Process Engineering Control & Manufacturing Issue 39 2019

Process

MANUFACTURING

Control &

Engineering

PECM

Global Success Through Innovation Issue 39 2019 ÂŁ3.95 www.pecm.co.uk

QUANTUM CONTROLS - 9

MICRO - 122

BARNSHAW - 102

Your unique drive asset management system, view the full maintenance history of each of your drive assets anywhere, anytime.

Inline and robot-mounted 3D inspection system enables fast, reliable defect detection on non-reflecting surfaces

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Engineering Process

Sections Editors Choice Advanced Material Show Preview Automotive Engineering Boilers & Maintenance Calibration Solutions Control & Automation Electrical & Electronics Facilities Management Fasteners & Fixings Fluid Handling Gears, Drives & Motors Health & Safety Hydraulics & Pneumatics Machining & Machinery Measurement & Monitoring News & Events Pumps Process Technologies Product News Software & Systems Storage, Handling & Distribution Training & Recruitment Valves & Flow Control

Control &

MANUFACTURING

Inside...

Inside Issue 39 4 46 50 58 59 62 68 74 80 81 89 98 101 102 110 128 131 134 142 147 150 152 157

REO Why modern electrical applications demand new core materials SANDVIK Sandvik Additive Manufacturing has created the first ever 3D printed diamond composite.

ARROWSMITH ENGINEERING A leading Coventry aerospace supplier is tapping into the ‘march of the robots’ to help it capitalise on 20% growth over the last twelve months.

ADNAMS Adnams still operates out of its original 18th century site in Southwold, but its commitment to tradition has not stopped it implementing a 21st century endof-line automation solution.

THE ADVANCED MATERIALS SHOW The Advanced Materials Show – the very first in the series – taking place at The International Centre, Telford (UK) from 10th-11th July 2019. This event will offer industry leading insight into current and future materials development, with experts from all sides of the industry in attendance.

AEMT TEC Electric Motors is a true success story, where continued investment and growth has seen the company relocate twice in the past 12 years to keep pace with the needs of its customers.

“The Centre of Excellence for Strainer and Filtraaon Technology”

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

Coalescers & Seperators Pressure Vessels Flame Arresters Sight Glasses Silencers Spools

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

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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.

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EDITOR’S CHOICE

FACILITY EXPANSION CORTECROS

HIGH-TECH INTEGRATED SOLUTIONS FOR CORROSION PROTECTION!

CorteCros®, part of Cortec® Corporation Europe has expanded its warehouse location in Split, Croatia, with new manufacturing facility and laboratory.

Cortec’s proprietary VpCI®/MCI® products are now manufactured in Split in accordance with REACH regulation, which enables them to be shipped everywhere inside the European Union in record time. CorteCros’s new facility and lab are equipped with modern instruments and perform testing compliant to EU and ASTM standards. Each batch is tested on-site according to high standards which allow the company to provide valuable services to its customers.

CorteCros® also released a new updated brochure covering a broad range of new services.

The company provides integrated solutions and full technical support for Cortec’s products and services in southeastern Europe. CorteCros® offers product selection,

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PECM Issue 39

application, and consulting services for corrosion prevention and collection of spilled oil derivatives and chemicals.

Integrated corrosion protection services enable clients significant cost savings with environmentally responsible materials protection technology.

optimum corrosion control solutions to meet their needs. The company provides services for all industries with extensive experience in military and oil and gas industries as well as package preservation. CorteCros® also provides environmental biotechnology solutions from Bionetix® International.

The brochure highlights the company’s full range of products and services while covering its brand-new production facility and laboratory that play an integral role in manufacturing Cortec’s corrosion control products

CorteCros® Values: • Integrity • Delivery • Design of protection and preservation projects • Consulting • Service and Supervising • Professionalism • Safety

CorteCros’s team has over 20 years of experience protecting drilling and workover equipment. Its mission is to offer technical and logistics support to Cortec’s distribution network. Split, Croatia is the main European location for production, storage, and on-site testing of CorteCros® products. CorteCros® is focused on providing each customer with

To view the full brochure, please visit the following link: www.cortecvci.com/Publications/ Brochures/CorteCros_Brochure.pdf

Quantum’s Unique Drive Asset Management System Drives & Motor Supplier of the Year

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CASE STUDY CASE STUDY

CASE STUDY CASE STUDY

Johnston Logistics UK Johnston Logistics UK Environment: Logistics Environment: Logistics

BayLED Eco BayLED Eco

TLT TLT GET GET FIT

FIT

Tomorrow's Tomorrow's Lighting Lighting Today!

Today!

Financed Financed Installation Installation Today!

Today!

UPGRADE NOW! UPGRADE NOW!

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

“Thewe lights been installedbill areare very good, they instant,isno delays thethan energy savings of 75% will that makehave on our electricity very good.

Theare visibility 100 timesand better it was”.

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.

200W 200W

PERFORMANCE THAT MATTERS PERFORMANCE THAT MATTERS

Energy Efficient Energy Efficient

Environment Environment

Storage area Storage area Energy load Energy load Operating hours Operating hours Annual running cost (£0.09 per kWh) Annual running cost (£0.09 per kWh) Annual energy saving of 75% Annual energy saving of 75%

£8,289 £8,289

Annual Savings Annual Savings

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

50,000 50,000

Up to 100,000 lifetime (hrs) Up to 100,000 lifetime (hrs)

GG Lighting Solution GG Lighting Solution

41 x 200w BayLED Eco PIR 41 x 200w BayLED Eco PIR 8.2kw 8.2kw *3,744 *3,744 £2,763 £2,763 £8,289 £8,289

LIGHTING LIGHTING

SOLUTIONS SOLUTIONS

MADE MADE SIMPLE! SIMPLE!

TLT TLT

GG Lighting’s Light as a Service makes it easy for your business to GG Lighting’s Light as a LED Service makes it easy forno your business to upgrade to a new turnkey lighting solution with upfront costs! upgrade to a new turnkey LED lighting solution with no upfront costs!

GG Lighting use best in class components that deliver energy and GG Lighting savings use best in will class components deliver energy and maintenance that finance your newthat lighting. maintenance savings that will finance your new lighting.

We design, install and maintain. WE MAKE IT EASY! We design, install and maintain. WE MAKE IT EASY!

LIGHT AS A SERVICE ASyour Abusiness SERVICE Using GG Lighting’s ‘LightLIGHT as a Service’, can benefit from a ‘zero’ upfront

Usingcost GG Lighting’s ‘Light fully as a Service’, your business can benefit from a ‘zero’ upfront state-of-the-art maintained lighting solution.

GG LIGHTING WILL: cost state-of-the-art fully maintained lighting solution. GG LIGHTING WILL:

DESIGN

Survey your existing lighting installation DESIGN andyour propose a low energy, low Survey existing lighting installation and maintenance propose a lowsolution. energy, low maintenance solution.

Certificate Number 1979-QMS-001 ISO 9001 Certificate Number 1979-QMS-001 ISO 9001

INSTALL

Arrange and organise installation INSTALL around yourand requirements with minimal Arrange organise installation disruption to your business. around your requirements with minimal disruption to your business.

MAINTAIN

As part of our full service offer, we will MAINTAIN maintain yourfull new lighting solution As part of our service offer, we will throughout thenew life lighting of the contract. maintain your solution throughout the life of the contract.

gglightingsolutions.co.uk gglightingsolutions.co.uk +44 (0) 1842 763 752 | upgradenow@ggls.co.uk

+44 (0) 1842 763 752 | upgradenow@ggls.co.uk

EDITOR’S CHOICE

BEVERAGE/FOOD ENGINEERING LOBO SYTSEMS

BEVERAGE AND FOOD PRODUCTION COMPANIES CHOOSE THE LOBO SYSTEM TO INCREASE SAFETY & REDUCE COST PepsiCo, Anheuser-Busch, Tyson, Heinz, Kraft, Kelloggs, Unilever, Nestle, Cargill, Heineken, Cott Beverages, Coca-Cola, Miller Coors, Nestles, Allied Mills, William Grant, Pernod Ricard, Britvic, Muller Dairies, McCain, ADM, Dairy Crest, Bunge and Arla Foods all use the LOBO System for facility maintenance, and here’s why:

MAINTENANCE: Food processing machines are difficult to access for maintenance and cleaning tasks.

Traditional scaffolding and aluminium tower systems could be used, but as they cannot be quickly or easily assembled and are not tailored to fit each individual application, they cannot be deployed from one machine to another. They do not meet the industry’s day to day changing requirements.

Outsourced scaffolding labour is expensive and not available 24 x 7, aluminium frame systems are cumbersome, inflexible and will not adjust to fit into awkward areas.

When not in use, they take up a lot of space and cannot be easily transported around the production facility.

Regular access to elevated areas, for example above conveyors, is awkward and difficult to reach. Safety is a key component of working at height which cannot be compromised.

THE SOLUTION The LOBO System is a re-configurable work platform product that combines the flexibility and strength of traditional scaffolding with the simplicity and mobility of tower systems.

This combination provides a versatile access system that has applications right across the Food Industry.

The LOBO System, utilising its unique patented clamp, can be reconfigured and adjusted, without the need for tools, into any shape or size required. This simple system can be assembled by anyone, as the components are modular. LOBO’s electroplated steel legs and components can be flat packed when not in use and transported easily, for storage or utilisation elsewhere.

Your own in-house maintenance crews can assemble the LOBO System quickly, easily and safely around, under or above machinery or conveyors. To ensure safety, handrails can be fitted in seconds, at any point in the system, and at any stage of the assembly process.

Staff should never be exposed to the risk of a fall.

This means out-sourced scaffolding labour costs can be reduced without comprising safety. Areas, previously considered difficult to get to, can now be accessed with ease for maintenance and cleaning purposes. As it is available 24/7 it puts you in control of what and when you schedule your maintenance tasks.

PRODUCT BENEFITS LOBO is scalable, adaptable and adjustable to meet your ongoing and changing requirements.

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Simply add more components or alter your existing configuration to satisfy the demands of the next task. Protect your initial investment with a product that will meet all your access needs safely.

LOBO is a rigid and stable product, which meets or exceeds current safety regulations.

LOBO TOWERSTORE The Towerstore offers security on or off site. The Towerstore provides a secure and yet simple way to store your LOBO components, which also makes managing all the component parts that much simpler.

Designed specifically for LOBO’s advanced work platform system, it is fitted with feet for easy pallet truck or forklift manoeuvrability. Also, it can be locked with a padlock for security or storage. The Towerstore can be vertically or horizontally mounted to suit the workshop or can be transported for rapid deployment, on and off site.

will be achieved – easily within a 12-month period.

With this quantifiable reduction in costs comes the added savings associated with reduced equipment down time and greater productivity from your maintenance department.

LOBO’s electroplated steel structure ensures many years of product life and a system that will not shake or rattle.

Available 24/7, quick to erect, and above all safe.

