering-based by giving these entrepreneurs an opportunity to share their innovations with thousands of professionals with the power to guide them to success. The showcase and awards will deliver an unrivalled platform for eight engineering start-ups and a £10,000 prize package to the winner.

ENABLING PARTNERSHIPS AND DRIVING BUSINESS: THE SUBCON EXHIBITION As with every previous year, Subcon will deliver the contacts, connections and content that engineering and manufacturing businesses in the UK need to succeed. Visitors will be able to harness new innovations from over 300 world class suppliers to help increase capacity, optimise productivity and improve flexibility while driving down costs to stay competitive in a global market.

Subcon exhibitors span a massive range of engineering businesses. Ahead of the event this year, Subcon hit the road and spoke to exhibitors across metal fabrication, 3D printing, measurement and other sectors. As this diversity of exhibitors shows, there will be huge opportunities to forge strategic partnerships and improve existing processes.

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Goodman Metalworks Goodman Metal Works is a Nottingham based, full-service metal fabrication company returning to Subcon. Director Richard Goodman explains what keeps them coming back: “It is a very compact event, spread out over three days, so it is a very easy way to meet the critical people you need to meet.”

To maximise the value of the event, Subcon is once again co-locating with The Engineer Expo and Advanced Manufacturing Show.

The Engineer Expo delivers the innovation, inspiration and insight businesses need to optimise future engineering and manufacturing strategies. From an exhibition of next generation design and technology solutions from the UK’s most ground-breaking suppliers, to an unrivalled conference programme featuring industry leaders responsible for some of the UK’s most inspiring engineering and manufacturing projects, The Engineer Expo will keep visitors abreast of the biggest issues around, from Brexit and Industry 4.0 to the challenges of diversity and skills.

The Advanced Manufacturing Show will showcase live demos and the latest efficiencyboosting innovations from hundreds of world class suppliers. This is an unparalleled opportunity to review outsourcing and

Laserlines 3D Printers & Additive Manufacturing Systems reseller Laserlines is based in Banbury. This year at Subcon they are debuting not only new machinery but also new materials. Mark Tyrtania, sales director explains that for Laserlines: “Subcon is the right mix of visitors from varied industries...my top tip is to arrive early and leave late!”

Metpro Based in Smethwick, Metpro has grown to become a leading supplier to the mechanical and electrical market in the UK. Marketing manager, Jacob Rudge outlines that the value of Subcon is the quality of people that attend: “The majority of our conversations have been with key decision makers...some of the most successful outcomes we have had throughout the years have been from just striking up these conversations.”

procurement decisions and bring tools and technology up to speed, to reduce costs, cut lead times and increase productivity to stay competitive in a global market.

SHAPING THE FUTURE: THE ENGINEER CONFERENCE Following the success of the conference programme in 2018, Subcon will also feature presentations from industry pioneers such as Siemens and Rolls-Royce, as well as thought leadership from organisations including MakeUK, the Manufacturing Technology Centre (MTC) and WMG (formerly the Warwick Manufacturing Group). A total of 34 sessions will be announced in the run up to the event.

The conference programme will deliver insight on industry issues, with presentations from industry leaders responsible for some of the UK’s most inspiring and ground-breaking engineering and manufacturing projects.

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Speakers confirmed this year include: Brian Holliday, managing director, Siemens Digital Industries, delivering a keynote address, covering the latest developments and momentum around Industry 4.0 Mark Ireland, chief engineer, MTC, speaking on the MTC Sit Ski project and the role of collaboration Stephen Phipson, CEO, Make UK, covering the impact of Brexit and the changes felt throughout the manufacturing supply chain Riona Armesmith, chief project engineer, Hybrid Electric Propulsion, Rolls-Royce talking about the development of electric/hybrid aircraft and the E-Fan X project Lina Huertas, head of technology strategy, digital manufacturing, MTC, covering the technologies set to transform manufacturing Jeremy Pullen, Sartorious on what is next for additive manufacturing Steve Banton, channel manger, ABB Robotics on the development of cobotics and where it will make its impact felt Rachel Edes, WMG on the challenge and opportunity of creating a domestic supply chain for electric vehicles Nick Hawker, CEO and co-founder, First Light Fusion on the commercial application of nuclear fusion Martin Little, commercial director, Rail Alliance on the overlooked opportunities within rail Gordon Kirk, event director for Subcon points out that this wide range of opportunity and the chance to see so many diverse companies is no accident: “We are even more aware than ever of the pressures on UK engineering and manufacturing businesses, so we have crammed as much value into the event as we can. From the 34 sessions of The

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Engineer Conference to the showcase of new start ups and co-locating with Advanced Manufacturing Show and The Engineer Expo, Subcon 2019 will deliver huge value to visitors throughout the three days. We are incredibly excited to include so much new material and look forward to opening the doors at the NEC!” The Engineer Expo is dedicated to providing UK engineering professionals with the latest in-house manufacturing and design solutions, alongside cutting edge developments in advanced engineering technologies.

The show provides a unique platform for

engineers to source the latest advanced engineering technology, products and services, enabling them to optimise production and process throughout the manufacturing cycle.

The Advanced Manufacturing Show 2019 is the only UK event dedicated exclusively to advanced manufacturing technologies.

Designed with buyers’ needs at heart, the event offers visitors the opportunity to meet suppliers, view live demonstrations, benchmark and source the latest technologies in order to enhance your manufacturing strategy.

SUBCON SHOW PREVIEW

COMPREHENSIVE ERP SYSTEM SAPMAN V12

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

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

For manufactures 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 £2,450. Our licencing is £50 per month ( plus VAT) per user licence with no minimum contract obligation. Additional users can be added as required and, indeed, reduced.

A key market for us is Sage users. Sapphire Manufacturing Systems Ltd. The developer of Sapmanv12 has been an Authorised Sage Developer for over 20 years. So most of our users run on Sage50 and Sage200, and we

still have some clients on Sage Line 100 yet to upgrade.

One of the great advantages of Sapmanv12 for Sage users is that users can benefit from multi depot stock and full Serial Number and Batch Traceability without the need to upgrade their accounting engine from Sage50 to Sage200. This is an additional cost saving benefit We’d be delighted to visit you to demonstrate the product, or you can arrange to visit our demonstration suite in Bristol

COME AND VISIT US AT SUBCON IN JUNE ON STAND D2 64

PECM Issue 38

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

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

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

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

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

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

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

with collapsible/expandable nodes

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

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

SoP : The Sales Order Processing gets underway

WiP With Shop Floor Data Capture SFDC v12 knows :

MAKE IT

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

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

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

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

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

Alan Saitch, Managing Director, Lada Engineering Services Ltd

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

Colin Mallard, Finance Director, Lakeland Laboratories Limited

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

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

Mike Perkins, Managing Director, Encoders UK Ltd

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

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

for Nominal Codes, Sales Ledger & VAT Issue 38 PECM

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SUBCON SHOW PREVIEW

SHEET METAL ENGINEERING PLEASE VISIT! STAND H10

DUDLEY INDUSTRIES

THE KEY TO YOUR OWN BESPOKE METAL ENGINEERING SPACE

Are you looking to create a product from stainless steel, mild steel or aluminium?

Are you looking for new supplier that has the capabilities to support you as your company grows?

At Dudley Industries Ltd we are renowned for high quality sheet metal engineering and partnering with businesses across differing industrial sectors - ranging from construction fit-out to instrumentation manufacture.

The heart of our business is the highly experienced team of designers and manufacturing engineers led by the design manager, Richard Hooke, who has 32 years of experience in the industry. We understand the high degree of crossover between design and manufacturing functions that makes a project work to quality standards, timescales and budgets.

This multi-disciplinary approach enables our team to take products from concept to full production seamlessly.

We are proud to be led by the principles of 5S and lean manufacturing techniques.

We aim to continually improve and exceed your expectations in terms of performance

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and cost. We achieve this through company practices and procedures that are externally audited and accredited to the requirements of ISO 9001:2015, in addition to applying a ‘right first time’ DFM and DFA philosophy.

We regularly invest in the latest technology and techniques for laser cutting and ABB robotic finishing equipment. This is combined with our laser, punch and etching machines which are directly linked to the CAD system, along with CNC controlled folding machines and a variety of presses and rolling machines. This computer controlled design and manufacturing process ensures maximum accuracy and flexibility.

So, whatever stage your products are at, our team are at your disposal. As part of Rentokil group, you can tap into our expertise and resources of a FTSE100 listed company with the skills of an engineering team honed since 1942. Beyond the external auditing and accreditations to ISO9001:2015, the team here work within a culture that delivers exemplary products within a safe environment that meets your specifications.

If you would like to talk to someone about your project call us on 01253 738311 or visit our website at dudleyindustries.com

Dudley Industries Ltd Total solution provider for metal engineering.

We've been honing our metal engineering skills for over 76 years.

Our team of skilled design and manufacturing engineers can take your idea from design, prototype through to large scale production runs.

3 Quality as standard - ISO 9001:2015 Dedicated in house design studio On site tool room to create proďŹ les to your exact needs Flat bed laser cutting Power presses up to 400 ton Press Brakes to 2m width Punch press up to 6mm MIG & TIG Welding plus plasma welding robot for complex processes ABB Robotic linishing cell for complex product designs Dedicated team for assembly, branding and ďŹ nishing

CONTACT US TODAY TO DISCUSS HOW WE CAN SUPPORT YOUR PROJECT

Sales: +44 (0) 1253 738311 E-mail: sales@dudleyindustries.com www.dudleyindustries.com

ADVANCED MANUFACTURING SHOW PREVIEW

INCREASED CAPACITY WEC GROUP

ANOTHER SUCCESSFUL YEAR FOR WEC GROUP AS GROWTH CONTINUES WEC Group, one of the UK’s largest subcontract engineering and fabrication companies in the UK, will be showcasing its increased capacity at Subcon 2019 at stand C15.

This year marks a special occasion for the Group as it celebrates 40 years of business.

From humble beginnings in 1979, the company has now grown into one of the UK’s leading contract manufacturing specialists. 2019 also marks the Group’s 9th visit to Subcon where they will return to exhibit the extensive subcontract services they offer.

On the back of a series of large fabrication contracts throughout 2018 and early 2019, WEC has also seen an impressive increase in staff numbers from 875 to 940 since the last visit to Subcon.

In an effort to fuel further growth, the Group has unveiled an ambitious £6m investment plan. This investment will see the first fibre tube laser installed at the Group’s Knowsley site 5750 Components Ltd, to mirror the success the Group has had at its Darwen headquarters. The Darwen site itself will also benefit from the installation of a similar new fibre tube laser with step loader later in the year.

The new Adige LT8.10 fibre tube lasers will allow WEC to cut tubes, box section and special shaped tubes or open sections up to 8.5m in length and 240mm diameter which is a significant increase compared to our current offering. The machine will come fully equipped with an improved 3D tilting head which makes it possible to do (± 45°) chamfers and other complex cutting

existing CO2 flatbed lasers line-up are to be replaced with three new 4m x 2m 10Kw fibre lasers with sheet loading automation later in the year. This will increase cutting capacity by 33% and massively reduce the Group’s carbon footprint in line with the company’s environmental aspirations.

patterns including weld prep cuts in thick walled tubes. The Group will now also be able to process brass, copper, & galvanized tubes as well as complex shaped extrusions which were previously falling outside of their capability.

In addition to the new fibre tube laser, the Group’s headquarters in Darwen will see a complete overhaul as the company’s

Wayne Wild, WEC Group Commercial Director said: “Our investments in the very latest laser technology will enable us to retain our competitive edge and continue servicing our growing customer base to the industry’s highest standards with high processing speed and excellent part quality on thin gauge sheets and thick plates alike. The new machines will allow us to minimize downtime and increase our weekly cutting hours by a third which should pave the way for future growth.”

The recent investments complement the company’s already comprehensive subcontract manufacturing line-up which includes, waterjet cutting of almost any material up to 200mm thick, AS9100 accredited CNC machining as well as extensive welding/fabrication, structural steelwork and metal finishing services such as powder coating, wet painting and shot blasting.

http://www.wec-group.com/

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ADVANCED MANUFACTURING SHOW PREVIEW

METREEL LIMITED ARE MANUFACTURERS OF THE MET-TRACK® WORKSTATION BRIDGE CRANE MET-TRACK® - an enclosed track profile system enabling you to achieve effortless and reliable area-serving overhead handling.

Each system is configured with the operator in mind and includes the principle feature of ease of movement, designed to reduce fatigue and ensure accurate load positioning.

The range includes both ceiling and free standing workstation bridge cranes, jib cranes and monorails with load capacities up to 2000KG. Quality materials and construction ensure operational reliability, safety and facilitate long life combined with minimum maintenance.

The MET-TRACK® steel track design is one of high strength and low weight by combining the running track profile with standoff reinforcement to considerably increase span distances. The ‘V’ shaped profile of the running track ensure alignment of the trolleys and end trucks and also prevent dirt accumulation inside the tracks.

A fully functional MET-TRACK® Workstation Bridge Crane will be showcased at the Advanced Manufacturing Exhibition, colocated with SUBCON and The Engineer Expo – visit us on Stand No. B78 and discuss handling requirements with us.

The MET-TRACK® pre-engineered modular design allows for easy installation, relocation and/or expansion by simply adding runway sections and/or additional bridges.

Using the CraneBUILDER® Online Quotation Portal we can provide you with an instant quotation and 3D Engineered drawing within minutes!

www.metreel.co.uk

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SUBCON SHOW PREVIEW

Exhibiting on Stand D69

Electrical Control Panel Design and Manufacture

o Do your assemblies come under the remit of BS EN 61439? o Is your panel builder BS EN 61439 accredited?

‌No? - Are you prepared to take the risk?

We are BS EN 61439 compliant, highly qualified and broadly experienced meaning

You are ALWAYS safe in our hands.

Talk to us about your most complex requirements and we will be happy to help! www.sandfordelectrical.co.uk | 01628 668808 | sales@sandfordelectrical.co.uk

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SAFETY & HEALTH EXPO 2019 SHOW PREVIEW

SAFETY & HEALTH EXPO SAFETY & HEALTH EXPO 2019

THE MAIN EVENT FOR 2019: 18-20 JUNE 2019, EXCEL LONDON Safety & Health Expo 2018, the UK’s biggest event for health and safety professionals, will take place this year at ExCeL London on 18- 20 June.

The exhibition, together with its free-toattend CPD-accredited seminar programme, is a global hub for the profession, with products and solutions stretching across PPE, site safety, hazardous materials, hygiene, lone worker safety and more.

In proud partnership with NEBOSH, HSE, IOSH and RoSPA, Safety & Health Expo is once more driving change in the sector, bringing new products, new thinking, and new ways of working to an audience of over 13,000 H&S professionals.

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WHAT’S ON?

Showcasing top health and safety solutions from 300+ UK and international suppliers, visitors can source from a range of behavioural safety, risk management, training and occupational health products and services from trusted names including Safety Media, SoloProtect, MSA Britain, Boplan, Evac + Chair International and Birkenstock.

ACCESS WORLD-CLASS EDUCATIONAL SEMINARS

With 75+ hours of CPD-accredited seminars across five different theatres, keep up to date on critical legislation, technologies, trends and developments.

Sessions include: • Resourcing humans: What does an emotionally healthy workplace look like?

Why does it matter?, 11:30-12:30, 18 June, Workplace Wellbeing Theatre.

• An Inspector’s Review of Recent Investigations: Falls from Height and Machinery Safety, 14:15-15:00, 18 June, Keynote Theatre.

• Lone Working Case Study, 10:45-11:15, 19 June, Safety Technology Zone • Drugs and Alcohol in the Workplace: Identifying and Deterring Inappropriate Use, 15:45-16:15, 19 June, Workplace Wellbeing Theatre.

• Effective Investigation Implementation – Case Study: Lessons Shared, 10:45-11:15, 20 June, Operational Excellence Theatre.

With an incredible line-up of inspirational speakers, rugby legend Jonny Wilkinson, financial journalist and broadcaster Steph McGovern and Olympic ski jumper Eddie the Eagle will take to the stage with talks on risk, resilience and mental health. And don’t miss speakers with manufacturing case studies from Bosch, Siemens, Nestle and Avery Dennison Cramlington.

NEW FOR 2019 – WORKPLACE WELLBEING SHOW

Discover the latest developments in workplace wellbeing, with exhibitors, seminars in the Wellbeing Theatre and experts from IWFM sharing ideas on how to encourage workplace wellbeing at the Wellness Wall.

PPE ATTACK AND SAFETY TECHNOLOGY ZONES – NEW FOR 2019

The Safety Technology Zone is set to showcase the opportunities and risks of new technology and digital solutions, including robotics and AI; and the new PPE Attack Zone demonstrates the difference between passing-grade PPE, and equipment that far surpasses industry standards.

Safety & Health Expo is set to help the engineering industry with new, innovative products and thinking to boost safety on site and protect the physical and mental wellbeing of the workforce.

Visitors will also have free access to three

co-located shows, IFSEC International,

FIREX International and Facilities Show.

To find out more, visit safetyhealth-expo.co.uk and register for your free ticket today.

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SAFETY & HEALTH EXPO 2019 SHOW PREVIEW

LEGAL COMPLIANCE SAFETY & HEALTH EXPO 2019

NEW PALLET TRUCK TAG INCREASES EQUIPMENT SAFETY With the new Pallet Truck Tag and Powered Pallet Truck Tag from Brady Corporation, companies can increase legal compliance, support better pallet truck checks and share inspection results on the equipment itself to improve pallet truck safety.

INCREASED LEGAL COMPLIANCE

Article 5 from EU Directive 2009/104 / EC states that equipment, which includes pallet trucks, should be reviewed regularly by an authorised person and that these reviews should be recorded in writing and archived. Brady’s Pallet Truck Tag and Powered Pallet Truck Tag make compliance with the directive a lot easier because they can be attached to pallet trucks for easy inspection and because they can store respectively up to 21 or 31 inspection results and inspector signatures on a removable insert.

BEST PRACTICE EQUIPMENT CHECKS

On the reverse of each tag, an easy-to-follow operator checklist is included based on best practices to support quality equipment checks in order to achieve best-in-class equipment safety. Separate best practice checklists are available for pallet trucks and powered pallet trucks.

VISIBLE ON THE EQUIPMENT ITSELF

Both the Pallet Truck Tag and Powered Pallet Truck Tag holders can easily be fixed to pallet trucks with a cable tie or adhesive. This enables all relevant workers to see the latest equipment inspection status on the equipment itself. A signature from an authorised inspector will confirm the equipment was deemed safe to use after inspection. If the pallet truck did not pass inspection, authorised inspectors can remove the insert, leaving a clear ‘do not use’ message on the holder, informing coworkers they should use one of the other pallet trucks deemed safe to use. Both the Pallet Truck Tag and Powered Pallet Truck Tag can be supplied in a variety of languages.

Learn more about using tags to improve equipment safety in Brady’s free Visual Tagging guide available on the Brady website or via emea_ request@bradycorp.com.

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@SHEXPO #SHE19

Changing your perceptions of safety

Visit the UK’s biggest event for health and safety, and source the latest PPE, safety equipment, technology and training from over 300 global suppliers.

REGISTER FREE NOW AT WWW.SAFETY-HEALTH-EXPO.CO.UK/PECM

Presented by:

Show partners:

Running alongside:

Organised by:

Issue 38 PECM

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SAFETY & HEALTH EXPO 2019 SHOW PREVIEW

SUCCEEDING IN THE LONG RUN ROSPA

HIT THE GROUND RUNNING WITH IOSH At some point or other we’ve all heard the phrase ’hit the ground running’. For most of us however, the dream of being instantly successful at a new activity is just that: a dream. It’s hardly surprising. Imagine strapping on a set of skis before hurling yourself down the Alps. The results would not be pretty. That’s because the secret to success usually involves hours of hard work and dedication in order to make your exertions look effortless later on.

In many ways the same applies to a career in safety. Only by putting in the time and effort will you be able to arm yourself with the skills you need to succeed in the long run. That’s where IOSH comes in….

WHAT IS IOSH? The Institution of Occupational Safety and Health (IOSH) is a world-leading professional body for people responsible for safety and health in the workplace, providing training courses and practical tools so that individuals and organisations can create safer and healthier working environments. In particular, the IOSH Managing Safely training course is a practical solution to managing health and safety risks.

WHAT IS IOSH MANAGING SAFELY? IOSH Managing Safely is designed for managers and supervisors in any organisation or sector. It’s a pragmatic course with a sharp business focus, which is held in high esteem by delegates and delivered at locations throughout the UK as well as incompany, or online for those based overseas or who simply wish to learn at a time and place to suit their needs.

WHAT ARE THE BUSINESS BENEFITS? Above all else, businesses who employ holders of the qualification can expect to cut their costs without cutting corners or compromising on safety. But beyond that, there are a wealth of other key reasons why this occupational safety course is good for business: • Greater productivity from fewer hours lost to sickness and accidents • Improved organisation-wide safety awareness culture and appreciation of safety measures

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• Active staff involvement to improve the workplace • Internationally recognised certification for managers and supervisors • Enhanced reputation within the supply chain So, whether you’re a manager who needs to handle health and safety or simply looking to further your career in health and safety,

hitting the ground running with IOSH is a great place to start.

T: 0121 248 2233 E: enquiries@rospa.com W: www.rospa.com/iosh-managingsafely

The Royal Society for the Prevention of Accidents

IOSH Managing Safely

VISIT US

The practical solution to managing health and safety risks

STAND

SH3220

The IOSH Managing Safely course is a practical solution to managing health and safety risks in your workplace, giving your workforce the practical knowledge to increase productivity, improve safety measures and enhance your reputation. Delivered with a tailored approach at training centres throughout the UK, in-company and via e-learning.

www.rospa.com/iosh-managing-safely +44 (0)121 248 2233 | enquiries@rospa.com

UTILITY WEEK LIVE SHOW PREVIEW

UTILITY WEEK LIVE 2019 UTILITY WEEK LIVE

PREPARING UTILITIES FOR TRANSITION

What follows disruption? As the industry evolves, so must the businesses operating within it. But to what? And how?

Building on the success of 2018, UWL19 will explore transition in all its forms on the 21-22 May 2019 at Birmingham’s NEC. More than 5,000 industry professionals visited the 2018 event, and 2019 is set to be even bigger with an improved floorplan, inspiring show features, a brandnew location in Hall 3 and Platinum Show Sponsor O2.

UWL19 will be dedicated to the solutions turning disruption and turbulence into business as usual - the products and services utilities require to function and thrive in a brave new digital world.

Discover the latest utilities tech and hear about challenges and innovations from sector leaders and transformational companies. With

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6 content theatres, 200+ speakers and celebrity additions to the free-toall Keynote line up, UWL19 provides unrivalled opportunity to explore new innovations.

2019 SHOW FEATURES

Keynote Open to all for 2019 We’re opening up the UWL Keynote experience to all this year! Gone is the 2018 model of paying to attend the most high-profile speaker slots.

For 2019 all zones and areas, including the amazing Keynote Stage will be free-to-attend and accessible with the standard visitor pass. The Keynote stage will feature an eye-catching design and build, plus highlevel presentations from the mavericks and game-changers; the people leading the transition and transformation agenda.

GAS PRESSURE REDUCTION SYSTEM ALONG WITH A SELECTION OF REGULATORS AVAILABLE TO VIEW AT UWL – STAND G36

Gas Innovation Showcase The UK’s gas networks all in one place.

The depth and breadth of content on the energy industry has been expanded for 2019 with a new area dedicated to gas innovation.

Located within our hugely popular Network zone at Stand F2, the showcase will demonstrate the challenges faced by the gas distribution networks, how innovation is driving change and to seek new opportunities to deliver innovative approaches that deliver value to the UK gas consumer.

2019 Hackathon The award-winning hack is back.

The live 24-hour Future Systems Hackathon is all about transition making way for more dynamic interactions between utilities, service providers and consumers. We’re moving from ambition into action when it comes to delivering more environmentally, economically and socially sustainable ways of doing business.

If you haven’t already, make sure you register free for Utility Week Live – the UK’s leading utilities exhibition.

Book your tickets today at utilityweek.live/UWL19

FT Pipeline Systems supplies pressure reducing stations, heat packs, water baths and CNGs, able to deliver high quality products, often on a tight turnaround when a permanent or temporary measure is urgently required to ensure an unbroken energy supply.

As the exclusive UK agent of the highly regarded Gascat Ltd. range of pressure regulators, FT Pipeline Systems offers a choice of pressure regulators for small industrial lowpressure systems through to high flow, high volume distribution, biogas or CNG / LNG systems.

At Utility Week Live 2019 our team

will be on hand to demonstrate items from our extensive range of gas pressure control equipment including the innovative underground pressure reducing station, our large volume governor regulation system (Brise / Brise Plus) and our low pressure, high volume regulators which are also low noise. Visitors will be able to see firsthand the quality of gas products and discuss their product requirements. We look forward to welcoming you to Stand G36.

FT Pipeline Systems Ltd www.ftpipelinesystems.co.uk Tel: +44 (0)1543 416024 enquiries@ftpipelinesystems.co.uk

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Platinum sponsor

DISCOVER HOW TO NOT JUST SURVIVE, BUT THRIVE • Discover the use and application of the latest utilities tech • Gain fresh ideas and inspiration to keep your utility ahead of the curve • Explore the opportunities that come with transition • Network with 5,000+ industry colleagues and contacts

Book your free tickets today at utilityweek.live/UWL19

PREPARING UTILITIES FOR

AIR, GAS & ODOUR CONTROL

RENOWNED EXPERTISE AIR LIQUIDE ENGINEERING

AIR LIQUIDE ENGINEERING & CONSTRUCTION PARTNERS WITH SAMSUNG ENGINEERING FOR FEED CONTRACT FOR A METHANOL PLANT

Air Liquide Engineering & Construction entered into a partnership with Samsung Engineering, for the Front-End Engineering and Design (FEED) study of a methanol production plant for Sarawak Petchem, a state-owned oil and gas firm established and owned by the State Government of Sarawak, Malaysia. This FEED is a key step that will help decision makers get the necessary information to convert the contract into an Engineering, Procurement and Construction contract in the near future.

Leveraging their complementary strengths and know-how, Air Liquide Engineering & Construction and Samsung will carry out Front-End Engineering and Design (FEED) study. Air Liquide Engineering & Construction will be the technology licensor while Samsung Engineering will design the project’s utility systems and balance of plant.

FEED is a key step that will help decision makers get the necessary information. The FEED will be exclusively converted to Licensor, Engineering, Procurement, Construction and Commissioning (LEPCC) contract at the end of the year subject to final decision.

The methanol plant, which will be located in Bintulu, Sarawak State, Eastern Malaysia, will come into operation in 2023. This new facility will produce 5,000 tons of methanol per day based on Air Liquide Engineering & Construction proprietary process technology, Lurgi MegaMethanol™ , which converts natural gas into methanol.

Air Liquide Engineering & Construction is a world leading methanol licensor, with over 50 years experience in plant design, engineering, procurement and construction offering customers safe, reliable and energy efficient technology solutions.

David Maloney, E&C Chairman & CEO, said : awe are proud to have established this partnership which further enhances our position as the leading technology provider for Methanol plants. Our Lurgi MegaMethanol,,. technology for worldscale methanol plants with a production capacity of up to two million metric tons of methanol a year, enables reliable production with cost-optimized energy efficiency and lower environmental impact. This renowned expertise and strong presence in Malaysia combined with Samsung Engineering strong track-record in South-East Asia as Engineering Procurement Construction (EPC) and Project Management (PM) Company, have been key to gain the trust of Sarawak Petchem. “

www.engineering-airliquide.com

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AIR, GAS & ODOUR CONTROL

COMBATING DUST & FUMES VODEX

WHY RESPIRATORY PROTECTION IS SO IMPORTANT Dust and fumes are a problem with which we are all familiar in our homes, but it can be a much more serious problem in the workplace. The UK Health and Safety Executive (HSE) has already estimated that there are still 1500 new cases of work-related asthma per year.

Paul Riddick, Co-Founder and Technical Director at fume and dust extraction specialists Vodex explores how contaminates being produced on a daily basis in the workplace can damage your health and could even prove fatal.

Employers have a legal responsibility to protect their employees and the surrounding environment from airborne contaminants, but they also have a social responsibility to look after the health and wellbeing of their employees.

Repeated exposure to vapours, fumes and dust is a health hazard. Although vapours are invisible, and many dust particles can

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be very small (Less than 5 microns) and also invisible to the naked eye, this doesn’t mean the dangers for operators don’t exist.

Broadly speaking, dust can be classified into two types: inhalable and respirable dust.

Inhalable dust is generally visible to the naked eye under normal light conditions, but it is small enough to get into a person’s nose, throat, and mouth.

Respirable dust particles are generally more hazardous, as they are too small for most people to be able to see with the naked eye, so they may be unaware that there is any dust in the environment. These particles are small enough to get right into the smaller tubules of the lungs, and can cause physical blockage or irritation. It can extremely dangerous if the material is toxic or even carcinogenic, as the lungs may be able to absorb it quickly into the bloodstream.

Some exposure symptoms can be immediate, such as runny eyes and nose,

sore throat and chest pains. Left unchecked, they could lead to Occupational Asthma.

This can be a serious condition leading to severe chronic asthma if exposure to a respiratory sensitiser continues. It can take weeks, months or even years to develop, depending on the person and the substance.

HOW CAN YOU PROTECT YOURSELF FROM HAZARDOUS FUMES AND DUST AT WORK? Under COSHH Regulations, an employer has a legal responsibility in the UK to carrying out a risk assessment that will highlight any problem areas.

The first step to controlling exposure to fumes and dust is to normally examine how they are created in the first place. There may be ways to reduce the volume of fumes or dust that is made or to ensure that less of it becomes airborne.

In addition, you can reduce the hazard level if you are able to switch materials to an alternative that is less toxic, or to one that does not create as much vapour or dust.

One of the most common ways in which you can control fumes and dust is to extract it from the environment using a Local Exhaust Ventilation system (LEV) which uses filters or a duct to atmosphere system - depending upon the type and level of fume problem.

REMOVING FUMES AND DUSTS FROM THE ENVIRONMENT The vast majority of LEV systems are ‘recirc’ or recirculation extractors. Recirculation extractors are devices that pass air through a filter to trap the fumes and dust and pass the clean air back into the local environment near the source. These extractors can be portable, with the advantage that they can be moved to the area where there is the greatest need for fume and dust removal.

The other main type of extraction system is known as a ‘vented to atmosphere’

system, but these are mainly targeted at fume extraction rather than dusts, unless a degree of filtration is present first. These are more traditional and involve a combination of ductwork, extraction hoods, and filters connected to a fan in the wall or roof and an exhaust that releases air outside the building or to an area away from the initial source.

These systems are predominantly utilized for hazardous fumes but can also extract small volumes of fine dusts when necessary.

Particulates (Dusts and Smoke) can be filtered in a variety of ways and there are many grades of particulate filter. The most effective type and probably the most widely known is a High Efficiency Particulate Arrestor (HEPA). These filters are very fine and often remove higher than 99.99% of particles down to 0.3 microns. Other types of particle filters include F grade or EU (Eurovent) grade filters, dust bag filters, course dust filters, M Class filters, and inline dust filters.

Vapours or odours will pass right through a particle filter (even HEPA filters), so carbon filters are often used to adsorb these

vapours. Not all carbons are suitable for every type of vapour however so the type of fume has to be matched to the right type of carbon.

Activated carbon is the universal adsorbent and will filter “some of almost any vapour”.

Gases that are removed by activated carbon filter systems include: • Organic Compounds: Acids, Alcohols, Aldehydes • Chlorinated Hydrocarbons: Esters, Ethers, Ketones, Mercaptans, Amines • Inorganic Compounds: Halogen Acids, Halogens, Sulphuric Acid, Sulphur Dioxide, Phosgene • Odours: Human, Animals, Food, Waste Processes, Cooking Special carbon additives can be mixed with activated carbon to make it more effective at removing certain types of chemicals.

For more information, visit www.vodex.co.uk.

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BOILERS & MAINTENANCE

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

In turn, this is dependent upon processing operations that are efficient and economical – key objectives that are now being fulfilled by the Lanemark Combustion Engineering process gas installation.

Riello’s premix burners now up to 3MW

Fulton’s VSRT now comes with a 10-year warranty!

Riello RX premix packaged burners are now available in outputs up to 3MW, offering NOx levels of less than 40mg/kWh, with high turndown ratios of up to 8:1, across a wide range of models.

Fulton’s VSRT steam boiler, which already boasts ultra-low NOx emissions and high efficiencies, now comes with a 10-year “unparalleled” warranty on the pressure vessel, double that of the industry standard.

Riello RX burners feature an exclusive design that includes a patented woven wire gauze ‘sock’ covering the combustion head cylinder.

Gas and combustion air are mixed upstream of the combustion head and then pass through precision-located ports and the gauze ‘sock’ to ignite on the external surface of the combustion head. This arrangement enables a very compact flame with a diameter directly related to the burner firing rate, ensuring precise heat control and optimum efficiency at all loads.

Commenting, Fulton’s Leigh Bryan says: “The VSRT’s unique spiral-rib design creates a longer-lasting boiler that we believe will beat the competition in every category of durability so we have decided to include a 10-year warranty on the pressure vessel as standard!”

For further information visit www.rielloburners.co.uk

The patented spiral-rib heat exchanger design not only allows Fulton to improve boiler efficiency but, with virtually zero thermal stress and a thick-walled construction featuring vertical tubeless design architecture, the VSRT is one of the most durable steam boilers available.

For further information on the VSRT Series, call Fulton on +44 (0)117 972 3322, email sales@fulton.co.uk or visit www.fulton.co.uk.

www.lanemark.com

Gas Process Burners Lanemark gas burner systems offer users reliable, high efficiency, process heating solutions.

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

• • • • FD-C high turndown oven/

FD-E low cost high turndown

dryer air heating burners.

oven/dryer air heating burners.

FD-GA modulating gas + air process air heating burners.

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

• • • •

Midco HMA Series Air Replacement or “Make-Up” Air Heating Burners Direct fired, high efficiency burner systems, for high volume air heating applications such as paint spray booths, ovens and dryers.

Supplied either as Midco burner heads for OEM system integration or as Lanemark DB or FDB complete packaged systems including modulating gas valve trains and controls Wide range of firing rates to suit alternative temperature rise and air velocity system requirements DbCalc system design software

• • •

Midco HMA high efficiency,

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

TX high efficiency small diameter immersion tube tank heating systems.

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

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COMBUSTION ENGINEERING

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CABLES

KEY CONNECTORS ELAND CABLES

WHY QUALITY, COMPLIANT CABLES ARE AT THE HEART OF YOUR WHOLE OPERATION When was the last time you thought about cables? They underpin so many applications and processes yet are often overlooked in terms of importance. They power equipment, transmit data and signals for control and monitoring, and are embedded in the infrastructure of your buildings – they may even be integral to the product you’re producing. Surely it’s time to pay these key connectors some more attention?