LOBO’s modular approach means components fully integrate and can be hand carried.

It is immediately adjustable for your next job with no staff waiting time while new fixed-frame structures are built.

Fully constructed systems can also be made mobile by the addition of wheels.

Re-configurable, again and again, this product comes with no disposal costs and minimal replacement and on-going training costs.

COST BENEFITS Experience shows that deploying the LOBO system reduces the costs associated with hiring scaffolding and constructing bespoke fixed access systems. By reducing your reliance on out-sourced scaffolding and engineering companies, cost savings

WHY CHOOSE LOBO? Increases Safety | Available 24/7 | Reconfigurable | No-tools assembly | Protects Investment | Reduces cost | Scalable

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

North America: 1-800-640-5492.

Email: sales@lobosystems.com www.lobosystems.com Issue 39 PECM

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EDITOR’S CHOICE

CONTROL PLATFORM SOLO ENERGY

FLEXIBLE, RENEWABLE ENERGY

THE CHALLENGE In order for the energy to be stored and shared securely, Solo needed to find a control platform capable of remotely communicating with and controlling the batteries and chargers, as well as enabling vast amounts of data to be recorded and stored. The platform needed to enable Solo to control and remotely communicate with all its distributed assets individually and collectively, allowing energy to be quickly shared between them.

It also needed to provide visualisation tools that would enable Solo to visualise and analyse all its energy data so that it could identify trends and improve performance of

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PECM Issue 39

the VPP, and present this information back to its customers as a user-friendly interface. In order to allow Solo’s software to grow along with the business, the software also needed to be fully scalable.

With data security of paramount importance, Solo also needed to find the most secure environment in which to host the control platform - one which required zero IT infrastructure in order to deliver a costeffective option, and which could be set up quickly, deliver 24-hour monitoring and comprehensive customer support, and guarantee uptime.

THE SOLUTION In 2017, industrial IT solutions provider SolutionsPT recommended Wonderware System Platform 2017 as the software most suitable for Solo’s needs.

Andrew Graham, SolutionsPT’s Wonderware Product Manager, said: “System Platform 2017 is an operating system for industrial applications. It provides configuration, deployment, security and data connectivity, bringing essential context to organisations’ data and providing valuable system documentation throughout the system lifecycle – everything Solo was looking for.

For example, one in the Orkney Islands – a new housing development of circa 30 houses - was required by building regulations to have renewable energy, however the network operator was unable to connect all the homes to the grid. We used FlexiGrid to get all the households connected by storing renewable generation from their solar panels in our FlexiGrid-controlled batteries and prevented any excess generation from being exported to the wider grid.

“We’re now in a position to begin rolling out our service commercially across the UK and Ireland and that’s not something that would have been possible without the new control platform.”

About Solo Energy Solo Energy is a Cork-based renewable energy specialist that deploys and operates distributed energy storage systems, in the form of home batteries and ‘Vehicle-to-Grid’ (V2G) electric vehicle chargers, at any home or business in the UK that wants to host one. Hosts store excess generation in exchange for low cost, 100% renewable electricity, which is supplied by one of Solo’s local energy supply partners.

Solo has created an energy trading economy that allows consumers to share renewable energy across the grid via a blockchain-based, peer-topeer energy trading platform known as FlexiGrid. It centrally controls the batteries and chargers, enabling hosts to share excess local generation quickly and conveniently.

“It also includes the first ever fully responsive Operations Management Interface (OMI), which provides improved situational awareness and an intuitive experience through its modern user interface. This enables users to bring together information from all relevant systems and give it real context, allowing them to understand current performance and accurately predict future behaviour.

“System Platform also allows screen resolution-independent asset templates to be digitally modelled and shared on any device. This allows Solo to receive insights from its operations regardless of location and keep development and maintenance costs minimal. It also enables application scaling and, using drag and drop technology, assets can be easily deployed onto other machines, allowing users to scale up from a single box solution to multi-tier deployment and delivering a future-proof investment.”

As an organisation unrestricted by the safety or latency concerns that would make an

on-premise solution necessary, Solo made the decision to host System Platform in a cloud environment, eliminating the need for additional IT infrastructure and delivering a fully scalable and easily deployable system that could be installed with minimal resource.

THE OUTCOME By embracing a cutting-edge control platform and hosting it in a cloud environment, Solo has: completed a number of pilot projects which have enabled it to prove its business model in the UK and Ireland moved from a testbed agreement to a commercial agreement with the Cork Internet Exchange by proving the viability of its business model, and begun preparations for its commercial rollout Daniel Dransfield, VP of Engineering at Solo, said: “System Platform has really helped with the pilots we’ve been working on.

This digitally connected series of chargers and batteries is known as a Virtual Power Plant (VPP) and enables the flexible supply and demand of energy across the grid. This flexibility helps balance the intermittency of renewable energy generation and allows hosts to receive energy that is stored by other hosts whenever necessary, allowing Solo to shape demand to follow renewable supply.

By remotely controlling the hosted batteries and chargers, Solo can charge them from onsite solar and wind generation facilities, or from the grid when sufficient renewable generation is present. When renewable generation decreases, the energy stored in hosts’ batteries or electric vehicles is used to supply homes and businesses instead, enabling the energy to be supplied cheaply.

Contact: solutionspt.com/contact-us/ Phone: 0161 495 4600 Website: solutionspt.com

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EDITOR’S CHOICE

THE RIGHT CONNECTION DIXON

A FULL HYGIENIC OFFER FROM DIXON Dixon offers the right connection for your hygienic process; from stainless steel hygienic fittings and adapters to food/ beverage standard hose assemblies and actuated valves to the food, dairy, beverage, brewery, cosmetic, chemical and pharmaceutical industries.

Over the last 30 years Dixon has significantly extended its range of Valves, Fittings and Couplings for the Hygienic markets through product development and acquisition.

Of particular note is Dixon’s range of high quality process valves which include ball, butterfly, diaphragm, seat, sample, and mix-proof valves which can be actuated to customer specifications and fitted with a range of stocked accessories that includes limit switches, solenoids and positioners.

The Dixon Breakaway Check Valve is an innovative solution that is designed to eliminate product loss too. It incorporates the Breakaway Coupling and a Hygienic Check Valve. It acts as a single unit that has a diverted breaking point which will break at a determined break-load. Then the check valve will close protecting the loading bay pipe system and avoiding product spillage.

The new compact sight glass launched in 2018 is used widely in food, dairy and beverage hygienic processes to view

products and fluids. This design is perfect for hoses and high traffic areas due to its Lexan™ glass and a stainless steel body construction. Ideal for arduous applications, heavy manual handling, high traffic and high activity areas to provide site added protection and asset security.

The sight glass is available as one of the many hygienic hose fittings

complementary to Dixon’s extensive hygienic hose range which now includes Heat Traced, Hot Water Thermal and Duplex hose assemblies as part of the standard range along with a range of rubber, silicone, PVC and PTFE hose assemblies which can be custom made to exact requirements with accessories including wash down guns and steam lances.

Here in the UK, Dixon offers, specialised support and bespoke engineered solutions from concept, to design, through to installation. Dixon’s onsite manufacturing and engineering department means that new designs, animations and 3D modelling can rapidly be produced to support customer’s requirements. This has included pump carts, bespoke valve configurations and innovative display sight glasses used on beer pumps to infuse product.

Contact Dixon with your requirements today and find the right connection.

Dixon Group Europe Ltd T: +44 (0) 1772 323529

W: www.dixoneurope.co.uk E: sales@dixoneurope.co.uk

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PECM Issue 39

Your Right Connection For Hygienic Process Systems Dixon’s extensive hygienic and pharmaceutical range of products includes: fittings, tubing, hygienic unions, manual and automated valves, pumps, hose assemblies and a range of accessories.

Mixproof Valves

Sample Valves

Fittings & Tubing

Seat & Process Valves

Fabrications

Pumps

Dixon offers a full range of FDA approved hose and hose assemblies offering odourless and taste free properties suitable for the transfer of liquid foodstuffs.

Food Grade Rubber

Silicone

PTFE

Dixon Group Europe Limited Tel: +44 (0)1772 323529 Email: sales@dixoneurope.co.uk www.dixoneurope.co.uk

EDITOR’S CHOICE

TRUE INNOVATION SANDVIK

SANDVIK CREATES FIRST 3D PRINTED DIAMOND COMPOSITE Sandvik Additive Manufacturing has created the first ever 3D printed diamond composite. While this diamond does not sparkle, it is perfect for a wide range of industrial uses. The new process means that this super-hard material can now be 3D printed in highly complex shapes and can thereby revolutionise the way industry uses the hardest natural material on the planet.

The diamond composite will be unveiled at the RAPID + TCT show in Detroit May 21 23, 2019, North America’s leading event for Additive Manufacturing.

Diamond is harder than anything else in nature. It is a key component in a large range of wear resistant tools in industry, from mining and drilling to machining and also medical implants. Since 1953 it has been possible to produce synthetic diamond, but since it’s so hard and complicated to machine, it is almost impossible to form complex shapes.

Until now, production of super hard diamond materials only has allowed for a few simple geometric configurations to be formed. By using additive manufacturing and a tailor-made, proprietary postprocessing method, Sandvik has managed to 3D-print diamond composites which can be formed into almost any shape.

The difference between Sandvik’s diamond and natural or synthetic diamond is that Sandvik’s is a composite material. Most of the material is diamond, but to make it printable and dense it needs to be cemented in a very hard matrix material, keeping the most important physical properties of pure diamond.

THE OPPORTUNITIES ARE ENORMOUS

Delivery Manager at Sandvik Additive Manufacturing. “Even now we are just starting to grasp the possibilities and applications that this breakthrough could have.

“On seeing its potential, we began to wonder what else would be possible from 3D-printing complex shapes in a material that is three times stiffer than steel, with heat conductivity higher than copper, the thermal expansion close to Invar – and with a density close to aluminium. These benefits make us believe that you will see this diamond composite in new advanced industrial applications ranging from wear parts to space programs, in just a few years from now.”

THE 3D PRINTING PROCESS

Due to Sandvik’s use of additive manufacturing, diamond components can now be created application ready, in very complex shapes, without the need for further machining. This will open up the possibility of using it in applications that were previously considered impossible.

“The additive manufacturing process used is highly advanced,” explained Mikael Schuisky, Head of R&D and Operations at Sandvik Additive Manufacturing. “We are printing in a slurry consisting of diamond powder and polymer using a method called stereolithography, where complex parts are produced, layer by layer, using ultraviolet light.

“Historically, 3D printing in diamond was something that none of us imagined was achievable,” explained Anders Ohlsson,

The step after the 3D-printing is however even more demanding. This is where Sandvik has developed, a tailor-made,

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proprietary post processing method making it possible to achieve the exact properties of the super-hard diamond composite.

“This step was extremely complicated.

However, after extensive R&D efforts and several trials we managed to take control over the process and made the first 3D printed diamond composite.”

“It was incredible to see what we can achieve when we combine Sandvik’s leading expertise in materials technology with our strong capabilities in additive manufacturing and post processing,” commented Mikael Schuisky. “We have some of the world’s leading experts in both materials and additive manufacturing, which in a case like this can benefit many industries around the globe making it possible to use diamond in applications and shapes never conceived possible before.”

“Rather than looking to actually develop completely new materials, today the big push within the industry involves the oftenradical restructuring of existing materials,” said Annika Borgenstam, Professor at the Department of Materials Science and Engineering at Stockholm’s KTH Royal Institute of Technology.

“Using revolutionary new processes such as additive manufacturing will open up completely new ways of using the same types of materials that we have today, by building in the properties that we need.”

“Sandvik’s 3D printed diamond composite is a true innovation. It means that we can begin to use diamond in applications and shapes never conceived possible before,” said Susanne Norgren, Adjunct Professor in Applied Materials Science at Uppsala University. “Just imagine what it could do to industries, when it is possible to print anything, in any shape – in diamond.”

Sustainable with superior properties Another key advantage of additive manufacturing is that it allows engineers to minimize material waste, making the technology more sustainable. The diamond

powder in Sandvik’s process can be extracted from the polymer in the slurry after the printing, and then be recycled and reused in another print-job.

The diamond composite has been tested and found to have extremely high hardness, exceptional heat conductivity, while also possessing low density, very good thermal expansion and fantastic corrosion resistance.

“We now have the ability to create strong diamond composites in very complex shapes through additive manufacturing, which fundamentally will change the way industries will be able to use this material.

As of now, the only limit to how this superhard material can be shaped and used is down to the designer’s imagination,” Mikael Schuisky concluded.

Diamond is harder than anything else in nature.

Sandvik’s 3D printed diamond composite was created using the additive manufacturing process called stereolithography, where complex parts are produced, layer by layer, using ultraviolet light.

A slurry containing diamond powder and polymer is used in the process.

After the printing, the next step in the process is even more demanding. This is the critical step where Sandvik has developed, a tailor-made, proprietary post processing method that is able to produce the exact properties of the diamond composite.

Excess printing slurry can be reused to reduce waste – and the diamond powder can also be extracted from the slurry and then recycled, making the method more sustainable.

Sandvik has a patent pending for the diamond composite process.

More information about the world’s first printed diamond composite and Sandvik’s capabilities in additive manufacturing can be found on Sandvik Additive Manufacturing’s website: additive. sandvik Issue 39 PECM

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EDITOR’S CHOICE

THREE-DIMENSIONAL PRINTING OPTIMAL INDUSTRIES

PAT MINIMIZES REGULATORY CONCERNS AROUND 3D-PRINTED MEDICINES Three-dimensional (3D) printing is revealing its potential in the pharmaceutical industry as it turns personalized medicine into reality. In fact, additive manufacturing has the unique ability to deliver quickly, flexibly and economically set amounts of patientspecific drugs with bespoke properties, such as formulations, dosages or geometries.

To achieve that and meet strict regulatory requirements, the pharmaceutical industry needs to set-up solid Quality by Design (QbD) strategies and process analytical technologies (PAT).

in order to efficiently monitor the 3D printing line and delivery accurate personalized medicines, it is important to implement a system that can gather, analyze and store analytical and process measurements.

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Martin Gadsby, Director at Optimal Industrial Technologies, looks at how PAT is key to success in additive manufacturing of drugs.

3D printing is a gamechanger in drug manufacturing, as it gives industries the ability to fully customize medicines - mostly oral solid dosage forms - with realistic production costs. In this way, patients can be treated with more specific dosages and drug combinations that fully address their needs. Even more, this technology empowers pharmaceutical industries to develop medicines with sophisticated bio-functional constructs, which are not achievable with traditional manufacturing practices.

The methods used to produce 3D-printed drugs, or “printlets”, conform to conventional additive manufacturing technologies, such as inkjet printing or fused deposition modelling (FDM). In these systems, the product is often built by depositing highly accurate doses of material layer by layer, until a 3D shape is formed. As a result, reproducibility is a key feature and conventional pharmaceutical manufacturing operations, such as milling, granulating or compressing, do not take place in additive manufacturing.

3D printing is a gamechanger in drug manufacturing, as it gives industries the ability to fully customize medicines - mostly oral solid dosage forms - with realistic production costs.

Instead, in FDM, manufacturers first design a 3D theoretical drug model. Secondly, they choose appropriate printing process parameters, such as layer thickness, extruder diameter, base plate, extruder temperature, printing and extrusion speed. Subsequently, the 3D printing machine reads the models and executes the commands in order to produce the final product.

Therefore, to deliver personalized medicaments with specific drug properties, manufacturers must have a thorough understanding of the different 3D printing processes involved and how they affect the final drug attributes. In this way, they can plan, control and fine-tune the relevant mechanisms to suit.

QbD is a prerequisite for precision medicine Process understanding and monitoring, typical of additive manufacturing of pharmaceuticals, are also the foundations of QbD. This model focuses on designing quality into a product from the earliest stages of planning - controlling critical process parameters (CPPs) at any point on the manufacturing line in order to affect the drug’s critical quality attributes (CQAs). In this way, manufacturers can be certain that the end product satisfies a set pharmacological specification and complies with regulatory requirements.

Whilst the processes involved in 3D printing of pharmaceuticals greatly differ from traditional preparations, the PAT process used to support the QbD approach remains the same. More precisely, multivariate nondestructive analysis, such as colorimetry, chemical hyperspectral imaging, infrared, near-infrared and Raman spectroscopy, can be integrated in the printing system as in-line, real-time quality control tools. In this way, drug manufacturers can monitor CQAs and adjust CPPs accordingly.

In order to efficiently monitor the 3D printing line and delivery accurate personalized medicines, it is important to implement a system that can gather, analyze and store analytical and process measurements. Then use these to create and validate models, generate predictions based on these models and provide feedback to the 3D printing system. In this way, manufacturers are empowered with clear actionable insights.

What is called for is a PAT knowledge management tool, a leading solution being Optimal’s synTQ. This is used by over half of the top ten global pharmaceutical

manufacturing companies, as it offers a regulatory-compliant, user-friendly platform to detect when a process is moving out of its optimum operating window and correct the relevant CPPs live and in-process.

Taking drug 3D printing to the next level PAT is fundamental to making this a quantum leap in 3D printing of medicines.

In fact, this technology is not limited to batch processing, as continuous additive manufacturing, whilst in its infancy, can also be implemented. By adopting this continuous manufacturing approach, 3-D printers can reduce production times and costs even further by enabling the real-time release of regulatory compliant drugs.

To shift from batch to continuous printing, it is necessary to install reliable and robust PAT along the entire system. In this way, CQAs of each single personalized drug can be monitored at all times. A consequence of continuous manufacturing is the generation of even larger volumes of process data.

Therefore, PAT knowledge management platforms, such as synTQ, hold an even more central role.

Additive manufacturing is beginning to gain interest among the pharmaceutical industry, as its opportunities, benefits and successes become more and more apparent.

As its visibility increases and its technology matures, especially strengthening the continuous processing capabilities, its adoption will become ever more widespread.

So will PAT, which is already becoming a new industry standard, as this is the key tool to ensure that personalized drugs fulfil their specific pharmacological and regulatory requirements. By choosing a well-accepted PAT knowledge management software tool like synTQ, additive manufacturers can call on a solid, customizable solution to build new production processes upon.

www.optimal-ltd.co.uk Issue 39 PECM

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EDITOR’S CHOICE

COST SAVING POTENTIAL 3DPRINTUK

ADDITIVE MANUFACTURE AND FOOD PACKAGING MACHINERY SYSTEMS One industry that has taken a fresh look at additive manufacture for machine parts is food packaging. Whether the requirement is end-of-arm tooling with complex internal vacuum lines not possible with conventional machining or unique machine parts, that provides a specific function, these can easily be achieved with additive manufacture.

3DPRINTUK work with many machine makers including Brillopak, CPACK and Astrapc, all specialists in their respective field with one similarity, they have all adopted additive manufacture into their supply line.

CPACK is a specialist packaging machine systems manufacturer. Based in Burnley their production facility is home to a team of designers, programmers and sales staff all focused on delivering outstanding machines and exemplary customer service. CPACK are at the forefront of food packaging technology and are always looking for ways to improve machine design as well as exploring new ways to save on part costs without sacrificing quality.

Additive manufacture isn’t new to CPACK; as one of the first in their industry to use additive manufacture their initial experience was that parts were far too expensive to produce from other suppliers.

Having met with their Director Charles Reilly, 3DPRINTUK were certain they could help bring down some of their part costs and deliver a standard of part that would exceed their expectations of additive manufacture.

Working with their team, 3DPRINTUK were able to demonstrate how they could take advantage of their pricing system; by breaking down larger parts into smaller pieces (ready to assemble post print) and how to nest parts together which has even more potential for generating a cost saving.

Nesting works by filling unused space around larger parts or by arranging parts to take up a smaller space within the printers.

By nesting parts, it meant that in some cases CPACK could get two parts for the price of one.

“We use SLS printing services when parts are too complex or too costly to

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Above, CPACK - Pleat finishing press tool. Below left, Pleat mould 3D printed in Nylon PA2200.

Below right, Astrapac - Water tight cap on heat sealer machine.

manufacture using traditional methods.

The flexibility and level of detail possible with SLS printing is unmatched for the price. 3DPRINTUK have provided excellent support to our technical and purchasing staff, and using their website to quickly quote parts couldn’t be easier.” Ben Chaffer, CPACK Another company taking advantage of Low volume production with 3DPRINTUK is Astrapac. Established in 1974, Astrapac specialise in the manufacture of bag sealing machinery. In addition to designing and building a wide and diverse range of Heat Sealers Astrapac are also the sole UK and Ireland representative for the technically advanced Gandus Medical Heat Sealers / pouch sealers. All models in the Gandus range are built to European medical standard ISO 11607 and many models are

fully validated, a requirement in the medical sector for seal quality control.

The problem with manufacturing a variety of specialist machines is that they each require their own bespoke parts. Two applications where 3D printed parts have proven ideal are: a domed cap (pictured) that seals the arm to make it water tight and custom end caps for a safe and professional finish to the sealing arms. For 80 complex small nylon parts with an approx size of 25mm x 45mm x 26mm the cost with 3DPRINTUK were only £63+vat. With no additional tooling costs and viable batch production from 1 – 10,000 units, the benefits of additive manufacture speak for themselves. www.3dprint-uk.co.uk

55-75% cheaper to produce parts compared to cnc milling.

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EDITOR’S CHOICE

SAFETY MANAGEMENT KORA 3D

HSE REPORT RAISES CONCERNS OVER 3D PRINTER SAFETY Kora 3D, one of the UK’s leading manufacturers of FFF/FDM style desktop 3D printers, has developed a unique universal safety cabinet to protect 3D printer users, following the release of a Health and Safety Executive (HSE) report which found that the printers can create harmful emissions, potentially endangering users.