Cables, like most other products, are manufactured against precise specifications and in line with relevant standards and legislative requirements. Compliance is, of course, mandatory however it’s not something that can be taken for granted and there remains reported incidents of sub-standard cables finding their way into the marketplace. When they’re so fundamental to everyday operations – and when any unplanned downtime caused by cable failure can be so costly – are you confident that your chosen supplier is doing everything it can to ensure it meets these quality and safety standards?

Importantly, can they demonstrate this if asked?

In-house quality assurance testing can be a light touch or a deep dive into the product, and it will differ from supplier to supplier.

From a cable buyer’s point of view, the more rigorous the better as it leaves less to chance – a lot can happen between the point of manufacture and delivery to you.

The most stringent QA testing will involve laboratory testing under independently monitored conditions, recording accurately and impartially the results and quarantining any cable that fails to meet those requirements.

UKAS – the United Kingdom Accreditation Service – is the pinnacle of UK laboratory testing credentials. ISO17025 declares that the testing results and reporting are accurate and without bias, bound by strict parameters and conducted on state-of-theart calibrated equipment. There are few suppliers that can claim to offer such a high level of due diligence on their cable.

QA testing establishes a solid baseline for quality and compliance but you can go a step further. The BSI Cable Testing

Verification Kitemark™ certifies cables from specific batch manufacturing runs, testing the component layers of the core and size configurations against relevant British and International standards to determine the overall compliance. This is particularly important when specifying cables that are made ‘generally’ to a standard such as the SY, CY and YY cables which is used extensively through automation. It’s a prestigious mark of quality recognised the world over and gives you peace of mind that your cables are consistent across your installation.

At Eland Cables, we believe it is our responsibility as cable experts to take a lead in offering this extra level of due diligence; being able to confirm to customers that the products supplied by us are compliant with standards and legislation, and provide the technical support and guidance that will help you achieve the optimum result.

The Cable Lab®, our in-house cable testing facility, holds both the coveted ISO 17025 accreditation and the BSI Kitemark. It’s a unique achievement for a UK cable supplier.

Whilst the investment in such an advanced laboratory has been substantial, the result is both a facility and a team of technical experts who can categorically demonstrate cable compliance.

Ivan Cleere, Head of QA & Technical for Eland Cables’ The Cable Lab says; “With strict quality controls and product testing there’s no reason for non-compliant cables to reach the marketplace, yet too many times there’s news of this happening within the industry. Having achieved the ISO 17025 UKAS accreditation for our cable testing facility it sets us apart in the eyes of quality-conscious organisations both in the UK and worldwide, but it also helps raise the standard across the board.”

As we continue to automate more processes and push the boundaries technologically, we can’t afford to lose sight of the importance of these connections. A cable might not be the largest component part in any installation, but you’ll certainly notice its absence. It all underlines our stance that compliance is non-negotiable.

It’s time to demand the same high level of quality from end to end.

For more information on Eland Cables including The Cable Lab® and its testing capabilities: 020 7241 8787 Sales@elandcables.com www.elandcables.com Issue 38 PECM

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CONNECTORS & FITTINGS

NERO BOOSTS PRODUCT RANGE WITH STAINLESS STEEL PRESS FITTINGS Nero, the market-leading distributor of stainless pipeline products, has invested in a new range of press fittings, which can be used by installers for both domestic and commercial applications.

The stainless steel Press Fittings range includes elbows, couplings, bridges, adaptors, tees, valves and reducers, from 15mm up to 108mm. With no need for welding or soldering, the fittings can be assembled in situ, offering a safe, fast and cost-effective solution.

The products have a maximum operating pressure of 16bar and a temperature range of -35°c to +135°c, although higher temperatures can be achieved using optional FPM seals. All the fittings come with a blue press indicator which will break off once a full seal has been achieved.

Darryl Spencer-Hicks, Operations Director at Nero said: “This significant investment in our range adds to the 15 product groups we already offer, providing customers with enhanced choice across a broad range of applications.

“The Press Fitting products can be used for installing building services in all types

of properties, so are ideal for construction projects across sectors.

be delivered next day if stocked items are ordered before 4:30pm.

“We pride ourselves on our high levels of customer service, so have also invested in new storage to accommodate the range ensuring the highest levels of stock.”

The Press Fittings range is 316L / 1.4404, WRAS / DVGW approved and complemented by tubes in all sizes to fit.

The new products are available from Nero’s central warehouse in the Midlands and can

ENGINEERING CONNECTIONS

5 STAR CUSTOMER SERVICE

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For further information or to place an order, visit www.nero.co.uk or call 0121 665 3900.

CONTROL & AUTOMATION

SMART AUTOMATION DOESN’T ALWAYS MEAN AI! Universal Robots outlines why collaborative automation and implementing robots simply as a tool, is the answer to many UK manufacturers’ current concerns.

In most cases the automation needs of UK manufacturers are relatively simple.

They must increase levels of output per worker to address labour shortages and a competitive marketplace. Plus, they must enable greater levels of product customisation to meet customer demand.

Some will argue the factory of the future requires a wholesale (and expensive!) digital transformation, with buzzwords like artificial intelligence freely bandied about. However, for those that find this overwhelming, we have a simple message.

Robotics is nothing to be frightened of. In fact, you can bring automation into your business simply by viewing robots as a tool!

Our cobots are already delivering real value for manufacturers of all sizes by carrying out straightforward tasks that were previously done by hand. They don’t need to “think” for themselves. Instead they take on the dull, dirty or, dangerous jobs, leaving human co-workers to make more rewarding contributions.

For example, the staff at Singapore-based, Clearpack has discovered first-hand the benefits of introducing cobots into its production line. Clearpack was quickly able to design a safe, compact and easyto-use palletising solution comprising a UR10 cobot and the LIFTKIT by SKF Motion Technologies. The right application and a proper design of accessories allowed the team put together a system without a safety guard, negating the need for additional costs for the installation and

factory floor re-design. The only job of the cobots is to take on the heavily lifting. Yet this simple change has helped numerous Clearpack customers in the FMCG sector to optimise their warehouse space and enjoy a fast return on investment (ROI).

To find out more, read the full case study here: www.universal-robots.com/casestories/clearpack/

COBOT AUTOMATION TOUR 2019

Save the date

Practical Training in

Collaborative Automation MAY 14TH BIRMINGHAM JUNE 18TH EDINBURGH JULY 16TH SOUTHAMPTON

Sign up for an event near you: urrobots.com/eventsUK19

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INDUSTRIAL ROBOTICS FANUC

MOULDING SUCCESS INTO UK MANUFACTURING The adoption of industrial robotics in UK manufacturing is still seen as divisive among industry. While it is widely accepted that technology has an important role to play, there are still a number of UK manufacturers yet to fully take advantage of the latest innovations.

Some argue that adoption of industrial robots can lead to people being replaced, but one UK manufacturer, Advanced Plastics, is proving that this is not the case.

With staff growth reaching an impressive 83% in five years, Advanced Plastics continues to develop thanks to continued investment in both technology and skills in recent years. This use of technology has now seen the award-winning injection moulding manufacturer become a success story for UK manufacturing, and establish itself as a supplier to a number of OEM and tier one companies across the HVAC and automotive sectors.

NEW TECHNOLOGY With more than 200 people now working at Advanced Plastics, the technical injection moulding manufacturer utilises a combination of the latest technology and extensive experience of its engineers to provide robust solutions for client requirements. Moulding a diverse range of products, from gas boiler front panels, to automotive interior, exterior and air filtration components, Advanced Plastics has built up a healthy list of blue-chip clients over the years as it looks to continue its impressive growth.

One of the reasons for this success is the company’s adoption of the latest industrial technology, including automated systems and industrial robots. The investment has allowed them to grow at a pace that may surprise many onlookers, as the automated processes in place ensure a high demand of technically-challenging orders are delivered on time.

Edwin Darling, Process Manager at Advanced Plastics, explains: “Our moulding machines produce the parts, but we now use robots to tend the machines on a constant basis, with consistent cycle times and dependable overall equipment effectiveness (OEE). All of our injection

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moulding machines have a robot, which is situated inside a cell and performs various applications, many with vision systems to provide 100% automated verification.”

82% of the robots used by Advanced Plastics are produced by FANUC. Due to the variety of orders that the company receives, it requires a multitude of different robotic technologies to be able to commit and complete the desired components on time.

As a result, Advanced Plastics has purchased and utilised a number of different systems from FANUC, including the M-10iA, M-20iC, M-6iB and R-2000 series, as well as ROBOSHOT injection moulding machines.

One of the benefits of FANUC’s R-2000 robots is their ability to work with preexisting automation equipment. At Advanced Plastics, two R-2000 robots work with a moulding machine and deliver the parts to another piece of equipment that help place foam gaskets around plastic components, such as boiler covers. The R-2000 series features high performance capabilities and is perfect for applications involving high payloads. Its compact design makes it an ideal solution for Advanced Plastics, to ensure compact and efficient cell designs.

TRAINING AND UPSKILLING One of the benefits of utilising FANUC technology is the training service the company provides both at its UK headquarters in Coventry and on-site.

Four of the Advanced Plastics team learnt how to service the robots and provide the maintenance themselves, allowing the engineers the opportunity to enhance their skillset and ensuring Advanced Plastics has the tools to become even more selfsufficient as a business.

As a result, Advanced Plastics now mould more than 1,000 products on-site. Each product has its own robot programme, which are all easy to understand and maintain, with one employee operating up to six moulding machines at a time.

mould a vast range of different products of varying technical difficulty. Currently using FANUC robots that range from 6kg to 165kg all of which are IFT approved, Advanced Plastics are able to fulfil orders for many different components at the same time.

Edwin continues: “We have found that FANUC has the most user-friendly robots we’ve ever used and having the opportunity to go down to its headquarters for comprehensive training ensures we are well-placed to manage our operations. The speed in which we are able to complete orders means we can continue to grow and invest in further technology.”

When it moved into its current home in 2012, Advanced Plastics had 16 injection moulding machines. Today, this number has increased to 37, effectively more than doubling its capacity in the last seven years.

As it continues to grow, the company is now looking to expand its capabilities with a new car park and warehouse facility, freeing up an additional 40% of manufacturing space.

Time savings and future growth plans One of the robots that has proven to increase the capacity the manufacturing site is able to produce is the M-10iA. Through working with FANUC, Advanced Plastics has moved from a 3-axis robot to FANUC’s 6-axis M-10iA robot. Processes which were complicated and difficult to handle are now automated, including picking up inserts and putting them into the moulds, some of which can reach between 80-90°C making them unsafe to handle, as well as trimming tab gates from cavities once the plastic has been injected. Additionally, the adoption of the M-10iA robots has seen Advanced Plastics’ effectively double its payload, compared to its previous system, from 6kg to 12kg.

The compact system has also helped the manufacturer improve its cycle time, providing significant time savings over a year, as Edwin explains: “The machines are fast and because they have a constant cycle time, they can provide time savings of two seconds or more each time. While this doesn’t sound like a lot, by reducing the time by one to seconds each cycle, we can save around four to five weeks of time per year. Given the increase in orders that we have received, this time helps us to keep growing as a business.”

As FANUC’s robots come in a variety of different sizes, Advanced Plastics is able to

It is clear that the future is bright for Advanced Plastics. Producing a high volume of components for a growing client roster has shown the benefits of introducing technology and industrial robots over a steady time period. Combining technical expertise with advanced technology has allowed the company to continue its impressive growth in East Yorkshire.

FANUC UK At its state-of-the-art headquarters in Ansty Park, Coventry, FANUC UK brings together world-leading capabilities in industrial robots, machine tools and plastic injection moulding machines to facilitate the complete integration of factory automation systems for UK manufacturers.

FANUC UK works in partnership with FANUC Europe Corporation to provide a range of customer support services, including sales, product support, parts, repairs, and training, as well as development of bespoke engineering systems. FANUC UK is a subsidiary of FANUC Europe Corporation and employs approximately 107 staff.

For more information, please visit www.fanuc.eu/uk and www.advanced-plastics.co.uk.

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CONTINUOUS TRANSPORT MK PROFILES

INTERLINKING FOR CANISTER TRANSPORT WITH A BRIDGE When a customer came to mk saying that they needed to achieve continuous transport without complicated stopping and turning for their production line, mk said no problem!

Two machining stations in a plastic canister production process needed to be interlinked and the solution had to cope with inconvenient spatial constraints: Empty canisters needed to be conveyed along a curve and past another machine so that they could be brought back to the original feed height at the discharge point, where they were allowed to accumulate.

The canisters were transported standing and transverse to the conveying direction, and they needed to have the same alignment at the end of the interlink that they had when they entered. Each canister weighs about two kilogrammes.

The interlink needed to run reliably in a two-shift operation. Additional spatial constraints regarding the length and height of the interlink had to also be observed. mk devised a transport system built from the mk modular construction kit. A KMF-P 2040 curved modular belt conveyor was used to feed the products in. This allowed the canisters to be transported in the correct position without complicated stopping and turning. Two ZRF-P 2040 timing belt conveyors with a timing belt equipped with longitudinal grooves serve as the incline. They were positioned at an upward incline of about 30°.

The canisters travel between the two lines.

The high friction of the timing belt and gentle clamping between the lines ensure that the canisters are transported upwards.

A closed-loop controller is used to precisely synchronise the two timing belt conveyor lines so that there is no offset. A GUF-P 2000 belt conveyor serves as the bridge, while two additional timing belt conveyors transport the canisters downwards again.

An additional belt conveyor with an end stop is used as the discharge and removal station. The entire frame is built using the mk profile construction kit. www.mkprofiles.co.uk

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Curved modular belt conveyor Efficiently handle any route

Wide variety of layouts with a single drive Compact overall width and a maximum usable width Lateral movement of conveyed products are possible

www.mkprofiles.co.uk

mk Profile Systems Limited a company of the mk Technology Group

CONTROL & AUTOMATION

PRODUCTIVITY & EFFICIENCY ONROBOT

SMART MANUFACTURING IS BEING DRIVEN BY COLLABORATIVE ROBOTS

By Thomas Knudsen, General Manager Northern Europe, OnRobot

Engineers and manufacturers are always in need of smart solutions, which not only drive productivity but efficiency too.

Automation is increasingly being adopted to enable this, with robotics in particular developing extensively over the last few years.

End-of-arm tooling devices (or EOAT) have been at the forefront of this, and have driven some exciting trends in the market, making life easier for producers and encouraging smart manufacturing environments. New-age intelligent robot accessories offer the innovation, expertise and precision that smart manufacturing requires. These technologies, however, are also changing the economics of manufacturing, e-commerce and agriculture, and below are the areas that we’re seeing the biggest changes:

INDUSTRY 4.0 INTEGRATION EOAT have a significant influence on how successful a robot is in terms of performance and flexibility. In fact, automation process efficiency largely depends on the grippers and other intelligent tools that interface with the robot.

The potential of intelligent robot accessories is enormous as modern grippers and power sensors are becoming so sophisticated that they maximise efficiency, enabling manufacturers to programme complex sequences. However, with collaborative applications, manufacturers want more than just efficient automation from machines – they also want to access the robots remotely and diagnose problems online.

Intelligent EOAT with smart hardware and software helps collect and analyse data to deliver feedback and increase capabilities.

Considering the new emphasis on big

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data and the potential of IoT hardware, collaborative robots which feed into this is incredibly valuable for a manufacturer’s productivity analysis.

INCREASING SOPHISTICATION IS ADDING VALUE IN SURPRISING VERTICALS A robot’s efficacy relies on the tools and accessories it’s fitted with. EOATs have seen such demand because of the value of its two-way information sharing between the robot itself and the tools on the end of the arm. When we think of grippers, torque grippers often come to mind, to detect an object’s presence for greater accuracy.

However, we are seeing an increase in demand for grippers which mimic human fingertips. These grippers are used in agriculture to pick and place herbs and other delicate items without damage. With the current pressures on food production, we fully expect this trend to continue, as seasonal fluctuations mean that harvesting planning becomes increasingly difficult.

PICK AND PLACE IS UPPING ITS GAME Pick and place was a prime example of automation and has been present in manufacturing for years. However, with some items being picked and placed now more delicate than previously (think technology, tablets etc), the grippers themselves need to adapt. We are seeing a trend that these sorts of arms will learn to pick up items without compressed air or

external power, ensuring no marks on the item and a more efficient process.

Robotics accessories are becoming increasingly smart and will be crucial to the future of automation. As manufacturers come to rely increasingly on robotics to boost productivity and enable humans to add value elsewhere, we expect that EOAT will boom over the coming years, enabling a transformation in how factories operate.

About OnRobot Established in 2015, the company merged with Perception Robotics and OptoForce in 2018, followed by a recent acquisition of Purple Robotics. Now, the OnRobot product range features a wide assortment of robot equipment, including: electric grippers, force/torque sensors, gecko grippers, and tool changers. This new combination of offerings from OnRobot makes it quicker and simpler to automate tasks such as packaging, quality control, materials handling, machine operation, assembly, and welding. The headquarters is located in Odense, Denmark and OnRobot also has offices in Hungary, Germany, Poland, Spain, USA, China and Singapore. The company plans to expand further through acquisitions in the coming years.

For more information, visit www.onrobot.com.

CONTROL & AUTOMATION

PRYOR MARKING TECHNOLOGY UK designed and manufactured industrial marking machines: • Dot Peen • Scribe Marking • Laser Engraving Traceability software: • Avoid duplicate serial numbers • Touchscreen Controller embedded or PC installed • Windows based for easy integration • Database management access control

Mark a range of inscriptions directly onto a component or label: • Serial Numbers and Part Codes • Automotive VIN Marking • 2D Data Matrix Code • Company logos • CE Marking www.pryormarking.com info@pryormarking.com +44 114 2766044

SPIROFLOW LAUNCHES PIONEERING REMOTE MONITORING SYSTEM

A New Range of Industrial Panel PC Solutions to meet demanding environments 10.4” to 24” Baytrail, Apollo Ba & Skylake Platforms Customisable I/O PCAP 10pt Touch (standard) OEM/ODM Service Available

Bulk materials handling specialist, Spiroflow, has launched an innovative monitoring system that remotely provides real time information on the performance of their complete machinery range, from flexible screw conveyors to tubular drag and aeromechanical conveyors.

The system is known as SAM – Spiroflow Active Monitoring.

The aim of the initiative is to automatically monitor customers’ equipment through sensor-based technology, thereby providing key performance related, safety and operational benefits.

• Automaaon • Power Industry • Transportaaon • Manufacturing • Medical • In-Vehicle • Machinery

info@crystal-display.com +44(0)1634 327420

With IIoT (Industrial Internet of Things) becoming increasingly established, the use of sensors, data processing and wireless networks to collect and securely analyse digital inputs/data across entire facilities, is enabling connected businesses to improve their overall effectiveness, safety performance and reduce downtime. Relevant data could include the machine runtime hours, safety infractions, pinpointing production

bottlenecks, motors operating at higher amps, vibration, temperature, unusual spikes or issues on site that may cause failure.

As an ‘upgrade’, SAM is built into the standard electrical panel on Spiroflow’s machinery by an in-house team of skilled electrical engineers and connected remotely via 4G/5G or Wi-fi.

Spiroflow has been a Global leader in the field of powder handling and dry bulk solids processing for more than 45 years.

To learn more visit spiroflow. com/samsaves, email sales@ spiroflow.com or call +44 (0) 1200 422525 in the UK or (1) 704 246 0900 in the US.

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LOGISTICS SOLUTION AMH HANDLING

AMH MATERIAL HANDLING COMPLETES £3.2 MILLION AUTOMATION PROJECT FOR WILKO’S E-COMMERCE OPERATION AMH Material Handling has completed a £3.2 million project for Wilko at its 110,000 sq ft e-fulfilment facility managed by Clipper Logistics in Ollerton. The project has automated the packaging, labelling and destination sortation for 85 per cent of online orders for both home and store delivery. The logistics solution, which was implemented ahead of Black Friday, has already handled a quarter of a million items in the first month of its operation.

FINDING A COMPLETE SOLUTION Colin Holland, project manager, Clipper Logistics explains, “Wilko needed to facilitate growth and make room for extra product storage. In addition to this, they wanted to limit reliance on manual labour. This was especially important during peak order times when it was difficult to source additional colleagues at short notice. Furthermore, the system needed to increase throughput efficiencies and accuracy.

“We asked three different companies to tender for the project, however, the decision to select a supplier wasn’t solely based on cost. We also took into account the project timeline, their availability, the solution itself and how it would work for us. On this occasion, we decided AMH Material Handling met our criteria and presented us with the best option.

“AMH came onto site and they interrogated our processes. They got to the bottom of what our issues were and came up with an innovative solution. They analysed our packaging and reduced our seven carton sizes down to four to simplify the operation.”

NEW AUTOMATED PACKAGING AND DESPATCH SYSTEM The bespoke solution has seen AMH install the automated system over three floors at Ollerton. A carton erecting machine has been installed on each of the two mezzanine floors along with licence plate number (LPN) labelling machines. The first floor handles small and medium sized cartons and the second floor is for large and extra-large cartons. Once erected, the labelling machine

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applies a unique LPN to each carton so that it can be correctly tracked and routed throughout the system.

Completed orders on the mezzanine floors are placed onto a conveyor infeed which merges them onto a powered spiral conveyor.

The spiral conveyor transports cartons down to the ground floor where they join the main conveyor system. AMH also installed a multi-level goods lift so that trollies carrying orders requiring picks from more than one floor could be easily moved between the three levels.

Once on the main system, cartons travel down a decline conveyor where they merge with any cartons inducted from the ground floor infeed. Cartons continue to travel down the line and turn a 180 degree bend before being checked automatically for their expected weight. The warehouse control system (WCS) validates the actual completed order weight against the system’s expected weight and any cartons with weight issues are diverted to a reject spur for rectifying.

Further down the conveyor line, the warehouse management system (WMS) alerts the conveyor if a carton contains any fragile items. If so, the system diverts the carton to the fragile repack work benches.

Here, colleagues suitably repack any fragile items before placing the carton back onto the main conveyor system.

After items have passed both the weight and fragile repack stations, one of three document inserting machines place the customer’s shipping note into each carton.

When the shipping notes have been placed into the cartons, they are then sorted by size before they reach either of the two carton lidding machines. The machine measures the height of the products and reduces the carton to a suitable height. Folding the carton to remove empty space and sealing it with glue increases the strength of the packaging. A lid is then automatically placed and sealed on top of the carton.

Once lidded, the cartons run through two labelling systems. The first label machine applies the shipping labels, with the destination address, to the top of the cartons. The second label machine applies a label to the side of each carton with both the customer’s name and the carton weight.

This is important for store orders as it allows colleagues to easily identify customers’ parcels when they are stacked in store. As the labelled cartons continue to travel to the despatch area, they are scanned again to

ensure that both the LPN and the shipping label match up correctly.

In the despatch area, AMH has installed a total of eight despatch lanes. The first four lanes are used for the parcel carrier companies. Here, AMH has installed four telescopic loading booms to transfer the parcels directly into the back of the trailers for rapid loading. Three of the remaining despatch lanes transport parcels for in-store collect orders whilst the eighth lane is a reject lane for any incorrect or unreadable parcels.

AMH provided the controls and software to operate the automated system. A new WCS was designed and installed by AMH to integrate with the customer’s WMS. This allows orders to be processed automatically throughout the integrated solution. AMH also supplied a SCADA (supervisory control and data acquisition) software system. The SCADA displays a real time model of the system which can be accessed from any computer terminal on-site by both the operational team and AMH’s engineers.

OVERCOMING PROJECT CHALLENGES Colin Holland continues, “Initially, we asked AMH to come up with a solution for a facility at a different location, however, our plans changed and we decided to stay at Ollerton.

This was a challenge for AMH as the Ollerton site is spread over three floors which wasn’t part of the initial design. Additionally, the site was fully operational and AMH needed to come up with a time plan to install the system without disrupting the day to day operations.

“Despite the site change delaying the start date, our end deadline remained the same and we still needed to be running in time for Black Friday. Throughout the installation

process, AMH handled everything on-site in order to meet our deadline. They appointed a project manager to run the site, however, the directors were always available when we needed them.”

AN EXTREMELY SUCCESSFUL PROJECT AND PARTNERSHIP Colin Holland concludes, “The system that AMH has designed is capable of handling our forecasted peak throughput capacity up to 2020/21. In addition to this, the system is fully adaptable so if our volumes should change, we can add additional automation to accommodate an increase in order processing.

“Overall, AMH surpassed our expectations.

The quality they have delivered throughout the entire project has been second to none, they couldn’t have been more efficient. During the whole process they have been extremely open, honest and helpful. It truly felt more like a friendship than a partnership – it’s been very refreshing working with them.

“Through AMH, we have employed two full-time maintenance and service engineers who were involved with the commissioning and launch support to ensure site set up and familiarity. They now provide us with effective engineering site maintenance and support utilising the 24/7 telephone hotline and callout function.

With this high level of technical support always readily available it not only gives us total peace of mind that the automated system is always serviced and maintained, but also that it meets health and safety, and compliance requirements.”

Telephone: +44 121 550 4342 Web: www.amhlifeservices.com Issue 38 PECM

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SPECIAL PURPOSE MACHINERY TF AUTOMATION

TF AUTOMATION WORKING WITH MANUFACTURERS TO PROVIDE BESPOKE PROCESS AUTOMATION SOLUTIONS TF Automation design, engineer and manufacture process automation solutions as well as supplying pneumatic and industrial components. Supporting a wide range of manufacturing industries from automotive, aerospace and pharmaceutical, to food and beverage, printing and packaging, we provide special purpose machinery designed to clients’ bespoke requirements.

Our projects range from full manufacturing units to specialist components all engineered to integrate fully with existing production lines. Our engineering and design expertise is extensive and we offer the latest technology across a wide range of disciplines including pneumatics, robotics, automated assembly, in-mould labelling, pick and place and leak testing, with process automation as our core focus.

We deliver a wide range of automation solutions for clients, from bench-top checking/gauging fixtures to multiple 6 Axis robotic pick & place systems. We also have particular expertise working with plastic components including assembly, machining and finishing, and in-mould labelling.

again, offering accuracy and repeatability far superior to the same task carried out manually, thus ensuring increased output and efficiency.

Component assembly and testing is a crucial part of many of our clients’ manufacturing processes. Using the latest pneumatic and linear drive technology, we design systems to include multiple testing stations including vision, force and distance with checks in place to reject noncompliant components.

All projects are carried out in-house, including concept design created in Solidworks 3D CAD, CNC machining, manufacturing (mechanical and electrical), testing, commissioning and programming.

Where we do bring in expertise and components, we source only the most renowned and innovative brands, ensuring that all materials and components meet strict quality standards.

We work with some of the largest manufacturers in their respective fields, all requiring product handling and automation solutions to support some of the world’s leading brands particularly in the aerospace and automotive industries.

Consistency, improved production efficiency and precision are our clients’ key drivers, with the majority of our projects concentrating on improving product handling and automating manualhandling processes.

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With over 40 years’ experience, our strength is in our assessment and understanding of the requirements of each project, end user and operative. As a Tier 2 supplier, we take the time to consider all possible solutions for clients, ensuring that both their expectations and their clients’ are met and the optimum solution provided.

The need to improve process and productivity is a constant challenge for all manufacturer. Our focus is on providing solutions to reduce the risk of human error in tasks that are constant, predictable and repetitive. We engineer and program our machines to perform tasks over and over

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

CONTROL & AUTOMATION

NEW SINGLE STAGE NORDBLOC.1 HELICAL GEAR UNITS NORD DRIVESYSTEMS has extended its range of single stage NORDBLOC.1 helical gear units with three larger sizes. The new drive units provide high output torques as well as maximum radial and axial load capacity.

With its single stage NORDBLOC.1 helical gear units the NORD DRIVESYSTEMS range includes innovative drive units with high efficiency and long service life. The drive specialist has now extended its successful series with three larger sizes.

The three new products SK 871.1, SK 971.1 and SK 1071.1 have powers from 0.12 to 45 kW and cover the torque range up to 1,000 Nm. Thanks to optimised bearings, they can reliably handle large axial and radial forces. The robust, cast iron gear units are therefore optimally suitable for pumps and agitators.

The innovative NORDBLOC.1 helical gear units impress with their high efficiencies, compact design and ultimate reliability.

They do not have any separating joints or closing caps. This increases the stability of the product and at the same time provides a smoother surface on which neither liquids nor solid materials can accumulate. The FEM-optimised UNICASE housing ensures maximum strength and rigidity.

The modular design provides wide application flexibility due to numerous configuration and mounting options. All variants are available as flange mounted (B5 or B14), or foot/flange mounted versions. Options for IEC and NEMA motor mounting as well as a wide range of equipment variants for shafts, bearings and lubrication can be flexibly implemented. www.nord.com

Two way Wireless Safety the safe, reliable UH 6900 Customer benefits Long range ultra reliable radio transmission, (> 800 m) Maximum safety up to PL e, SIL 3 3 x Dual channel safety inputs 8 x Cross operated inputs & outputs Fast setup via free windows compatible USB software Extensive signal quality & operation diagnostics

FIRECHEK® HEAT ACTIVATED SHUT-OFF VALVES: TESTABLE, RESETTABLE, SELF-ACTIVATING, EASILY RETROFIT Any spring return pneumatically operated API 607 rated valve can be transformed into an emergency shutdown valve with the simple addition of a FireChek shutoff.

Adding the FireChek enables the valve to perform emergency shutdown while maintaining its original process functionality, whether on/off or modulating.

When the FireChek senses excessive heat from a nearby fire, the memory shape alloy undergoes a phase

induction change and produces the force and motion to immediately close the air supply line preventing the air from feeding the fire. It simultaneously vents the spring return actuator to allow the return to fail-safe position-no other power source is involved.

SIL 3 PL e

800 m

DOLD Industries Ltd Telephone 01245 324432 • Fax 01245 325570 admin@dold.co.uk • www.dold.co.uk

Assured Automationassuredautomation.com/ FireChek- https:// assuredautomation.com/firechek/

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EMBRACING TECHNOLOGY WOOD AUTOMATION & CONTROL’S U.K

MAKE AUTOMATION TALENT WORK FOR YOU The UK’s manufacturing base is operating within an unusually challenging environment at present, as a result of both potential political change and the fact that some export markets are less than buoyant.

Combine these issues with the fact that the UK still lags behind in the productivity stakes, when compared to other G7 nations, and it’s clear that we need to embrace the technologies that will enable UK manufacturing to be competitive on the world stage.

Here in lies the dilemma: outside of the automotive sector, the UK generally performs poorly in the uptake of automation and robotics with just an average of 74 robots per 10,000 employees.

This is much lower than many of our European cousins, and around a quarter of the total for Germany alone. There are undoubtedly many reasons why this is the case, however recurring themes include a lack of understanding of how automation could transform a manufacturing process, and also a fear of complexity and technical risk.

In this informative article, Tim Bednall, sales & marketing manager for Wood Automation & Control’s Systems Division, highlights the depth of expertise and talent that UK manufacturers can draw upon to ease the path to automation and, in turn, greater productivity.

Despite the overall statistics, there are great examples of UK manufacturers embracing high levels of automation and making it a key element of their manufacturing processes. There are other companies that have introduced a lower level of automation, often for relatively simple pick and place, handing or assembly tasks. However, there are still a majority missing out on the potential benefits that automation can deliver. This is especially true of those who may perceive their applications to be too difficult or overly complex, as there are several, often different technologies involved in the manufacturing process.

For those concerned about complexity or technical risk, the productivity and reliability of our automotive sector installations should be seen as a shining example of how large multi-technology

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projects can be successfully implemented.

It’s not uncommon for a car manufacturing line to have several hundred robots, all of which need to operate in a complex sequence using a wide range of different technologies, and perform these tasks with high overall efficiency levels on a 24/7 basis.

robots, special purpose automation and a diverse range of proprietary technologies, including machine vision and laser systems.

We alone have 400 technically focussed staff across our UK organisation, working with customers in a multitude of different industry sectors and applications, so the knowledge and resource is there.”

Outside of the automotive sector, there will be few applications that will require such high levels of mechanical automation combined with sophisticated control software and robot programming. The resources, skills and tools used to achieve these world-class manufacturing lines are all readily available to other UK companies considering robots and automation as part of their manufacturing process.

Clearly if technical risk is seen as the barrier to automation, then this needs to be highlighted at the earliest stage and there are several ways in which this can be addressed. One option is ATG’s “Virtual Commissioning” software, where the complete cell or production line is developed in a virtual environment, enabling the customer and their engineers to see exactly how the system will function.

This allows specific events, such as error messages and recovery procedures to be tested as it utilises the actual Robot, PLC and HMI codes and is integrated to the 3D CAD of the entire system.

Tim Bednall commented: “ It’s unfortunate that some manufacturers still shy away from automation and robotics through either a lack of understanding and / or a perception of unacceptable technical risk.

There is an immense pool of automation talent that prospective users can draw upon. For example, Wood Automation & Control’s Systems Division has been at the heart of many multi-robot installations within automotive facilities, and we are also regularly involved in delivering innovative manufacturing solutions that include

In addition to addressing technical risk, virtual commissioning can save significant time getting products to market, especially on larger scale projects, when compared to the traditional build, develop and commissioning route.

This “Digital Twin” approach, provides other benefits such as Operator and Maintenance training, without interfering with production, and the validation of the software and hardware design within regulated industries. The production of a “Proof of Principle” system is a more traditional “Hands-On” approach to evaluating automation concepts and provides the opportunity to trial grippers, parts feeders, fixture design and robot movements etc.

Tim Bednall explains: “A typical example of this approach, which ultimately provided the confidence for the customer to proceed with a fully automated system, was the request for the development of an automated process to tie a knot in a twisted-pair of wires. The justification criteria for this particular application were to improve both consistency and quality.

Whilst tying a knot is straightforward and intuitive for a human, it is not easy to automate, and especially at speed. The first step in determining the final solution was to run a Virtual Reality (VR) simulation.

Once the right solution had been designed virtually, a PoP rig was then assembled to

further develop the hardware and process, and to demonstrate what was later to become the final, delivered solution.”

to design, develop, install and maintain the automation systems which will provide the competitive advantage that the UK needs.

Tim Bednall continues: “Wood Automation & Control’s Systems Division specialises in the design and manufacture of special purpose machines, integrating them together with both new and existing equipment. Our mechanical and control system engineers have the machinery design experience to provide robotics and automated product handling solutions for a variety of industries. Once we have fully established the customer’s requirements, our holistic approach delivers design, interface with existing equipment, simulation, vision systems, manufacture, testing, installation, commissioning and comprehensive service availability.”

Recent initiatives that focus on science, technology, engineering and maths (STEM) will definitely help encourage more young people to embark on a career in engineering, but this needs to be bolstered by both manufacturers and robotics and automation specialists ensuring that they bring on their own home grown talent.

DEVELOPING TOMORROWS AUTOMATION TALENT POOL As for every sector, an aging workforce, and in certain areas a current skills shortage, means that apprenticeships and ongoing training are essential if, as a country, we are to retain the skills needed

The 30 apprentices currently training within Wood Automation & Control’s U.K Division’s own IET accredited academy, will acquire skills in a broad range of automation disciplines through a combination of hands-on and academic courses. This way, the company will ensure that the skills and innovation required to deliver tomorrows automated production systems will be readily available to assist UK manufacturers.

www.the-atg.com Issue 38 PECM

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ELECTRICAL & ELECTRONICS

NEW DIN RAIL AC INRUSH CURRENT LIMITER FOR CAPACITIVE & INDUCTIVE LOADS Powersolve’s new PSICL series is a low-cost peak inrush current limiter designed for capacitive and inductive loads in a variety of applications. These include installations across complex automation systems and machinery as well as isolation transformers or LED lighting applications where they are particularly useful because you can have a large number of LED driver power supplies operating in parallel and all taking high peak currents together on switch on.

The PSICL series is a true current limiter and cuts off all peak currents when starting loads under practically every AC condition.

Extreme conditions can occur on AC lines in the event of a break in the supply and when power returns, high current peaks can often cause havoc and will trip circuit breakers. In decentralised areas, this will often lead to increased maintenance costs as the breakers require re-setting. The PSICL current limiter prevents this happening and can result in reduced cable cross section used and smaller and faster circuit breakers.

The PSICL Series is available in three 230VAC single phase models with continuous operating current rating of 12A, 16A and 25A. Current limiting time is 100-

500mS with repeat intervals of 1000mS. They have an operating temperature range of --40ºC to +70ºC and conform to EN60950-1 and EN61000-6-2,3 standards and are CE and RoHS. MTBF figures are 300,000 hours.

The PSICL is a housed in a low profile V0 flammability rated plastic case measuring 91H x 71W x 57Dmm. The same design

designated PSESB Series is also available in a very slim width enclosure with measurements of 100H x 22.5W x 112Dmm. Both items are DIN Rail mounted and internal circuitry is identical for both versions. powersolve.co.uk/product-category/ inrush-current-limiters/

KRAUS & NAIMER Now available from Kraus & Naimer - an Industrial interlocked switch & socket, housed in a grade 304L brushed stainless steel sloping roof enclosure. Ideal for use in non-hazardous areas within the food and drinks industry.

The enclosures have a 15 degree sloping roof and integral canopy to assist with the prevention of liquid pooling. The isolators are IEC 60947 compliant with handles that can be padlocked in the OFF position.

They are also interlocked with the socket, preventing turning the isolator on when no plug is inserted and the removal of the plug

while the socket is energised, ensuring safe operation.

• High dust and water ingress protection (IP66) • With or without auxilliary contacts (2 n.o. or 1 n.o.+ 1 n.c.)

• Ample wiring space • Now available from stock.

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

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

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

TSP Series AC-DC Converters output power power 70 to 600 Watts output Universal (up (up to to 90W) 90W) or or auto auto select select AC AC input input Universal 12V, 12V, 24V 24V or or 48V 48V DC DC output output versions versions Optional Optional external external redundancy redundancy modules. modules.

Full Full safety safety approvals approvals and and ATEX ATEX certification certification for for hazardous hazardous locations. locations.

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

TSP TSP Series Series Function Function Modules Modules Redundancy Redundancy Module Module enables enables two two units units to to operate operate in in parallel parallel mode. mode.

Buffer Buffer Module Module allows allows hold hold up up time time up up to to 44 seconds seconds depending depending on on load. load.

Battery Battery Controller Controller Module Module enables enables as AC-DC UPS. AC-DC UPS. TSP TSP to to be be used used as

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

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

TIB EX EX Series Series AC-DC AC-DC Converters Converters TIB 80 to to 480 480 Watts Watts output output power power 80 Universal 85-264 85-264 VAC VAC input input with with Universal Power Factor Factor Correction.

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ELECTRICAL & ELECTRONICS

ULTRA LOW-PROFILE MINIATURE SURFACE MOUNT BALL TEST POINTS Responding to the increasing packaging density of today’s PCBs, E-Mark has introduced a low profile version of its popular ball test point, enabling simple attachment and removal of test probes without taking up unnecessary board real estate.

and evaluation purposes or on 2000 piece tape and reel for production applications using pick and place equipment; the 1 mm diameter spherical ball is fully compatible with high-speed placement machines.

The new 02-1180 measures only 1.4 mm in height and, with a base of 1.5mm in diameter, it requires the smallest space possible on the board. Contact resistance is < 2 mO and the current rating is 3A. The test points are supplied on cut tape for prototyping

To receive a fully dimensioned drawing and samples on cut tape, contact E-Mark either via its online enquiry form, by email or by calling toll free on (800) 831-5383.

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ELECTRICAL & ELECTRONICS

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Award winning brand, Goodlight, have announced that Middlesex Aerospace, a leader and strategic manufacturer of aerospace engineering components has made between 50-80% energy savings following the replacement of their old fluorescent lighting with energy efficient, low maintenance LED tube lighting from the Goodlight range. Payback on the installation is on target and expected to be achieved within 18 months. The company adopted Goodlight LED lighting to meet their commitment towards ISO14001.

Installation of the LED lights was carried out over the weekends to limit the impact on production times and reduce disruption for staff. Middlesex Aerospace specified Goodlight GX1 Plus (150W) LED

High Bays, G5 LED Battens, T8 LED Tubes and LED Ceiling Panels for their main production factory and inspection area at the 50,000 sq ft manufacturing site in Hampshire, replacing energy hungry fluorescent lighting.

Goodlight LED lighting technology offers more efficient light at lower cost and reaches full brightness instantly with no warm-up required. The lights are specifically designed for retrofit applications and can be quickly and easily installed into existing fixtures. They provide immediate energy savings and are virtually maintenance free. Goodlight LED products are guaranteed for five years and rated at 50,000 hours.

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Issue 38 PECM

103

ELECTRICAL & ELECTRONICS

AMBITIOUS GROWTH PLAN BRANDAUER

BRANDAUER MAKES ITS FIRST EVER ACQUISITION WITH PURCHASE OF CB CABLE CLIPS The company behind the self-adhesive cable clip has been acquired by one of Birmingham’s longest-established manufacturers.

Brandauer, which is a specialist in metal pressings and stampings, has purchased CB Cable Clips in an undisclosed deal that will safeguard three jobs, create two new positions and see all customers, intellectual property (IP), stock and assets transferred over.

Under new ownership, it is expected that the business has the potential to double its £110,000 annual sales over the first twelve months and will complement its own product range that currently includes turnkey precision tooling, motor laminations and Elopin ® press-fit connectors.

It is the first acquisition Brandauer has ever completed in its 157-year history and is part of an ambitious growth plan that will see it achieve £10m turnover by the end of 2020.

“We have been manufacturing the CB Cable Clip range under a sub-contract agreement for more than 40 years so are synonymous with the innovation and the production process,” commented Rowan Crozier, CEO of Brandauer.

“When the possibility of selling was sounded out, it seemed the logical decision to incorporate the business into Brandauer.

We knew the quality and customer service expected, we knew the delivery patterns and, most significantly, it was another product we could add to our growing range.”

He went on to add: “We are already looking to double the size of the team and believe there is an opportunity to access new markets and customers.”

Brandauer will manufacture and supply the CB Cable Clip range of versatile selfadhesive, aluminium cable clips that offer a quick, strong and economical method of fixing round, bunched or ribbon cables easily and without causing damage to clean, dry surfaces.

The adhesive is strong, durable and acts instantly for quick and easy installation for

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PECM Issue 38

customers spanning domestic building, construction and industrial.

In fact, since the invention came to market in 1972, over 566 million clips have been produced and used across the world.

Rowan continued: “There’s definitely some early growth opportunities for us to crosssell to existing Brandauer customers and, longer-term, we will be branching out from the B2B marketplace and actively growing Business 2 Consumer (B2C) platforms.

“This could be through identifying new channels and starting with growing the cable clips demand on eBay and Amazon.”

Brandauer produces millions of high tolerance metal pressings and stampings every week for customers in the plumbing, automotive, domestic products, electrical, medical and renewables sectors.

Most of the products it makes are invisible to the user, but fundamental in making many everyday items work effectively. A few examples are; electrical connectors that are fitted in 90% of the world’s kettles, edge connectors for the dimming of rear view mirrors in 50% of modern day cars and over 7 million nose bridge clips per month that are used in medical/ personal protection face masks in over four continents.

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

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ELECTRICAL & ELECTRONICS

DRALLIM WORKING WITH DV POWER Batteries are crucial components in the overall reliability of powerplants, substations, telecommunication systems, generator excitation systems and protection & control systems. The inability of a battery string to provide sufficient voltage/power to protection circuits may lead to catastrophic consequences that cause damage to site equipment, resulting in reduced safety and costly downtime.

Listening to the demands of test engineers from around the world, DV Power have developed state-of-the-art battery testing and monitoring solutions to meet IEEE and IEC standards alongside a wide range of customer specific test procedures.

The essential test for the condition assessment of a battery string is the capacity test which can be carried out using the BLU series of Battery Load Units.

In addition to this critical test the DV Power portfolio of battery test equipment is designed to measure and monitor intercell connection voltage, internal resistance, cell and ambient temperature and cell voltage.

On completion of testing the DV Power BAC25A Battery Charger can be used to rapidly recharge the tested lead-acid and Ni-Cd batteries.

RMO-H-Final.pdf 1 22/06/2018 15:34:58

DV Power are renowned for using cutting-edge-technology to produce light, powerful, and highly accurate battery, circuit breaker and transformer test equipment. Intuitive controls allow for manual and fully automated test procedures. Easy to use analytical software ensures that DV Power test instruments are efficient whilst remaining user friendly.

DV Power are represented in the UK and Ireland by Sussex based Drallim Industries

Ltd whose team of experienced engineers offer full product support. DV Power provides a 3-year warranty on all test instrumentation. This is a guarantee to our customers that they will receive the highest quality test equipment on the market.

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PECM Issue 38

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

CABINETS & ENCLOSURES UK Primary source and Channel partner for Nvent Schroff nVent Schroff electronic cabinets are designed to help you keep your systems running smoothly for the long term.

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CASE STUDY CASE STUDY

Johnston Logistics UK Johnston Logistics UK Environment: Logistics Environment: Logistics

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Jason Pullen Warehouse Manager Jason Pullen Manager “The lights that Warehouse have been installed are very good, they are instant, no delays and the energy savings of

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75% we will make on our electricity bill are very good. The visibility is 100 times better than it was”.

Johnston Logistics UK, a specialist provider of third-party logistics has just completed a new LED lighting installation Johnston Logistics UK, a specialist provider of third-party just completed a new LED lighting installation using GG Lighting’s BayLED Eco Philips component poweredlogistics high bayhas luminaires.

Johnston’s remit to GG Lighting was to using GGlight Lighting’s BayLED powered high bayreduce luminaires.

Johnston’s remit to GG Lighting was to improve levels for healthEco andPhilips safetycomponent reasons and to significantly energy and maintenance costs. improve light levels for health and safety reasons and to significantly reduce energy and maintenance costs.

The original installation consisted of 400W metal halide luminaires which were in use in excess of 7,500 hours per annum The months). original installation consisted 400W metal halide which were in use in excess of Eco 7,500 hours annum (8.5 The new GG Lightingof installation consists ofluminaires one-for-one replacement 200w BayLED high bayper luminaires (8.5 months).

The new GG Lighting installation consists of one-for-one replacement 200w BayLED Eco high luminaires fitted with passive infrared detection (PIR). On paper the energy saving is 50%; however in real terms duebay to the use of fitted with passive infrared detection (PIR).

On paper energy saving is 50%; however in real terms due to the use of lighting controls energy savings will be in excess of 75%the with a short 24 month payback period. lighting controls energy savings will be in excess of 75% with a short 24 month payback period.

The use of lighting controls also positively impacts service life which at an already impressive 100,000 hours (11 years) The yield use of lighting controls savings. also positively service life first which at an already impressive hours (11 years) will huge maintenance Due toimpacts the success of the installation GG Lighting has100,000 now been requested to will yield maintenance savings.

Dueand to the success of the first installation GG 75% Lighting has now been bill requested to carry out huge a second.

The resulting energy carbon footprint saving was a massive off of their energy excluding carry out a second.

The resulting energy carbon footprint maintenance costs to purchase and installand replacement lamps. saving was a massive 75% off of their energy bill excluding maintenance costs to purchase and install replacement lamps.

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Current installation Current installation 41 x 400w Metal Halide 41 x 400w Metal Halide 16.4kW 16.4kW 7,488 7,488 £11,052 £11,052

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Don’t let Forklifts bring dirt and water into your warehouse

Looking at the Benefits of Vacuum Drying

Now available in the UK with a modern design, clear-focus vials for levelling work in tight spaces. It’s always been Hultafors Tools’ vision to give professional tradesmen and women the best quality tools for optimal onsite performance. That’s why these NEW Mini Pocket spirit levels have now been added to its range of best in class levelling and marking equipment.

Why? Because this could cause a serious slip hazard in your warehouse and that is the last thing you need. There is an even higher risk if your forklifts are going in and out of your warehouse regularly. The wheels carry a lot of dirt and water from outside, especially if it’s raining. However, there is a solution to prevent slips and falls in your warehouse – Waterhog Forklift Mats.

The ergonomic design includes a crushproof vial with a +60% magnifying effect and luminescent effect for easy reading in light or dark conditions. Both new models look great and, added to all the other products in the Hultafors’ range, there’s something to suit every conceivable levelling requirement.

Waterhog Forklift Mats are the answer to your problem. Not only does it prevent slip hazards, but it also keeps the environment safe and clean. These mats are designed for forklift entrances, such as loading bays. To ensure safety and protection, the mats scrape and wipe away dirt and moisture from the wheels. This can also prevent the forklifts from skidding.

Vacuum dryers are a multifaceted product used in a wide variety of processes in the food, chemical, pharmaceutical, and plastic industries. Vacuum dryers work to remove liquids from materials or to change a material’s molecular and physical chemistry. It removes liquid by heating the material through conduction, and vaporizing the liquid.

Vacuum dryers can change molecular and physical chemistry through chemical reactions and solid state polymerization. The vacuum drying system consists of a vacuum dryer, media heating and circulating, vacuum, and solvent recovery components.Vacuum drying can provide several benefits. Because vacuum drying controls atmospheric pressure, it reduces the boiling point required to remove the liquidProcessors have been searching for a more efficient vacuum dryer to better control their particle size and reduce the process time.

To answer these specific needs, Processall has developed the U-Max Dryer.

Getting more information on the Hultafors Tools range of Spirit Levels easy. You call the Helpline on 01484 854788 or check out www.hultafors.co.uk and download a digital catalogue.

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PECM Issue 38

To request a free sample, or to place an order, please call 0121 313 6748 or visit www.mats4u.co.uk today.

www.processall.com/

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Hilsonic Hilsonic is is aa specialist specialist in in the the supply supply of of ultrasonic ultrasonic cleaning cleaning equipment equipment for for the the powerpower7HO 7HO generation generation and and ZZZ KLOVRQLF FR XN ZZZ KLOVRQLF FR XN marine marine industries industries Issue 38 PECM 111 Issue Issue 16 16 PECM PECM 15

FASTENERS & FIXINGS

DOING MORE WITH LESS STAR FASTENERS

HUCK® FASTENERS BOOST EFFICIENCY AND IMPROVE RELIABILITY Industry is under continued pressure to do more with less: less weight, less cost, and less time. Understanding how different joining technologies function from the perspective of weight, cost, productivity and reliability is crucial.

While adhesives are often a popular joining technology when trying to address weight concerns, structural blind fasteners should also be given strong consideration as they create reliable, effective, tight joints between various materials.

Structural blind fasteners offer similar benefits to those of non-structural blind fasteners, while also providing a distinct advantage: quantifiable and predictable shear and tensile strength.

Structural blind fasteners such as Auto-Bulb™ and PentaLok retain their mandrel after installation. This retention of the mandrel is made possible by the interaction of the mandrel and mandrel sleeve during the installation process.

The presence of the mandrel accounts for a 60-80% increase in load-carrying ability in shear and tensile over conventional non-structural blind fasteners. Not only can these fasteners improve joint reliability due to their added strength, numbers of fasteners required can be optimised.

In turn, this improves the weight of the project, speeds-up the manufacturing process and reduces inventory costs.

THE HUCK AUTO-BULB This Huck fastener offers the perfect solution. It works by clamping the joint with a broad, blind side bulb, which makes it a good choice for use within thin materials, and within oversized, misaligned, or slotted holes. Unlike other bulbing blind fasteners, Auto-Bulb’s unique bulbing system creates superior blind side bearing strength and its positive mechanical bolt retention ensures structural integrity. Auto-Bulb is available in both steel and 400 stainless steel for corrosion resistance.

Available Sizes: 3/16”, 1/4” Materials: Steel, 400 Stainless Steel Headstyles: Protruding, Countersunk

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THE HUCK PENTALOK The Huck PentaLok has been specifically designed to work with celled, honeycomb, plastic panels and multi-composite board. Its wide blind-side footprint is well suited for use within thin materials and delicate composites. Pentalok’s uniquely engineered peel system installs with ease into shallow panels.

Available Sizes: 1/4” Materials: Steel Headstyles: Protruding Innovative materials and manufacturing techniques are changing at a rapid pace.

There are numerous reasons why engineers

should use Huck products, such as the ease by which potential fastening solutions can be calculated and dimensioned, as well as the consistent quality of products.

Selecting an appropriate fastener can be challenging. Star Fasteners work closely with engineers and procurement teams to share their specialist fastener knowledge.

A smart customer focused response, as well as large stocks ensures that customers’ requirements are met quickly.

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

FLUID HANDLING

STEAM EQUIPMENT EXPERTS MAGNETROL

THE CHALLENGES OF ACCURATE INTERFACE MEASUREMENT Interface or multiphase level measurements exist throughout the oil & gas streams as well as petrochemical. While level measurement technologies have come a long way in effectively measuring liquids and solids, multiphase level measurement continues to be the biggest challenge and opportunity that exists today to which there is no perfect technology. However, experience has shown that process optimization and increased uptime can still be achieved in many separator applications through reliable, best-in-class, level technology.

Magnetrol® recognizes that interface measurement is a key concern for these industries, as well as many others. With that in mind, MAGNETROL has developed a white paper addressing the challenges and considerations around interface measurement and currently available technologies for process optimization.

THE BASICS OF INTERFACE In the oil & gas and petrochemical industries, the need for reliable interface measurement arises whenever immiscible liquids, those incapable of mixing, reside within the same vessel. The lighter medium rises to the top and the heavier settles at the bottom. In oil production, for example, water or steam is used to extract oil from a well. Well fluids then route to production separators where they settle into their primary constituents as a hydrocarbon over water interface.

Interfaces can form between liquids and solids, liquid and foam, and liquid and gas; but the emphasis here will be concentrated on liquid/liquid interface (often with a vapor space above the top/lighter liquid). Immiscible liquids meet along an interface layer where they undergo some amount of emulsification.

This emulsion layer (also referred to as a “rag” layer) may form a narrow, distinct boundary, but more frequently it is a broader gradient of the mixed liquids. Generally, the thicker the emulsion layer, the greater the measurement challenge.

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INTERFACE MEASUREMENT CHALLENGES While monitoring the top, or total level, is critical for safety and overfill prevention, knowing the level of an interface is necessary for maintaining product quality and operations efficiency. If there is water in oil that is not separated effectively (water carryover), then this can induce processing problems, equipment failures and unplanned shutdowns. If there is oil in water (oil extraction), then there can be production loss, environmental fines, penalties and forced shutdowns.

Of all the level switches and transmitters available, only a handful are suitable for reliable interface measurement. The leading interface measurement technologies include guided wave radar (GWR), buoyancy-based displacers and magnetostrictive, RF capacitance, nuclear/ gamma radiation and thermal dispersion.

Ideally, the technology utilized for interface applications does not have to differ from other level instruments installed at the facility in order to maintain familiarity with users.

Standardizing on a technology helps reduce training, installation & commissioning, maintenance and downtime.

MORE INFORMATION To learn more about interface measurement challenges and the technologies available to more accurately monitor interface, download the interface white paper.

The white paper covers: • interface challenges; • case studies in Oil & Gas and Petrochemical; • comparison of level technologies for interface measurement; and • the future of reliable interface measurement.

interface.magnetrol.com

FLUID HANDLING

Fluid Carrying

Flexibility Articulated Torsion Pipework In Hoses Rotating Cylinders

Swivel Joints Swivel joints allow pipework to pressure 1/4” to 40” and beyond.

Vacuum to over 20,000psi.

Stock and bespoke production.

Unique bearing/seal design for longer life.

ISO 9001 CE marked where applicable.

Tel:

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

+44(0)1663 735003

E-mail:

ROTAFLOW DONATES SWIVEL JOINT TO CHARITY RAILWAY Alongside providing high specification swivel joints to some of the worlds leading oil and gases companies, Derbyshire based swivel joint specialist Rotaflow have helped out the charity run Spa Valley Railway in Royal Tunbridge Wells.

The railway was undertaking extensive renovation of their equipment and needed a solution to help them bring their water hose system up to date, allowing them to move water from the water holding tower to the engine water tank faster and with less effort.

Rotaflow donated a 3” twin sealed 316L stainless steel flanged swivel joint to help them achieve this.

The Rotaflow swivel joint has been installed on the hose arm that fills up the water tank on the steam engines. It allows the newly refurbished hose arm to rotate easily from the water tower out over the engine,

making the job of filling the water tanks significantly quicker than before.

The swivel joint donation from Rotaflow means that getting the water tanks full and the train moving is a much easier job, reducing technician time and helping get the train moving in a lot less time! www.rotaflow.com

LABTEX Stand number C4.

Labtex supplies leading laboratory products including HUBER liquid temperature control systems, DIEHM glass reaction systems to 100 litres, PREMEX and AMAR high pressure autoclaves, POPE wiped film or short path evaporators and distillation systems, Nutsche filter dryers, BOLA labware in PTFE and other technical plastics, Vacuubrand vacuum pumps, ASECOS storage solutions for hazardous materials to BS EN 14470-1 and SICCO desiccators.

We also work with LLG Germany, the 3rd largest lab supplies distributor in Europe and have a catalogue of 20,000 items from over 200 respected brands.

We are now distributing the advanced metering pump range developed by the highly regarded and innovative Heidelberg based company, ProMinent. This exciting new specialism will further enhance our ability to offer solutions for an increasingly wide range of scale-up processes.

The foundation of ProMinent’s global success story is highquality products based on decades of engineering expertise, an in-depth understanding of applications and continuous innovation.

The modular ProMinent range, integrated into carefully designed solutions, will enable customers in a wide range of industries to achieve maximum safety and efficiency in their production processes.

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

Greg Smith, Managing Director at Labtex, said “ProMinent group’s position as a global market leader means a continuous commitment to excellent products and services and an obligation to think and act responsibly. It is a real privilege to be working with such a great company, with an innovative culture and commitment to excellence, very similar to ours.

I look forward to the journey ahead.”

Sales & Service 01484 600 200 info@labtex.co.uk

We share Prominent’s commitment to environmentally

Issue 38 PECM

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FLUID HANDLING

FLOTRONIC INTRODUCES ‘ONE NUT’ BARREL UNLOADING Flotronic has introduced a new barrel and drum unloading system, combining the unique ‘ONE NUT’ pump with their barrel unloading skid. The new system enables you to pump highly viscous materials out of your barrel at significantly increased flow rates.

This system is built around our ‘ONE-NUT’ sanitary style pump which is based on our 3A and EHEDG design. This style of pump has already proven itself in the hygienic / sanitary industries and is a match for any environment or process where avoidance of product contamination is paramount. The system can be Cleaned in Place using the pump itself or an external CIP rig or, because of the ‘ONE NUT’ design of the pump, it can be easily stripped down for cleaning.

“Using an inflatable seal, the system ensures minimal wastage is achieved and the minimum of product remains in the barrel.” Says Leighton Jones, Sales Director, Flotronic Pumps. “As the seal inflates it creates an excellent seal while moving down the barrel and at the end of the process it deflates for easy removal. There is less hold up compared to other systems, which means you can empty challenging viscous fluids from full size drums in a matter of minutes, improving productivity with increased profit potential.”

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

Using Dynamic Modelling to Troubleshoot Pumping System Trip

SPX Flow Inc. appoints AxFlow UK to distribute APV components

Dynamic modelling provides a cost-effective means to troubleshoot and determine solutions for such system issues. The benefits include reduced downtime, re-instated availability and improved system reliability. Recurring trips on a 6.9 MW motor driven multistage barrel type centrifugal pump was the cause of severe outage on a North Sea (UK) crude oil processing platform. Plant shutdown lasted sometimes a full day, or more, resulting in significant loss in production. The pump tripped on high suction pressure and the trips were observed during start-up. The problem on the crude oil pumping system was solved by installing a larger Cv recycle valve and system availability was restored. This case not only shows how dynamic modelling can help troubleshoot pumping systems, but also provides a deeper insight into the role of each of its key components. .

AxFlow UK Limited has announced its appointment by SPX Flow Inc., (NYSE: FLOW) as its primary distribution partner for APV brand process components and parts in the UK food and beverage market. The agreement includes APV pumps, valves, homogenisers, mixers and sanitary heat exchangers. This is a major step forward for both companies and follows the long term successful partnership between SPX Flow and AxFlow representing the Waukesha Cherry-Burrell (WCB) brand in the UK.

For more information, please check www.fluensys.co.uk.

www.axflow.com

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Tony Peters further commented: “We will add sales and technical support personnel to our team and look forward to providing additional sales impetus to the APV product lines. Further, we will build upon our investment in APV stock at our European Distribution Centre to ensure best-in-market lead times”.

www.flotronicpumps.co.uk

Leybold’s pump for food processing and packaging Leybold will present its100% oil-free screw type vacuum pump NOVADRY for food processing and packaging at the international trade fair for the meat industry IFFA in Frankfurt am Main from 04 to 09 May 2019 in hall 11, booth A41.

The completely newly developed, oil-free screw vacuum pump ensures significantly greater safety and efficiency in food and packaging processes.The demands placed by manufacturers and consumers on the quality, shelf life and resource efficiency of food and packaging processes are constantly increasing.

This applies even more to such perishable products as for example meat or fish. Vacuum is considered as an enabling technology, contributing significantly to optimizing these processes. Leybold developed the Novadry as a new 100% oil-free, air-cooled pump.

E-mail: sales@leybold.com

4 types of interface.

16 process streams.

150,000 barrels per day.

Zero margin for error.

This is why level matters.

Reliable interface level measurement keeps production flowing. If water and oil are not separated effectively, you face processing problems, equipment failures, production loss, fines and shutdowns.

That’s why Magnetrol® matters. Our technologies are proven to accurately measure total level and emulsion layers, from upstream gun barrel tanks to downstream boots. So you get effective separation and true process optimization. That’s critical.

Because when it comes to interface, level matters.

©2019 Magnetrol International

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

FLUID HANDLING

INDUSTRIAL PROCESSES BURKERT

MINIMISING COSTS THROUGH PROCESS OPTIMISATION The control of industrial processes can be a complex operation involving multiple valves, sensors and controllers which means there are many considerations when looking for opportunities for process optimisation. Using best practice and ensuring control protocols are updated when process changes are implemented however, ensures the process remains efficient and effective.

Greg Wainhouse, UK Water Segment Manager at BĂźrkert, looks at some examples from different industries, where process optimisation can deliver significant improvements and reduce costs.

Process control engineers are constantly aiming for perfection while all the time tackling the challenges that stand in their way. From variable inputs to changing conditions and complex infrastructure, there is always another obstacle to overcome, but by taking advantage of expertise within the industry, it is possible to make significant practical improvements.

WASTE WATER PROCESSING

One of the major challenges in the water treatment sector involves the sludge dewatering process, which in many cases involves high speed centrifuges that separate the solid and liquid fractions. To assist this process, a polymer is added to the sludge to help bind the solid particles together. The goal is to produce a final product that has the right consistency that makes transport efficient, without moving excess water to the fields, where it is spread as agricultural soil enhancer.

The process has a number of variables, including the percentage solids of the raw sludge, the flowrate of the sludge, the amount of polymer being added and the speed of the centrifuge. Of these, the solid content of the sludge is crucial to determine the settings for the rest of the process.

There are several ways in which this can be determined, including a process where a sludge sample is placed in a petri dish, and the water is evaporated off to obtain the mass of the solids. This is not a very efficient process and can take 45 minutes to complete.

Once the results are available, the centrifuge and polymer settings can be adjusted and an improvement in the consistency of the dewatered sludge should be apparent.

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Precision control of cleaning processes in hygienic applications can improve productivity.

However, changes in the solids content can occur frequently, which makes this process quite ineffective and labour intensive. In addition, it is a reactive process, more often used when the consistency of the dried sludge doesnâ&#x20AC;&#x2122;t meet expectations. During the time taken to observe the change, complete the test and alter the settings, the centrifuge has continued to discharge a substandard end product.

By creating a pro-active system that makes adjustments based on data from the inlet, as opposed to a reactive system that observes the results before implementing a change, process engineers will be following best practice. Furthermore, this setup reduces the amount of operator intervention and delivers a more stable output.

BREWING PERFECTION

In the first instance, assessing the percentage of solids using a turbidity sensor located on the intake to the centrifuge will significantly increase the response time to any changes.

These sensors look at refracted light to provide an approximation of the solids loading of the incoming sludge, but they can suffer from fouling problems, and the calibration process can be interpreted differently by various operators.

An important part of the brewing process is adding oxygen to the wort to allow the yeast to thrive and create the alcohol and carbon dioxide. After the boiled wort has been chilled to fermentation temperature, oxygen is used to start the fermentation process.

If air, which contains 20% oxygen, is added, then the process can only achieve an O2 concentration of eight parts per million (ppm). For higher levels, around 10 ppm, typically used by commercial breweries for higher strength beers, pure oxygen is required.

By constantly monitoring the inlet of the process, adjustments can be made quickly and the amount of processed sludge that falls below the required standard is minimised. Further improvements can be made by adding a flowmeter, or better still a device that provides a mass flow measurement.

However, the ability of the wort to absorb oxygen is affected by its specific gravity, which is measured on the Plato gravity scale.

This measures the concentration of dissolved solids in the wort. Furthermore, each yeast strain has an optimum oxygen level and if this is not achieved precisely, the optimum fermentation rate will not be achieved.

DEALING WITH SOLIDS IN SUSPENSION

MASS FLOW ACCURACY FOR GASSES

Some of the most important flavour contributors to beer are fermentation products such as esters, higher alcohols and sulphur compounds. The concentrations of these flavour compounds will be altered if the growth characteristics of the yeast are less than perfect.

Achieving the optimum O2 level in the wort for each beer therefore is very important in terms of product quality, so an effective process to control the oxygen levels is essential. Using a mass flow sensor to establish the concentration of dissolved solids, and total volume, coupled with a mass flow controller to deliver the gas, is an efficient starting point.

To improve the accuracy of the system even more, the signal from a dissolved oxygen (DO) probe in the fermenter vessel can provide feedback to adjust the setpoint and obtain the exact level of dissolved oxygen required. This offers the opportunity to maintain precise levels of dissolved oxygen which have a major impact on the quality of the final product.

PH IN WATER

Carbon dioxide (CO) is used to reduce the pH of the water for a number of reasons.

Primarily, it is a gas that is easy to handle, non-corrosive and its most appealing feature is that it will not lower the pH of water below 7.0. In addition, the only maintenance required for the dosing system is to replenish the gas cylinders periodically.

The control structure for this dosing system needs to cope with variable flow as well as decreasing gas pressure as the volume in the cylinders deceases. Using a mass flow controller that is calibrated for the gas and delivers accurate measurements independent of temperature and pressure, is very important.

Oxygen levels can be accurately controlled during fermentation to ensure optimum product quality.

The CIP process can involve a range of chemicals that are used to clean and disinfect the equipment. The concentration of these chemicals is very important in achieving an effective cleaning cycle without wasting expensive materials. Also, using control systems that are purely timer-based offers no confidence in the effectiveness of the process and also retains no meaningful data, which may be required for regulatory compliance.

By examining the temperature and the conductivity of the cleaning fluid it is possible to determine if too much energy or too much chemical is being used. Any reductions in energy consumption or raw materials will have a beneficial effect on operational costs. Working with sensor manufacturers that have experience in this application to create a more sophisticated control and sensor feedback-loop system can therefore offer many benefits.

Many will use a pH sensor after the dosing point and use this information to adjust the gas flow rate. This reactive process can be optimised by adding a pH sensor to the input side and using the readings from this sensor to set the CO2 dosing rate. The second sensor then acts as validation of the process setting.

This offers a quicker response to changes in the pH levels at the input.

Correctly positioned pH sensors for example can provide data on the effectiveness of the process, while conductivity sensors can provide a measure of contamination â&#x20AC;&#x201C; once this figure has reached almost zero, the procedure can then be concluded with minimum delays to production.

STREAMLINED PROCESSES

Ultimately, improving data collection, interpretation and analysis can offer many advantages. Working with experienced process control manufacturers, such as BĂźrkert, can yield benefits across the board. From designing new installations to improving the efficiency and effectiveness of existing equipment, getting the right sensor in the right place will have a significant impact.

Process optimisation is primarily about acquiring the correct data and using it as effectively as possible. This requires experience in the application as well as with the equipment itself to ensure a costeffective and reliable installation. BĂźrkert has over 100,000 catalogue items, including cutting-edge flow measurement equipment that can also provide mass flow data.

This expertise in manufacturing and expansive knowledge of numerous applications helps customers to reduce operating costs, improve productivity and ensure compliance with regulatory bodies where necessary.

OPTIMISED CLEANING

For those working in hygienic applications, clean-in-place (CIP) is a very important process that maintains the cleanliness of equipment. Using a combination of chemicals, water and heat, the process offers a very efficient method of cleaning vessels and pipework without dismantling them.

However, time taken for cleaning is time lost from production, so this needs to be kept to a minimum whilst also ensuring that the process has been effective. Optimising the control of CIP reduces costs as well as minimising chemical usage and improving productivity.

About BURKERT Burkert Fluid Control Systems is one of the leading manufacturers of control and measuring systems for fluids and gases. The products have a wide variety of applications and are used by breweries and laboratories as well as in medical engineering and space technology. The company employs over 2,500 people and has a comprehensive network of branches in 36 countries world-wide.

Comprehensive process control installations can deliver considerable savings.

www.burkert.co.uk Issue 38 PECM

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GEARS, DRIVES & MOTORS

CONTINUED INVESTMENT ROTAMEC

ROTAMEC EXTENDS ITS 24/7 SERVICE INTO SOUTH WALES

Rotamec Engineering Solutions, expert in motor rewinds, gearbox repairs and drive solutions has expanded its operation into South Wales following the acquisition of Pontypool Rewinds. As part of a continued investment process, Rotamec will maintain the high standard of repairs associated with the business and expand the range of services on offer to customers.

Hugh Williams and Lyn Kenney, who have owned the business for 30 years and will continue to run the branch, see the acquisition by Rotamec as a means to ensure their customers continue to receive a premier service.