The use of Fused Filament Fabrication (FFF) and Fused Deposition Modelling (FDM) 3D printers has grown rapidly in recent years, however concerns have consistently been raised over the safe use of the products and their impact on surrounding air quality.

Concerned about the unregulated nature of 3D printer use, in 2015 the HSE formed a working group including HSE scientific and regulatory staff, Kora 3D and the British Standards Institute to identify the risks and to develop a series of good practice guides for the safe use of FFF/FDM style desktop 3D printers.

Kora 3D committed to working with the HSE to investigate the risks, making the commitment to suspend sales of its own FFF/ FDM style 3D printers until the research was complete.

The HSE has now released its report Measuring and Controlling Emissions from Desktop 3D Printers which found that the 3D printers emitted many particles of a size range that could potentially enter the airways and lungs. The report also found that ‘emissions from FFF 3D printers are likely to be released into the general environment because many desktop printers have no form of control or particle capture.’

Worryingly, the HSE’s research also found that some of the plastic filament materials used in the 3D printers were found to release vapours known to be hazardous to health when heated. During testing, the HSE found that placing the desktop 3D printer inside an enclosing hood with filtered ventilation reduced particle emission rates by 97 per cent.

Businesses using 3D printers without adhering to new guidance could find themselves in contravention of Provision and Use of Work Equipment Regulations 1998 (PUWER), Control of Substances Hazardous

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to Health (COSHH) guidelines and the HSE’s ‘Management of Health and Safety at Work’ code of practice.

In line with the recommendations from the HSE, Kora 3D’s talented team of engineers have developed the universal and economical Kora SC-01 Safety Cabinet, designed to fit most standard sized FFF/FDM style desktop 3D printers. It uses a specialist filter cartridge at the top of the cabinet to draw clean air from the area in which it is situated and to remove potentially harmful emissions. The SC-01 is, to date, the only FFF/ FDM style 3D printer safety cabinet to have been officially tested by the HSE’s specialist Health and Safety Laboratory (HSL).

Steve Burrows, Managing Director of Kora 3D, said: “It’s clear that FFF/FDM style 3D printing is a growing sector and one which offers fantastic benefits to business.

However, our four-year study alongside the HSE has confirmed the importance of having a greater understanding of the equipment and the need to pay more attention to safety management. It was a huge commitment and a risky commercial decision to cease sales of our FFF/FDM style 3D printers.

However, we strongly believed that although FFF/FDM style 3D printing delivers huge

benefits, not enough had been done until now to investigate the potential risk to users and bystanders.

“At the heart of Kora 3D is a real passion for problem solving, so our talented team has worked closely with the HSE to develop a product which finally makes FFF/FDM style 3D printing safe. As the only company currently with an HSE/HSL tested product, we believe we are now in a very strong commercial position to ambitiously grow our business.”

www.kora3d.com

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

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01926 512475

gjw@mcs-corporate.com Issue 39 PECM

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EDITOR’S CHOICE

PREPARE YOURSELF….

RITTAL

SUMMER IS COMING! Karl Lycett – Rittal UK’s Product Manager for Climate Control Winter may have been the focus of the hugely popular TV drama Game of Thrones but in the real world the mercury is rising and we will soon be firmly into summer.

Despite any rainclouds that may still be lingering, don’t be fooled.

Summer will bring higher temperatures, which may be good for the weekend BBQ, but it doesn’t bode as well for your electrical equipment.

At this point in the year, the alarms on your cooling units will probably still be non-existent which means you’re spending less time maintaining overheating panels. However, this is the ideal time to start considering your climate control, to understand what changes or improvements need to be made.

In a few months’ time, things will be very different. Fans and filters won’t be effective if the ambient temperature in the workplace is higher than you require inside your enclosures! So now’s the time to assess any problem enclosures and make the necessary changes to ensure that when summer comes you are free to spend your time on tasks other than climate management.

EVERY DEGREE ABOVE SET-POINT SHORTENS EQUIPMENT LIFE

two per cent of that equipment each year because of burnt-out componentry, then the costs can quickly mount up and it’s an entirely unnecessary spend.

But it’s not just the cost of repair and replacement of the actual componentry. There are also the add-on operations costs caused by componentry breaking down and stopping the processes it controls. This lost output will continue for as long as it takes to repair the fault, and is bound to have consequences for your wider business, impacting productivity and efficiency, and thereby reducing profits.

BOOK A RITTAL CLIMATE MANAGEMENT REVIEW Correct climate control is often overlooked during the installation of electronic equipment because the focus is all on the equipment, not on regulating the environment that it operates within.

This is where Rittal can help you, we are the world leaders in enclosure climate control products and pride ourselves on being your trusted advisor.

It’s important to remember that every degree above your set-point will be time removed from the life of your expensive equipment, including PLCs, variable speed drives and transformers.

With our RiAssure service, one of our trained staff can visit you and provide a FREE Cooling Review. This review is a short, visual inspection of your existing enclosures and cooling equipment; from this we can ascertain the next best step for your equipment and also provide ongoing, best practice suggestions so that your operations benefit from increased longevity, life and profit.

Collectively, this can easily have a replacement value that tops £100,000, even in a relatively small setup. If you replace just

So before summer arrives, reap the benefits of the optimising your climate control.

Reduce Downtime Maximise Profit ENCLOSURES ENCLOSURES

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RiAssur CLIMATE CLIMATE CONTROL CONTROL

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For more information or to arrange a FREE Cooling Review, visit www.rittal.co.uk, or call our customer service team on 01709 704000 or E-Mail cooling@rittal.co.uk. @rittal_ltd.

Claim a FREE review of your existing enclosure cooling equipment Visit Visit www.rittal.co.uk www.rittal.co.uk for for more more info* info* IT IT INFRASTRUCTURE INFRASTRUCTURE

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*Limited-time *Limited-time offer. offer. Terms Terms and and conditions conditions apply. apply. For For full full details details please please visit visit www.rittal.co.uk www.rittal.co.uk

EDITOR’S CHOICE

INNOVATIVE SOLUTIONS ULMA PACKAGING

OPTIMISING PRODUCTION FOR MANUFACTURERS WITH AUTOMATION

In today’s increasingly demanding business environment, it is vital companies identify efficiency and productivity gains if they are to continue to thrive. With that in mind, Steve Craddock, Business Manager – Automation Projects at ULMA Packaging UK, explains how implementing automated packaging technology can help manufacturers optimise production processes and lower labour costs.

The manufacturing sector’s needs are diverse and ever-changing, and packaging machinery has become more sophisticated to meet these requirements. Automation could help lower company labour costs while increasing operational efficiency and upping production capacity, creating a stable platform for further growth.

This is especially the case for manufacturers producing a wide array of products, where adopting innovative solutions could help site owners and operators adapt to more complex packaging needs.

Product quantities are a key consideration when selecting appropriate machinery.

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Automated lines, for example, would be an ideal recommendation at sites requiring product packaging and processing on a larger scale.

Consequently, an automated packaging solution can boost output while lowering cost, helping these companies realise new avenues for growth. Existing lines do not need to be scrapped to install a bespoke automation solution – instead, it can be adapted to fit current site processes. Indeed, some of the best automated packaging lines feature a very simple design, far away from any stereotypes around overly-complex robotics and complicated trials.

A good example of this is Border Biscuits Ltd., which worked with ULMA Packaging to overhaul the packaging line at its Lanark factory. The factory produced over 300,000 packets of biscuits every week, which needed to packaged quickly and to a high level of quality. ULMA installed two Atlanta Hi-tech flowrappers with Dakota infeed units, which automatically carry biscuit packets into cardboard containers

for storage and distribution. As a result, the company doubled the output of its most popular range.

Manufacturers that are already satisfied with their current packaging processes can potentially implement an end-of-line solution to realise efficiency gains. By introducing an automated loading system into the line’s final stages, for example, packaged goods can be moved into baskets and pallets to enable quicker delivery.

As a result, the company can redeploy its workforce to carry out more complex tasks, further improving production.

By making the switch from manual or semiautomated packaging lines, companies could transform their production capacity while markedly reducing operational costs.

To find out more please visit: www.ulmapackaging.co.uk/, alternatively, contact ULMA Packaging UK.

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

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 owner of the world-renowned INTEMP trademark

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

EDITOR’S CHOICE

Middlesex Aerospace signs Women in Aviation and Aerospace Charter

Brammer Buck & Hickman Launches ‘Mecaline’ Power Transmission Products

Cistermiser valves help to conserve water at Cambridge Assessment’s new HQ

Supporting the importance of working together to build a more balanced and fair industry for women, Middlesex Aerospace have added their name to an impressive and growing list of leading industry signatories. Committed to supporting the progression of women into senior positions and providing fair opportunities for women to succeed at all levels, Laurie Foulds MD sees this as a positive move and fits the values installed at Middlesex Aerospace.

Middlesex Aerospace is a participant of the UK aerospace supply chain’s productivity and competitiveness programme Sharing in Growth (SiG). Signing at a SiG event they joined 19 other signatories from the programme joining companies such as BAE Systems, Rolls-Royce and Boeing to support the Charter.

Mecaline from Brammer Buck & Hickman, the UK’s leading industrial supplies specialist, is an exclusive new range of power transmission products that combines quality and reliability, backed with Brammer Buck & Hickman’s extensive engineering experience and added value services.

The Mecaline range has been designed in collaboration with world-leading manufacturers in their respective fields, to very strict specifications whilst at the same time are highly competitively priced. Mecaline features electric motors, gearboxes, chain drives, belts and couplings.

Washrooms at The Triangle, the prestigious new international headquarters of exams group Cambridge Assessment, feature the latest infrared water management technology from Cistermiser.

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

Mecaline products are available exclusively from Brammer Buck & Hickman. For more information on Mecaline, please go to www. bbh-rubix.com

96 Cistermiser Direct Flush ‘Discreet’ infrared urinal flush control valves (DFDs) have been installed in The Triangle’s 20 washrooms by M & E sub-contractor Allied Mechanical Services, the main contractor being construction company Bouygues.

The Direct Flush automatically flushes the individual urinal after use, using as little as 0.5 litres of water each time. This ensures high levels of hygiene from the minimum volume of water. ourworldiswater.co.uk

UKAS Accredited Flow & Air Velocity Calibration Services

Major expansion delivers biggest facility in Yorkshire

Material and Component Testing at SATRA

The Young Calibration UKAS accredited laboratory (Lab 0604) makes the transition to ISO/IEC 17025:2017, whilst further continuing to offer world leading flow calibration services. The latest UKAS calibration schedule offers ultra-low flow water infusion and leak calibrations from 1 ml/hour up to a 1000 l/min on DN80 flowmeters.

The UKAS accredited air flow rig covers 1 cc/min to 1250 l/sec allowing flowmeters up to 300 mm diameter to be accommodated within the flow calibration rig.