“Our customers are very important to us, so we want to ensure that the business will continue to serve them when we decide to hang up our tools in the future. Rotamec is a responsible, forward-looking company that will be able to offer the service our customers expect”, explains Hugh.

Simon Brooks, Managing Director of Rotamec, commented: “Hugh and Lyn have

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built up a very loyal customer base and we will continue to deliver the same highquality service as well as offering additional services for machining and the repair of other equipment. We will be investing in the staff as well as the facilities to expand the customer base and offer a wider range of services.”

Rotamec has a long history of taking on apprentices, most of whom stay with the business, and there will be opportunities for the same scheme to be operated in Pontypool. Simon Brooks is a strong believer in helping young people to learn new skills and achieve their potential.

Customers in South Wales will be able to take advantage of a range of additional services including pump repairs, fan services, gearbox maintenance and a range of machining facilities. Rotamec offers a comprehensive service, from in-house CAD design, to CNC machining to enable standard products to be modified to suit a specific application.

With a large stock-holding of new motors, gearboxes and drives, customers can be assured of short lead times for new equipment as well as for repairs. The experienced field service teams are fully equipped to carry out diagnostics as well as removal and installation of equipment on site. In addition, the 24/7 promise means that they are available whenever a breakdown occurs, minimising downtime and keeping customers’ processes operational.

Simon concludes: “Modern industry relies on electric motors, pumps and gearboxes to operate continuously, so when there is a problem, you need a fast solution. Rotamec understands the importance of speed and high-quality repairs and now we have a great opportunity to bring our expertise and facilities to customers in South Wales and further afield.”

www.rotamec.com/

GEARS, DRIVES & MOTORS

Tel: 01243 869905 Fax: 01243 810799 sales@remco.co.uk www.remco.co.uk

Leaders in the supply of FHP motors • Split Phase • Capacitor Start / Induction Run • Permanent Split Capacitor • Three Phase • ERP Complient Axials A Regal Brand

www.regalbeloit.com

SDP/SI INTRODUCES A NEW FLEXIBLE COUPLING EQUIPPED WITH VIBRATION DAMPING TECHNOLOGY Stock Drive Products/Sterling Instrument (SDP/SI), a leader in providing mechanical based design, engineering, and precision manufacturing services for critical motion control and small power transmission applications has introduced several new series of high-gain couplings.

These Antivibration Flexible Couplings are designed for use with high gain servomotors. When a servomotor drives a mechanism, as in applications such as semiconductor manufacturing equipment, blood analyzers or high speed printers, a change in direction causes a phenomenon called hunting. Hunting is vibration in the system which reduces transit time making the equipment less efficient.

For more information go to: https://www.sdp-si.com

ABSOLUTELY DRIVEN NEW RANGE OF DRIVES AND VARIABLE SPEED GEARBOXES

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

ATEX compliant to EC Directive 94/9/EC

Distributed in the UK by:

www.labtex.co.uk Issue 38 PECM

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GEARS, DRIVES & MOTORS

SAFETY AT WORK LEUZE

HOW CAN MACHINE TOOLS AND SYSTEMS OPERATE SAFELY AND EFFICIENTLY? For a while now, sensors are not only a matter of process control – today one of their primary tasks is to link processes together. With its extensive range of Safety@work products, Leuze electronic optimizes collaboration between man and machine: sensor and control systems, like those of the RSL 400 safety laser scanner, can be integrated intelligently into the processes performed by machines and safeguard these machines in a reliable and tamperproof manner. At the same time, the processes are structured efficiently and cost-effectively.

MACHINING WORK PIECES

In machining centers, parts of various materials are machined, turned, and drilled. The prerequisite for processing work pieces in complex machining centers with a high degree of precision is having the right tool available for each work step.

In addition to checking whether the tool is present and identifying it, the drill or milling cutter must also be monitored for tool breakage. Inductive switches or camera-based code readers clearly identify whether the correct tool is mounted for the respective processing step. Focused laser photoelectric sensors can – thanks to their very small light spot – reliably check whether even the smallest drills or milling cutters are intact.

INCREASED LEVEL OF AUTOMATION

Industrial robots, which can perform a large number of swivel and gripping movements in a very short period of time, are often used for automated loading and unloading of machine tools. Their movement zones must be reliably protected against access over a large area. Before a robot picks up a part, the part must be uniquely identified to ensure that the correct processing step is carried out. This is done using the DCR 200i camera-based code reader.

The DCR 200i is a reader used to detect and identify Data Matrix codes. The fast imager, integrated high-performance LED illumination, as well as high resolution in combination with a very high depth of field guarantee reliable decoding, even with fast processes and high object speeds.

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SAFETY-RELATED MONITORING OF MACHINES AND SYSTEMS

Safety laser scanners such as the RSL 400 from Leuze electronic are used for the safety-related monitoring of areas in and around machines and systems.

A maximum operating range, robust operation and simple handling are crucial here. The simultaneous monitoring of four protective fields means the working area can be split up and the speed safely reduced.

FIGURE 1: RSL 400 – SAFETYRELATED MONITORING OF ROBOT WORKING AREAS In future, an important aspect in addition to the automated loading and unloading of machine tools will above all be the linking together of multiple machine tools in combination with automated production processes. This includes, for example, storage systems that optimize material flow, but also a wide variety of transport equipment such as linear gantries, pallet handling systems and conveyor systems, which all increase the level of automation considerably. For the safeguarding of large access points, safety

laser scanners with vertical alignment of the protective field are used, e.g. to detect vehicles and persons.

The RSL 400 safety laser scanner provides a solution for such applications. Its large operating range of 8.25 meters allows large areas to be monitored. With two parallel protective fields and two integrated safetyrelated switching outputs, only one RSL 400 safety laser scanner can also monitor two stations independently of one another.

FIGURE 2: COMPLETE SAFEGUARDING OF TWO STATIONS WITH JUST ONE SAFETY LASER SCANNER

A further option is safeguarding using multiple light beam safety devices. These devices provide a greater operating range and therefore an efficient solution for safeguarding access points over long distances of up to 70 meters – even “around the corner” solutions with multiple mirror columns are possible. Intelligent products such as the MLD 500 safety light curtain have an integrated laser alignment aid for time-saving and cost-effective alignment.

Simple configuration by means of wiring and integrated indicator lights for status display are possible, even over long distances.

Different safeguarding options are available depending on the respective requirements and application. A comprehensive range of products helps in choosing the best possible solutions to ensure safety at work and also in optimizing collaboration between man and machine.

In-house logistics with automated guided vehicles (AGVs) An AGV, which moves autonomously and flexibly in space, transports blanks into the working area of the robot or machine tool.

On completion of the production process, the machined work pieces are collected again. The transportation path of the AGVs must be safeguarded with safety sensors which monitor the presence of persons and objects.

An important consideration here is the flexible adaptation of the protective fields to the movement situation and the different loads. In the case of the triangulation principle, an AGV must be equipped with two different scanners. Unlike the contour navigation principle, just one scanner is needed for safeguarding and navigation.

This means that safeguarding and data capture for navigation requires one single safety laser scanner. In other words, the scanner simultaneously also provides the measurement data needed for navigation.

In addition to that, the measurement values have an extremely high angular resolution and accuracy. This is important to precisely determine the position of the AGV. The RSL 400 safety laser scanner enables such a combined solution.

FIGURE 3: SAFETY FUNCTION AND HIGH-QUALITY MEASUREMENT DATA OUTPUT IN ONE DEVICE

The safety laser scanner is available in various models. The extensive range of scanners from Leuze electronic includes a total of nine functional variants – three of which with data output for AGV navigation. All variants are available for the four operating ranges of 3.0, 4.5, 6.25, and 8.25 meters. Models with PROFIsafe/PROFINET interfaces are also available.

www.leuze.com

Cross+Morse

Power Transmission Manufacturing Specialists Since 1984

◊ Manufacturing up to 1450mm diameter

◊ Turning - CNC lathes, Vertical Machining Centre ◊ Gear Cutting - Hobbing, Planing, Shaping Gears ◊ Bevel Gears, Helical, External & Internal cut Gears ◊ Rack Shaping, Broaching, Keywaying ◊ Vertical Boring, Centreless & Rotary Grinding ◊ Bore Honing ◊ Induction Hardening ◊ Drilling & Tapping ◊ Large stocks of Transmission Drive components ◊ CAD - CAM Design & Development ◊ ISO 9001 : 2015

Yes we can make it.

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

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HEALTH & SAFETY

PRESSURE RELIEF REMBE

PREVENTING DIFFUSION OF AMMONIA IN THE KALINA PROCESS

Fig. 1: Rupture disc KUB® installed downstream from the safety valve

Until now, the secondary circuit in geothermal power plants, which is used in the Kalina process for the ammonia-water-steam generation at low temperatures, has always been protected by safety valves. Due to the limited leak-tightness of re-sealable relief devices (safety valves) especially over longer periods of time, some operators have now begun installing rupture discs downstream from the safety valves.

Manufacturers such as REMBE GmbH Safety + Control are now offering rupture discs specifically for this type of application. Dr. Stefan Rüsenberg, the man responsible for this development, said “The KUB® GT is specially tailored to the needs of geothermal power plants.

We use high-quality, corrosion-resistant materials to ensure the rupture discs are permanently leak-tight and can be in service for a long period of time. The key word in this application is zero emissions.

This is also important for the acceptance of these power plants amongst the population.” The GT in the product name stands for geothermal”, Rüsenberg added.

These rupture discs are used to secure a vast range of steam and condensate lines as well as condensers, evaporators and heat exchangers. By installing the rupture disc in a special holder on the process side of the safety valve, the valve will be protected from the process medium during normal operation. The KUB® GT rupture disc has a completely smooth surface on the process side. In combination with the corresponding holder, a metal-on-metal gasket is created which guarantees a much higher leaktightness than the use of a safety valve as a stand-alone solution would provide.

Even if the Kalina process was primarily used by geothermal power plants, it is fundamentally also suitable for all processes that use corrosive, hazardous or polluting media and require a high degree of leak-tightness.

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About REMBE REMBE is a global specialist for pressure relief and explosion safety. The company offers customers cross-industry safety concepts for systems and equipment. All products are manufactured in Germany, and meet the demands of national and international regulations. The customers who purchase REMBE products are among the market leaders of various industries, including the energy, food, chemical, pharmaceutical and wood industries. www.rembe.com Fig. 2: REMBE rupture disc KUB® with holder

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

Made in Germany

Your Specialist for

PRESSURE RELIEF and

EXPLOSION SAFETY

© REMBE® | All rights reserved

Consulting. Engineering. Products. Service.

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

HEALTH & SAFETY

KEEPING EMPLOYEES SAFE ANT TELECOM

WHAT ARE THE RISKS OF NOT RESPONDING TO A CRITICAL ALARM IN TIME?

protected, as well as train employees on how to deal with the risks. With a critical alarm system in place, staff can feel confident in the knowledge that their welfare is being monitored so in the event of an incident on site, it will be acknowledged and rectified as quickly as possible. In order to make this a reality, businesses must therefore ensure that the workforce fully understands the critical alarm response processes that are in place.

Contribution from Klaus Allion, Managing Director at ANT Telecom For any organisation that operates within a high-risk environment, critical alarms are a fundamental component to assure the safety of staff and continuity of operations.

The manufacturing industry, in particular, is known to be a high-risk environment as workers typically have to deal with heavyduty machinery and potentially hazardous materials. This environment can be especially dangerous for lone workers who perform their roles without supervision from other colleagues.

By law, employers must control any potential risks to injury or health that could arise in the workplace by undertaking risk assessments, provide information about potential hazards and how staff are

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But what are the risks if a critical alert is not responded to in good time? While alerts are useful, unless critical alarms are managed and responded to efficiently, they are of little use to an organisation in terms of keeping employees safe and ensuring machinery continues to function at an optimum level.

Inadequate alarm management and poor processes can lead to a number of consequences for organisations. If an employee is injured on site and requires emergency assistance, the time it takes to respond could be the difference between life and death and could mean the individual is left with life-changing injuries.

By failing to respond appropriately to critical alarms or failing to put measures in place to keep staff as safe as possible, significant fines could be imposed by the Health and Safety

Executive (HSE). Not only can these fines be financially damaging, the subsequent reputational damage can also be severe.

There is also a likelihood that organisations will also be faced with wasted time, product and money if machine alerts are not dealt with in a timely manner. For example, an alarm on a food production line could be alerting to faulty temperature regulation.

If the alarm is responded to and resolved efficiently, the quantity of spoiled produce could be minimal. However, if there is a delay in acknowledging the alert and performing a subsequent fix, the fault could escalate and the amount of wasted food could rapidly increase. In a worstcase scenario, if the entire production line has to be stopped or the building has to be evacuated due to safety concerns, the knock-on effect in terms of time and money could be significant.

In any high-risk environment, incidents will occur but by deploying a combination of appropriate technology and processes, companies can effectively safeguard their operations and staff and mitigate risks as much as possible.

www.anttelecom.co.uk

HEALTH & SAFETY

Sven-Philipp Abraham, SMARTER PRODUCT USABILITY

IT’S NOW EASIER THAN EVER TO READ CODES — CAMERA-BASED CODE READER DCR 200i

Product Management – Product Center Ident + Vision

Using the setup wizard, the new DCR 200i is ready for operation in just a few minutes and can detect 1D- and 2D-codes quickly and reliably even with demanding reading tasks.

easyhandling.

Phone 01480 408 500 – www.leuze.co.uk

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HEALTH & SAFETY

IS YOUR HEARING PROTECTION COMPLIANT WITH THE NEW PPE REGULATION?

From 21st April 2019 all hearing protection products used in the workplace must comply with the new Personal Protective Equipment (PPE) Regulation (EU)2016/425.

Setting the standard in custommade and universal-fit hearing protection since 1994, ACS is one of the first UK companies to achieve compliance to the new regulation and is ready to serve the market beyond April 2019.

ACS has become the trusted provider of hearing protection and communication solutions to a diverse range of industrial and aviation sectors across the world.

All products are fully certified to EN 352-2 and EN352-6 and PPE regulation (EU)2016/425.

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ACS ambient noise filters offer a choice of 6 SNR’s between 15dB and 28dB which ensures the correct amount of sound reduction can be achieved in any environment: communicating safely, hearing warning alarms without causing muffling and allowing ears to breathe.

Other key benefits of using ACS products include reducing your HPE costs, environment waste and highlighting your corporate social responsibility.

Find out what your cost saving could be on certified and compliant hearing protection by contacting ACS at: info@hearingprotection.co.uk 01295 266665 www.HearingProtection.co.uk

KEEP YOUR COOL WITH THE HARDCAP AEROLITE® - THE LIGHTEST BEST PERFORMING FULL SHELL BUMP CAP AVAILABLE The HardCap AeroLite® from JSP is the lightest, best performing, full shell Bump Cap on the market weighing less than 135g without compromising on performance.

It is designed to be worn in work environments where there is a risk of impact to the front, top and also scrapes to the side of the head from stationary objects. The sleek textile cover has large open weaved panels to facilitate the transfer of cool air to the head reducing heat

build-up and discomfort making it one of the coolest caps on the market. Underneath the textile cover is a tough HDPE shell and a lightweight EPP impact liner offering class leading impact performance.

Adjustable to fit head sizes from 53cm to 63cm and available in black or blue, with either a 50mm or 25mm peak. www.jspsafety.com

HYDRAULICS & PNEUMATICS

EXPLORE AN ECOLOGICAL FUTURE Electric vehicles are gaining momentum around the world, with more and more major cities increasingly switching to electric buses for public transport. The global Dürr Technik Group devotes itself to all aspects of “e-mobility” and has developed oil-free compressors that are powered by their own electric motor(s). These compressors offer energy savings with fewer pollutants in the “Automotive” sector.

Precision fluid system components

For vehicles over 3.5 tons, a reliable and robust compressed air supply is essential - for applications ranging from brake release air to door opening to air suspension. Instead of mechanically connecting the existing compressors with the vehicle engine in a conventional manner, the newly developed and efficient Dürr Technik compressors have their own electric motor(s). These are extremely environmentally friendly, run independently of the vehicle engine and only draw power when needed, meaning the a very low energy consumption.

The compressors that we manufacture are oil-free meaning oil control or oil changes are a thing of the past.

Coupled with their compact and robust design, very low noise / vibration, low whole life costs, ease of installation and the fact that they are almost completely maintenance free, they can be installed into many positions within the vehicles that would have been impossible in the past. Depending on the product selected our compressors can achieve temperature ranges of between -40 and +40OC and can be operated with a duty cycle of 100 percent.

The compressor B-304 WR from Dürr Technik is especially suitable for vehicles with a total mass of up to 13.5 tonnes. With a centralised air intake system, this allows flexibility of installation to suit the manufacturers requirements.

For vehicles over 13.5 Tonnes, the E-Bull-300 from Dürr Technik is the ideal choice. At 400 V and 50 Hz, the compressor delivers 280 l / min at 10 bar - at a sound pressure level of 72 dB (A), similar to a vacuum cleaner.

With the E-Bull-300 weighing in at only 45 kg, with dimensions of 474 x 286 x 496mm and an IP67 rating it is suitable for all types of vehicle. In addition, Dürr Technik can make individual adjustments to suit specific customer requirements. Durr Technik pride themselves by offering complete solutions with dryers, after coolers, ambient cooling fans, support brackets and enclosures as required.

Further information can be found at www.duerr-technik.com

An ISO 9001:2015 certified company, FITOK is an industry leading developer and manufacturer of superior quality instrumentation valves and fittings for general service and instrumentation panels. High performing products suitable for the oil, gas, alternative fuels, powerplants, chemical and petrochemical industries. Call Tom Parker Ltd for more information.

STAINLESS STEEL n

Twin ferrule fittings

n

Needle valves

n

Check valves

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316 stainless steel filter elements

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High pressure instrumentation ball valves

Sales: 01772 255109 | Online: tom-parker.co.uk Request a catalogue: marketing@tom-parker.co.uk Issue 38 PECM

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MACHINING & MACHINERY

NEW SALES TECHNICIAN APPOINTED AT MASTER TOOL SERVICES has increased and the department’s service capability has expanded. The department has also held its own stand at exhibitions such as the Safety Health + Environment (SHE) Show, exhibiting its solutions to power tool safety issues such as Hand Arm Vibration management.

To support growth in its Master Tool Services (MTS) department, Master Abrasives has appointed Mike Timofte as its new MTS Sales Technician, offering support to local industry and collection of tools for repair and service.

Mike joined Master Abrasives last year as a Technician in MTS, carrying out services such as tool repair and on-site Hand-Arm Vibration (HAV) testing for customers. He will continue to do this alongside his new role to support local industry, offering collection of tools for repair and service. This service will be available to customers in nearby regions, covering areas such as Northamptonshire, Oxfordshire and Buckinghamshire. Mike will also be offering technical support for tools and services, with customers able to reach out to him directly by email or mobile number.

Carl Lewington, Operations Manager and Manager for MTS, explained: “Mike has a strong knowledge and experience of electric and pneumatic power tools.

This along with our range of reputable electric and pneumatic tool brands means he’s well equipped to give advice and recommendations to customers for their applications. So whether it’s aerospace,

automotive, foundries or other industries, we can offer the best tools, repairs, service and training according to the needs of the workforce.”

MTS has grown significantly since it was relaunched as a separate business unit in 2013 and moved to a larger location on-site to expand its capacity. Since then, the team has multiplied, the range of tool brands offered

PUWER inspections by machinery safety experts

Nickel alloys cut three times faster

Machinery can be hazardous, hence the legal requirement for periodic PUWER inspections to ensure the safety of workers and compliance with health and safety regulations. Procter Machine Safety’s experts understand the regulations and standards, plus they have extensive knowledge of machinery across many different industries. They can therefore inspect your machines in the knowledge of what safety measures should be present and when any residual risks are ‘as low as reasonably practicable’. The TÜV-certified machinery safety specialists can inspect individual, linked or multiple machines at one or more sites. At the end of the PUWER inspection an illustrated report is presented, showing any noncompliances.

Specialist stockholder serving the oil and gas industry, Howat Group, perhaps better known by its trading names AMS, ESS and Ancon, has installed a 14th Kasto bandsaw - a KASTOwin pro AC 5.6 - at its new centre in Barnsley, which opened at the end of 2018.

If requested, advice and support can be provided to help make machines PUWERcompliant. www.machinesafety/puwer

The facility represents an investment of more than £2 million by owner Malcolm Howat and has been timed to coincide with the oil and gas sector’s nascent emergence from a downturn that started in 2014.

Half of the sum went on acquiring a freehold, 60,000 sq m property on Cortonwood Drive in the Dearne Valley area of the city. The remainder was spent on infrastructure, materials handling equipment, two further Kasto bandsaws and refurbishment of all the older models, some of which have been in service since the 1990s and still cut accurately. www.kasto.com

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MTS has long enjoyed close relationships with top power tool manufacturers like Atlas Copco, Dotco, Dynabrade and Cleco, allowing the company to offer a large range of power tools. Since its re-launch, MTS also became a distributor for Metabo’s high-quality electric and pneumatic power tools and Cengar air saws. The team also helped introduce to the UK ZIPP Group’s cost-effective range of air tools which boast unique designs at low costs, such as incorporating low-vibration elements in tool designs. The company also introduced fastening tools into its product range including impact wrenches, oil impulse tools, torque wrenches and riveters, by welcoming the addition of ZIPP Air Tools fastening range. www.master-abrasives.co.uk

Wilkinson Star announce new partnership with Tecna SPA, Bologna Italy TECNA is a high quality Resistance Welding product which Wilkinson Star has distributed for over 30 years. From 1 August 2018, we are pleased to announce Wilkinson Star as the UK’s sole exclusive importer of TECNA Resistance Welding Equipment.

Wilkinson Star, Manchester, is one of the largest UK independent Importers and Distributors of Industrial Equipment. Founder and Chairman, Dr. John A. Wilkinson, OBE, commented; “My Company is looking forward to a renewed exclusive agreement with TECNA S.p.A. We have enjoyed the last 33 years but now we will go in many new directions and fields to become number 1 in the provider of Resistance Welding Product in the UK”.

Wilkinson Star have heavily invested in testing and repair facilities for this new partnership to be able to provide a complete support package to Wilkinson Star distributors. www.wilkinsonstar.com

MACHINING & MACHINERY

Tool maintenance - Tool Repairs

- HAV consultation: risk

- Preventative maintenance plans

assessments, advise and training - HAV testing of tools; on-site or at

www.master-toolservices.co.uk

Tool Sales

HAV Services

- Pneumatic & electric power tools - Offering quality brands such as Cleco, Metabo, Zipp and Atlas Copco

Tel: 01327-703813

@MasterAbrasive

TECH GROUP – 119 MOULD HEATERS It is a fact that mould heaters are not the most interesting – or expensive – pieces of equipment that you will find in a plastics processing facility. But without mould heaters, the much more interesting and expensive injection moulding machines will not operate properly.

It is also a fact that a reasonably well maintained mould heater can have a fairly long and healthy life-span. Dan Horne, the General Manager at Renmar Plastics Machinery, is still sending mould heater spare parts to a company for a machine which

is approaching thirty years old.

However, this is an exception; there are not many companies who are prepared to keep, a relatively inexpensive piece of equipment that long. Most companies have a replacement policy and one of the most progressive is Dublin based Tech Group, part of West Pharma, who manufacture a wide range of Consumer, health care, and medical products.

For more information please contact Renmar Plastics Machinery on 0844 6933225.

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INCREASED IMPORTANCE HK TECHNOLOGIES

A NEW ERA FOR WIRE EDM Wire Electro Discharge Machining (EDM) is growing in prominence across UK manufacturing and it’s becoming increasingly more important for machine shops to have access to this technology.

Scott Elsmere, EDM Technologies Team Leader and Applications Engineer at HK Technologies talks us through the new era of Wire EDM and some of the latest developments from Mitsubishi.

better surface quality faster. The new V350 generator in Mitsubishi EDM machines has a significantly higher effective clock rate and the voltage is built up faster and with greater precision thanks to reduced capacitance loss. As a result faster voltage build-up, spark duration and working voltage producing noticeably higher surface quality and lower power costs.

Wire EDM traditionally captured a unique market; users of EDM produce plastic injection moulds, carry out tool and die work, or wire-cut precision features on aerospace and medical components. However, over recent years EDM machining is reaching new markets, building a reputation as a cost effective method to cut hard materials to an extremely accurate degree and even sometimes used as an alternative to milling. The real beauty of EDM is that it enables you to produce the most sophisticated parts with superlative surface finishes.

The latest intuitive controls with highly Intelligent graphical interfaces allow even the most inexperienced operator to make expert-level precision adjustments to the machine without necessarily needing to know the operating technology. The D-Cube is the control that helps crunch the numbers and maximise profits and comes as standard on new machines.

With the rise of Industry 4.0 technologies, there has been an increasing presence of

STAYING IN CONTROL

Metal Additive Manufacturing on shop floors up and down the country and thus, a noticeable increase on the demand for wire cutting for AM metal parts.

EXTREME ACCURACY AND PRECISION

What sets Mitsubishi EDM apart is the accuracy and precision of the machines. It is known that an EDM machine that reacts with greater speed and precision achieves

CONNECTING YOUR SHOP FLOOR

All consumables and power are monitored; including number of part used wire bobbins, which are presented with their anticipated remaining life on screen. These records, together with component wear tracking help with cost analysis and the costing of pending machining jobs.

1

PROTOTYPING TO AUTOMATED LIGHTS OUT MANUFACTURING CALL 01788 577 288 TO LEARN HOW TO MAKE PROFIT

3D PRINTING APPLICATIONS IN MANUFACTURING WWW.HKH3D.COM WWW.HKH3D.COM

2

DESIGN Initial Prototyping Functional Prototyping Testing

The use of continuous carbon fibre in 3D printing (AM) adds strength to fixtures and tools, which can also be used in the EDM process to hold difficult parts.

A list of jobs depicted over time make capacity utilisation easier to grasp and assist forward-looking production planning and the overview - taking your manufacturing to the next level.

LIGHTS-OUT OPERATIONS

Automation is giving manufacturers even more ways to take advantage of the unique capabilities of EDM for example, diamond wheel dressing in the diamond cell.

The Mitsubishi’s Intelligent AutoThreading system means wire threading at break point is required with maximum dependability ensuring that jobs left to run unattended are completed with no worries. The systems McAnywhere

3 4

remotely allows the user to, if necessary, monitor and adapt programs running with connectivity via a PC, laptop or tablet.

EDM FOR AM

AM, Additive Manufacturing or 3D printing is a process that fundamentally differs from conventional machining methods.

Unlike subtractive manufacturing, in which material may be milled or turned (subtracted away), additive manufacture involves the addition of material built up layer by layer, which is melted or bonded to create prototypes and end-use parts.

The lights out operation means that jigs and fixtures can be printed overnight allowing machining centres to generate profit not undermining the cost of the job.

Alternatively, the revolutionary affordable metal AM technology developed by 3D printer manufacturer Markforged may provide additional income from printing in metal, either finished parts or metal fixtures. This AM technology uses a filament comprised of metal powder and plastic binder — after printing, the binder is dissolved away, and the metal powder is sintered into a full metal part and a technology that is used at our customer demonstration centre in Rugby, Warwickshire.

Demonstrations and sample parts of Mitsubishi EDM cut pieces and Markforged 3D printed parts can be arranged by calling 01788 577288 or visiting www.mitsubishiedm.co.uk / www.hkh3.com

MANUFACTURE Tooling Development End-Use Parts Assembly Inspection Production

EDM TECHNOLOGIES WWW.MITSUBISHIEDM.CO.UK WWW.MITSUBISHIEDM.CO.UK

5

EDM Wire EDM Sinker EDM Fast Hole Drilling EDM

MACHINING & MACHINERY

SWIFT AND EFFECTIVE SERVICE SULZER The stub shaft was shrink-fitted to the shaft before being welded in place.

FAST ROTOR REPAIR ALSO IMPROVES EFFICIENCY

Cracked steam turbine rotor repaired and reinstalled with 8% improvement on performance When a damaged steam turbine rotor needed to be repaired, a power generation plant in Indonesia turned to Sulzer for an expert service. Rather than wait for at least a year for a new rotor from the original equipment manufacturer (OEM), the plant opted for a repair that took only sixteen weeks. This swift and effective repair also managed to achieve an 8% improvement in efficiency.

The Indonesian geothermal power plant had been experiencing some issues with one of its 60 MW steam turbines. During the previous two years, the pre-existing maintenance provider had repeatedly tried to repair the turbine, but the vibration issue had persisted. Despite several attempts to low speed balance the rotor at their premises, it still exhibited high vibration levels.

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INITIAL INVESTIGATION During one of these off-site balancing procedures, the plant engineers discovered deep cracks that were suspected to have been caused by a previous repair by another service company. As well-known experts in the repair of steam turbines, Sulzer was called in to resolve the problem.

Sulzer’s initial inspection revealed that the rotor had cracks on the radius section between the last stage disk and the gland seal area located on both the governor and the generator sides. In addition, there was considerable evidence of erosion on the blades, the disks and the balance correction holes.

REPAIR RE-EVALUATION The initial plan was to machine out the material until the cracks were removed and then rebuild the shaft using submerged

arc welding before machining it to nominal dimensions. However, after comprehensive inspection at Sulzer, the crack propagation already had a spiral shape through the center of the shaft, making it impossible to machine out the crack area only. Sulzer then came up with a repair proposal that involved designing a stub shaft that would be used to join the two pieces together before the shaft was rebuilt to its nominal dimensions.

Andrianto Hapsoro, Head of Engineering, Sulzer Indonesia, explains: “There was always a customer representative in the workshop, which helped maintain excellent communications and keep them up to date with progress. Any rotor repair is time-critical, with lost revenue making every day count in this project.”

With the location of the repair being so close to the 6th disk, some additional repairs would be needed to this disk, which would extend the overall time to complete the project.

Dye penetrant testing was completed to ensure the new rotor had no flaws.

in order to save time, Sulzer proposed both stage 6 disks would be removed and possibly reinstated at a later date. This was then agreed by customer.

Joining two sections of a turbine rotor requires considerable expertise, including computer modelling and finite element analysis (FEA) to ensure that the proposed design would withstand the stresses of normal operation. The FEA was also carried out at an overspeed of 3’600 rpm to ensure that the centrifugal loading on the disks would not cause any damage to the rotor shaft after the repair. With all the necessary analyses completed, the machine shop started to prepare the two rotor shaft sections for the addition of the stub shaft.

In-house precision machining enabled the stub shaft to be shrink-fitted into the prepared connections before the whole joint area was preheated prior to the

welding process. Using precision-controlled, submerged arc welding equipment, the stub shaft was built up to a level that would allow it to be machined back to the required dimensions. Once the original dimensions had been achieved, a series of nondestructive tests (NDT) was carried out to ensure there were no flaws in the completed rotor assembly.

These processes were repeated to remove the cracks in the thrust end of the rotor as well, bringing the completed assembly back to finished dimensions. Once all the machining was complete, the rotor was dynamically balanced before being shipped back to the customer.

IMPROVING PERFORMANCE While the repairs were being completed on the rotor, the field service team was working at the customer’s site to repair the diaphragm

and improve the sealing of the casing. This work would be influential in improving the efficiency of the steam turbine.

Prior to the project being started by Sulzer, the turbine required 393 tonnes of steam per hour to produce the 53.4 MW of energy. Despite one set of disks being removed, the repair to the static and rotor components of the turbine delivered

by Sulzer, enabled it to maintain an output of 55.1 MW but using only 374 tonnes per hour of steam, which is an 8% improvement in efficiency.

When the repaired turbine rotor arrived back on site, the field service team carried out the installation and commissioning, which included vibration testing at full load. All the results were well within the original specifications and the generator has remained at full capacity ever since.

Andrianto concludes: “The customer was very impressed with the results of this project. In total, the whole repair took only 16 weeks, which is considerably less than the estimated lead time for a new rotor from the OEM, which is closer to 52 weeks.”

About Sulzer Sulzer, headquartered in Winterthur, Switzerland, since 1834, specializes in pumping solutions, services for rotating equipment, and separation, mixing, and application technology.

Sulzer provides cutting-edge maintenance and service solutions for rotating equipment dedicated to improving customers’ processes and business performance.

Precision machining was required to ensure a perfect fit.

www.sulzer.com Issue 38 PECM

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SPECIALISTS IN TOOLS & GAUGES WISEMAN THREADING TOOLS LTD

WISEMAN THREADING TOOLS LTD SPECIALISTS IN TOOLS & GAUGES FOR SCREW THREADS We have been supplying threading tools and gauges since 1987.

Together with supplying plain plug and ring gauges this is all that we do, we therefore consider ourselves to be specialists in this field.

We supply worldwide.

We hold extensive ready stocks that include all of the standard stuff that others offer, but also includes taps, dies, die nuts, die head chasers, thread rolls and gauging for threads not normally available 'off the shelf '.

Our real time stocks can be checked and purchased online at www.threadtools. com Just enter the thread details into the search box on the home page.

You will be directed to the item, if stocked, or to our specials, (custom manufacture), sales team. who will quote to supply at competitive rates, in good time.

As an account holder you can also order online from our listed in stock items, at your normal terms. We realise that you need the right item at the right price and quality, and in a reasonable time frame.

We are geared to provide that.

We can ship stocked items same day.

Our experienced sales staff can assist and advise you on any technical issues.

We welcome enquiries from resellers and can offer terms to suit.

WISEMAN THREADING TOOLS LTD

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

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Threading Tool Specialists

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

THREAD CUTTING AND ROLLING HEADS and parts and repair service

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

HSS TAPS Huge Stocks for all Standard threads CUSTOM MADE taps our SPECIALITY! We stock taps for many non standard (SPECIAL) threads

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!

All types; Spiral flute and point, Fluteless, Left Hand, etc, etc.

Wiseman Threading Tools Ltd 11 Padgets Lane, South Moons Moat. Redditch B98 0RA Worcs UK 004(0)1527520580 sales@threadtools.com www.threadtools.com Issue 38 PECM

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TEMPERATURE SENSORS LABFACILITY

TEMPERATURE AND PROCESS TECHNOLOGY

Labfacility will be present at the below Exhibitions; HCA 10th – 12th April 2019 Celtic Manor Stand No. 50

TEMPERATURE SENSORS

Labfacility manufacture a wide range of temperature sensors to suit your application. An extensive range of Thermocouples in IEC or ANSI calibration, PRT’s, Detectors, Environmental Sensors and Hand-Held Sensors / Thermometers are available to buy via our ecommerce website.

VERIGO COLD CHAIN DATA LOGGERS

Labfacility are now UK distributors of the Verigo Cold Chain range of Data Loggers for monitoring temperature, humidity and food storage quality - Introducing the new Pod Range. Cold Chain Monitoring - Easier than ever. Save time, ensure quality, and increase visibility of your temperaturecontrolled logistics operations. NO wires or Wi-Fi required.