A leading galvanizing business has completed a major expansion that increases capacity by 50 per cent. Humber Galvanizing Ltd has installed a new bath to create the biggest facility of its kind in Yorkshire.

The accredited wind tunnels continue to offer world leading measurement uncertainty for UKAS air velocity calibrations on pitot, thermal, vane, cup, omni-spherical and ultrasonic anemometers encompassing one of the widest available air velocity ranges of 0.05 to 80 m/s.

General manager Richard Speake said: “This is a major investment that will increase the number and size of jobs we’re able to do. It will ensure we’re ‘Fit for the Future’ and provides the platform from which to grow even stronger.”

SATRA assists manufacturers and suppliers with independent assured testing services against a wide range of OEM testing specifications, national (BS, ASTM, DIN, JASO) and international (ISO, EN, SAE) standards.

SATRA’s testing services are accredited to ISO 17025. SATRA is a leading research and technology organisation with expert knowledge in testing and assessment of materials and components, including weathering, corrosion, ozone, wear resistance, abrasion and scratch resistance, chemical, staining and clean ability, flexing endurance to name a few. SATRA has an innovation and development arm for bespoke research and testing and can also perform chemical analysis for restricted substances to meet European REACH legislation and CPSIA in the United States. Please use code AUTO19 for a 15% discount off your first test, valid until 31st December 2019.

www.youngcalibration.co.uk/calibration Email : ay@youngcalibration.co.uk Tel : 01273 455572

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It has also extended its yard, installed new ‘triple acid’ tanks and made a string of changes to improve health and safety in a multi-million pound project. The new galvanizing bath is 7.5m long, 1.2m wide and 2.7m deep.

Contact Richard Speake Humber Galvanizing Ltd Tel: (01482) 322466 Email: Richard.speake@wedge-galv.co.uk

+ 44 1536 410000 | www.satra.com

EDITOR’S CHOICE

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

BLACKFAST CHEMICALS ARE PROUD TO ANNOUNCE THE LAUNCH OF ITS NEW ONLINE STORE AND WEBSITE!

Visit our New Website

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

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If you work in the engineering, tooling, automotive or manufacturing industries and regularly need to black small metal parts and components thus enhancing both appearance as well as tested corrosion resistance, then BLACKFAST’s chemical products are what you have been looking for.

Specifically designed for you to use in-house, proving to be easy, cost effective as well as safe to use, our products, knowledge and assistance are now just a click away.

For more information on our blacking processes and other chemical products, or should you wish to place an order or arrange an on-site demonstration, please visit our new exciting website www.blackfast.com.

We, The Blackfast Experts, look forward to welcoming you there.

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

Issue 39 PECM

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EDITOR’S CHOICE

Our parent company Muller Coax was established 58 years ago and is now a recognised leader in valve design and innovation within the valve industry.

We are synonymous for quality, experience and reliability in valve technology, this has been the case since the beginning of our dynamic development and it will continue to stay that way.

Valve pictured was built for a specific application for one of our many blue chip clients, below is a case study and solution provided to match the requirement.

APPLICATION: Customer required high pressure 2” BSP valve for

controlling water at 200 bar for fast shut off and giving feedback position sensing.

SOLUTION:The Muller Coax 5 VMKH50 valves meets all the criteria with leak tight shut off, and full open and close cycle of 200 milliseconds with reliable position sensors fitted.

The reliable proven high valve solution met all the clients exacting criteria.

For details of how we can assist with your requirements contact co-ax valves uk: john.osborn@coaxvalves.co.uk or visit www.co-ax.com.

Muller Coax Original valve manufacture for 58 years for arduous & varied applications we have a valve to suit High pressure valves ATEX Valves Direct Acting/Externally Controlled Threaded/Flanged Contaminated Medias Fast Actuation Position Indication Switches Available Compact Size All Valves SIL 2 Rated SIL 3 available on request

Contact us Tel: 01908 067583 Email: john.osborn@coaxvalves.co.uk Web: www.co-ax.com

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.

Call to order your

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.

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PECM Issue 39

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

hygienic furniture & equipment

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

Reduced dirt traps

Easy access from both sides

Diamond bracing doesn’t collect dirt

Higher tie bar position for easier cleaning

Central tie bar, rear rail or undershelf option

For more information get in touch today Quality

Value

Service

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

EDITOR’S CHOICE

UV CURE-IN-PLACE TECHNOLOGY HERNON MANUFACTURING

HOW TO USE CURE-IN-PLACE GASKET TECHNOLOGY TO IMPROVE OIL SHAFT SEAL PRODUCTION UV Cure-in-Place (CIP) gasketing technology was created to replace an inferior sealing process for automotive oil shaft seals or rotary seals. Direct contact with the shaft is secured using a rubber gasket while the exterior of the seal, where it meets the housing, has traditionally been sealed using a solvent based sealant. Solvents have well-known problems with toxic fumes and material loss due to evaporation.

By contrast, UV CIP does not use any solvents. Instead, it is designed to be cured by UV LED curing lights, built by Hernon®.

These lights are optimized to a specific wavelength for the sealant.

Once cured, the bead for this application is soft and tack free, allowing the seal to adjust its form to fill the gap between gasket and housing.

The dispensing and curing system for this sophisticated application was developed by Hernon Manufacturing as part of their Total Solutions approach. Hernon® experts coordinate mechanical engineering capabilities with precision chemistry to ensure a copacetic application process.

The journey of components through the machine starts with an inbound conveyor where intelligent sensors track part locations.

The sensors communicate to robotic arms when parts are ready to enter active stages.

The steel components are picked up using simple permanent magnets. This method reduces the complexity of moving parts from stage to stage when compared to pneumatics or electromagnets and keeps energy usage to a minimum. The seals are first moved to a dispensing station where a robotic spindle arm rotates the seal under Hernon’s proprietary SureShot® 3000 valve.

The valve dispenses sealant onto the spinning seal creating a controlled bead. With the bead in place, parts are moved to a UV curing station. To protect users, the parts are inserted into a protective housing before four high intensity UV LED lights cure the bead for specified exposure times.

The final stage is a laser inspection where the bead location and width are analyzed. The bead is also checked to be smooth and contiguous. If the finished part meets all specifications it is transferred to a conveyor out of the machine.

When oil shaft seals come off the outbound conveyor, they can be instantly used or packaged. Parts are processed at speeds of 12-15 parts per minute, depending on the size of the seal. The larger the size, the longer dispensing and curing times needed.

With no solvents used in the new CIP sealant, production is more environmentally friendly, sustainable and much less messy.

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

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PECM Issue 39

EDITOR’S CHOICE

MARCH OF THE ROBOTS ARROWSMITH ENGINEERING

£200,000 ROBOTIC INVESTMENT HELPS ARROWSMITH ENGINEERING DELIVER SOARING SALES A leading Coventry aerospace supplier is tapping into the ‘march of the robots’ to help it capitalise on 20% growth over the last twelve months.

Arrowsmith Engineering, which is part of the AS.G Group, has invested over £200,000 into a new Doosan 4th axis machining centre and robotic cell that will help it boost production speed and increase capacity by 50%.

The company is using ‘lights-out’ manufacturing to run a precision engine part 24-hours a day, seven days per week, supplying more than 200 components every month to customers based in Spain and the US. Integrating robots into the process has removed the need for a second machine, freeing that up to cope with new contract wins that have seen turnover soar to £7.5m and the workforce grow a further 10% to seventy people.

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PECM Issue 39

Jason Aldridge, Managing Director of Arrowsmith Engineering, commented: “I’m a big fan of automation and don’t’ sign up to the notion that it’s taking jobs - if anything it will make us more competitive so we can take additional people on.

“The Doosan CNC machining centre and cobot system is our first investment in robotics and has been configured to suit our specific requirements for 24-hour manufacturing on a complex component for the aerospace sector.

“It has removed the need for an operator to load and unload the parts and this person has gone on to a different production process that is more skilled.

This is just the start of what we hope will be a continuous investment drive in robots at our factory on Bayton Road.”

He continued: “It’s made us 15% quicker and given us a 50% capacity boost, that’s some payback already. Automation shouldn’t be seen as something that only the big boys do… SMEs can access it cost-effectively and we need to ‘grasp the nettle’ in order to bring the UK’s productivity up and in line with our international rivals.”

Arrowsmith Engineering is a specialist in precision turning, milling, thread rolling and grinding, providing components to aerospace tier 1s and primes in titanium, nimonics, stainless steel, exotic metal and engineering plastics.

The company, which has been supported

by Coventry University and Coventry City Council on its latest investment, supplies parts that are used all over the world in aerospace engines, landing gears and air frame.

It has been able to overcome Brexit uncertainty to boost its export business by 400%, thanks mainly to delivering world class manufacturing performance, with ‘On Time In Full’ at 98.5% and quality running at 99.95% for the past twelve months.

This level of continuing operational excellence has seen it recently secure the Supply Chains for the 21st Century (SC21) Silver Award for the third consecutive year, which has contributed to it becoming one of the first firms to be entered into the Competitiveness & Growth Programme.

Jason continued: “It’s all about pushing the boundaries in what we want to achieve, challenging our staff to drive growth by giving them access to training and the best technology.”

He concluded: “The SC21 Silver Award is a great achievement for our business and proves that SMEs can compete with the best in the world when it comes to manufacturing excellence. This is just the start; we want to be at £9m by the end of 2020 and then looking at how we break the £10m barrier before too much longer.”

For further information, please visit www.arrowsmitheng.co.uk Issue 39 PECM

39

EDITOR’S CHOICE

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

Adcock

More Speedor Storms

Adcock design and installs energy efficient, modern and sustainable solutions for all your HVAC needs, whatever size of premises or sector. Working with products from leading manufacturer partners, expertly installed and maintained.

Working for a haulage company specialising in waste disposal, Hart Door Systems has completed the installation of two Speedor Storms at a Midlands facility.

Adcock provides air conditioning solutions from close to control to comfort cooling for all sectors and all types of buildings.

Adcock specialise in the bespoke storage solutions for pharmaceutical, medical and healthcare sectors. Our designers and engineers are experts in refrigeration technology for maintaining all temperatures in scientific research labs, chilled storage areas and process cooling.

Maintaining your HVAC systems is cost effective and keeps your system safe, reliable and compliant. Adcock provides a first-class service whether we originally installed them or not.

The two fast-action Speedors were installed to minimise the escape of dust and smells as well as keeping out birds and rodents. “The fast action allows for a quick arrival and tipping of waste within a closed harsh environment so reducing the chance of smells leaving the building,” says a Hart spokesman.