L60 THERMOCOUPLE & FINE WIRE WELDER

The Thermocouple Welder, manufactured

by Labfacility, is a compact, simple-to-use instrument designed for thermocouple and fine wire welding.

THERMOCOUPLE CABLE / WIRE

THERMOCOUPLE CONNECTORS

We are Europe’s largest manufacturer of thermocouple connectors and accessories in IEC, ANSI and JIS Colour codes. The full range of connectors are available from stock for immediate despatch.

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Northern Manufacturing 2nd – 3rd October 2019 Manchester Advanced Engineering 30th - 31st October 2019 NEC Birmingham Stand No. N16

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

BI-METAL THERMOMETER TEMPERATURE GAUGES

Bi-Metal Stainless Steel Thermometer with bottom or back entry and ‘anyangle’ versions available. Use our custom configurator to send us your specific requirements, made to order.

Nuclear Solutions 15th May 2019 Birchwood

We offer a wide range of thermocouple, PRT and extension cable / wire in stock for immediate despatch.

Thermocouple cables are available in IEC or ANSI Colour codes.

Insulation types include PFA, PTFE, PVC & Fiberglass.

In addition to the stocked items, Labfacility also offers bespoke Temperature Sensors.

We are specialists in the design and manufacture of custombuilt temperature sensors at our 12,000-square foot Yorkshire plant located in Dinnington Quality and Service are key elements in the continued growth of Labfacility; technical support for both sensing and instrumentation is always freely available from our experienced technical sales teams. www.labfacility.com

MEASUREMENT & MONITORING

THE 2060 MARGA METROHM

A RE-INVENTED WAY OF AIR QUALITY MONITORING Ambient air quality is critical for our health and the environment. According to the World Health Organization 91% of the world population lives in places where the WHO air quality guideline levels are not met. To monitor the air quality, Metrohm Process Analytics has re-invented the well-known Monitor for AeRosols and Gases in ambient Air (MARGA) as the 2060 MARGA. When considering the effects of aerosols on health and the environment, it is necessary to understand how they are formed from their precursor gases and how their concentration and composition vary with diurnal and seasonal cycles. To achieve this, continuous measurements are required with sufficient time resolution so that the various aerosol formation processes can be clarified.

Metrohm Process Analytics has developed the 2060 MARGA, which is a fully autonomous sampling and measurement system that continuously measures the water-soluble gas and aerosol components that have a direct effect on air quality. Air is drawn in to the instrument by a vacuum pump at a constant flow rate. Before entering the instrument, the maximum size of particulate matter (PM) can be limited by utilizing a size-selective inlet (e.g. PM 1.0, PM 2.5 or PM 10). A dual-channel ion chromatograph (IC) quantifies anions and cations in aerosols and water-soluble gases simultaneously with high accuracies to reach detection limits as low as 0.001 µg/ m3.

Gases measured: Hydrochloric Acid (HCl), Nitric acid (HNO3), Nitrous acid (HONO), Sulfur dioxide (SO2), Ammonia (NH3) Aerosol ions measured: Chloride (Cl-), Nitrate (NO3-), Sulfate (SO42-), Ammonium (NH4+), Potassium (K+), Calcium (Ca2+), Magnesium (Mg2+) The 2060 MARGA is available in two versions: The 2060 MARGA Research is an excellent choice for air monitoring during research campaigns (e.g. to study seasonal cycles).

When the 2060 MARGA R isn’t being used for air monitoring, the IC can still be used as a stand-alone laboratory instrument.

The 2060 MARGA Monitor is used to monitor the air quality 24/7 at a fixed position.

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www.metrohm.com/en-gb/productsoverview/process-analyzers/ applikon-marga/

CODEL Monitoring Solutions

Continuous Emission Monitoring

Road, Rail and River Tunnel Monitoring

Biomass and Raw Gas Monitoring

Safety and Process Control

EnergyTech TunnelTech

sales@codel.co.uk

SmartCem CODEL live

www.codel.co.uk

+44 (0)1629 814351

software incl.

£ 5580

from

Thereʼs no two ways about it: Our exchangeable microscope optics for IR cameras come with a detail resolution of 28 μm and a frame rate of 125 Hz.

Also interested in really fast, rugged, light, accurate, customised and inexpensive infrared thermometers and cameras for non-contact measurements between −50 °C to +3000 °C? Visit www.optris.co.uk

Microscopic.

MEASUREMENT & MONITORING

Innovative Infrared Technology

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Innovative Oil in Water Analysis from Turner Designs Hydrocarbon Instruments Turner Designs Hydrocarbon Instruments introduces the new standard in grab sample oil in water analysis. The TD-550’s optics are suitable for crude and other heavy oils. The TD-560 adds a second optical channel for detecting lighter hydrocarbons, such as BTEX, gas condensates, fuels, and lube oils.

Applications: Industrial discharge, waste water, cooling water, intake protection, produced water, and treatment verification.

Features • Low cost per sample analysis • Large full-color touch screen interface • Advanced data logging and graphing capabilities • Results can be correlated to official lab methods such as USEPA 1664A and ISO 9377-1 For more information on the TD-550 and TD-560 Oil in Water Analyzers as well as the complete TDHI product line, visit oilinwatermonitors.com.

Newmax Precision Ltd NEWMAX PRECISION Ltd, component manufacturers based near Heathrow on M25, are always striving to stay technically ahead by acquiring the latest in 5-Axis machining technology.

With our Matsuura MX-330, 90 tool multi pallet Machining Centre, backed up with the latest Hypermill 5-Axis programming software, we can meet all the latest technical demands needed for the modern Sub-Contracting Industry.

Detecting Leaks from Electrical Circuit Breakers FLIR Systems has published a new application spotlight that addresses the challenge that electrical power stations face in detecting gas leaks from their Sulfur hexafluoride (SF6) circuit breakers. Sulfur hexafluoride circuit breakers protect electrical power stations and distribution systems by interrupting electric currents, when tripped by a protective relay. Advantages of sulfur hexafluoride circuit breakers over other media include lower operating noise, no emission of hot gases, and relatively low maintenance.

For a copy of this application spotlight please visit www.flir.eu/instruments/ utilities/application-spotlight-inspect-sulfurhexafluoride-sf6-circuit-breakers/. For more information about using optical gas imaging cameras for leak detection in electrical power substations / transmission please visit www.FLIR.com/substation-transmission or contact FLIR Systems on +32-3665-5100 / gasimaging@flir.com.

Submersible Load Cells Lower the Cost of Large Tidal Turbine Designs The EPICTidal Team (Lab-Sea-Systems, Cranfield University and Designcraft Ltd) wanted to know the performance implications of employing lower cost manufacturing methods of large scale tidal turbine rotors.

SOLUTION – Applied Measurements DDEN Submersible Load Cells

Utilising the 10 Pallet system, gives us the ability to run unmanned, ensuring us the flexibility to work with and meet all client deadlines.

We are an ISO 9001:2015 registered company, committed to high standards of quality, delivery and competitive pricing. Go to our web site www.newmax.co.uk and upload a drawing for us to quote.

The rotor blade design was coupled to a submersible tidal turbine test rig containing 2 DDEN submersible load cells. Once placed in a state-of-the-art test tank, the team were able to increase the size, flow rate and turbulence levels within the tank. The first DDEN load cell measured the torque and the second measured the thrust of the tidal rotor design.

Newmax Precision Ltd T: 01753 631112 www.newmax.co.uk

If you have a torque application you would like to discuss, please contact Applied Measurements on (+44) 0118 981 7339 or visit appmeas.co.uk/discuss-torque/

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The new ACEINNA MCX1101 current sensor is the industry’s first high accuracy current sensor based on AMR Technology Highly accurate, wide bandwidth, fully isolated and affordable current sensing, this “All in One”, easy to integrate Current Sensor provides power management for power inverters and motor control, industrial robots and manufacturing systems, telecom and server farm power supplies, automotive EV charging stations, IoT appliances, home automation and many other tech applications The new ACEINNA integrated, Current Sensors provide the best performance for the price in the industry. There are other AMR based current sensing solutions on the market, but they require a great deal of integration to make them work.

Ours are plug and play. www.aceinna.com/current-sensors

PhoenixTM Ltd - Phoenix Temperature Measurement PhoenixTM Ltd design and manufactures ‘thruprocess’ temperature monitoring systems for the heat treatment industry. Providing solutions for various industrial sectors including heat treatment of aluminium and steel, ranging from raw materials (Slab, billets etc) to finished products, such as carburizing automotive components. Other applications include Paint and Powder Coating, Food Processing (HACCP), Glass Processing and Ceramic Firing. Protected by a thermal barrier, the data logger travels through the process and thermocouples measure the product temperature. A historic temperature record (Profile graph or TUS) is collected which then can be analysed using Industry specific software to generate AMS2750E and CQI-9 compliant reports.

Understand, Control, Optimize and Certify your furnace process to guarantee product quality, process operation efficiency and regulatory compliance.

Tel:+44(1353)223100 | sales@phoenixtm.com www.phoenixtm.com

Continuous monitoring of aerosols and gases in ambient air 2060 MARGA - fully automated analysis 24/7 Ambient air quality is critical for our health and the environment.

Metrohm Process Analytics present MARGA: the fully autonomous sampling and measurement system that continuously measures the water-soluble gas and aerosol components that have a direct effect on air quality.

www.metrohm.co.uk

MEASUREMENT & MONITORING

INSTRUMENT DEVELOPMENT KOBOLD

KOBOLD INSTRUMENTATION – PRODUCT DEVELOPMENTS FOR WATER AND WATER BASED LIQUIDS

For 2019 the KOBOLD Group continues a program of pragmatic instrument development with enhanced editions of the class leading MIM electromagnetic flow meter, introduced earlier in 2018, now featuring connection sizes from ½” to 2”, and a remote version for process temperatures up to 130°C. New for 2019 is model MIS, a full bore electromagnetic flowmeter featuring the unique and versatile electronics module from the popular MIM instrument, allowing for all flow directions due to the indexing programmable digital TFT display screen. As with its instrument parent, model EPS/DMH, the cast steel bodies will be available with a choice of hard rubber, soft rubber, PTFE/PFA, EPDM, and ceramic liners. Also for 2019, both the MIM and the MIS instruments now feature IO-Link, a useful and increasingly requested feature, especially for Industry 4.0 compliance.

Standard analogue, frequency, and pulse outputs are standard as well as alarm, dosing, and totalising features. The MIM however remains unique with the inclusion of a built-in Pt1000 sensor.

With elements borrowed from the MIM and EPS/DMH models, the new MIS model is clearly a very competent full bore electromagnetic flowmeter, suitable for a wide range of standard applications, and price competitive too. However, where a higher technical specification is required, such as HART® or ATEX, or even larger pipe sizes up to DN1200/ANSI 48”, the EPS model with revised UMF2 electronics launched in 2018 to replace the DMH model covers all bases. For applications where insertion is the preferred method of installation the revised PIT model is ideal and utilizes the familiar UMF2 electronics.

As well as electromagnetic flow meters, for water applications KOBOLD manufacture an extensive range of flow instruments including variable area, rotating vane, turbine wheel, ultrasonic, vortex, differential pressure, and Coriolis. With a great range of pressure, temperature, level, and analytical instruments, KOBOLD are one of the world’s most comprehensive manufacturer and supplier of process instruments.

2019 promises to be a very good year for KOBOLD with further developments and product launches; watch out for new and innovative pressure and temperature products during the course of the year!

www.kobold.com/en info.uk@kobold.com

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MEASUREMENT & MONIROTING

GAS DETECTION FLIR SYSTEMS

FLIR SYSTEMS ANNOUNCES THE FLIR GF77 GAS FIND IR, ITS FIRST UNCOOLED THERMAL CAMERA DESIGNED FOR DETECTING METHANE This new handheld camera offers inspection professionals the features they need to find potentially dangerous, invisible methane leaks at natural gas power plants, renewable energy production facilities, industrial plants, and other locations along a natural gas supply chain. The GF77 provides methane gas detection capability at roughly half the price of cooled gas inspection thermal cameras, to empower the oil and gas industry to reduce emissions and ensure a safer work environment.

Based on the award-winning design of the FLIR T-Series camera platform, the lighter weight GF77 features an ergonomic design, a vibrant LCD touchscreen, and a viewfinder to make it easy to use in any lighting conditions. The camera is engineered specifically to detect methane in order to improve gas inspections and reduce the chance of false readings. The GF77 also offers FLIR’s patented High Sensitivity Mode (HSM), which accentuates movement to make tiny gas plumes more visible to the user.

FLIR designed the GF77 to include its most up to date technological features, including laser-assisted autofocus to help inspectors target leaks better, and one-touch contrast improvement that makes gases stand out clearly against the background. Additionally, a rapid-response graphical user interface helps professionals increase efficiency by allowing them to organize job folders, record notes, and add GPS location annotation on the camera.

“Optical gas imaging technology is a real benefit to industries that use or produce methane, but the cost of the technology has been a barrier for some customers,” said Jim Cannon, President and CEO of FLIR Systems. “The FLIR GF77 Gas Find IR gas detection camera is built around an uncooled, longwave infrared detector, which costs less to produce than our higher performance, cooled cameras, and therefore we can provide it to customers at a more attractive price point. By providing the industry with access to this groundbreaking technology, we can help improve the safety of professionals on the job.”

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FLIR Systems, Inc. is a world leader in the design, manufacture, and marketing of sensor systems that enhance perception and awareness.

FLIR’s advanced thermal imaging and threat detection systems are used for a wide variety of imaging, thermography, and security applications, including airborne and ground-based surveillance, condition monitoring, research and development, manufacturing process control, search and rescue, drug interdiction, navigation, transportation safety, border and maritime patrol, environmental monitoring, and chemical, biological, radiological, nuclear, and explosives (CBRNE) detection.

To learn more, please visit www.flir.com/ GF77. or contact FLIR Systems on +32-36655100 / gasimaging@flir.com.

For more information, go to FLIR’s web site at www.FLIR.com.

MEASUREMENT & MONITORING

IOT PLATFORM CAPTION DATA

FINDING AN IOT PLATFORM AS A SERVICE [PAAS] THAT REALLY WORKS FOR INDUSTRIALS! If you have an asset base that runs into hundreds, thousands or more and you want to connect them to an Industrial IOT platform there are a few key questions you will need answering. For example: Does this platform really work? Whats the evidence? Whats the installed user base?

What sort of comm’s protocols will it handle?

What happens when comm’s are interrupted?

Is it multi national [not just language but date stamping events, storage of data, and of course language as well]? What about Cyber security – is it hackable? Whats the evidence?

And crucially how easy is it to configure, deploy and scale? And a host more besides!

exact needs for refinement of the basic system. If your assets have existing comms output we can take that directly to our SmartHub. If not our NanoULTRA Edge will act as a gateway

not, as the unit has no comms ports and no operating system so nothing to attack, and uses its own microcontroller to control the outwardly initiated communication process to our servers via a modem.

WHATS THE INSTALLED USER BASE?

HOW EASY IS IT TO CONFIGURE, DEPLOY AND SCALE? Ask to explore other user sites with numbers of devices/users similar to yours. Quiz the architecture for systems administration functionality – can you mirror your actual operating structure so the information and analytics can really be used in your organisation as is? You may want a variety of dashboards serving different levels from field technicians, through team management up to board level oversight. Where is data actually stored [local servers, AWS, etc] and where does that take you in terms of security/ uptime etc.?

So taking the above questions in turn:

Ask your proposed platform supplier about their user base, and to talk to some actual users. There are a couple of angles here: firstly the breadth of experience across different hardware and comms options and how they work in different market sectors.

Secondly about the user experience in terms of support, UI/UX of the product, on-going relationships with the supplier. In CDL case our declared mission is “to help power our customers businesses through our technology”, and we think intuitively about the lifetime value of our relationship with our customers, and they with their customers – not just the next sale! You can check out some of our client reviews here.

DOES THIS PLATFORM AS A SERVICE REALLY WORK? WHATS THE EVIDENCE?

WHAT ABOUT CYBER SECURITY – IS IT HACKABLE? WHATS THE EVIDENCE?

Ask your prospective partner to hook up a couple of your units to demonstrate. CDL often get involved in this and it proves really useful to us to understand your needs and your equipment, and we like to think it helps you by seeing live [and with minimum fuss] how your product looks on-line. It will quickly become obvious what the evidence and knowledge base is. In CDL’s case this often shows up in the speed with which we can get equipment talking, demonstrate immediate analytics and quickly start specifying your

A whole topic on its own, but you do need to discuss things like password policies and security – is Multi factor authorisation relevant? Where and how is data stored? For how long and who owns it? In our case it is always the client who owns it, we are the custodians, and use AWS cloud. When did your prospective partner last do a pen test?

How good is their operational resilience? How are your assets going to talk to the Platform as a Service? Is this a point of weakness – if we use our NanoULTRA Edge we are sure its

Well, whatever your questions the engineers at CDL will work with you to answer them.

We have been providing industrial IOT systems for over a decade now [it wasn’t called IoT back then, but remote monitoring!] and we provide end-to-end IIOT hardware solutions to industrial customers, including many global blue chips, but we also provide access to our CDL SmartHub portal for clients who already have quantities of already installed hardware with comms possibilities.

This means they can tap into the knowhow we have developed over 10 years as a company and hundreds of man-years experience from our own employed software, firmware, server and support engineers, and thousands of installed systems with millions of reporting data events every day.

As you can see there is a lot to consider and the key message here is not about the technical answers or ways of doing things but about the need to find a partner to work with you who “gets all this” and lives and breathes it, so you reduce your risks and increase your probabilities of successful implementation via an Industrial Platform as a Service. Take a look at our purpose video for more on how we work with our clients.

If you would like to know more about our Industrial IoT solutions and how we can help you monitor your assets, please call us +44 (0) 1905 754 078 and ask for one of our IoT Application Specialists. info@captiondata.com www.captiondata.com Issue 38 PECM

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Introducing New Generation of Portable Dewpoint Hygrometers •

Full colour screen displaying multiple units

•

Desiccant Dry-Down Chamber for fast response

•

Automatic Calibration

•

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

•

Display in choice of 10 languages

•

Full data logging capability

•

Real time logging with screenshot feature

•

Wireless Bluetooth & USB connectivity

•

View display screen on smart phone or tablet

•

Wireless printing to dedicated printer

•

Integral pressure calculator to display pressure dewpoints

•

Easy to use with icons and intuitive control

•

Strong, durable and rugged, IP66 construction

•

Rechargeable batteries, 150 hours use in continuous operation

•

Certificate of Test & Calibration

•

Generous 2 Year Warranty

SADPmini2 shown

SADPmini2-Ex

Intrinsically safe for use in hazardous areas. Certified to ATEX, IECEx & cULus listed.

Alpha House, 96 City Road, Bradford, West Yorkshire, BD8 8ES. www.amsystems.co.uk

Call us on 01274 733 100

or email: SADPmini2@amsystems.co.uk for further information

MEASUREMENT & MONITORING HIGH-DEF MAPPING SERVICE

We give you access to a fully integrated and supported end-to-end IoT solution to effectively manage your assets.

Combining hardware from our NanoULTRA range that seamlessly connects to our cloud based application, the CDLSmartHub™, allows you to turn raw data into actionable insights.

We are an agile company that delivers our customers an Industrial IoT solution, from hardware and software-as-a-service through to implementation and support.

SCS offers a high-definition thermal mapping service for inaccessible components. Understanding the thermal properties helps to design more efficient and environmentally friendly engines.

SCS’s technology is based on coatings with a thermal memory, which luminescent properties permanently change when heated during operation. After operation, an automated optical read-out device measures these changes across the entire component surface, which can be correlated to the peak temperature, covering a range from 150 °C to 1,400 °C.

The 3D temperature data is mapped straight onto customers CAD drawings.

With the development of this time and cost-effective temperature measurement system, SCS’s technology replaces and compliments current thermometry methods. The technology will be beneficial in all industrial sectors, where temperature information is essential.

Our purpose is to harness the Industrial Internet of Things to help power your business

enquiries@sensorcoatings.com Phone: 02037639456 www.sensorcoatings.com

www.captiondata.com solutions@captiondata.com

MIKRON THERMAL IMAGING CAMERA MCS640 The MIKRON MCS640 from LumaSense Technologies, an Advanced Energy company, is a short wavelength infrared (SWIR) thermal imager with internal digital signal processing. This camera is designed to accurately measure temperatures between 600 and 3000°C, suitable for applications such as measurements on metallic surfaces, graphite and ceramics, etc.

Images in real-time at 60 Hz (60 images per second) for dynamic temperature processes can be displayed.

The compact design of the MCS640 enables the integration of the camera into compact production machines, while the solid and robust housing guarantees reliability even in harshest industrial environments.

The MCS640 thermal imager can be used in many metal applications including: preheating, annealing tempering, welding, forging, hardening, sintering, melting, soldering, brazing, and rolling.

The built-in Gigabit Ethernet interface (GigE) allows the camera to be connected to the network for long data transmission or to LumaSense’s application software for further analysis

LumaSense offers a wide variety of compatible optics for the MCS640, allowing each instrument to be configured exactly to the measurement needs of the desired scene. Microscopic lenses are also available, allowing accurate measurement of small objects, such as filament temperatures.

The 640 x 460 resolution pixel detector enables to display 307,200 measurement points with superior measurement accuracy of 0,5% of reading and is designed to allow precise targeting of small objects in a wider field of view.

LumaSense Technologies GmbH -An Advanced Energy CompanyLTI.info@aei.com www.lumasenseinc.com

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Why pay for features you can’t really use, asks Metrel?

Saving the complete test results including the 6 mA DC for the first of a string of car charging points could not be simpler with this Metrel multifunction tester’s graphical interface.

“Over the years there have been many versions of downloading test meters, but none have caught on.” said Brendan Beaver, the UK manager of Metrel, the provider of innovative electrical test solution.

“We believe this is because the manufacturers of these testers fail to put themselves in the minds of their customers.”

“Right now lots of electricians own, and use daily, testers that are capable of storing their test results but find the feature too complicated and long winded to use, because they need to make notes about which circuit and board each relates to which location in the testers memory. They prefer to fill a copy of a certificate by hand and then make a fair copy either in their best hand-writing, or by typing it up in to a computerised certificate when they get home. What a waste of their time! “ “Ideally what an engineer needs to be able to do his testing, and save both his results and notes on his tester without recourse to a pencil and paper, ready for sending to the depot or down loading quickly and without drama on return to the office.”

“This is not available when a conventional LCD screen is all that is provided, as on ordinary multi-function tester.

This probably accounts for the fact that, though many downloading testers have been purchase, there are very few operators using the download feature.”

“With the introduction of dot-matrix displays by Metrel, increasing numbers of users of multi-function testers like MI3152 and MI3155 are finding the ability to make notes using the touch screen’s full keyboard allows them to leave the pencil and paper at home. The on-board fuse table and connection help screens allied with the pass and fail indicators give the operator confidence to pass the results to storage.”

“Meanwhile Metrel’s new memory management system is unique.”

“Again benefiting from the dot-matrix touch screens, it allows the operator to visualise the installation, highlighting components with coloured icon, making it easier to post the results to the correct circuit without writing anything down. This simplicity is continued when the results are downloaded, quickly and easily into an 18th Edition certificate via the USB port.”

“Is it any wonder that a high proportion of Metrel customers are using the results storage and download features of their testers?”

www.metrel.co.uk

NEWS & EVENTS ON-CAMPUS AND ONLINE PROGRAMMES; WORKING IN SYNERGY

ABERDEEN MARINE CHOOSE SEASHIELD 2000FD™

It’s the start of the year and already there is a great example of shared experiences. During January we host an additive manufacturing residential primarily for online students.

During the residential experienced engineers studying on the programme presented the real-world challenges they are facing within their oil and gas business.

This was an opportunity for discussion for undergraduate graduates who are also able to share their ideas and ambitions within the sector.

This is just one example among many of how offering flexible suite of on-campus and online programs for general engineering, manufacturing, and now civil engineering and the built environment can work synergistically together.

It’s not just the students sharing but also one of the reasons we have data visualisation from the

core computing programme in our manufacturing programme.

Changing a business process typically has a knock-on effect in a number of areas including the supply chain. Visualising these changes is a key skill to help businesses gauge the impact.

derby.ac.uk/online/ UDOLenquiries@derby.ac.uk

When Aberdeen Marine Ltd were awarded the contract to protect six piles on the Eriskay Causeway Bridge in the Western Isles they suggested the use of the Winn & Coales (Denso) Ltd SeaShield 2000FD™ System as an alternative to the original specified system.

They submitted details of the technical merits of the SeaShield 2000FD™ system and the benefits in using this tried and tested system to the Western Isles

Council, who agreed to the change in the specification.

Seashield 2000FD™ is a heavy duty robust system which provides protection against corrosion on Marine piles. It consists of Denso S105 Paste™, Denso Marine Piling Tape™ and a HDPE Jacket which is applied by pneumatic tensioning equipment and secures with stainless steel bolts. www.denso.net/

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

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

Could your company qualify for widely available funding?

A STRESS-FREE EXPERIENCE FROM START TO FINISH

From R&D claims, Patent Box to Land Remediation and Creative Industry tax relief, publicly funded incentives and grants are a valuable resource for businesses – yet so many fail to claim.

Is your company one of the 97% of businesses that incorrectly assume they can’t apply for funding to support their innovative work? Don’t miss out on the potential of this valuable financial support simply because you didn’t choose to make a quick call!

We’re here to help you…

We know that perceived barriers such as complicated reporting requirements and a lack of awareness or difficulty in identifying eligible activity can stop businesses from accessing this crucial funding. But we can do all that for you…

With our proven track record of successful client claims and extensive experience

At MCS Corporate, we take care of the full process, ensuring that it’s smooth and hassle free at every step – to reduce the impact on you and your team.

Speak to one of our friendly experts today and let us: • Find grants and incentives in your sector.

• Evaluate your eligibility.

• Identify the criteria you need to meet to get funding and assistance.

• Prepare and submit full applications and documentation on your behalf.

• Liaise with the awarding body, including HMRC, on your behalf.

WHY CHOOSE TO PARTNER WITH MCS?

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

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

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

Research, innovation, new products, process design and business development are driven by the range of valuable funding schemes that are readily available for companies of all sizes and in all sectors.

We partner with ambitious companies to extend the global, domestic, technological and economic effects of their work. You can read a selection of case studies and view additional resources on our website.

Take 10 minutes to get in touch and we’ll be able to quickly and efficiently assess your funding eligibility.

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

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NEWS & EVENTS

GDPR AND BREXIT EMS

WHAT DOES THE FUTURE HOLD FOR MANUFACTURING?

By Jonathan Plummer, General Manager of Electronic Manufacturing Solutions

GDPR and Brexit both seem to be all anyone has talked about over the past few years.

Yet no one seems to be any clearer on these topics.

GDPR (General Data Protection Regulation) came into force in May 2018. But many companies (particularly smaller ones without a specialist, dedicated team handling data) are still unsure about what exactly this entails. As for Brexit, no other country has left the EU before so there really is no yardstick.

And with more scare stories available than facts, it is very difficult to know what may or may not happen post 29th March 2019.

So, in light of this – what does the future hold for the manufacturing industry?

manufacturing industry, GDPR offers a framework for building trust and being more transparent. It doesn’t stop companies working with personal data. It just allows them to redefine their relationships with customers, employees and suppliers.

As a result, manufacturers which work to gain the proper consent and demonstrate they are using the data properly will be rewarded with customers that are willing to consent to their data being used. Enabling companies to continually improve and personalise the services they deliver.

HOW DOES EMS FIT IN?

THE GDPR OPPORTUNITY

Although GDPR came into play almost a year ago, it’s still a hot topic. The regulation protects the personal data of any EU resident and applies to any company that has employees, suppliers or customers in Europe. Meaning even a US-based manufacturing company that uses a UK supplier for component parts will be bound by the rules of the regulation. And while there is a lot of uncertainty about Brexit, one thing is clear: GDPR is here to stay (the UK government has already said the regulation will continue no matter what the outcome is).

As many manufacturing companies move from mass production to customisation, GDPR could be seen as a potential threat to innovation. On the surface, the regulation appears to restrict a company’s use of personal data. Making it difficult for manufacturers to tailor products and services based on their customers’ behaviours and preferences.

However, it also presents a significant opportunity for the future. Within the

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of Procurement and Supply (CIPS) found that 32% of UK businesses who used EU suppliers in 2017 were already looking for British suppliers. So, what are some of the benefits of reshoring?

Many people will argue that offshore manufacturing is cheaper, but this isn’t always the case when you take the logistics costs into account. Plus, there are fewer hoops to jump through if all parts of the supply chain remain in the UK. Local manufacturing also offers added flexibility, improved communications, enhanced control and visibility, better lead times and often higher quality end results.

Additionally, reshoring UK manufacturing presents a great opportunity when it comes to retraining people and reskilling them in new techniques.

OVERCOMING BREXIT UNCERTAINTY

When it comes to Brexit, things are more uncertain. We don’t yet know what the final deal will be (or even if there will be a deal at all). And there are still talks about a second referendum to potentially ‘cancel Brexit’ altogether.

In terms of trading, leaving the EU without a deal would likely result in the most change and disruption. This scenario could potentially see supply chains become more complex and the cost of moving goods to or from the UK increase – as well as restrictions on the free movement of labour.

But rather than being something to be feared, this could actually present a good opportunity for manufacturers to move production back to the UK in the future.

In fact, a survey by the Chartered Institute

Many manufacturers have already realised the benefits of reshoring, but the process is far from straightforward.

Cost and profitability are critical to the success of any reshoring. At EMS, we have helped several customers reshore their requirements for electronic manufacturing services back to the UK from both the Far East and Europe. Tools such as the CostDifferential Frontier (CDF) calculatorcan also help companies compare the options of producing locally or offshoring, by looking at demand variability and putting a number on the costs.

As a sole UK manufacturer, all our production is carried out in Newbury, Berkshire – allowing our customers to benefit from all the advantages associated with using a local company. Our specific New Product Introduction (NPI) teams are also always on hand to ensure communication is clear at every stage of the process and that everything runs smoothly – while eliminating any ambiguity regarding data, production and processes.

www.emsolutions.uk.com/ sales@emsolutions.uk.com

NEWS & EVENTS

PRACTICAL ASPECTS OF PROFINET, PROFIBUS AND IO-LINK Presented by PROFIBUS and PROFINET International and hosted by Endress+Hauser, this event addresses the key practical issues arising from the use of digital communications technologies in automated manufacturing and process industry applications, with particular attention to Industry 4.0 and the Industrial Internet of Things (IIoT).

Covering key application areas such as control systems and energy management, pulp & paper, chemical, utilities, pharmaceutical, mechanical handling and logistics, robotics, automotive engineering, electrical and electronics assembly, packaging and printing, it focuses on the practical aspects of using PROFINET, PROFIBUS and IO-Link, from system design and safety considerations through to faultfinding and maintenance.

Supported by an exhibition with demonstrations of actual tools used in configuration and maintenance, the seminar will be of great value to Designers, Production/System Engineers, Instrument Technicians/Engineers and C&I Engineers involved in the design, operation and maintenance of modern automated factories and process plant.

With nearly 80 million nodes installed worldwide, PROFINET, PROFIBUS and IOLink are truly market leaders, providing state of the art digital communications addressing all the needs of manufacturing and process industries, significantly lowering capital expenditure on installation, commissioning and maintenance. They offer unprecedented integration of automation, control, monitoring and safety systems using standardised and widely supported communications and networking solutions.

This seminar is ably presented by specialists from PI UK member companies. Attendance is free of charge to pre-registered delegates from the User community, i.e. companies that own, operate, design, build or maintain automated process plant and manufacturing facilities. The event will provide delegates with an excellent networking opportunity and the ability to speak to experts.

For more information and registration go to: https://wp.me/p2ChOt-6Uo or email admin@profibus.org.uk

Helping you improve safety, efficiency and compliance

LEARN

SOLVE PROBLEMS

EEMUA’s goals are member focused and aimed at helping you to operate safer sites with a skilled and competent workforce.

EEMUA provides a broad-based resource for all those for whom good practice in a range of industries is a critical feature – engineers, purchasers, specifiers and those involved in training.

Publications

Industry news

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

SHARE EXPERIENCES

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

Learn more on the benefits of EEMUA membership – contact membership@eemua.org

Upcoming EEMUA events:

Strengthening your cyber security weak spot – 23 May 2019 – Birmingham Detecting and managing HTHA – 20 June 2019 – Manchester

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NEWS & EVENTS

Transvac continues to inspire Nottingham University students For the 5th consecutive year, Transvac has opened its doors to a group of Nottingham University Students. Each year, students tour Transvac’s Derbyshire Head office to get a firsthand look at departments such as technical sales, process, R&D and manufacturing. It’s a great opportunity to see how newly-learned engineering skills can be applied in a UK based engineering SME. The tour was conducted by two previous UoN students (now Transvac employees) and a student currently on placement. Yet again, the tour was a great success and Transvac look forward to welcoming another student group next year.

To enquire about tours, Ejector solutions and more please visit www.transvac.co.uk.

Fulton achieves CPD certification for its new VSRT training course Fulton is delighted to confirm that its VSRT Steam Boiler Operation & Maintenance course has been certified by the CPD Certification Service as conforming to the continuing professional development principles. The news follows the company’s announcement in late-2018 that it had achieved similar CPD Certification status, but for its Vertical (J Series) Steam Boiler Operation & Maintenance course.

Commenting for Fulton, aftercare and business development manager Jeff Byrne says: “You could be forgiven for thinking that achieving certified status for the VSRT course was easy as we had recently achieved similar for our vertical steam boiler course. However, given the radical design of our double-award-winning VSRT steam boiler and the fact that it was only launched in early-2018, it took months of extra assessments to achieve. We are therefore delighted to have gained certification for the training course so quickly.” www.fulton.co.uk.

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BevExpo 2019

New partnership!

BevExpo 2019 is an opportunity for the wider beverage industry to meet, learn and discover the excellence of products and services within the entire beverage industry supply chain.

OEM Automatic Ltd is proud to announce a new partnership with SONY image sensing solutions.

OEM Automatic Ltd will be exhibiting products from two leading manufacturers in the hygienic process sector. Definox specialises in the design and manufacture of valves and pigging systems for industrial processes in the food, dairy, brewing and chemical industries.

Anderson-Negele specialises in sensors and measuring equipment for hygienic applications focussing on the special needs of the food, brewing, beverage and dairy industries.

This new partnership offers customers a wide range of cameras thereby providing a reliable, dependable total machine vision solution from one source encompassing lenses, lighting, cameras, industrial PC’s, software and filters.

SONY have recently focussed on refreshing their line of cameras to better represent the quality, functionality and reliability of the SONY Pregius range of CMOS image sensors. T

With products on display from both manufacturers OEM Automatic look forward to meeting you on our stand (88) at the Ricoh Arena on 25th / 26th June.position-no other power source is involved.

he XC revitalised high speed range of vision cameras for general automation, quality and robot guidance applications: GIG-E in 1.6MP, 2.4MP and 5.1MP USB3.0 in high speed 1.6MP CAMERA LINK in 5.1MP and 12.4MP On sensor polarised cameras for ITS, QC, Glass and plastics inspection

For more information visit www.oem.co.uk or call 0116 214 5267.

For more information visit www.oem.co.uk or call 0116 214 5267.

Plymouth-based Waterjet Industries re-financed their state-of-the-art machinery to raise £80,000 with Henry Howard Finance to complete a management buyout

Dawson Shanahan invests in new machines to meet demand

Launched in 2007, Waterjet Industries aims to be the first choice for any water cutting requirements. A waterjet is an industrial tool that’s capable of cutting a wide variety of materials using high pressure water. With two precision waterjet machines, Waterjet Industries work with businesses in numerous sectors including aerospace, automotive, marine, oil and gas, power generation and precision engineering. Waterjet cutting technology is also more environmentally friendly than traditional precision cutting technology as there are no noxious gases or liquids used, nor hazardous vapours.

To contact Henry Howard Finance please contact 01633 415222, www. henryhowardfinance.co.uk

Dawson Shanahan, the leading specialist in precision engineering and cold forming, is continuing to expand its UK production facilities with the installation of two further Citizen machines. The L20-VIII and the new L32-VIII are high precision CNC lathes which are both flexible and versatile enough to meet high production demands. Dawson Shanahan’s long-term commitment to quality and service is helping to swell its order books and necessitating investment in new capital equipment to keep up with global demand for its products. The Citizen L32-VIII sliding headstock CNC automatic lathe is a 7-axis model and was a logical choice for Dawson Shanahan. With its modular design, up to 30 tools can be mounted at any one time.

Supported by a high level of control features, the machine can produce phenomenal work rates, improving both productivity and profitability. www.dawson-shanahan.co.uk.

NEWS & EVENTS

ADAPTABLE AND RELIABLE LED MODULES In recognition of the demand for highperformance reliable LED modules, that do exactly what luminaire manufacturers want, Forge has introduced a custom module to do exactly that. Forge has never been a one size fits all manufacturer and, with the release of this latest customisable module offering, the added-value they bring to product development and manufacturing is evident.

Every luminaire has different LOR, thermal and optical properties, and every luminaire manufacturer wants a USP. Forge has the technical expertise to ensure manufacturers get only the very best modules in their fittings. How? With the ability to: lengthen and shorten heatsinks, choose connectors and wire lengths, pick heatsink colours, add logos, and even incorporate specific fixing and mounting methods. All whilst giving manufacturers the peace of mind that their module will perform thermally, optically and reliably to pre-determined L70 expectations, through in-house testing.

Forge has also recently developed a <10⁰ optic to suit the module perfectly, fulfilling that demand for a tight crisp beam pattern to complement the medium and wide offering. With Forge’s optic design and

manufacturing capability, you can also create your own bespoke beam pattern and achieve specific light distribution. All of this is before you even consider your light CCT and CRI requirements - you really can put light where you want it!

Forge is on hand to deliver what you really want and will do all the hard work and even

test the solution in your fitting for complete peace of mind. So, don’t make do with something off the shelf – choose Forge.

For more details on Forge’s latest product developments visit forge.co.uk or call our sales team today +44(0)1229 580000.

H.B. FULLER UNVEILS INNOVATIVE DUO OF SOLUTION AND TECHNOLOGY SERVICES IN EIMEA H.B. Fuller (NYSE: FUL) marks 20 years of Advantra® food safe packaging adhesive performance with the launch of the ‘perfect pair’ of future-thinking adhesive technologies in the EIMEA market – Europe, India, Middle East and Africa. This innovative duo includes the combination of the new Advantra® SMART high performance hot melt range for food-safe compliance, with FullVision™, a unique and powerful data analytics consultancy service designed to connect packaging manufacturers with continuous performance and quality improvement.

Martin Riswick, H.B. Fuller’s EIMEA packaging solutions business director, refers to this innovative performance duo introduction as an industry game-changer that “came at the right time to celebrate our 20 years of leadership in the hot melt packaging adhesives market”. Specifically, on the new polymer technology behind Advantra® SMART adhesives, he says that “leverages an extraordinary potential to offer some of the highest levels of food-safety compliance to manufaturers and brand owners who want want the confidence of food safety compliance today, and to be ready for future regulation”.

helps manufacturers to gain a better understanding of their packaging production line data. When combined with H.B. Fuller enhanced adhesive expertise, customers are able to convert and utilise this information into actionable intelligence to continuously to boost production line efficiency, without compromising quality.

This forwarding-looking adhesive range resulted from an experienced, tailored product development approach based on our advanced R&D expertise, deep market knowledge and the insight we have inhouse from working at the heart of food safety.

FullVision™ is a services platform designed to work seamlessly with measurement equipment and is easy to introduce. It

This technology service uses H.B. Fuller proprietary software to analyze data from which customers can draw meaningful, at-a-glance data reports. It all adds up to actionable insights that help manufacturers continuously improve their in-line and in-use performance and profitability by optimizing specifications, reducing waste, and achieving savings.

To benefit from the competitive advantages of H.B. Fuller’s forward-looking adhesive technology for food packaging and case and carton sealing, connect with our experts and test the combination of Advantra® SMART and FullVision™.

www.hbfuller.com.

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PACKAGING

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. www.storopack.co.uk

FOAMplus® Your products deserve the best protection.

Expanding polyurethane foam pads mould around any product shape within seconds. Exceptional protection for fragile or awkwardly shaped products.

Contact us for a FREE* trial

T: +44(0)114 249 2004 E: packaging.uk@storopack.com *subject to qualification

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www.storopack.co.uk

SUPERIOR INDUSTRIAL PACKAGING PROTECTION PAPERplus® - Paper pads provide maximum performance, high density, and strength.

Ideal in-the-box protection for heavy products.

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PLASTICS, DESIGN & MOULDING

PLASTIC AWARE SYMPHONY

THINGS YOU MIGHT NOT KNOW ABOUT OXO-BIODEGRADABLE PLASTICS 1 - THEY DON’T JUST FRAGMENT INTO HARMFUL MICROPLASTICS

One long-perpetuated myth is that oxobiodegradable plastics break down into smaller plastic fragments which are still harmful to the natural environment. While microbeads and microplastics are a real issue, they are not the end-product of oxobiodegradation. d2w rapidly accelerates the degradation process beyond microplastics, the molecular weight decreases to a point where it is no longer a plastic and is available as a food source to microorganisms in the environment, in the same way as nature’s waste. This leaves behind a substance called

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humus (not the chickpea dip, but the organic material found in soil).

2 - REDUCE, REUSE, RECYCLE STILL APPLIES

It’s a noble attempt to try and eradicate plastic waste from the natural environment – and reducing, reusing and recycling is a very simple and effective step towards this.

But let’s be realistic – some plastic is always going to escape the process and end up in our oceans. We need a strategy for this eventuality and oxo-biodegradable plastics could be a piece of the puzzle. Plastics that escape into the natural environment that would otherwise linger and cause harm to

wildlife can instead be reduced to a small amount of harmless organic matter.

Oxo-biodegradable products are designed to be reused. With oxo-biodegradable technology, the plastic will only start degrading when exposed in the environment as litter, meaning you can reuse your plastic bags several times.

Finally, d2w does not affect recyclability, in fact more than 500,000 tonnes of oxobiodegradable plastic has been recycled in the last 5 years[1]. So please dispose of your oxo-biodegradable plastic products responsibly and recycle with your other plastic products.

3 - ANY ENVIRONMENT WILL DO

We have all seen images of the effects waste plastic has on the natural environment; beaches that are covered in litter, animals being suffocated by packaging, and the infamous Great Pacific garbage patch. Some people think that oxo-biodegradable plastics will not break down in the ocean or when hidden from direct sunlight. All oxo-biodegradables need to degrade is oxygen. Sunlight may make it go a little faster, but it is not essential to the process.

4 - THEY WON’T DISRUPT THE PLASTIC INDUSTRY

The d2w additive that causes oxobiodegradation, is a ‘drop-in’ technology that can be applied during the manufacturing process with equipment that is already used in existing factories.

There is no need for new machinery or retraining factory workers.

Very little of the d2w is required to make plastics oxo-biodegradable, so there is little-to-no difference in price when compared to conventional plastics.

The additive does not affect the material properties of the plastic. The product will still be as strong, light, waterproof and flexible as ever but, once its life cycle is over, it will biodegrade into organic matter.

The technology is commonplace in several countries around the world. It is even mandatory in some of them, meaning that specified short life or single use items, must be made using oxo-biodegradable plastic, and according to a YouGov survey, 88 per cent of Britons would support the UK government passing similar legislation[2].

Perry Higgs, Senior Scientist at Symphony Environmental believes: “It’s important to highlight that oxo-biodegradable materials are not a general solution to our environmental problems, but they do provide benefits for the environment in specific applications.

Climate-change is an even bigger problem than plastic pollution. Banning plastic encourages the use of paper, bioplastics, glass, and other materials which Life Cycle Assessments (LCAs) have shown to have a higher global-warming potential than plastic made with d2w[3].

Our survey showed that 90 per cent of UK adults would support treating everyday plastic items (e.g. shopping bags, plastic packaging) with oxo-biodegradable technology. So, despite the myths surrounding oxo-biodegradables, the science and the public opinion show that they can play a crucial part in the future of plastics.”

www.symphonyenvironmental.com/ Issue 38 PECM

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WIRELESS SENSOR SYSTEM HYDROTECHNIK

INTRODUCING HYDROTECHNIK UK’S HTUK WATCHLOG

Hydrotechnik are proud to announce their new Wireless Data Monitoring and Acquisition system, designed for continuous measurement and monitoring of critical machinery, processes and systems. Rapid deployment, long transmission distances and stability of signals make this system easy to install and specify when wired options present problems.

The HTUK Watchlog wireless send and receive system is designed for continuous monitoring and logging of multiple pressure and temperature sensors over distances of 800m and/or 1.6Km. HTUK Watchlog represents a huge step in the provision of a secure point to point wireless transmission of sensor signals.

Hydrotechnik pressure transducers and/ or temperature sensors fitted with HTUK sender boxes are powered by two standard AA batteries giving up to 2 years of life, even when used continuously. A huge range of pressure sensors are available from 0 - 60 Bar up to 0 - 600 Bar and -50°C - +200°C temperature probes (more sensor ranges are also available). Up to 100 sensors can sit on the same system.

Sensor signals are beamed to a single receiver box, plugged into a PC via a USB cable.

Sensors and receivers can be up to 800m away. If longer distances are required we offer a repeater/booster box that can increase wireless transmission distances up to 1.6Km. Distances are suitable for industrial building/

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site applications. The booster box can be solar powered to give continuous service if mains power is not available.

Each set up can handle up to 100 sensors per system. All sensors talk to a single wireless receiver and Watchlog software.

Data is displayed numerically or graphically.

Alarm levels can also be set for each channel individually, both a pre-warning and critical alarm. Alarms can also be set to start logging data numerically or graphically to record events.

The software can be used to wake and sleep each sensor or all sensors at the same time.

All sensors are individually calibrated and set up via an easy to use software. The software sets up the sampling and transmission frequency to adjust the accuracy/stability of readings as well as optimising battery life.

Cloud integration will follow shortly which will give engineers alerts via text message and the ability to login remotely to check on the status of their equipment.

COMPONENTS OF A SYSTEM 1. Pressure & Temperature Sensors Sensors connected to the HTUK Watchlog technology wirelessly beam readings to the receiver with a 5ms up to 1 minute sample time. Each system is capable of handling up to 100 sensors simultaneously.

2. Receiver Box & PC Software The receiver decodes the sensor data and displays it on a PC screen up to 800m away.

Display and log data, set alarms, cloud integration 3. Booster Box An intermediate booster box can extend the range of the wireless signal by an additional 800m, totalling 1.6km distance. The booster box can be solar powered if mains supply is not available.

HTUK Watchlog features at a glance: Wide range of pressure sensors: 0-60, 0-250 and 0-600bar (more on request) Temperature Sensors: -50°C to +200°C Truly wireless sensing system with no need for any external power or cables View and log sensor data using user friendly Windows “Watchlog” software Configure graphical backgrounds for unique display of sensor data Settable alarms (two levels) 100 sensors can run simultaneously Battery life up to 2 years Data logging can start on trigger events Wake, sleep and interrogate sensors For more information please contact: Richard Price, Managing Director: richard.price@hydrotechnik.co.uk Chris Banks, Commercial Director: chris. banks@hydrotechnik.co.uk Matthew Davies, Marketing Assistant: matthew@hydrotechnik.co.uk

PROCESS TECHNOLOGIES LORIEN LAUNCHES SEARCH FOR ENGINEERING STARS OF TOMORROW

Lorien Engineering Solutions has launched its graduate recruitment scheme for 2019, which has been extended to include all engineering disciplines.

The engineering and project management business, based in Burton-upon-Trent, UK and Wroclaw, Poland, works with some of Europe’s top food and drink, brewing and pharmaceutical manufacturers.

Lorien’s graduate scheme provides young engineers with a platform to learn and develop on the job.

This influx of new talent plays an important role in the ongoing growth of the business.

This year’s successful applicants could follow in the footsteps

of young Lorien engineer Lou Charpentier-Dusoir, who was named Graduate Learner of the Year at the Engineering Construction Industry Training and Development Awards 2018. Lorien also received a commendation in the SME of the Year category.

Applications for 2019 will be reviewed in May and successful candidates will join the firm in September.

For more information about graduate careers at Lorien please visit: www.lorienengineering.com/ en-gb/careers/graduateprogramme

Manufacturing Processes Cooling & Heating Fluids

The manufacturing sector is amazingly varied, from autoclaves to aerospace, furniture to pharmaceuticals, plastics to printing, radiators to rubbers. A factor common to all, is the need for precise temperature control, as provided by efficient cooling and heating.

Hydratech specialise in the manufacture of heat transfer fluids, glycols, antifreeze solutions, inhibitors and cleansers.

tel: 01792 586800 www.hydratech.co.uk

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SUPERPLASTIC FORMING AFRC

WHAT CAN BE DONE TO ENCOURAGE SMALLER COMPANIES TO EMBRACE IT?

Craig Knowles, Senior Manufacturing Engineer at the University of Strathclyde’s Advanced Forming Research Centre.

questions - where is this technology going in the future, and what can be done to encourage smaller companies to embrace it?

Superplastic forming (SPF) of sheet metal is a niche technological process which enables the manufacture of light weight metallic components with highly-complex geometries.

Superplastic forming takes advantage of a material phenomenon defined as strain rate sensitivity. Strain rate sensitivity, in conjunction with suitable grain structure and material temperature requirements allows for elongations of up to 1000% to be achieved in traditionally difficult to form alloys, such as Ti-6Al-4V. This allows for the manufacture of complex shapes whilst achieving a lightweight component such as those required for the aerospace industry and very intricate body panels on super cars. The light weight is achieved through manufacturing components from a single sheet of material thus removing the need for joining techniques; the use of multiple sheets formed to create a hollow structure or through the use of strong light weight alloys which can achieve the required performance with minimal weight.

Industrial ‘know-how’ has historically been the tool of choice to define the superplastic forming process but by using the most up to date material testing, finite element modelling and process methods, the Advanced Forming Research Centre is able to achieve optimal output. This approach is resulting in the realisation of the ultimate potential of the materials and overall process.

The Advanced Forming Research Centre has a globally unique offering in SPF. No other research facility in the world can rival its capabilities with the process. This puts us in a position of being able to pose – and potentially answer – some of the tougher

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However, at present costs are high. SPF presses cost anywhere between £1m and £6m depending on the size, and to achieve the desired material behaviours machines must operate at extremely high temperatures for long periods of time The superplastic forming of titanium alloys is typically performed at 900-930°C. This results in high energy costs, necessitates the use of expensive tool materials and limits the number of parts which can be formed before the die requires cleaning. As a result, much of the research carried out by the AFRC’s forming team is focuses on investigating how companies can eliminate some of the costs associated with SPF by running at lower temperatures and completing the processes in a reduced amount of time, thereby decreasing the energy cost while still reaping the benefits.

There are many companies that could benefit from adopting SPF technology but the cost of the equipment is a significant barrier. This barrier brings with it an opportunity for kit manufacturers to develop a low-cost, lowtech investment opportunity for the initial kit. Not every company needs the same capability and we would like to see the SPF equipment manufacturers recognise this and develop more basic, lower-cost kit that would make the technology more accessible to smaller companies in the supply chain rather than just large multinationals.

We know and understand the many benefits of SPF technology and because of this we want to help companies embrace it. If the whole supply chain can work together, from the kit manufacturers to the AFRC in research and development to the OEMs, it will feed down to the smaller companies in the supply chain and get more companies embracing it rather than simply relying

on tried and tested processes. Adopting this technology could lead to a whole host of opportunities for smaller businesses – opportunities that could have a positive impact on the wider manufacturing sector. www.strath.ac.uk/research/ advancedformingresearchcentre Issue 38 PECM

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PROCESS TECHNOLOGIES

New High Performance Aerosol-Delivered Coating to Combat Corrosion Corrocoat, the Leeds based leader in anticorrosion coatings, announce the release of an aerosol-delivered high performance surface tolerant coating system.

Supplied in a convenient, easy to use, single pack 400ml aerosol, application is as simple as breaking the internal seal, shaking the contents and you’re ready to go. No need for scales, mixing containers, mixers, cleaning solvents, brushes or spray equipment. Based on Corrocoat’s proven Plasmet ZF materials and specially formulated for this application technology, the aerosol contains a high performance glassflake and MIO filled two pack epoxy, with both passivating and rust conversion properties.

Substrate protection and coating maintenance/ repairs, made easy.

Waste-free chemical dosing from IBCs

45 years of process plant linings from ARL

Following comments from our clients, H+E developed the SecureChem™ system for dosing of chemicals from IBCs which: • Eliminates all chemical waste, thereby minimising Operating Costs.

Applied Rubber Linings have been supplying abrasion and chemical resistant rubber linings for fourty five years. Within many industries including water, waste and effluent treatment, chemicals, mining, quarrying and aggregates, manufacturing and metal finishing we provide protective linings and coatings for all types of process plant.

• Automatically changes to a Standby IBC & signals the changeover, ensuring 24/7 operation.

• Avoids the need to have somebody permanently on site.

• Can be used with all chemicals supplied in IBCs. • Can also be used to collect waste chemicals etc., again with automatic changeover to a standby IBC. The picture above shows part of a recently supplied SecureChem™ system.

Our aim is to provide cost-effective solutions to the problems of corrosion, abrasion, noise, and product protection that occur when process plant is operating in extreme conditions. We focus on building strong relationships with our customers that are based on reliability, quality, integrity and trust.

For further information visit our website : www.applied-rubber.co.uk phone 01452 381849 or email keith@ applied-rubber.co.uk

he-water.co.uk

www.corrocoat.com

UVC Sterilisation - Clean, Dry & Effective Sanitising Cutting Edge Services are proud to work in partnership with SterilAir, the world-leading manufacturer of revolutionary UVC sanitising technology for the food industry. SterilAir’s UVC sanitisers are HACCP and FDA compliant solutions, providing clean, safe, chemicalfree disinfection with minimal costs and energy usage. Our exclusive range includes evaporator disinfection systems to directly target any type of surface, air recirculation systems for rooms with low convection, belt surface disinfectors designed to integrate perfectly into your production line and fully submersible immersion systems ideal for sterilising water tanks and cooling towers.

Our expert team of specialists and field service engineers provide full installation and servicing to meet your exact requirements.

SterilAir UVC solutions are available now exclusively from Cutting Edge. www.cuttingedgeservices.co.uk 01772956249

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DIN11864 and DIN 11853 Aseptic Unions for Orbital Welding DIN11864 and 11853 unions were developed to meet the exacting needs of the food, chemical and pharmaceutical industries. This range of unions has been developed from the three most common systems used in the hygienic and sanitary industries; namely the “Aseptic” screwed union to DIN11864-1; the “Aseptic” flange union to DIN11864-2 and the “Aseptic” clamp union to DIN11864-3.

Available with optional lengths to suit both orbital and manual welding, these unions have been designed to match tube and pipe specifications to DIN11866 Table A (DIN11850); DIN11866 Table B (ISO 1127) & DIN11866 Table C (ASME BPE).

Size range: 10mm to 150mm and 1” to 4” Specials are available up to 304mm Materials: 316L SS 1.4404 and 1.4435 Specials available in Duplex and Alloy 22 Tel: 01269 841 324 Web: www.alchemprocess.co.uk

Process Valves & Instrumentation Ltd We are a global provider of an endless selection of process equipment. Established in 2010 and based in Congleton, Cheshire. PVI boast a combined industry knowledge of over 60 years with our team having varying experience with both mechanical and instrument solutions in all industrial sectors such as Chemical, Pharmaceutical, Oil & Gas & Food/ Beverage and have exclusivity with WEIR BDK for their sleeved & Lined plug valves.

We also have partnerships in place with ARI, IFM & Gestra and many more giving us unrivalled access to their many products and global support. In addition, we also work closely with other brands ensuring we are able to offer you the very best products at the most competitive price.

01260 277025 www.pviltd.co.uk www.datastorgroup.com sales@pviltd.co.uk

PROCESS TECHNOLOGIES

HIGH QUALITY SURFACE TREATMENTS FROM CURTISS-WRIGHT SURFACE TECHNOLOGIES Curtiss-Wright Surface Technologies (CWST) provides high quality surface treatments which will improve the life and performance of critical components through its global network of over 70 operating divisions and specialist onsite teams.

Our surface treatments have been successfully used by OEM’s in major industries such as aerospace, automotive, oil & gas and power generation for many years.

We are only too aware of the logistical challenges and costs faced by our customers and so we can offer a “One Stop Shop” solution providing a wide range of surface treatments including Controlled Shot and Laser Shock Peening, bespoke and trade Coating Applications, Thermal Spray Coatings and Parylene Coatings for metal, alloy, plastic and electronic components as well as Analytical Services.

We offer our customers a single source solution and point of contact for all their

surface treatments, supporting their requirements through our global network of over 70 worldwide facilities and on-site field teams, improving and reducing turnaround times and costs.

We are specialists in protecting components from common failures and reducing maintenance costs for key industries such as aerospace, oil and gas, automotive, medical and general industrial markets.

Building on the unique heritage of Glenn Curtiss and the Wright brothers, CurtissWright Surface Technologies has a long tradition of providing innovative solutions and building solid and trusted customer relationships.

Full quality and customer approvals including NADCAP, ISO 9001:2008 and AS9100 Rev C. To find out more please visit www.cwst.co.uk.

www.cwst.co.uk T: 01635 279621 Shot peening is a cost effective method to help prevent: l Metal fatigue l Pitting/Fretting Engineered coatings help with: l High lubricity/low friction l Anti-corrosion l High release/anti-stick l Low noise/anti-squeak C.A.S.E.TM super finishing is used to: l Increase gearbox efficiency l Reduce surface/contact fatigue l Decrease lubricant temperature l Reduce transmission noise

Engineered technologies Surface treatments for critical components Issue 38 PECM

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PROCESS TECHNOLOGIES

INNOVATION FROM TITUS TITUS

ADDING VALUE TO THE RTA FURNITURE INDUSTRY THROUGH IMPROVED PRODUCTS AND PROCESSES The Titus Group develops, manufactures and sells innovative precision components and solutions that enhance the competitive position of its customers across a wide range of industries. Through innovative product design, expertise in high volume manufacturing and efficient service, the Group helps business partners to improve their productivity and quality while reducing the cost of assembly, manufacturing and allied processes.

The precision engineering competence gained in the field of furniture hardware manufacture, which is the Groupâ&#x20AC;&#x2122;s core activity, has now been applied to other areas. These include multipurpose damping technology, tooling and

ultrasound fastening techniques, die casting, and automated assembly systems, with applications in diverse industries, such as furniture, home appliances and automotive, as well as medical devices and hardware.

The furniture industry in the RTA category has been facing three major challenges over the past ten years: lack of wood mass, simplicity or guaranteeing user assembly friendliness, and flexibility of production processes.

To address the problem of thousands of people who consider ready-to-assemble furniture as being time-consuming and complicated to put together, with a lot of opportunities to make mistakes in the course of the assembly process, Titus engineers delivered innovative, out-of-box solution offering a simple approach for tackling furniture assembling.

The lack of wood mass is becoming an increasing problem with the growth of the population (market growth). Traditional materials used by the industry such as MFC chipboard, MDF and solid wood will be adjusted in the future. The recycled chipboard is already of great importance for the furniture industry. The result of the recycled chipboard is the quality of the MFC panels themselves. Metal and plastic inserts, poorly prepared chipboard structure (larger particles) and reduced use of adhesives cause a significant reduction in the load capacity of such panels. In addition to the challenges mentioned above, the density of the furniture panels decreases.

THE CHALLENGE AND ITS SOLUTION PRODUCT INNOVATION The Titus innovation is intended for use in a large segment of the furniture industry â&#x20AC;&#x201C; RTA (Ready to Assemble). This is a furniture industry that provides packaged preprepared furniture panels equipped with all furniture fittings (included in the bag) and installation instructions. The end user assembles RTA furniture at home.

Usually, connection fittings in such panels do not allow the expected load capacity.

Innovative expansion dowel with metal expansion sleeves in new materials is adapted and allows comparable load capacities with dowel connections.

Titus FastFit Machine

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Titus Quickfit TL5 Dowel

Easy furniture assembly is an important aspect for the end user of the furniture.

An easy and quick assembly significantly improves the user experience in furniture assembly and thus the satisfaction of the end user. In the Internet age, this aspect is becoming extremely important for RTA furniture manufacturers. End users of furniture can make a review of product satisfaction on the manufacturer’s website.

Poor reviews have, of course, a negative impact on the decision of potential customers. This means that increasing ease of assembly is a key ambition for virtually every furniture manufacturer. But what’s the best way to transform this admirable ambition into reality?

Titus Steel Quickfit expansion dowel brings two key novelties to the field of user-friendliness and quick assembly.

First, the number of assembly operations is reduced from a few dozen (classic expansion dowels) to only 3 to 4 operations. Secondly, with its design and expansion technology, the dowel allows the installation into the furniture panels already in the furniture factory. Titus offers a complete solution in the form of a prefabricated FastFit insertion machine for Quickfit TL5. The final customer receives furniture panels with built-in fittings, which significantly reduces the time of furniture assembly.

High productivity in the RTA furniture industry brings limited flexibility in manufacturing processes. Any replacement or modification of the type of drilling of furniture panels means a serious barrier for the industry, which in most cases is not acceptable. Using Steel Quickfit expansion dowels does not require drilling changes. The product is useful in panels designed for use with conventional expansion dowels with thread.

PROCESS INNOVATION The RTA furniture industry faces the challenges of increasing competitiveness.

One way to increase competitiveness is to offer additional functionality. The most important of these is a simpler and faster assembly. To achieve this, the RTA furniture industry uses the most advanced connections and other fittings and pre-prepared furniture panels. The latter allow very fast assembly of elements, significantly reduced possibility of errors and complaints, reduce the assembly time and increase satisfaction as well increase the chance of a positive online review.

Pre-prepared panels have an exceptional competitive advantage that, despite the high cost of labour force in the EU and America, forces manufacturers of RTA furniture to pre-prepare panels by hand.

Most often, 3-5 workers per shift are needed to pre-prepare one panel, which means production of 1100 panels/shift.

Each cabinet has two panels with inserted fittings. Such organized production can produce up to 400,000 cabinets per year.

With the use of Titus FastFit insertion machine for Quickfit TL5, the capacity rises up to 1,200,000 cabinets.

WHAT IS TITUS INNOVATION ABOUT? The first innovation concerns the much improved product characteristics and performance. The high-performance Quickfit TL5 ‘Full Metal Jacket’ has exceptional pull-out load capacity and provides optimum strength and performance in MDF, chipboards and solid wood – even without using wooden dowels. Its expanded steel body ensures reliable span in holes for 5 mm dowels, which makes it possible to use Quickfit expansion dowel inserting technology without tools (screwing) in a wide range of applications. Its structure allows high

tolerance to drilling errors ±1mm from the centre to the hole, which still provides for the establishment of a reliable and high load capacity connection.

The Titus Quickfit TL expansion dowel family allows for manual insertion into the furniture panel, which provides for a unique solution for intuitive and quick assembly of the cabinet right at home.

For maximum efficiency, it is possible to automate the process of insertion of connecting eccentric cams and expansion dowels TL using its own Fast fit insertion machine for Quickfit TL5.

The second innovation is about improved process. The advantage of the FastFit machine for automatic inserting of expansion dowels, connecting eccentric cams and wooden dowels into furniture panels is in the extremely short inserting time of these semi-finished products into the chipboard panel, the quality of the finished product and, consequently, the reduced working force. The insertion time of the semi-finished products is thus approximately 3 seconds for smaller panels and up to 7 seconds for larger multiinserting panels. The final time of panel assembly is reduced by approx. 85%.

THE RESULT? Titus was able to achieve thousands of satisfied customers since the implementation of the solution into their processes lowering the manufacturing costs, time and customers’ claims resulting into improved quality of life for many people.

Experiment Titus innovations at Interzum Cologne, 21-24 May 2019.

Hall 5.1, Titus stand A-018/C-011.

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PRODUCT NEWS

FITOK HIGH PRESSURE VALVES AND FITTINGS FITOK is an industry leading developer and manufacturer of superior quality instrumentation valves and fittings for general service and instrumentation panels. The range features twin ferrule stainless steel components, check valves and high pressure ball and needle valves.

The safety and performance of FITOK products is paramount. Standard testing for each valve includes testing with nitrogen at 80 and 1000 psig. Each valve is tested for leakage through the shell, packaging and ball seats. Valves offer tight shut off, long life service and low operating torque.

High pressure compression ball valves and needle valves are constructed of stainless steel and brass, with variable end connection types such as 2 port, 3 port, valve and NPT. Sizes range from 3 mm to 20 mm OD with handles featuring a selection: coloured nylon, metal and colour anodised aluminium.

Also from FITOK is their range of twin ferrule stainless steel components which are precision machined to ensure perfect deformation. Hardened threads with a smooth surface finish avoid galling and

Amazon Filters Introduce Replacements for Resin-Bonded Filters Amazon Filters has introduced a new variant of its VisClear spun bonded cartridge as a superior alternative filter solution for manufacturing processes using resin bonded filter cartridges.

While resin-bonded filters have traditionally been a product of choice because they can withstand high differential pressure and temperatures, increasingly health and safety considerations are driving users to look for alternatives.

For further information on the VisClear spun bonded filter range please visit https://www. amazonfilters.com/products/filter-cartridgesand-capsules/depth-filters/visclear/ or contact Amazon Filters on +44-(0)1276670600 / sales@amazonfilters.co.uk.

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help to extend the fitting service life.

The radius junction design with elbows provides a smooth flow path and every fitting is stamped with size, material, and heat code. Sizes range from 4 mm to 25 mm and fittings are easy to disconnect and retighten.

New Jasic TIG welding inverter Jasic, one of the leading manufacturers of inverter welding equipment have introduced the TIG 315P AC/DC Multi Wave Inverter.

This highly advanced AC/DC inverter offers superior multi wave versatility. Key features include TIG AC/DC with digital control, programme memory storage of up to 50 sets of data and microprocessor control of a wide range of functions. The current range offered on TIG is 30-315 amps and on MMA 10-270 amps. Other key features include VRD function, remote control interface and intelligent fan and cooler control. This TIG 310 P Multi Wave comes complete with TIG torch and adaptor, gas regulator, work return lead and clamp. The machine is supported by an industry leading 5 year warranty; registration is simple and easy at www.jasic.co.uk. Additional accessories include trolley, water cooler and a foot control unit.

If you would like more information about this topic, please contact Tina Wilkinson-Bell at 0161 793 8127 or email; tina@wilkinsonstar.com.

FITOK is an ISO 9001:2015 certified company, which demonstrates their ability to consistently provide superior quality products that meet customer requirements. Fitok products are available from Tom Parker Ltd. For more information visit: tom-parker.co.uk

Airfed Welding Systems meeting new HSE welding requirements Wilkinson Star, one the of the UK’s largest independent distributors of Welding Equipment, Welding Consumables and Air Compressors are the new exclusive UK and Eire distributor for Weltek Airfed Grinding & Welding Systems. The Weltek range of Airfed Welding and Grinding Systems has been designed to provide a new solution to active welding protection as well as providing the user the comfort, fit and versatility for everyday use. These systems meet the NEW HSE protective directive for welding on mild steel. For users needing side vision there are two models available. The Kapio S4 Auto darkening Helmet offers 160 degree side vision, 4 arc sensors, a viewing area of 93 x 43 mm with grinding function whereas the Navitek Side Vision S4 Auto darkening helmet offers all the same features as the Kapio but with an extra large clear grinding visor beneath the welding flip. Both units conform to EN166B, 175B, 379.

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

PROCESS TECHNOLOGIES

WEIGH MODULE SYSTEMS HANDBOOK AND ONLINE WEBINAR Take advantage of two great resources designed to make the implementation of weigh modules in large weighing systems easy and error-free.

METTLER TOLEDO has created a comprehensive handbook and an online seminar which detail the fundamentals of designing, building and installing customised solutions.

Covering the application of load cells and weigh modules for tanks, silos, vessels, hoppers or conveyor weighing systems, these are both free to access.

The Weigh Module Systems Handbook offers practical guidelines for engineers, designers and service personnel to avoid common errors. It covers the critical phases you should consider to achieve the required accuracy level in your process. These include design calculations, thermal effects, piping connections, designing of support structures and calibration.

In support of this document an online webinar is accessible on the METTLER TOLEDO website. This offers an additional opportunity to develop a greater understanding of implementing tank, silo and vessel weighing systems. Available on-demand, the session can be viewed at your convenience.

For a free download of the handbook visit: www.mt.com/ ind-system-handbook

With more than 150 pages it provides a complete library Or to access our online webinar of information regarding the visit: www.mt.com/ind-24x7application and use of load cells and Sepura ad 132x180L_Whats Inside advert 28/03/2018 16:53 Page 1 webinar-tankweighing weighInside modules.

It’s what's inside that counts Why choose a typical multi-blended polypropylene filter when you can have SILEXA™ inside...

• removes more - will remove oil content to below 10ppm • lasts longer - extends filter life by 20% • cost effective - 3rd party service kits that out-perform genuine OEM products Only SEPURA™ separators contain the superior SILEXA™ filtration media.

Sepura is part of the Bowman Group

Multi Factor Europe Ltd Harrison House, Rackery Lane, Llay, Wrexham LL12 0PB

t: 01978 855995 e: sales@mfeuk.co.uk Issue 38 PECM

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PRODUCT NEWS

A FORCE TO BE RECKONED WITH STAR FASTENERS

NEW! HUCK RANGE FORCETM BATTERY INSTALLATION TOOL Available from Star Fasteners, the Huck® Range Force battery installation tool has been designed to combine industry-leading performance with superior reliability. This new advancement in battery-powered installation tooling is the only battery tool on the market with electronically adjustable pull force for installation of pintail-less BobTail lockbolts.