“Both Storms were supplied with heated motor hoods and IP66 electrical control panels to combat moisture and the largest door was 8m high and 6m wide. It is our reputation for our capability of delivering reliable, very large, highspeed automatic doors for the waste industry that leads to contracts such as this.” www.hartdoors.com t: 0191 214 0404

ourworldiswater.co.uk

www.adcock.co.uk

Automated laser marking helps improve speed, quality and flexibility at Jaguar Land Rover

Hydra-Cell Metering Pump Shows its Versatility

Process, engineering and manufacturing

The Vehicle Identification Number is a car’s unique fingerprint. Applying the VIN has always presented challenges to manufacturers, however. In 2013, production engineers at Jaguar Land Rover were wrestling with these problems and wondered if laser marking technology might provide a solution, they approached marking and verification specialist Pryor for support. After looking at the requirements of the task, it quickly became clear to the Pryor team that conventional laser marking technologies would not be up to the task. Pryor developed a high-powered laser system that could be adapted to give a consistent mark of the right depth in very short cycle times. For Pryor, the work with Jaguar Land Rover is the next step in a continuous evolution of product marking technologies that stretches back to the middle of the 19th Century.

To call Wanner’s new Hydra-Cell® MT8 a low flow high pressure metering pump would do it a serious injustice. This amazing triplex diaphragm pump can achieve a minimum flow rate of 0.227 litres per hour with the accuracy, linearity and repeatability demanded by API 675, but is capable of generating a maximum flow of 30.28 lph. The Hydra-Cell MT8 is designed to perform at pressures, up to 241 bar, while generating a smooth virtually pulse-less flow for homogeneous metered injection.

With no cups, packing or seals to leak and its ability to handle a wide range of aggressive and abrasive liquids and even run dry without damage, new uses for the MT8 are surfacing daily. Applications to date include methanol injection in the oil and gas industry, personal care products and pharmaceuticals, food and beverage processing and additive injection in polyurethane foam production, highlighting the pump’s flexibility.

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

Find out more about the solution www.pryormarking.com/jlr

www.hydra-cell.co.uk/

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PECM Issue 39

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

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.

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

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

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

Issue 39 PECM

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EDITOR’S CHOICE

CONSISTENT PRESSURE WITH ONE TURN

The new robust stainless steel pressure regulator from Eisele is designed for applications in aggressive environments and industries with stringent cleaning requirements. Compact and userfriendly - the functional fitting simplifies compressed air supply in industrial and artisan applications.

A completely new design from Eisele is the pressure regulator made of stainless steel 1.4301, first presented at Hannover Messe 2019. It can be used as pressure reducer for supply pressures from 2 to 10 bar, and controls the outlet pressure to the consistent required working pressure. The screw-in

fitting from the Eisele INOXLINE has a control pressure range from 2 to 8 bar and is designed for very fine adjustment with low fluctuation.

In addition, the flow-optimised pressure regulator reduces the vibration behaviour of the control system, and it is also designed for quiet operation. The choice of high-quality materials facilitates cleaning. The Eisele pressure regulator is mounted with 1/8-inch threads and can be used for water and air applications.

www.eisele.eu

THE BENCHMARK IN BEARINGS Ball, Needle and Roller Bearing solutions, ensuring precision engineering to give you maximum results!

Our demanding applications lead to our innovative and class leading new Spherical Roller Bearing design.

+44 (0)1908 289 311

sales@koyo.co.uk

Where our expertise lies... + AEROSPACE & AVIATION

+ MACHINE TOOL

+ REPLACEMENT MARKET

+ AGRICULTURE

+ MARINE

+ STEEL

+ AUTOMOTIVE

+ MEDICAL & HEALTHCARE

+ TRANSMISSION & GEAR

+ CONSTRUCTION

+ MOTORCYCLE

+ WIND

+ ELECTRICAL

+ RAILWAY

INDUSTRY LEADING SPECIFICATION SPHERICAL ROLLER BEARINGS

CALL US FOR DETAILS

koyo.co.uk Koyo UK Ltd, Whitehall Avenue, Kingston, Milton Keynes, MK10 0AX

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PECM Issue 39

30 & 31 October 2019 | NEC, Birmingham

The UK’s largest annual gathering of engineering supply chain professionals 15,000 engineering professionals in attendance

"I found the event a great networking opportunity to meet industrial professionals from different backgrounds with different products."

Kat Clarke, Wing Manufacturing Engineer, Airbus

500+

Over 200

exhibitors showcasing their products/services

hours of free-to-attend industry content

Benefit from co-location with: AERO ENGINEERING

AUTOMOTIVE ENGINEERING

PERFORMANCE METALS ENGINEERING

COMPOSITES ENGINEERING

CONNECTED MANUFACTURING

NUCLEAR ENGINEERING

MEDICAL DEVICE ENGINEERING NEW FOR 2019

HEADLINE PARTNERS HEADLINE PARTNERS HEADLINE PARTNERS

NetComposites NetComposites S U P P O R T I N G A S S O C I AT I O N S

SUPPORTING S U P P O R T I N G A S S O C I AT IASSOCIATIONS ONS

H E A D L I N E M E D I A PA R T N E R S H E A D L I N E M E D I A PA R T N E R S

REGISTER TODAY SUPPORTING MEDIA SUPPORTING MEDIA

T: +44 (0)20 3196 4300 | E: aeuk@easyfairs.com www.advancedengineeringuk.com

EDITOR’S CHOICE

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

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

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

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

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

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

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

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

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

Issue 39 PECM

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ADVANCED MATERIALS SHOW PREVIEW

INDUSTRY LEADING INSIGHT THE ADVANCED MATERIALS SHOW

SHAPING THE FUTURE OF ADVANCED MATERIALS

The Advanced Materials Show – the very first in the series – taking place at The International Centre, Telford (UK) from 10th11th July 2019. This event will offer industry leading insight into current and future materials development, with experts from all sides of the industry in attendance.

The Advanced Materials Show, co-located with Ceramics UK, will be spread over two days and will welcome over 200 exhibitors and approximately 3,000 visitors. Providing a unique opportunity to access the global leaders in Graphene, Nanomaterials, Ceramics, Advanced Composites and Coatings all in one place, the Advanced Materials Show also features a free-toattend, four track conference.

buyers, materials scientists and senior executives from all these sectors will discover in The Advanced Materials Show a fascinating new forum for an invaluable exchange of ideas and, of course, excellent networking opportunities.

The Advanced Materials Show is especially unique as it’s co-located with Ceramics UK,

which represents the largest ceramic trade show in Europe in 2019.”

Companies already registered to attend the show include Airbus, Rolls Royce, Collins Aerospace, GKN, Mercedes AMG, Jaguar Land Rover, Dyson, National Rail, Solvay, Sun Chemical, Johnson Matthey, Morgan Advanced Materials and many more.

The two-day conference will include the latest innovations and thought-leadership in the advanced materials industry with world-class speakers from industry, academia and research including experts from 3M, BAE Systems, BP and Siemens.

Event Director, Steve Bryan says “Modern materials play a critical role in the enhanced performance and continuing success of industries such as space/aerospace, automotive, energy, renewables, medical, electronics, construction and defence, and the project managers, design engineers,

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To register for The Advanced Materials Show visit: www.advancedmaterialsshow.com/ conference/register/

10th – 11th July 2019 The International Centre Telford, United Kingdom

F R E E -TO - AT T E N D

EXHIBITION & CONFERENCE

100+ 3000+ 200+ SPEAKERS

ATTENDEES

EXHIBITORS

The show will be attended by business leaders, innovators, academics and researchers involved in the procurement, R&D, integration and manufacture of advanced materials. It will provide an opportunity for investors to learn about the future opportunities within advanced materials and engage directly with the

Register now online

companies and individuals shaping that future.

www.advancedmaterialsshow.com

F E AT U R E D

F E AT U R E D

SPEAKERS

EXHIBITORS Graphene • Nanomaterials • Coatings • Composites • Polymers

Patrick Dodds CEO Hexigone Inhibitors

Sheetal Handa Director BP-ICAM

Landon Mertz CEO Cerion Nanomaterials

Claire Skentelbery Director General NIA

Selena Ambrose CEO Promethean Particles

Steven Harris Head of External Partnerships & Programs BAE Systems

Full conference agenda available at https://www.advancedmaterialsshow.com/

Co-located with

Ceramics UK

https://ceramics-uk.com/

ANALYTICAL TOOLS FOR COMPREHENSIVE CHARACTERIZATION OF LI-ION BATTERIES The increased demand for portable electronic devices, including mobile phones, laptops and new ‘wearables’, has required advances in battery technology to provide a low-cost, lightweight, long-lasting and stable power source.

With fossil fuels dwindling and CO2 regulations becoming more stringent, battery technology is increasingly being used in applications such as renewable energy storage and electric vehicles, which require ever more lightweight, safe, high-power and fast-charging batteries.

Schematic of a Li-ion battery. During discharge, lithium ions (Li+) move from the anode to the cathode, conducted via the electrolyte, with flow in the reverse direction occurring when the battery is charged. Anodes are typically graphite-based, while cathodes are often manufactured using lithiumiron phosphate, lithium-cobalt oxide, lithium-manganese oxide, lithium-nickel cobalt manganese oxide, etc.

The cornerstones of battery performance are power, which impacts current and discharge characteristics, and energy storage capacity. Battery power is determined by the rate of reaction between the electrodes and the electrolyte, while storage capacity is a function of the volume of electrolyte within the cell. These properties are intrinsically linked to the intercalation structure and primary particle size of the electrode particles, which determine how well the mobile ions are taken up and released by the electrode1. Particle size distribution and particle shape also influence particle packing and hence the volume of electrolyte that can be accommodated within the interstitial voids of the electrode, which affects storage capacity.

Particle sizing of electrode materials is commonly performed using laser diffraction technology, such as the Mastersizer 3000; although the Zetasizer Pro and Zetasizer Ultra can also be employed for analyzing the much smaller particles used for electrode materials or separators. Automated imaging (Morphologi 4) is commonly employed for particle shape analysis but can also be coupled with Raman spectroscopy to give particle-specific structural information. The primary tool for studying the structure of electrode materials, however, is X-ray diffraction (XRD) with Aeris or Empyrean diffractometers widely used in this sector. Empyrean also allows small-angle X-ray scattering (SAXS), an important tool for evaluating the primary particle size or crystallite size of nanoparticle electrodes which tend to exist in aggregated form.

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PECM Issue 39

Manufacture of the cathodes and anodes involves mixing the active electrode material with some form of conductive additive such as carbon (e.g. carbon black and/or graphite) and a polymeric binder dissolved in a solvent to form a slurry. The slurry/suspension is then applied to a metal foil in a continuous coating process and the solvent driven off to produce a dried coating which is subjected to calendaring, a compression process that involves feeding the coated foil through a series of rollers. The electrodes are then punched or cut to size prior to winding or stacking between the separator film before inserting into the case, wetting with electrolyte, and sealing. The cells are then activated over several weeks through a series of charge/ discharge cycles.

These processes exert a significant influence on electrode structure and are related to the rheological, or flow properties, of the battery slurry. These properties can be influenced by the extent to which raw materials are dispersed during the slurry manufacturing process, affecting the size of particles deposited on the foil or the impact of compressive forces applied during calendaring, which affects the porosity of the finished coating.

These are not discrete effects - rather changes made during one step can have an impact on consecutive processes, as well as the properties of the finished electrode2.

Slurry rheology is influenced by the size, shape, concentration and charge of dispersed components, hence it is important to optimize electrode particle properties not just for their individual electrochemical performance but for the electrode manufacturing process as a whole3. Ultimately it is the performance, and safety, of the final battery cell which is of critical importance. The most common tool for measuring the general rheology of battery slurries is a rotational rheometer, such as Kinexus, although a capillary rheometer such as the Rosand RH7 or RH10 may better represent the electrode coating process4.

So, what happens to the electrode structure during initial formation, as well as the repeated charge/discharge cycling of the fabricated battery cell? The repeated transfer of charge-carrying ions in and out of the electrode lattice puts strain on the cell structure and can induce unwanted phase changes, even more so if fast charging and/ or discharging is required. Deterioration in performance is most commonly due to the build-up of defects within the electrode which

The manufacture of Li-ion battery electrodes is a multi-step process with each step having potential to influence the electrochemical performance of the finished device2

hinders ion mobility. The mechanism of these processes on the electrode structure can be studied with in operando XRD, using hard X-rays (Mo or Ag KÎą) capable of penetrating a battery cell, ideally (but not limited to) a pouch cell5.

It is then possible to correlate variations in the crystallographic structure of the electrodes with the amount of Li incorporated in to them. The spatial resolution of in operando transmission XRD (approx. 1 mm) also makes it an ideal tool for probing localized wear, since cells close to the connector tend to degrade faster than those further away. It can also identify areas within the cell that are not functioning properly due to ageing or incomplete wetting with electrolyte. Empyrean equipped with the GaliPIX3D detector is ideally suited for this application since it offers the highest resolution data in the shortest possible time frame.

References 1) Julien, C.M., Mauger, A., Vijh, A., Zaghib, K.; Lithium Batteries: Science and Technology; Springer: Heidelberg, Germany, 2015 2) Bockholt, H. et al. ‘The interaction of consecutive process steps in the manufacture of lithium-ion battery electrodes with regard to structural and electrochemical properties’; Journal of Power Sources 325 (2016) 140-151 3) White paper: Exploring the impact of particle characteristics on suspension rheology 4) White paper: Establishing an analytical toolkit for the optimization of Li-ion battery electrode manufacturing 5) Application note: High-quality in operando X-ray diffraction analysis of pouch bag lithium-ion batteries

AUTOMOTIVE ENGINEERING

TEC MOTORS AEMT

CONTINUED EXPANSION THROUGH CUSTOMER SATISFACTION

With nationwide coverage, TEC Electric motors offers a true 24/7 breakdown service.

When the AEMT last visited TEC Electric Motors in 2016 (see Journal 16-2), they were operating from a 65,000 square foot site with stock levels of over £2 million. Three years later, their stock levels have grown exponentially to £12 million, and they have consolidated their warehouse and offices into a 100,000 square foot purpose build site on the Hartlebury Trading Estate, Worcestershire.

TEC Electric Motors is a true success story, where continued investment and growth has seen the company relocate twice in the past 12 years to keep pace with the needs of its customers. Managing Director, Scott Edwards has no doubt that the company’s achievement is rooted in an enthusiastic team that always puts the customer first.

They are one of the UK’s largest electric motor distributors, offering a wide range of products from stock as well as custom built motor units, gearboxes and inverters. With

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nationwide coverage, the company offers a true 24/7 breakdown service that delivers even on New Year’s Day!!

Established in 2006, the vision was to create a motor distribution company that could be relied upon to provide excellent customer service backed by a wide range of high quality, reliable products. The business model was a success and within two years the company had outgrown its original premises and made its first move to accommodate the expanding stock inventory.

EXPANDING BUSINESS By 2011, the warehouse was overflowing and demand continued to grow necessitating the purchase of an additional site -making space for the new gearbox department and the specials division. All the while the team continued to grow and with each new addition, came increased product sales.

With a well-established headquarters in the Midlands, the next step was to open the TEC North branch near Sheffield in 2013.

This was closely followed by establishing a base in Scotland one year later with the opening of their Glasgow branch. Each of the satellite branches has a mirrored stock profile, albeit in reduced quantities, which ensures customers’ needs are always met 24/7 365 days a year.

In 2018, the company achieved its biggest year in terms of sales, surpassing the £17 million mark, a major achievement in just 12 years. So, how has this been achieved?

Scott Edwards explains: “There is no doubt that everything we have accomplished is a result of teamwork; we have created a group of people that are dedicated to delivering customer satisfaction.”

Working with original equipment manufacturers (OEMs) TEC Electric motors has developed bespoke motor designs that are a perfect fit for specific applications.

TEAM BUILDING In fact, when it comes to the sales meetings, everyone is invited to take part and see what the company has achieved, where it is planning to go and how they will get there.

Everyone is involved in hitting the sales targets, from the warehouse staff to the sales team and the technical support department.

Gareth Richardson, Sales Director, explains: “It is important that we listen to everyone when it comes to making improvements in our processes. In many cases, simple changes can make a big difference, so we make sure every employee has the opportunity to contribute their suggestions.

“The team we have built over the years is very loyal, to the point that several have relocated their families when we have moved to new premises. That loyalty is repaid by the facilities we provide at work and our continuous efforts to improve the working environment.”

The team ethic is encouraged throughout the company and employees will often rotate jobs, learning new skills and making sure that every role can be covered when staff members are on holiday or sick. Taking on new roles brings a fresh perspective to the job and often results in process improvements.

STOCK HOLDING Over the years, TEC has increased its stock levels, to the point where it now has over £12million worth of stock ready to fill customer orders. This is made up of gearboxes, standard motors as well as special builds that are developed in partnership with customers.

In contrast with most distributors, TEC holds motors up to 630 kW on the shelf and the technical team can make a variety of modifications that may be necessary to meet the requirements of an application.

With full machining capabilities, motors can be modified with new shafts, encoders, brake units and cooling fans where necessary on reduced delivery times.

The warehouse contains both single and three phase motors as well as ATEX rated designs, a range of gearboxes and variable speed drives to match most applications. In addition, further products are available from Europe, where a joint venture holds around €50 million worth of stock.

AEMT (Association of Electrical & Mechanical Trades) member TEC Electric Motors now occupy warehouse and offices; sized 100,000 square foot, purpose built site on the Hartlebury Trading Estate, Worcestershire.

With distribution key to their strategy, TEC have ensured warehouse locations in the North, Scotland, and Wales, to supply a growing number of re-sellers including AEMT members such as Beatsons Fans and Motors, Wilson Electric, Rotamech, , Deritend , Cleveland Electrical , Bellwood and numerous others. This growing mass of suppliers are all part of their overarching strategy to have a TEC motor available to anyone within 50 miles.

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BESPOKE SOLUTIONS TEC Electric Motors has expanded its capability to include design changes to existing products, the creation of bespoke motors as well as the delivery of matched motor/gearbox combinations.

Working with original equipment manufacturers (OEMs) TEC has developed bespoke motor designs that are a perfect fit for specific applications. Each solution can be supplied with marine or offshore C5M custom paint applications.

Having created the ideal motor solution, TEC also works closely with the OEM to establish the correct stocking levels to ensure that the production line always runs smoothly.

Forward planning is a speciality at TEC and it is an essential part of delivering a reliable service to every customer.

This is enhanced by the flexible approach that TEC uses to ensure customer needs are met. Apart from providing a managed inventory that can cope with increased sales, the company also ensures that every delivery is best-suited to the customer’s needs. For example, if a forklift is not available to unload the delivery, TEC will make sure that the shipment is delivered by a tail-lift lorry; a small point for some,

but this attention to detail can make all the difference in customer satisfaction and retention.

GOING THE EXTRA MILE Of course, making planned deliveries is relatively straightforward. What really counts is the level of service when a customer has a more urgent requirement. Unfortunately, electric motors rarely break down at convenient times, so having a loyal TEC distributor network that honours the 24/7 promise is a major benefit.

This was illustrated in a recent case where a customer called TEC at 08:30 on New Year’s Day with an urgent request for a replacement motor. The warehouse was open within half an hour and a courier was arranged to collect and deliver the motor the same day. As a result, the customer’s operation was back up and running by 1:45pm.

Gareth continues: “This high-quality service helps to develop and convert emergency breakdown enquiries into regular, loyal customers, who know they can depend on us to always deliver. Of course, loyalty only goes so far in business, but with our highquality products, competitive pricing and unfailing customer service, we have created

a model that has delivered success year on year.”

As the business continues to grow, TEC continues to listen to its customers and put plans in place to meet new demand.

David Ede, Business Development Manager, explains: “The next step is to increase our stock of medium and high voltage motors, to meet the demands of the water, mining and aggregates industries, amongst others. This is an area where, typically, there can be long lead times for new or replacement machines and this is something we want to address.”

CONSOLIDATING SUCCESS TEC Electric Motors has been careful to build the necessary business infrastructure and put in place dedicated and experienced staff to ensure that every customer receives the level of service that they require. Scott Edwards concludes: “Everything we do is designed to improve the service we offer to our customers. We can deliver costeffective solutions whatever the situation; from emergency replacements to inventory management and long-term manufacturing supply, anywhere in the UK and Ireland.

www.theaemt.com

TEC Electric Motors has increased its stock levels, to the point where it now has over £12million worth of stock ready to fill customer orders.

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PECM Issue 39

AUTOMOTIVE ENGINEERING

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

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

SOURCING CUSTOM PARTS OVERSEAS NEED NOT INVOLVE HUGE QUANTITIES OR HIGH RISK Due to its extensive experience in working with trusted suppliers in the Far East, Blue Diamond Technologies can offer custom parts in low minimum quantities (500 pieces) without the need for high minimum orders that run into thousands of pieces. This allows our customers to source a custom part with very little risk and minimum cost.

No matter what industry you’re in, we can manufacture the custom parts you need

Over 40 years experience manufacturing custom parts 023 8025 8966 • www.blue-diamond.co.uk

“There are many ways we can help our customers get the best outcome from sourcing low cost custom parts. Using our services removes many of the problems and risks associated with sourcing directly from suppliers in the Far East.” explains Mike Doel, Director, Blue Diamond Technologies. “Customers often contact us because they cannot find a standard product to do the required job and they don’t want to compromise on product design or quality. Frequently, they also want to buy low quantities to test the market before daring to commit to the higher volumes often demanded by large overseas manufacturing organisations”.

Further options include the provision of labelling, bar codes and packaging, which can also be incorporated into customer agreements.