It can install the complete Huck range of structural and non-structural rivets (up to 1/4” / 6.4mm) as well as two-piece fasteners (up to 1/4” BobTail® / Hucktainer® / Magna-Grip® / C6L®). In addition, it boasts exceptional quality for superior reliability and durability (tested to 50,000 installations). The high pull force is adjustable and it features a long stroke length, providing considerable versatility. What’s more, there’s crosscompatibility with Huck nose assemblies and Makita 18v batteries.

WORKSHOP SERVICES With a fully equipped workshop and experienced team, Star Fasteners tool workshop services are reliable and timely, so there’s minimal down time and a quick turnaround for every job.

Star Fasteners’ comprehensive range of spares and genuine components ensures a timely service, with large stocks of spares from leading manufacturers such as Huck®, FAR® and VVG®.

Star Fasteners can arrange to pick the tool up by its van or courier. A quote detailing all parts and costs is raised. If required, Star can guide you through a process to make a decision and find the most economical outcome. Each tool gets a unique reference so Star Fasteners can view its full maintenance history.

SERVICE AND MAINTENANCE A regular maintenance programme supports every production environment.

• Helps to ensure that fasteners are being installed properly • Satisfies health and safety obligations • Keeps production moving and ensures tools are operating correctly

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If tools are brought back into the workshop, a typical tool service will involve a complete strip down, de-greasing and cleaning of all parts with a specialist hotparts washer. Once assessed, if necessary, Star will replace seals and worn parts.

Finally, the tool is re-primed, re-set as required and thoroughly tested. Servicing can be arranged to fit in with shutdowns or down time to suit factory schedules.

The firm’s extensive stocks of tooling spares (including for many obsolete models) are also on hand for those who prefer to carry out their own servicing and

repairs. Generally, Star can offer next day delivery and talk you through some simple preventative maintenance measures to get the most out of your tool and ensure minimal downtime, as part of the service.

HIRE AND SERVICE HIRE Should your workshop suddenly become busy, or a specialist tool is needed for a specific contract, Star Fasteners can offer short or long-term hire tools. The firm also offers service hire whilst a tool is in the workshop for service or repair.

Hucktainer® C6L Huckbolt®

Bobtail®

SALES Star offers quality tools that can stand up to the rigours of a busy workshop environment and can demonstrate the latest models and provide advice on tool options best suited to the application and the environment.

Star Fasteners is committed to continuously improve and expand its tooling product portfolio to ensure that it remains at the forefront of modern assembly requirements.

“As the UK’s largest Huck® fastener distributor, Star Fasteners has become synonymous with the constant quest for innovation. We offer factory visits to tailor a tooling package that can address issues

Magna-Grip®

such as noise reduction and trip hazards.

When standard solutions do not fit, we work together to find a resolution.”

TRAINING And that’s not all – Star Fasteners is happy to send an expert member of the team to provide on-site training in your own workplace or you can visit the purpose-built workshop: “Our team are experienced in working in production environments and understand the complications that tool downtime brings.

“We can take the training back to basics.

From checking optimum air pressures, to knowing what to look for when inspecting

equipment, this knowledge then leads onto detecting and correcting potential problems ideally before they occur. Major downtime is then avoided.

“If you partner with Star Fasteners, we can solve fastener installation issues, boost production output and therefore profitability. We are confident that our fast and reliable repair service will meet your requirements.”

For more information on Star Fasteners tool services, call on +44 (0) 115 9324939 or alternatively email sales@starfasteners.co.uk Issue 38 PECM

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PRODUCT NEWS

DESIGN CHALLENGES REO

OVERCOMING POOR POWER QUALITY IN SMALL SPACES to supress EMI. EVs, much like petrol ICE vehicles, feature an inverter and a DC-DC converter, using high frequency switching, to manage power conversion.

By using high frequency components like REO’s transformers, filters and choppers, engineers can protect any sensitive semiconductor power electronics in the vehicle.

Despite being invented around the same time as the production automobile, electric vehicles (EVs) have only become commercially viable in the last decade. So, while internal combustion technology has undergone a century and a half of design refinement, engineers now face several design challenges while developing the next generation of EVs, as Steve Hughes, managing director of electric vehicle power quality specialist REO UK, explains.

Soon, all cars will need to be capable of zero-emission driving. Battery-electric and hybrid cars are leading the way to more efficient and sustainable driving, but automotive manufacturers are under significant pressure to design components as robust as those designed for internal combustion vehicles.

Internal combustion engines (ICEs) as we’ve known them for the past hundred years have been chosen over alternatives like the steam engine because they’re relatively well-suited to powering automobiles.

Now that the environmental cost is clear, however, the UK Government has announced plans to stop sales of pure ICE vehicles from 2030, with The Road to Zero Strategy.

While sales of electric vehicles are rising, manufacturers are profiting and governments are considering the burgeoning EV market, there are still various challenges that could hamper innovation and development in the market.

According to Toyota, the average car is made up of 30,000 components. In EVs, the number of components is a great deal less, especially when considering the number of moving parts.

To explain more clearly, for an internalcombustion engine (ICE), there is typically the crankshaft, fuel pumps and fuel injectors. In addition to this, there will be two valves per cylinder, or at least four valves per cylinder in the latest more economic engine designs. Outside of the engine, there are even more moving parts including a multiple-speed manual or an automatic transmission.

In comparison, EVs have been created to have the simplest architecture possible.

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Take the Nissan Leaf for example, which has been manufactured with no clutch or torque converter, but features a simple reduction gearbox, with a single gear ratio and the motor itself has just one moving part.

While the number of components may differ, the design principles for these components are virtually identical. For example, each of these parts must be able to withstand repeated bouts of acceleration and braking, as well as low and high-speed driving over smooth and rough areas. The same parts must be able to perform in a variety of extreme environmental conditions, from hot and humid to cold and wet.

At REO UK, we’ve identified one of the key constraints for EV components to be poor power quality because of issues like electromagnetic interference (EMI). While electrical and electronic components provide a much more efficient transfer of energy, having so many parts operating in close proximity makes the vehicle susceptible to electrical noise.

EMI, if unaddressed can result in overheating, efficiency losses and even interference with the vehicle’s data communication systems. When looking to integrate features that can mitigate issues like EMI, design engineers are also faced with the problem of having the limited space of fitting more electrical components into a vehicle that already has high component density.

Automotive manufacturers, as we explain in our latest electric vehicle power whitepaper, should look to integrate inductive and resistive components

For example, our chokes have been designed to eliminate electrical noise in the inverter and can effectively store and discharge magnetic energy from the core. This is regardless of whether its core is made from a ferrite, amorphous or nanocrystalline material.

According to the Department of Energy, petrol or diesel cars can only convert between 14 to 26 per cent of the battery’s energy. EVs, however, can convert up to 80 per cent of the battery’s energy. This is because vehicles traditionally use friction to convert mechanical braking energy into heat and wear on the brake pads. In an EV, braking choppers are responsible for converting any energy created as a result of high speed changes.

Components like inverters are also at risk of overheating. As we’ve discussed, design engineers are already limited on space and so traditional air-cooling methods, that involve using a fan to dispel any heat generated, are not viable. Instead manufacturers must integrate liquidcooling systems to manage the thermal properties of the electrical components while allowing them to meet the space constraints in the vehicle.

As EVs become increasingly mainstream, it’s important that design engineers and automotive companies keep pace with consumer demand and not at the cost of reducing efficiency, by using poor quality or the wrong components. Instead, automotive manufacturers should look to assemble their future models with the latest components that address prominent issues for EVs, like poor power quality.

www.reo.co.uk/news

PRODUCT NEWS

INNOVATIVE TECHNOLOGY WILLIAMS ADVANCED ENGINEERING

WILLIAMS ADVANCED ENGINEERING SETS OUT NEW APPROACH TO USE OF CARBON COMPOSITE STRUCTURES Williams Advanced Engineering has published a White Paper to showcase its proprietary, patent-pending innovations in carbon composites and the benefits they offer to the automotive industry and beyond. The company has developed a pair of innovative technologies that promise a step-change in the affordability of composite materials.

Known as 223™ and Racetrak™, these technologies offer comparable performance to existing composites solutions, but with a range of additional benefits, and at a cost that brings them within reach of mainstream applications. These are not simply manufacturing innovations: they are end-to-end, whole-life solutions that address every aspect of the manufacture, use and recycling of carbon fibre reinforced polymer (CFRP) and the way in which its remarkable properties can enable new approaches to vehicle design and manufacture.

“Racetrak™ and 223™ are just two examples of a new generation of technologies, developed and commercialised by Williams Advanced Engineering,” says Chief Technology Specialist, Lightweight Structures Iain Bomphray, the Williams Advanced Engineering innovator behind these two breakthroughs. “With this approach, we have the potential to develop new, growing areas of business that will also make significant contributions to the industries in which we work.”

CFRP is a material of huge promise. Its exceptionally high strength-to-weight ratio, impressive stiffness and excellent fatigue and environmental resistance make

it an attractive choice for a wide variety of industries and applications.

This is particularly pertinent to the automotive industry, where lightweighting is seen as one of the primary tools needed to meet increasingly stringent fuel economy and emissions targets, as well as support the range required from electric vehicles.

However, the advantages of CFRP extend across many sectors, from railway carriages to wind turbines.

Despite these compelling benefits, and recent process advances from the automotive and aerospace industries, a number of factors have held back the mass adoption of CFRP. Chief among these is cost, with traditional composite production methods involving expensive materials and lengthy process times. They also incur a relatively high scrap rate (typically around 30 per cent), compounded by the challenges of recovering the carbon from pre-impregnated off-cuts, and of finding value from the material at the end of the product life.

These challenges have seen the application of CRFP largely confined to niche applications. In the automotive sector, for instance, a body-in-white structure produced with traditional composite techniques is typically around 60 per cent lighter than one

manufactured in steel, yet around 20 times the cost. This has limited its application to vehicles that are low volume / high cost, or where the vehicle manufacturer subsidises the process as part of their learning around new technologies.

The innovations from Williams Advanced Engineering aim to address these challenges to unlock the benefits of CFRP. “We are focussing our expertise on energy management, aerodynamics, thermodynamics and lightweighting. As tools for efficiency improvement, these are all highly synergistic, so considering them as an integrated system allows us to increase significantly the total benefits,” explains Williams Advanced Engineering Technical Director Paul McNamara. “While we have undoubtedly learnt a great deal from success in Formula 1 and Formula E, they are highprofile examples of what we do. Behind closed doors, we are solving challenging problems for world-class companies across a wide range of sectors and working with some of the most highly-regarded manufacturers on next-generation, low carbon technologies.”

For more information see www.wae.com Issue 38 PECM

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PRODUCT NEWS

SIGNIFICANT SAVINGS MBA ENGINEERING

PC FABRICATIONS SAVES UP TO £20K PER YEAR FOLLOWING NITROGEN GENERATION SYSTEM INVESTMENT Steel and aluminium fabricators, PC Fabrications, has experienced significant savings after investing in a Noblegen nitrogen generation system.

Provided and installed by supplier of leading laser cutting and metal fabrication equipment, MBA Engineering, the Noblegen Nitrogen generation system has been installed in PC Fabrication’s Leedsbased factory to produce nitrogen for the company’s laser cutting machine.

Having previously bought nitrogen in bulk pack form, PC Fabrications can now produce its own in-house, eliminating the expenses and CO2 emissions associated with regular deliveries of the gas. The systems are set to run as required, so no nitrogen is wasted, and there’s no need to stop production completely to replace gas cylinders – another process which costs valuable time and money.

PC Fabrications has received continued support following the purchase of its laser machine from MBA 2 years ago, and the same applies to its most recent purchase with MBA Engineering on hand to assist with any servicing and maintenance needs.

“The investment really speaks for itself,” said Paul Close, managing director at PC Fabrications. “The monthly savings mean PC Fabrications will have paid off the cost of the nitrogen generation system in less than three years. Instead of outsourcing our gas, we can produce it on site, creating valuable floor space as the generation system takes up less space than storing cannisters. Knowing the MBA Engineering team is on hand 24/7 offering servicing support is incredibly reassuring when downtime can be so costly to a manufacturer.”

MBA Engineering exclusively partnered with Noblegen last year to save laser users up to £1,000 per month on gas costs.

Bradley McBain, Managing Director of MBA Engineering said: “One of our key aims is to provide valuable cost savings to our customers and help reduce their

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overheads. Combining the British-made nitrogen generation system with a laser cutting system creates a sustainable, costeffective laser cutting solution.

“As well as providing the equipment, we will also manage the installation and provide complete support once the equipment is in-situ.”

MBA Engineering Established in 2009, MBA Engineering is the exclusive distributor of Kimla fibre laser cutting equipment in the UK. More information about MBA Engineering, its services and its partnership with Kimla is available at www.mba-eng.co.uk.

PRODUCT NEWS

AUTOMATED DISPENSING INTERTRONICS

NEXT GENERATION OF FISNAR BENCHTOP DISPENSING ROBOTS AVAILABLE FROM INTERTRONICS

To give manufacturers access to the latest in automated liquid dispensing technology, adhesives specialist Intertronics is introducing the next generation of modular Fisnar F4000 ADVANCE series robots. Manufactured by leading supplier of fluid dispensing systems and equipment, Fisnar, the new series comprises the most extensive range of robots in the industry.

This enables manufacturers to specify a dispensing automation system that meets their own specific requirements.

The Fisnar F4000 ADVANCE series of robots have a new modular connectivity design, which allows simple and easy interface to a range of new robot accessories, including a tip alignment module and a vision system for visual programming and fiducial position adjustment, including automatic X, Y & Z tip

alignment. These accessories can be readily added as required, to further improve process control, increase productivity and reduce overall operational costs.

Other improvements include increased work areas on these 3-axis, 4-axis and 5-axis robots to a maximum of 600mm x 500mm, with corresponding increased Z-axis travel and clearance. Programming is straightforward with the standard teach pendant; there are some enhanced programming functions and the robots include a copy of the Windows-compatible Robot Edit software for additional functionality and program storage.

“This new Fisnar ADVANCE series of dispensing robots is a significant step forward,” says Kevin Cook, Technical

Manager of Intertronics. “They represent an upgraded foundation for the automated dispensing systems which we offer for bonding, potting, sealing, gasketing, temporary masking or lubricating. By configuring these robots with appropriate dispensing valves or pumps, customising them with holding tools and fixtures, benches and safety enclosures and providing installation and training, our customers can quickly realise a return on their investment and a productivity win.”

The Fisnar F4000 ADVANCE series is available for demonstration at Intertronics’ Oxfordshire-based Technology Centre.

Details are available at www.intertronics.co.uk/robot.

Issue 38 PECM

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PUMPS

PUMPS FOR NUCLEAR POWER SULZER

SPECIALIST PUMP MAINTENANCE RESOURCES AVAILABLE 24/7 As an innovative pump manufacturer and independent maintenance provider, Sulzer is uniquely placed to offer specialist technical knowledge and support for all types of pumps, including those from other manufacturers. One area that requires specialist skills and expertise is the nuclear power sector and Sulzer has established a service center in Chattanooga, TN, that offers a comprehensive suite of resources tailored to this application.

The nuclear industry operates in quite a unique position in that it has a defined date when the site will be decommissioned so the aim is to ensure that all the assets on site will provide reliable service throughout the plant’s life. Operators look to minimize running and maintenance costs by introducing design changes that will preserve the existing assets and add to reliability.

SPECIALIST RESOURCES There can be no margin for error in a nuclear power plant, everything must perform exactly as it was designed, but there is still room for improvements to be added. Sulzer specializes in assessing legacy equipment and adding value by modifying a design or changing a material so that durability is improved.

Renowned for its expertise in pump manufacturing and maintenance, with

service centers across the world, Sulzer offers industry-leading support to all pumping applications. However, there is one service center in Chattanooga, TN, that offers stateof-the-art solutions to the nuclear industry, a specialist sector that demands particular attention to detail.

Eric Jenkins, Manager Nuclear Sales at Chattanooga, explains: “We offer a specialist service that is tailored to the exacting requirements of nuclear power plants. Every part of a project is handled by highly experienced engineers, managers and designers to ensure that every repair, upgrade or reverse engineering task is delivered on time with particular attention to industry specifications.”

CASE IN POINT In a recent project, Sulzer has designed and manufactured a set of six replacement raw water cooling pumps for a nuclear installation. The new pumps had a lower specific speed than the originals, reducing their power requirements, which improved the margin on the diesel generators. The pumps met all of the required specifications as well improving performance and reducing vibration.

The key to this improvement was understanding the pump curves and how they interact with each other. Previous issues

with original pumps were resolved but, more importantly, the amount of power required from the diesel generators to run the pumps was significantly reduced. This action removed any need to re-rate the generators, which could have cost millions of dollars.

MAKING THE GRADE Where necessary, Sulzer assumes responsibility for the design, reverse engineering and certification of pumps and assemblies for most original equipment manufacturers (OEMs). The quality assurance program employed at Chattanooga Service Center is certified and audited to meet the requirements of 10CFR50 Appendix B, part 21, and ASME N and NPT Class 1, 2 and 3.

The focus on improved durability can often involve improving the metallurgy of a component or refining impeller geometry to minimize cavitation. Every application has its own set of challenges and Sulzer is fully equipped to assess performance, deliver specific recommendations and implement them.

Using state-of-the-art data capture tools, laser scanners and precision machine tools, Sulzer can create new components with improved hydraulic performance and extended durability.

ROUND-THE-CLOCK SUPPORT In addition to planned support, there is also a demand for out-of-hours assistance.

The power generation industry operates round the clock and as a key provider of engineering support, the service center at Chattanooga offers support 24/7.

Eric Jenkins concludes: “The ideal scenario is for all maintenance projects to be carefully planned, but occasionally unexpected issues can arise that require an immediate response and Sulzer has the necessary resources to support customers, day or night. In this way, repair projects can be delivered in the shortest possible time, minimizing disruption and returning assets to full operational status at the earliest opportunity.”

For more information on Sulzer, visit www.sulzer.com

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PUMPS

Wanner announces new HydraCell heavy duty, high pressure, multi-diaphragm seal-less pump

No Problem Metering Non-lubricating Liquids with Hydra-Cell

Wanner has launched the Hydra-Cell® T200 Series Medium Pressure, multi-diaphragm pump range, which in terms of flow rate and pressure are the highest performing pumps in the Hydra-Cell range and the biggest pumps ever produced by the Company. They feature a sealless design that eliminates leaks, hazards and the expense associated with seals and packing; lowering the cost of ownership and giving a longer service life than competitive pumping technologies. There are two models, currently, in the T200 Series, rated at 207 bar (3000 psi) and 241 bar (3500 psi) with maximum flows of 387 l/min (102.2 US gpm) and 349 l/min (92.4 US gpm) respectively. The new pumps are ideal for oil and gas production, mining operations, boiler feed and high-pressure cleaning, along with chemical and petrochemical process and transfer applications.

Hydra-Cell API 675 Metering Pumps have solved a problem for one of the world’s largest suppliers of polyurethane automotive foams The external gear pump used to pump nonlubricating, water-based catalyst were prone to wear, exhibited low efficiency and caused unacceptable high shear within the product.

Hydra-Cell API 675 diaphragm Metering Pumps, with their inherently low shear pumping action, provided the ideal solution to the problems. Since the application could not risk contamination by the hydraulic fluid, extensive testing with Mesamoll® oil, was conducted before a Hydra-Cell Metering Solutions model P200 was installed for evaluation. This first P200 pump performed exceptionally well, eliminating the low-efficiency, high-shear, and nonlubricating pumping problems. Hydra-Cell P200 pumps are steadily replacing the gear pumps on the customer’s systems installed in automotive plants around the world.

www.hydra-cell.eu

Pump Vibration Monitoring Pumps are crucial components of many processes across most industrial applications.

Vibration monitoring is a cost-effective way to maintain pump and overall machine health, minimize downtime and reduce operating costs.

Key indicators of pump health are, Balance, Alignment, Cavitation, Vane pass frequency, Bearing health.

Our range of 4-20mA loop powered sensors provide an economical means, when connected to a monitoring system such as a plant PLC, DCS or SCADA system, to continuously monitor your pumps. Trending this vibration data over a period of time will give you an early indication of the pumps health which can then be investigated further.

KDP Electronic Systems 01767 651058 www.kdpes.co.uk

www.hydra-cell.co.uk

Perfected Sealless Pumps

ROBERT WATLING RETURNS TO UK SALES ROLE AT HMD KONTRO SEALLESS PUMPS

Continuous innovation means HMD Kontro magnetic drive technology is now even more robust, reliable, economic and suited to even more applications • ZeroLoss™ composite containment shell • VapourView™ instrumentation that detects the presence of gas in a liquid • Secondary Containment options to enhance safety even further With new derivatives including vertical, high-pressure, low-flow, multi-stage and even extended sump versions, there is an HMD Kontro sealless pump that is perfect for your next project.

Enquire today.

+44 (0)1323 452141 vince.lee@sundyne.com www.hmdkontro.com

Representing a renewed focus on their important home market, HMD Kontro Sealless Pumps have returned Robert Watling, also known by his nickname Spring, to the key Sales Manager role for the UK and Ireland. In particular, Robert is to represent the company in the important chemical and industrial market sectors, also a renewed focus for the company.

Robert has over thirty years’ experience with magnetic drive pumps from HMD Kontro, much of it spent representing the company in the UK and in other European, American Asian and Chinese markets. He will work closely with HMD Kontro’s Channel Partners

for these sectors, AVT Pump (UK) and CPI Technology (Ireland).

HMD Kontro are also improving response times, for both new pumps and spare parts, where required, by making a significant investment in component stock, which will allow faster delivery times for pumps used by the chemical and industrial process industries.

To contact Robert, please email robert.watling@ sundyne.com or call 01323 452172 / 07714 257938.

Alternatively, please see www.hmdkontro.com.

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Stay ahead, whatever the challenge using Patent Solutions by Minesoft

All of the greatest, most renowned inventions start with an idea. Patents are often the first and only source of these ideas, with over 80% of technological and scientific information never published elsewhere. Anyone with access to patent data can improve upon, combine or invent around the initial patented idea. Therefore, companies around the world are protective of the value in their own intellectual property (IP) and realise the importance of monitoring the IP of their competitors.

Minesoft is a world-renowned service provider for the Intellectual Property industry, to help companies harness the knowledge found in patents, gain competitive intelligence and build on the ideas of others to drive innovation worldwide.

This current era of knowledge-driven economies has led to 3.17 million patents filed worldwide in 2017 (World Intellectual Property Organisation Indicators 2018), a 5.8% increase from 2016. IP professionals face daily challenges due to the volume and complexity of patent data currently available. Therefore, having access to a global, high-quality and up-to-date patent database such as PatBase is essential.

PatBase’s family structure collates all necessary information on one invention in one place and reduces duplication, boosting efficiency without losing accuracy.

With over 60 full text collections, including non-Latin data, PatBase provides access to ideas and innovations from key countries around the world. PatBase makes it easier to conduct a Freedom to Operate search.

With a range of innovative tools including

PatBase Thesaurus to craft a comprehensive search strategy and Advanced Highlighting to review large numbers of documents, fast.

PatBase Analytics V2 (fully compatible with PatBase Express) can be used to visualise market trends and key competitors as well as identify potential business partners and licensing opportunities. The latest groundbreaking addition of Citation Network, provides a new way to interrogate your result set, creating highly engaging and visually stunning representations of complex citation networks. There are a range of features and settings that allow users to manipulate and arrange the networks so that they can be tailored to be as insightful and analytically useful as required.

Minesoft’s company ethos is to ensure the products developed continue to assist companies harness the worlds innovations.

This motivation led to the recent creation of IP-Share. Store, review, rank, highlight and organise patent documents and non-patent literature in one central location. The ideal solution to encourage collaboration and share insights with clients and end-users.

In this coming year, Minesoft are excited to soon be introducing a new, even more powerful search engine for PatBase with a significant increase in functionality and speed.

Whether you have a practical problem to solve, valuable IP you wish to keep track of or competitors to monitor, Minesoft’s intelligent and reliable solutions can help you take the lead.

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PECM Issue 38

Stay ahead, whatever the challenge!

Patent information can be challenging.

Minesoft provides intelligent & reliable solutions that will help you take the lead.

Our solutions boost efficiency, without losing accuracy.

Search patents intuitively and comprehensively with PatBase Explore the IP landscape with powerful PatBase Analytics V2 Effortlessly track any legal status changes to patents, receive automatic alerts from Legal StatusTracker Monitor, capture and manage relevant global patent intelligence with Pat-KM

www.minesoft.com Issue 38 PECM

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SOFTWARE & SYSTEMS CAPM347 HIGH SPEED 24VDC EMBEDDED PRINTER FOR RETAIL, VENDING AND KIOSK APPLICATIONS BVM, official distributor for Seiko Instruments’ printer mechanisms and portable printers for the UK and Ireland, has announced the CAPM347, a 24VDC high-speed rugged thermal print and cut unit optimised for use in ticketing and vending machines, receipt printing, lottery terminals, ATMs or other industrial, retail or medical applications. Two versions are available: for Point-of-Sale receipt printers and similar uses, the “Easy Load” version with a removable thermal head that enables simple drop-in roll replacement.

The integral cutter has a hardened V-shaped blade specified to two million operations of either complete or partial cuts that leave a small centre point attached between receipts.

The “Auto Load” model has a hinged thermal head assembly for embedded designs such as kiosk and ticketing machines and an optical sensor that automatically initiates replacement paper loading. Both versions offer print speeds of 300mm/s on standard 58, 60, 80 and 83mm wide paper up to 90 micron thickness; the thick paper model prints at 280mm/s on paper up to 150 micron thick.

The communication interface with the host machine is via parallel, serial or USB with Seiko’s interface boards or control chips; Windows and Linux drivers are available.

The units feature an all-metal body, powerful motors and wide gears throughout to ensure reliability. They are designed to output more than 1.3 million x 150mm receipts with up to 640 dots/line. 16 x 8, 16 x 16, 24 x 12 and 24 x 24 characters are supported, resolution is 8 dots/mm.

Web: www.bvm.co.uk/CAPM347.html Email: info@bvmltd.co.uk

IP66/IP69K-RATED STAINLESS STEEL PANEL PC FOR FOOD, CHEMICAL, PHARMACEUTICAL AND OUTDOOR APPLICATIONS BVM announces the latest addition to the GOT800 family of stainless steel touch panel computers. With the addition of this 17” unit there are five models in the range covering sizes from 10” to 17”. The GOT817-511 is a 17” unit and has a full IP66/IP69K-rated water, dust and corrosion-proof enclosure which guarantees this all-in-one industrial panel PC can be deployed in harsh operating conditions. It supports a wide operating temperature range from -20°C to +50°C and can withstand vibration up to 1G. The GOT817L-511 is an ideal HMI for use in food and chemical factories, pharmaceutical industry and other applications where hose down cleaning is required. It is equally at home in heavy-duty outdoor applications.

The GOT817L-511 supports the Intel® Core™ i5-7300U KabyLake CPU. This industrial panel PC has a 17-inch SXGA TFT flat bezel LCD display with LED backlight. It comes with the choice of a projected capacitive touchscreen or 5-wire resistive touchscreen. The 316 stainless steel enclosure enables it to be used in critical environments that require a high level of resistance to corrosion. In addition, the 17-inch rugged panel computer comes with IP66 and IP69K rated enclosures, five IP66-rated M12-type I/O connectors and wide range power input of 9 to 36V DC, ensuring reliable operation.

www.bvm.co.uk/GOT.html | info@bvmltd.co.uk

RACK-MOUNT PCS FOR LONG TERM RELIABILITY BVM offers a range of industrial 19” Rack Mount PC systems designed and tested for applications in harsh and challenging environments. The carefully selected components that make up our Rack Mount PCs utilise industrial grade components that are designed to run 24/7 in a wide range of temperatures and environments and offer long-term supply availability of up to 7 years avoiding expensive re-design mid project. Available in 1,2 or 4U our industrial systems are built to perform and offer the latest CPU and storage options.

A comprehensive design and customisation service is available including operating system support. All units are CE certified, tested and ready to run. bvm.co.uk/rack-mount.html info@bvmltd.co.uk

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OEM Design and Manufacturing Service

Embedded Computer Design, Integration and Manufacturing Services

"A successful product not only requires a competent functional design...... ....it also needs to be designed for manufacture."

BVM have many years of experience in providing off the shelf and bespoke industrial PC systems. Whatever your application, talking your ideas through with our experienced engineering team might just provide that different angle youâ&#x20AC;&#x2122;ve been searching for to see your project over the line.

Concept multiple cameras

Design Ethernet and 4g wireless on ti connec

Weatherproo chassis

Manufacture

Why not call us today....

Call: 01489 780144 Web: www.bvm.co.uk Email: info@bvmltd.co.uk

f

SOFTWARE & SYSTEMS

VIRTUALISING FACTORIES TECHNIA

HOW DELMIA 3DEXPERIENCE CAN DIGITALLY TRANSFORM YOUR FACTORY Stefan is a Production Manager at an industrial equipment manufacturer. He and his team are responsible for building enormous equipment.

To build that equipment, they are dependent on their own heavy machinery. The more ergonomic that machinery is - the more perfectly adapted to Stefan’s workers - the more efficient Stefan and his team can be.

But efficiency can only be evaluated in action.

Adjustments made for the next, expensive, iteration. Right?

DELMIA 3DEXPERIENCE virtualises entire factories. It simulates workers. The objects they’ll interact with. Their surrounding environment. Individual machine parts can be evaluated virtually, any production issues flagged pre-manufacture. Approved parts can be manufactured automatically using NC machine paths generated within the program.

DELMIA 3DEXPERIENCE simulates production manufacturing, manufacturing processes, machine operations and human operations.

Users can identify process modifications during the planning and manufacturing phases - accelerating product development and bringing your product to market faster.

DELMIA 3DEXPERIENCE creates a collaborative workspace for every phase of the product life cycle. Manufacturing and production users can communicate and contribute within an integrated platform that encompasses virtual process and system definition, optimisation, scheduling and operation, and maintenance of real-time production systems.

DELMIA 3DEXPERIENCE KEY CAPABILITIES: # Additive Manufacturing Use DELMIA to plan, simulate and program additive manufacturing processes, to ensure optimum efficiency in the real-world. # Ergonomics Assess working conditions, ensure compliance and verify assembly across multiple platforms.

Realise ideal ergonomics and improve your workers’ productivity.

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# Lean Manufacturing Make lean manufacturing practices an integral part of shop floor operations. Virtual pre-planning ensures you only ever use what you need. # Machining Automate manufacturing by programming CNC machine tasks. Free your workers to focus on tasks that only a human can do. # Manufacturing Operations Management (MOM) Evaluate and adjust the entire manufacturing lifecycle as one. In real-time. DELMIA collects systems information to give you visibility and control of global production operations in a single system. # Process Engineering Create and optimise build-to-order manufacturing techniques, before going into production.

# Robotics Perform reachability studies, interlock analysis and offline robot teaching, and deliver optimised robotics programs to the shop floor. # Virtual Factory Create a complete 3D digital twin of your factory. Use pitch-perfect simulations of prominent systems to inform real-world decisions.

Welcome to Industry 4.0. Upgrade your factory with DELMIA 3DEXPERIENCE.

Visit www.technia.co.uk/software/ delmia/. Email us at info@technia. co.uk. Call us on +44 (0)1908 776776.

DISCOVER DIGITAL MANUFACTURING INTELLIGENCE Streamline product development and drive innovation for a competitive advantage, with DELMIA® powered by the 3DEXPERIENCE® platform.

Speak Speak to to TECHNIA TECHNIA today today to to get get started! started! Email Email info@technia.co.uk, info@technia.co.uk, call call +44 +44 (0)1908 (0)1908 776776, 776776, or or visit visit www.technia.co.uk/software/delmia. www.technia.co.uk/software/delmia.

Dassault Dassault Systèmes Systèmes 3DEXPERIENCE 3DEXPERIENCE and and DELMIA DELMIA are are registered registered trademarks trademarks of of Dassault Dassault Systèmes Systèmes or or its its subsidiaries subsidiaries in in the the United United States States and/or and/or other other countries. countries. All All other other trademarks trademarks are are owned owned by by their their respective respective owners. owners. All All other other trademarks trademarks are are owned owned by by their their respective respective owners. owners. Use Use of of any any Dassault Dassault Systèmes Systèmes or or its its subsidiaries subsidiaries trademarks trademarks is is subject subject to to their their express express written written approval. approval.

SOFTWARE & SYSTEMS

BREXIT GRIDLOCK AZZURE IT

DEALING WITH BREXIT UNCERTAINTY THROUGH INVESTMENT

Contrary to public opinion, the UK is one of the leading nations when it comes to manufacturing. We currently rank ninth in the world, and produce £3.82 billion to our economy from our manufacturing businesses (Office for National Statistics).

It’s critical that UK manufacturing businesses have next-generation digital infrastructure in place. The UK is taking steps to cement its position as a world leader in future technologies of full fibre and 5G through the £740m of funding from the National productivity investment fund that the chancellor announced last year.

The top companies are digitalising well, and there are numerous examples of medium-sized companies that are starting to do it quite well in implementing these techniques.

However, the gridlock of Brexit has dragged the UK economy close to stalling point. Growing numbers of manufacturing companies are delaying their spending plans, or cancelling their investment all together due to the uncertainty in the current marketplace, and not having a clear view on how Brexit could affect their supply chain.

Mr Phipson identifies that the challenge is the long tail - the 90% of businesses that are SME’s – and ‘really getting them to realise the value of investment’ and what they can achieve through digitalisation.

Manufacturing companies are now deciding to go to Europe themselves rather than exporting, putting off investment all together and, as Make UK Chief Executive Stephen Phipson describes it, ‘building inventory like crazy’.

The current uncertainty in the marketplace is forcing manufacturers to hoard more inventory, meaning that their stock holding capabilities need to improve rapidly to deal with the increased levels. One way of achieving this, is to digitalise their business, and introduce a sophisticated and sustainable business software solution.

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The fourth industrial revolution is currently taking place, with digitalisation touching every aspect of life, specifically businesses.

The introduction of next generation business software is allowing businesses to thrive in this time of uncertainty, automating their stock holding processes and giving them a full and clear overview of their whole business.

To understand how digitalising your manufacturing processes can help your business, contact Azzure IT today.

We have significant experience helping companies like Make UK, S+B and other process manufacturing companies like Snowdonia Cheese.

If you’re looking for expert business software advice, please get in touch: 0345 467 9950 info@azzure-it.com

SOFTWARE & SYSTEMS

INDUSTRY 4.0 WORLD WIDE TECHNOLOGY

THE CHALLENGES AND RISK OF ADOPTING TECHNOLOGY WHICH WILL DRIVE MAXIMUM VALUE OUT OF THE PLANT

Paul Robinson, Senior Consultant in the Digital Transformation Group at World Wide Technology, comments: “Material shortages, eroding profit margins, increasing international competition, and slowing productivity rates have created a perfect storm for the British manufacturing industry.

As if this weren’t enough, manufacturers are also facing more sophisticated cybersecurity threats and an ever-widening shortage of skilled precision engineers to support modern systems and get the most value out of the plants.

The Fourth Industrial Revolution is pushing manufacturers into a world of new technology, software, and connectivity with the potential to alleviate many of the industry’s pain points. Industrial Internet of Things (IIoT) has the potential to revolutionise the factory floor and significantly cut labour costs whilst enabling predicted maintenance to drive further efficiencies. Data collected through IIoT systems can flag up whether process lines are performing at their maximum capability

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and provide invaluable business insights.

However, as the connectivity in the plant increases so does the security attack vector which can only be addressed through a security model including both technology and education.

At the same time, pioneering machinelearning methods provide smarter business decisions in the plants which can tackle the growing talent shortage by translating decades of experience into an algorithm.

This can be used by artificial intelligence to automate and tailor solutions to each process, supporting the existing experience and expertise found at the plants Rushing to deploy massive transformational strategies may, however, be counterproductive. If you want to achieve the best results, it is essential that you conduct a series of ideation sessions to understand specific business needs before integrating new technologies. The first step would be to bridge the gap between Information Technology (IT) and Operational Technology

(OT) departments, which are often managed by siloed teams with differing priorities.

WWT’s Advanced Technology Center (ATC) can further support the adoption process by providing a globally accessible best-of-breed technology test bed showing the end-to-end integration of the IT and OT environments.

This environment also performs as a showcase for technology to counter security vulnerabilities and drastically reduce the risk of cyber attacks.

Finessing strategy before rushing to implement technologies will set your connected factory apart and ensure that your innovative approach will translate into real business outcomes long-term. The vital difference will be the approach taken to integrating Industry 4.0, rather than the technology itself.”

www.wwt.com wwt@flamepr.com

SOFTWARE & SYSTEMS

ONLINE WORK FLOW SYSTEM SUITS PCB MANUNFACTURER DOWN TO A ‘T’ Rustington based Photronix Ltd manufacture high quality printed circuit boards and whilst new to the market, have become one of the leading PCB suppliers to the UK electronics market. They have a simple aim of developing long-term partnerships for the manufacture of PCB’s by embracing new technologies and extending their facilities from design, prototyping through to volume manufacturing.

Photronix Managing Director Alan Millard believes that managing the progress of jobs simply and effectively is essential and with this in-mind invested in the T CARDS ONLINE workflow system to help them run their office more efficiently. Among the important benefits of the T Cards Online system is its simplicity and ease-of-use. Once the virtual board has been configured, T Cards designs can be easily tailored to requirements. There are standard templates for various applications to make it even easier.

Status and communication can be enhanced by using the Alarm, Signal, and email notification functions. There is also a facility to attach external documents to help collate documentation. Since a number of cards will appear on the same chart, they can be colourcoded for easier identification and as work

What is AutoCAD OEM? AutoCAD OEM is a platform for rapidly building unique applications that address specific needs and specific market niches - everything from cabinet making to shipbuilding to shoe design.

AutoCAD OEM supports Object ARX with C++, .NET, ActiveX, VBA, AutoLISP and Java Script APIs, and there is the option to develop applications in nine different languages (English, French, German, Italian, Japanese, Simplified Chinese, Korean, Portuguese and Spanish).

Customers can interact with applications via a desktop application, through a child window, Microsoft Windows .NET, or a web page. And application look and feel can be customized using one-of-a-kind images, splash screens, icons, drop-down menus, licensing, naming, and branding. Customers will experience an application that is uniquely yours.

Find out more about AutoCAD OEM here: www. techsoft3d.com/products/autocad-oem

progresses the cards are simply dragged and dropped into a new column.

When asked about his experience in using T Cards, Alan commented, ”T Cards has been a success in the way we manage our day-to-day enquires and the people at T Cards Online have been really helpful. The system continues to be developed and some of the new features have made big improvements to the way we work.

The new APP makes a particular difference to me as l travel regularly to China and the Far East, now it’s so easy for me to check the status of our Jobs, wherever I am, when I get a call from clients. It really has helped us streamline our business and enabled to expand even more.”

Photronixs’ experience in using the innovative T Cards Online system is another example of how an increasingly wide range of companies are exploring and benefitting from a simple, yet highly effective online management tool. The result is more efficient job management where ever you may be thanks to on-line access, along with more detailed financial information which is invaluable to cost-control.

Tel: 01732 871417 Web: www.tcardsonline.co.uk

MangoGem launches ORITAMES APS Scheduler v2.5 adding extended AI capabilities for improved planning and scheduling optimization MangoGem S.A., an innovative provider of intelligent software solutions for challenging enterprise problems, has launched Version 2.5 of its powerful ORITAMES Advanced Planning and Scheduling system.

The ORITAMES APS Scheduler v2.5 incorporates autonomous Artificial Intelligence (AI) capabilities for improved planning and schedule optimization as well as improved modeling of sequence dependent setups, batching and time constraints, making it ideally suited to large, real-life problems taking into account the complex constraints of real cases.

For further information, visit: www.mangogem.com.

State-of-the-art Industrial IoT communication solutions IoT applications have traditionally relied on higher bandwidth cellular or wired connections but new technologies are emerging. MultiTech has a long history in IoT connectivity innovation and leads in both traditional cellular and new Low Power Wireless Access technologies; cofounding LoRa Alliance™ and launching NB-IoT and LTE Cat M1 devices worldwide.

We make industrial connectivity EASY minimising cost, time and risk; FLEXIBLE scaling from the very simple to the complex; SECURE allowing you to trust your assets and data; and COMPATIBLE offering networking for Industry 4.0 today and in the future.

Get in touch and let us show how we solved our customers’ IoT connectivity problems in a number of industry verticals!

Multi-Tech Systems (EMEA) sales@multitech.co.uk +(44) 118-959 7774 www.multitech.co.uk Issue 38 PECM

191

STORAGE, HANDLING & DISTRIBUTION

LIFTING REQUIREMENTS SCAGLIA INDEVA LTD

MATERIAL HANDLING IN THE PROCESS AND MANUFACTURING SECTOR In the process sector, a lifting requirement is frequently more complex than a single heavy item being moved from one location to another. When using chemicals for example, bagged powdered products are often used, as are drums of (sometimes) corrosive or explosive liquids. Lifting bags of around 25kg in frequent and repetitive work cycles are commonplace, which discounts manual handling without a lifting device.

Weight is not the only consideration when lifting bagged powdered products, as health and safety legislation prohibits workers’ hands coming into contact with bags where a surface product may be present on the outside, thus exposing the operative to the potential of skin irritation or worse.

Lifting drums of chemicals or other liquids also presents a challenge to the manufacturer, as it is vital that drums of potentially dangerous liquids are kept level during transit. Many standard lifting solutions such as using a pneumatic manipulator can be rejected as they do not allow lifting and positioning of loads in a fast, smooth way that is needed for repetitive handling work cycles. In addition, the INDEVA load balancing feature ensures that containers are held steadily, on positioning and when the contents are being decanted.

WHAT ABOUT LIFTING AWKWARD OR NON-STANDARD ITEMS? Although bagged products and drums are reasonably standard in shape and weight, some processes demand the lifting of unwieldy products, for example, lengths of heavy extruded product such as pipes used in infrastructure projects.

Usually, in a factory environment, a forklift truck would be used to transport such an item from the extruder line to another area of the factory. But, as in many manufacturing environments, space is at a premium, and sometimes there is simply not enough room to easily and safely manoeuvre a forklift to carry out the task.

The default option usually comes into effect where manual labour is used, and if you consider that such items could be 3m or

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more in length and weighing around 50kgs, this is clearly a safety hazard with potential for operator injury, not to mention damage to the product itself, or other plant and equipment.

EMPLOYEE HEALTH, SAFETY AND WELLBEING MUST BE A MAJOR CONSIDERATION INDEVA Intelligent lifting devices have been ergonomically designed to protect the operator and reduce the risk of strain and injury. In the UK alone, an estimated 8.9 million working days are lost per year due to back or musculoskeletal issues caused by lifting or repetitive handling.

speed, fluid movement and precise positioning of load that is required in the process and manufacturing sector. It is a compact, lightweight system that can be fitted with custom-designed end-effectors for bespoke applications.

The Liftronic® Pro is ideal for custom handling solutions involving load rotation, vacuum gripping and/or special handling controls. It can lift and move up to 320kg capacity and can be commissioned with different mounting configurations, including column-mounted with an orbit arm, ceilingmounted, on overhead rail and bridge systems, as well as mounted to lift trucks.

BETTER PROCESS EFFICIENCY AND REDUCED PRODUCTION COSTS ARE ACHIEVABLE. Indeva leads the world in the manufacture of advanced industrial manipulators and material handling equipment that is designed to improve production processes, reduce costs and protect operator safety and wellbeing. The Liftronic® Pro is part of this world-class range of intelligent electronic lifting devices which gives users unparalleled safety and outstanding performance. This advanced range provides users with the ultimate responsiveness,

To find out more about our innovative and bespoke lifting solutions and to discuss how we can change the way your production line operates, please contact us today Tel: 01246 889129 Email: info@uk-indevagroup.co.uk www.indevagroup.co.uk/pecm

For Intelligent Processing and Handling…

Ask for an Indeva Industrial Manipulator

 Move awkward and heavy loads effortlessly  Intuitive operator controls and user interface  Unlike robotics, no programming is required

Call 01246 889 129 for more information Email:

support@uk-indevagroup.co.uk

Web:

www.indevagroup.co.uk/PECM

Tel:

01246 889 129

STORAGE, HANDLING AND DISTRIBUTION

ADDING GENUINE VALUE CROCODILE

DESIGNING BESPOKE PACKAGING SOLUTIONS TO PERFECTLY FULFIL CLIENTS’ NEEDS Crocodile began as a family company back in 1991 in response to a growing demand for innovative and versatile industrial packaging solutions. To this day Crocodile remains entirely family owned and run and the goal of providing high quality sophisticated packaging solutions that add genuine value to clients has not changed.

Crocodile has a truly global outreach, with manufacturing partners in China, Germany and the USA. But the key to Crocodile’s success is it’s commitment to quality, which is why all aspects of the business from design to manufacturing, right through to delivery of the product is managed under the same roof in Swindon.

By controlling every aspect of the business Crocodile ensures that only the best product and customer service is delivered.

Crocodile does not sell from a catalogue, but custom designs bespoke packaging solutions to perfectly fulfil clients’ needs.

We visit prospective customers and listen to them in order to ascertain as much information as we can about exactly what they want and need from their packaging.

Our team of CAD Engineers will then design a packaging solution based around these needs, which we will then present to clients for approval or feedback.

Crocodile’s unique clip system means that packaging can be flat packed and reused, which dramatically cuts customers’ total costs and provides a sustainable, environmentally friendly way to ship goods.

In 2006 Crocodile opened a Timber Frame Division in order to provide economical timber products to the growing timber frames industry in the UK. For the last 12 years Crocodile Timber Frames has been manufacturing high quality products for use in schools and homes across the UK.

Our aim is to win customers by delivering a first class but cost effective solution and performance. We then passionately wish from then onwards to continue supplying the customer every time they need packaging. This only happens if service is of the highest quality. We aim to provide

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this as a minimum requirement, every time and to never lose a customer. This can only happen if a company is made up of individuals that share this goal. Crocodile is very proud to have such staff.

www.crocodile.uk.com 01793821555

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CALL US ON: 01793 821 555

www.crocodile.uk.com Unit 62, South Marston, Swindon Wiltshire, SN3 4TA Email: quentin@crocodile.uk.com

SWITCHES & SENSORS

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www.comuseurope.co.uk

HOMECHIP LTD

Tel: 44 (0) 1255 862236

DISCOVER THE KIS ADVANTAGE

The KIS Double Cantilever Advantage

A UK based company, Homechip Ltd specialises in products based around the Dallas/ Maxim 1-wire protocol. Whether you are looking for iButtons® (used in a myriad applications: security, EPOS, environmental monitoring, data storage) or any of the equipment needed to read and program them: probes, adapters readers and software then Homechip can advise and supply. We also supply easy to use RFID readers and cards which will interface with existing 1-wire solutions and allow you to add RFID without changes to hardware or software.

Finally, we supply a range of wireless environmental monitoring equipment which let you measure and control temperature, humidity, lux and barometric pressure. Battery life is up to 6 months and range is up to 500m.

Give our friendly technical team a ring on +44 1908 410175 or send us an email at info@homechip. com and we’ll show you how to benefit from our range of solutions.

The unique KIS beam design allows moving or sliding of the load point with negligible effect on the output.

High Accuracy Process Weighing For processes where liquids, powders or granules are mixed and measured.

Thermal Expansion

Vibration

Twisting Forces

blhnobel.uk@vpgsensors.com • blhnobel.com

Find us at: www.homechip.com ©2017 Vishay Precision Group, Inc.

Issue 38 PECM

197

TRAINING & RECRUITMENT

SKILLS SHORTAGE DEAN GROUP

THE IMPORTANCE OF GROWING THE MANUFACTURING WORKFORCE An issue that has been concerning professionals in the manufacturing industry is the lack of a skilled workforce. While Brexit will end free movement, meaning fewer skilled EU workers will move to the UK, the truth is that a skills shortage already existed before 2016. Employers are in dire need of skilled manufacturers and engineers to combat the current gap, which continues to worsen as older employees retire and not enough properly trained young people enter the industry.

This is why it’s so important to invest in people and to implement learning opportunities.

Growing the manufacturing workforce is a crucial step that can’t be postponed; at the moment, approximately 186,000 new engineers and manufacturers are needed every year until 2024, but we’re currently facing a deficit of 20,000 graduates annually.

Tackling this issue is key to creating a strong manufacturing base and securing our role in the global economy.

Increasing the number of apprenticeships in manufacturing is therefore a great solution for businesses looking to bridge the skills gap. Apprenticeships help to increase awareness of the industry and to dispel the many misconceptions surrounding it and allow young people to have first-hand, on-the-job experience of the manufacturing world. This kind of experience is invaluable and can help many to make career decisions geared towards this industry.

WHY IS THERE A SKILLS GAP? From the 6,000 UK manufacturing businesses surveyed by the British Chamber of Commerce at the end of 2018, 81% of them found it difficult to hire employees with the right qualifications and experience. But why is the UK facing a skills gap in the first place?

The general public has a lot of misconceptions about the industry and what a career in manufacturing really means; the perception a lot of people have, including young students, is that manufacturing is not a stimulating or creative profession – or a rewarding one. In addition, many see manufacturing as a lower-quality choice with fewer career prospects. Crushing this stereotype is vital to increasing people’s interest in the industry.

But this is not the only contributing factor.

Education plays a major role in growing the number of people entering the industry.

An interest in manufacturing should begin earlier than university, so that businesses can partner with school and career events to raise awareness of the sector, in order to spark an interest in students who perhaps hadn’t considered this path. However, many don’t think education is currently doing enough. In their 2019 Annual Manufacturing Report, Hennik Research found that 57% of UK manufacturers believe the education

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There is nothing wrong in inspiring young people to pursue jobs that enable them to work with their minds; however, equal importance should be given to careers where they can work with their hands. For a long time, children have been taught that skilled labour is beneath their potential, so now it’s time to break this stigma.

system is disastrous for the industry and needs a total overhaul.

The manufacturing industry is continuously evolving and making use of new and improved technologies. This means that workers need to be able to keep up with these market and technological changes – otherwise, it can be difficult for businesses to meet the demands of increased output.

The modern workforce needs to have a completely different set of skills than the one required just a few years ago, and a lack of proper training can contribute to the widening skills gap in the industry.

Even though Brexit shouldn’t be blamed for this skills gap, it’s also not doing anything to bridge it. On the contrary; a large number of UK manufacturers employ citizens from the European Union in their businesses, but once free movement ends, a decrease in the availability of EU nationals will only worsen the existing skills shortage.

HOW TO GROW THE UK MANUFACTURING WORKFORCE? If the current skills shortage continues to grow, it’s likely businesses will be unable to fulfil their customers’ demands. Because it’s becoming a challenge to find trained and qualified employees, manufacturers may see their productivity decline due to slower production, increased costs and performance issues. Moreover, a lack of skills can affect a business’s ability to remain competitive in today’s global market.

Addressing the low number of women in manufacturing is also a good way to start closing the skills gap. Competency in problem-solving, excelling at conflict resolution, learning how to negotiate and communicate well and working well with others are crucial skills to have in manufacturing – and they’re not genderspecific. Empowering women to pursue a career in manufacturing, be it by participating in initiatives that engage them in manufacturing and STEM subjects or by encouraging more women to seek out mentors, is a win-win for your business.

Growing the manufacturing workforce will lead to higher levels of innovation and productivity, allowing manufacturers to stay competitive and to contribute to both the UK’s and the world’s economy. Reducing a skills shortage that has been years in the making may be a challenge for many; however, knowing where this gap is coming from and how it can affect manufacturing, will help businesses, workers, students and organisations to work towards a solution together.

www.deangroup-int.co.uk/

TRAINING Software && RECRUITMENT Systems

ONLINE LEARNING

WORK TOWARDS CHARTERED ENGINEER STATUS Our online MSc Professional Engineering course, recognised by a wide range of engineering institutes including IET and IMechE, to achieve a Masters qualification and further learning to support your application for Chartered Engineer (CEng) status.

Start May, September, January 2019

derby.ac.uk/PECM

Training & Recruitment

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Issue 38 PECM 199 Issue 16 PECM 131

TRAINING & RECRUITMENT

ILEARNRELIABILITY MOBIUS INSTITUTE

MAKE PLANT RELIABILITY YOUR REALITY

What is the difference between successful reliability improvement programs, and the very high percentage that failed? We know.

And we have put all the keys to success in iLearnReliability.

The most successful reliability improvement initiatives are owned and controlled by a team within the company.

They do not involve large consulting or software companies. They did not start with extensive (expensive) reliability analysis. They did not start with huge budgets. But they did start with passion and knowledge.

If you have the passion and desire to succeed, we can provide you with the knowledge.

What else made programs successful? They always have senior management support. iLR will help you achieve that. They all have a transformed culture, with people at all levels in the company understanding the value of reliability and contributing to the initiative. iLR will help you achieve that. They all have a plan, with goals, with knowledgeable and skilled people involved in maintenance, design, operation, and engineering. iLR will help you achieve that.

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WHAT IS ILEARNRELIABILITY? Imagine a suite of e-learning modules, filled with animations and engaging interactions, that have been specifically designed to help people at all levels of the organization, from the front-line operators and tradespeople (with Toolbox Talks), to the managers (with Manager Briefings), to the reliability engineers, planners, and many others (with Program Management Training modules), through to the people who needs special skills (with Skills Training).

The entire process is delivered on-line via your own customized “Learning Management System”. It is affordable to ensure that you can train everyone – because you really do need to train everyone!

OK, SO WHAT’S THE ALTERNATIVE? You could pay consultants to fix your problems – but that often ends up being expensive and ineffective. You have to take responsibility and ownership of this process.

You could develop the training for all of your staff. Do you have time for that (or the skills)?

You could have someone come in and train everyone once. Those who receive the training will receive a short-term lift, but six-months later it will be back to the old way of doing things.

Or you could start a small vibration program, add some other technologies, tackle a few issues like shaft alignment, lubrication, and so on. You will benefit, but it will be a fraction of what is possible.

No, you need to engage everyone, train everyone, and then update that training.

And you need a proven, detailed roadmap that will help you avoid the roadblocks and enjoy real success. iLearnReliability is the only way to do that.

Please visit www.mobiusinstitute. com/reliability to learn more, or e-mail dave.hupperich@ mobiusinstitute.com. Join other leading companies across all industrial areas that are on their way to improving reliability in their plants

ACHIEVE THE NEXT LEVEL

TM TM

TRAINING & CERTIFICATION

I

CATEGORY - I ADVOCATE

III

II

CATEGORY - II RELIABILITY ENGINEER

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CATEGORY - III PROGRAM LEADER

Practitioners Practitioners and and leaders leaders involved involved with with the the important important role role of of improving improving the the reliability reliability and and performance performance of of an an industrial industrial facility facility should should be be recognized recognized for for their their knowledge, knowledge, experience, experience, and and contribution. contribution.

The The ARP ARP CATEGORY CATEGORY I-III I-III training training is is aligned aligned and and available available through through global global Mobius Mobius Institute Institute training training centers centers and and via via online online learning. learning. Our Our certification certification is is accredited accredited and and recognized recognized worldwide. worldwide. ARP ARP certification certification is is quickly quickly becoming becoming recognized recognized as as the the highest highest standard standard in in reliability reliability certification. certification.

TRAINING & RECRUITMENT

MANAGING UNCERTAINTY THEO JAMES RECRUITMENT

RECRUITMENT CHALLENGES WITHIN AUTOMOTIVE MANUFACTURING INDUSTRY

Whether it’s Brexit or other market disrupters, there is a huge amount of uncertainty in today’s automotive manufacturing industry. Despite that, there has been a sharp increase in investment into UK automotive manufacturing, leading to increased job prospects. What the industry is lacking, at the moment, is the ability to attract people outside of the sector.

Despite the current climate, it’s been estimated that the automotive manufacturing industry will make two million cars a year in the UK by 2020.

Increasing against the current level of 1.5 million. However, this will only happen with the backing of the government to agree good trade deals and with the consistent reskilling of the workforce.

Technology and AI are also aiding to more changes in manufacturing, particularly in the automotive sector. Reports suggest that certain jobs may be replaced by machinery.

To avoid a lull in employment it’s essential that the government looks at the skills gap and that companies focus on upskilling their current employee’s through training and development. What may result in a few

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short-term job losses, should breed the development of new jobs. After all, humans are adaptable and can be retrained or developed – unlike their robot counterparts.

It’s important to reassure people that the UK still has an optimistic future within manufacturing and that its simply uncertainty hindering future recruitment predictions. Whilst the automotive industry is governed by a specific set of industry standards and is typically working to “JustIn-Time production” (JIT) which brings their own set of demands and pressures - it’s important that businesses keep an open mind with their recruitment processes and begin to look further for talent.

Increased apprenticeships and opportunities for graduate engineer placements are needed to sustain young talent within the industry. We have worked with a first-tier automotive supplier who have chosen to rebrand their recruitment strategy in order to cast a wider net. As a result, they have employed engineers straight from the armed forces, who have made use of their work ethic and their broad and diverse skill sets. These are a good match of relevant

transferable skills that can be used to excel in the job and may have otherwise not been utilised.

The automotive industry is still without a doubt an integral part of the UK’s manufacturing presence. To sustain this, market conditions must be improved, skills gaps need to be addressed and firms need to continue to be open minded - but automation will positively change the face of the industry. It will do this by creating more skilled and developed jobs. We just need to face these challenges head on by swapping our traditional recruitment strategies and appealing to the wide range of talent, fostered in the UK, in order to recruit the best candidates possible.

theojamesrecruitment.com/

TRAINING & RECRUITMENT

MAJOR RECRUITMENT DRIVE IN-COMMS

OVER 280 APPRENTICESHIP JOBS UP FOR GRABS AT IN-COMM TRAINING One of the Black Country and Shropshire’s leading training providers has more than 280 apprenticeship opportunities currently available and is urging companies and young people to get more involved.

Gareth Jones, joint Managing Director at In-Comm Training, made the rallying call this week and believes there are still lots of individuals looking to get involved in engineering and manufacturing that aren’t taking advantage of the world class training centres on their doorstep.

The firm, which operates a technical academy in Aldridge and the Marches Centre of Manufacturing & Technology in Bridgnorth and Shrewsbury, has recently embarked on a major recruitment drive to showcase how vocational learning can help bridge the current and future skills gap and provide excellent career opportunities for youngsters and more mature workers looking to switch jobs.

Over £7m has been invested in the three facilities alone, offering over 40,000 sq ft of dedicated manufacturing training space, including the latest CNC machine tools, automation, robotics, metrology solutions and 3D printing.

This is reinforced by access to industryexperienced trainers and 11 technical partners, who include Blum-Novotest, Ceratizit WNT, Engineering Technology Group, Guhring, Hexagon, HK3D and Hyfore Workholding.

“Companies are coming forward and saying they want to invest in apprentices…that challenge has been overcome to a certain degree. We now need to make sure that, as a region, we’ve got a pipeline of young people or more mature learners to fill them,” explained Gareth, who runs the business with his sister Bekki Phillips.

“At the moment we have 280 positions vacant at our three academies and these are for part and full-time trailblazer courses with a job at a local manufacturer at the end of it. This means you can learn from the best trainers, on the best equipment and get paid for it, with a recent partnership with University of Wolverhampton offering a pathway to a degree at the end of it – all without the

associated debt that can go with it. That’s a £100,000 opportunity.

“Current vacancies range from apprenticeships in machining and maintenance to mechatronics and welding.”

The recent annual In-Comm Training Barometer, which is designed to take the temperature of industry’s appetite for training, revealed that 83% of firms are still committed to taking on the next generation of engineers despite issues around the UK leaving the EU. Nearly three quarters (72%) of companies have already put aside budget to recruit apprentices over the next twelve months, with a surprising number of businesses (60%) stating they feel the Apprenticeship Levy is working.

Of those that felt the Apprenticeship Levy wasn’t working, more than half said a lack

of understanding was to blame for a lack of take-up, followed by 21% who felt the right training wasn’t available and 13% bemoaning a dearth of good quality training providers.

The report also highlighted that more than half of firms (54%) preferred parttime courses over the full-time option, whilst two fifths of companies engaged in apprenticeships don’t use them for upskilling.

This could be attributed to a lack of knowledge of what apprenticeships can be used for or the stigma still attached with this type of training and the notion that it is usually reserved for young people or someone at a basic skills level.

For further information, please visit www.in-comm.co.uk or follow @ incomm_training on twitter.

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VALVES & FLOW CONTROL

STEAM EQUIPMENT EXPERTS VALSTEAM

A STRONG PASSION FOR DEVELOPING EQUIPMENT AND FOR SOLVING PROBLEMS Focused on providing groundbreaking products for industrial steam and fluid systems, the Valsteam ADCA project has been in the market of steam equipment for more than 35 years.

Valsteam ADCA started as an industrial plant for pipeline and steam boiler house contractors. Already building pressure vessels and auxiliary equipment in-house, Valsteam ADCA has grown up to become steam equipment and valve manufacturers, using the knowledge acquired along the years, and can now assure the complete production cycle: design, machining, welding, assembly, tests, quality and packaging for a very wide range of products.

GIVING NEW WORLDS TO THE WORLD Right from the start, the family owned Portuguese company had a strong passion for developing equipment and for solving problems. Today, Valsteam ADCA has two production facilities with a total manufacturing area of 22 000 square meters, located in a small village in the ocean side of Portugal, and are currently growing again, expanding their main production facility.

The team today consists of almost 90 people that together drive the Portuguese caravel along the five continents and more than 80 countries, with the same ambition their ancestors were driven by: to reach more and to give new worlds to the world!

A “ONE STOP SHOP” Up to now, the company consolidated a very wide range of products and solutions for steam and other industrial gases and liquids, present in the process industry. Today, the company stands as a “one stop shop”, with more than 6.000 different products and more than 15.000 product parts for all kind of industries.

From standard and non-standard series to tailor-made products, Valsteam ADCA is one of the European companies with the largest range of products, which can be divided into six sections: • Steam traps • Pressure reducing valves • Control valves • Pipeline ancillaries

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

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

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

VALVES & FLOW CONTROL

DIXON QUICK RELEASE COUPLINGS

Quick release couplings from Dixon comprises of a full range of interchange couplings for both hydraulic and pneumatic applications, engineered to the highest specification in order to flawlessly fit existing hoses and couplings.

A wide selection of materials including Steel, Aluminium, Brass, 316 & 303 Stainless Steel are available; thread configurations including BSP & NPT and body sizes ranging from 1/8” through to 2” ensure compatibility in a variety of installations.

The range of manual quick release couplings is ideal for applications where full and smooth flow paths need to be maintained. Dixon specialise in the bespoke design of speciality couplings to meet the requirements of our customer including miniature and high pressure automatic connect couplings.

New to the range are our Correct Connect™ colour coded ISO 16028 Interchange HT Series couplings ideally suited for overcoming the challenges associated with product cross contamination, wasted time identifying connections and equipment damage caused by incorrect connections.

The HT-Series Correct Connect™ colour bands provide a solution by helping to

easily identify seals, materials or sizes for an application and helps with preventative maintenance schedules.

Dixon also offer Dry Disconnect and Safety Breakaway Couplings and Adapters; to find out more about the Dixon range head to dixoneurope.co.uk or ask us for our Quick Couplings brochure today by contacting our customer sales department on 01772 323529.

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©2018 Dixon Group Europe Limited

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

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OIL PRICES PJ VALVES

HOW THE RIGHT SUPPLY CHAIN CAN REDUCE RISK AND COSTS AND WHY THE OIL PRICE MATTERS LESS THAN YOU MIGHT THINK

By Dan Munro, CEO, PJ Valves The oil price is a source of endless fascination. Entire careers are built on following its daily peaks and troughs.

No wonder: for companies in the oil and gas industry, the oil price provides us with one of very few indicators of likely future demand for our products and services. But for engineering procurement and construction (EPC) companies in the sector, it matters less than you might think on a short-to-medium term basis.

A DIFFERENT WORLD While some in the industry would no doubt like to return to the halcyon days of 2013/14, most of it is steeling itself to thrive at lower project cost levels, mindful of the fact things may never return to how they were. Indeed, since Brent reached just under $85/bbl in October, prices tumbled, going nearly as low as $50/bbl in January. At the time of writing, a barrel trades at $63, more than $7 less than it did a year ago.

There has been a broadly recognised shift away from mega-projects with high breakeven costs towards smaller alternatives. However, there are still tightlydesigned mega-projects going – look at Mad Dog 2 or the Liza Field development – but nowadays you are more likely to read about new FPSO’s (offshore) and fast-track early production facilities (onshore).

NEW PLAYERS, NEW RULES So – though big players and major projects still have a significant role to play – it’s the leaner, hungrier operators that are the choicest target for many EPCs.

Valves have historically been over-specified and, for an EPC looking to put together a response to tender, it’s not commercially viable to spend precious time optimising the components that add up to £10m when they could be focusing on the £50-100m project spend for ‘big ticket’ items such as rotating equipment.

Despite being a small part of the overall cost, valves can cause big delays and expensive overruns. As someone once told me: “valves are 2 per cent of my cost, but 50 per cent of my problems.”

The trick is knowing where to find that engineering time and expertise. A good place to start is where the valves are designed and made: the manufacturers and suppliers.

PARTNER, NOT SUPPLIERS

However, being lean has downsides too.

During the downturn, engineering teams across operators and EPCs lost expertise. As an illustration, take a look at our world of valves.

In a traditional manufacturer-supplier relationship, the customer doesn’t get access to the expertise. They just get the valves.

Whereas, a partner’s engineering team can work with the EPC to optimise the valve list.

An oil and gas project can feature thousands of valves, each a small part of the overall picture but crucial for safe and efficient production.

Often, a valve has been specified because that’s what the specifying engineer for that component has done in the past and doesn’t have capacity to look at changing. Repeat

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that across a project and the list sprawls.

A partner-supplier which understands the valve application as much as the valve product can suggest alternatives and streamline that list.

For one customer, we reduced an initial list of roughly 1,500 distinct valve descriptions to 193. With this simplification of product and spares came both capex and opex benefits, in addition to huge time savings in administration.

This way of working provides greater value, hopefully creating long-term, trusted partnerships. For the operator or EPC, it means getting extra value from its supply chain to reduce costs and de-risk projects, ultimately building in resilience.

So, my challenge to operators and EPCs in today’s environment is to not fixate quite so much on the day’s oil price. Instead, consider the type of supply chain you want to build and the type of company you want to work with. By doing that, and looking for partners instead of suppliers, operators and EPCs can set themselves up for success whether the oil price is at $50/bbl or $100/bbl. www.pjvalves.com/

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THE VERSATILITY OF ZETRIX ARI-ARMATUREN

IMPROVING H&S STANDARDS WITH DOUBLE BLOCK & BLEED ISOLATION Various industries all over the UK and Ireland are benefiting from the added safety and efficiency that the ZETRIX valve can provide. With the advantages of a metallic sealing process valve combined with a butterfly design, these valves can be used for isolation and control. Boasting zero leakage and emissions, the triple offset principle guarantees a permanently tight seal, conforming to leakage rate A as per DIN EN 12266-1 standards because the valve fits precisely and closes without friction.

Setting the ZETRIX up as a double block and bleed isolation offers many benefits including improved Health and Safety standards, reduced downtime for maintenance repairs and considerable savings when it comes to energy and cost.

This double isolation model has been developed to meet the increasing demands of Health and Safety requirements where the traditional single isolation of plant is inadequate. HSE guidance suggests that double block and bleed is the only proved isolation in accordance with HSE Guidance 253 (Safe Isolation of Plant and Equipment) which states that double block and bleed is greatest in the hierarchy of mechanical security for isolation methods.

Using this method of double block and bleed isolation means that a section of plant can be isolated without having to shut down an entire system, as would need to be done with single isolation valves in place, therefore allowing for easier and safer upgrade or maintenance work.

The small face-to-face dimensions of the ZETRIX provides even more versatility in that should one wish to change from single isolation to double isolation with bleed, only small changes to pipe work are required.

A typical double block and bleed, which incorporates two ZETRIX, is the equivalent face-to-face dimension to the vast majority of single isolation valves (typically gate and parallel slide valves). Therefore, the ZETRIX can be used for modifying pipe work with single isolation to double block and bleed in order to meet Health & Safety guidance with very little alteration to the pipe work, ultimately saving time and money (plant downtime and labour costs dramatically reduced). There are major benefits to using double isolation in the space of one valve

more to the flexibility of this range. A version with butt weld ends is now available, in addition to the double flanged and fully lugged designs. as very little space is required, it reduces the possibility of leak paths and is a lot safer than relying on the integrity of a single isolation valve.

With the ability to make the spool piece to fit any gap, the system can be tailored to specific installation restrictions. Currently, other ranges on the market seem to have a costly, limited choice in comparison to the comprehensive range of pressure classes, materials and sizes available with the ZETRIX range from ARI-Armaturen. This solution can also be supplied with all forms of actuation including electric and pneumatic, if required.

Durable and reliable with high performance, the ZETRIX valve range has impressed the market for some time now and new types, sizes and pressure ratings now add even

With its impressively quick closing action, the valve can also be used as an Emergency Shutdown Device, providing the ultimate in tightness and safety. It is essential that a Plant can rely on its isolation valves and this speedy emergency shutoff action provides the reassurance of complete safety with a quality valve designed to stop the flow of a hazardous fluid or gas upon the detection of a dangerous event.

For more information, contact the UK sales office.

ARI-Armaturen UK Ltd Tel: 01684 275 752 Email: enquiries@uk.ari-armaturen.com Visit zetrix.ari-armaturen.com/uk

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