For further details, contact Blue Diamond Technologies Ltd, Rolwey House, School Close, Chandlers Ford Industrial Estate, Eastleigh, Hampshire SO53 4BY. Tel: (023) 8025 8966 Fax: (023) 8025 8989 E-mail: bdsales@rolwey.com Website: www.blue-diamond.co.uk

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AUTOMOTIVE ENGINEERING

AUTOMATED DRIVING SYSTEMS SIEMENS

MOVING TO A DRIVERLESS FUTURE

By Matthieu Worm, Programme Lead autonomous driving and Robin Van der Made, Product Manager, Simcenter The starting point of the vehicle development process is occupant safety.

Shifting responsibility from driver to carmaker to prevent accidents has a major impact on the development process. Carmakers will have to prove the thoroughness of their development processes when people get injured or killed by wrong manoeuvres from autonomously driven vehicles.

A key variable in automated driving systems is sensor configuration. New sensors are being introduced at a rapid pace and more advanced sensor fusion algorithms are being developed. There is an infinite number of possible compositions to generate a 360-degree image of the environment around the vehicle, supported by different sensor types, quantities and positions on the vehicle. Sensors are typically a significant cost factor in vehicles, making configuration selection a potential market differentiator.

Potentially the biggest challenge, however, is the confidence the vehicle will perform to its specifications. Not only during the development stages, but in real traffic with occupants and for many years. This requires a validation and verification process that allows for performance testing in a large number of circumstances.

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Finally, design decisions and verification results during the vehicle development process need to be traceable. To optimise the vehicle development process, supporting integrated hardware and software development with instant optimisation capabilities for sensor configurations and with a highly automated and repeatable validation and verification process is necessary. It is only scalable for mass production if the requirements, the system and simulation architectures, the models and the performance validation results are managed carefully.

SYSTEM ON CHIP

The time when automotive electronic control units (ECUs) are off-the-shelf components is about to end. The high compute loads and stringent requirements for low-energy consumption, combined with the specific environmental conditions, make it inevitable that specific chips will be developed for autonomous driving applications. This drives the need for the automotive industry to work much closer with the chip makers and have parallel product development processes with multiple interdependencies.

Long development cycles and the high cost of chip wafers put a stress on this relationship. However, Mentor, a Siemens business, supports the chip development process with virtual and emulated representations of early stage chip design.

This enables integrated design exploration

and early stage validation and verification of future system performances with realistic compute performances. Furthermore, Mentor simulation solutions can be used to optimise the thermal and durability performance.

AD COMPUTE PLATFORM

The autonomous platform covers the control system hardware configuration.

The system boundaries are the sensors on the vehicle and the actuator outputs at the vehicle’s communication bus. It is a complex assembly of electronics and wiring that requires optimised calculation time, energy consumption, thermal performance, electromagnetic capability (EMC) and multiple other attributes. Functionally, the autonomous platform translates an environment with all kind of actors into electric signals at the system outputs that make the car follow the anticipated trajectory.

Although currently automated driving solutions like adaptive cruise control, lane keeping assist and automated parking systems are typically delivered as a combined product of sensors and processors, there is a strong expectation the car of the future will have a centralised architecture for a combined array of functions. new.siemens.com

AUTOMOTIVE ENGINEERING DOMED CAR & AUTO BADGES All our domed car badges are manufactured to Automotive specifications. The adhesive is suitable for use as wheel centre and bezels or directly to body work.

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.

The inks used are either solvent or latex based depending on application. The resin used for the domed badges is a stable two-part polyurethane.

The finished product will not go cloudy and UV stable so they will not fade in sunlight. The scratch resistant surface will ensure your logo will remain clear and visible for years to come.

We can produce in a number of different finishes such as Silver, Chrome, Gold, White, Brushed Aluminium, Etc... Whatever you require.

Small Production Runs Here at Dash Dynamics, unlike many of our competitors, we specialise in small production runs. So if you just need a set of wheel centres for your newly purchased or refurbished alloy wheels, then no problem.

Turnaround time is fast! In most cases, if you order before 1.00pm, 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. International orders are accepted too.

Size matters For larger trade bulk orders, rates improve. Feel free to pick up the phone and call us on 01995 606 158 or email us at info@dashdynamics.co.uk for costs against volume.

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.

International orders are accepted too.

www.dashdynamics.co.uk

info@dashdynamics.co.uk

01995 606 158

www.dashdynamics.co.uk

GROWING UK STEEL SUPPLIER EXPAND TO MEET DEMAND FOR LOW COST STEEL UK steel importer and distributor, COBI Solutions Ltd, has moved to larger premises in Kidderminster following continued growth in the UK and international markets.

COBI Solutions Ltd, trading as COBI Global, import and distribute of all types of prime and nonprime steel products including both finished & semi-finished steel and raw materials, as well as cutto-length, sheets and slits.

The move follows sustained growth in sales, and a number of new and exclusive partner agreements, including Steel Invest. The larger and UK central premises will allow them to further expand their operations to meet the growing demand for quality steel products at low prices.

The Company, which has long established relationships with

some of the world’s leading steel producers, supplies customers with top quality, low cost steel via its UK stocks or direct from the producing mills. The Company offer flexible credit terms and quick delivery to customers in the UK, Europe, Africa, Middle East and South East Asia.

Managing Director, Chad Ward, said “Moving to our new, larger premises in Kidderminster not only allows us to continue with our expansion plans, it also brings us closer to the heart of the UK’s manufacturing industry, allowing businesses to benefit from better quality steel and raw materials, as well as lower prices and quick delivery”.

For more information please visit www.cobiglobal.co.uk or call 01562 270027.

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AUTOMOTIVE ENGINEERING

ENTERPRISE CAD ACCESS ACTIFY

UNLOCK OPERATIONAL EFFICIENCIES AND BUSINESS SUCCESS

While CAD tools themselves have come a long way in the past 30 years, most people think CAD files are exclusively for their company’s engineering and design departments. However, the business value of using CAD beyond the design team is incredible. Many departments across the organization need access to valuable information contained within CAD files.

Historically, it has been too expensive to provide CAD tools to non-engineers and in some cases the ROI for engineers who aren’t using CAD on a daily basis is questionable. With Actify’s Enterprise CAD offering, this is no longer an obstacle and giving your entire organization access to

CAD data has become very affordable. You no longer need to ration your CAD access, everyone in your company should have access to affordable CAD tools to gather information needed to support their daily tasks.

SpinFire Ultimate is an industry-leading application and Actify’s flagship CAD viewer. It’s a powerful desktop application with multi-CAD support for 3D and 2D viewing, measuring, mark-up and other investigative functions. SpinFire is able to convert CAD data into a compact and neutral format for sharing with internal and external teams.

Even if you are locked into using another CAD system as your primary CAD authoring platform, you can still take full advantage of Actify’s neutral enterprise CAD package to support communication and collaboration.

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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PECM Issue 39

BOILERS & MAINTENANCE

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,

TX high efficiency small diameter

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

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

•

COMBUSTION ENGINEERING

X4620 Lanemark Ad SDAW.indd 1

31/08/2016 09:04

G P BURNERS LAUNCHES FACILE RANGE OF SELF-REGULATING BURNERS Swindon based combustion equipment manufacturer, G P Burners, has launched its FACILE range of fully automatic burners.

The company claims that the new, state-of the-art models are the first self-regulating burners for industrial and commercial combustion applications. The patented FACILE burners feature innovative and smart technology to deliver ease of operation, faster commissioning, optimum performance, energy efficiency and reduced emissions.

FACILE burners independently and automatically set up plant parameters such as temperature, pressure and boiler power, as well as reacting to ambient variables including altitude and climate.

The system recognises and adapts to all types of boilers and processes for optimum performance.

These characteristics simplify installation and dramatically reduce commissioning time, compared with conventional burners. For the rare occasions when operator intervention is

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RIELLO’S PREMIX BURNERS NOW UP TO 3MW

required, FACILE units have a user-friendly LCD controller.

During operation, FACILE burners have a proactive and self-regulating mass flow sensing capability, automatically adjusting fuel and air flow.

The ignition point is burner determined and regulated to ensure optimum ignition.

These features help to ensure inherently safe operation, optimum combustion and reduced energy consumption.

The FACILE range includes six LO NOx models with emissions of less than 80 mg/kWh (Class 3) and a power output range from 100 to 810 kW Email: info@gpburners.co.uk Web: www.gpburners.co.uk

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

Riello RX burners feature an exclusive design that includes a patented woven wire gauze ‘sock’ covering the combustion head cylinder. Gas and combustion air are mixed upstream of the combustion head and then

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

For further information visit www.rielloburners.co.uk

CALIBRATION SOLUTIONS

METTLER TOLEDO WHITE PAPER REVEALS CALIBRATION AS THE SECRET Understanding the behavior of your balance is key to ensuring accurate and reliable test results. But how can you ensure your balance is providing the kind of accuracy that protects your lab’s reputation? “Calibration: What Is It?” shows how periodic calibration provides the answer.

In environmental testing labs, weighing is an essential step for the analysis of water, air and soil. Samples are tested on a routine basis, and often in high numbers, to ensure that high-quality, timely analytical results are obtained Testing according to customer specifications requires a good understanding of underlying process tolerances. If these tolerances are not wellunderstood, test-result quality decreases.

Rework can cause the unnecessary waste of unique sample material. A lab’s reputation may be at stake.

Calibration can help combat these issues in day-to-day lab processing. Periodic calibration helps to ensure:

Quality. A calibration that takes the specific process into account, as provided by METTLER TOLEDO’s Accuracy Calibration Certificate (ACC) in combination with the Good Weighing PracticeTM (GWP®) Annex, can ensure airtight measurement quality.

Routine balance testing established by such a review can also preempt declining accuracy, allowing appropriate action to be taken to minimize drift and ensure quality between calibrations.

Compliance. The ACC process is based on the globally recognized EURAMET cg-18 calibration guideline. Its modular approach is designed to fit your testing lab’s specific needs, and it is also available as a locallyaccredited (ISO17025-compliant) version.

Regardless of calibration type, METTLER TOLEDO’s white paper “Calibration: What Is It?” shows how important it is to accept only calibration results that disclose measurement uncertainty, which quantitatively indicates measurement quality. Without it, balance calibration is incomplete and inconclusive.

Learn more about measurement uncertainty and discover how periodic calibration can help you provide accuracy in your test lab by downloading the free white paper “Calibration: What Is It?” today.

www.mt.com

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CALIBRATION SOLUTIONS

GOING UNDERGROUND INDYSOFT

ENSURING THE SAFETY AND EFFICIENT OPERATION OF THE TUBE With a history that dates back to 1863 when the world’s first underground railway, London Underground, was formed in 1985. Having continuously evolved to meet the expanding transport needs of Greater London and parts of the counties of Buckinghamshire, Hertfordshire and Essex, London Underground Limited (LUT) has grown in to an immense network. Today’s far-reaching system serves 275 stations and embracers over 408 km of railway, ensuring that an astonishing three million passenger journeys are made daily.

To help ensure the safety and efficient operation of the tube, LUT engineers have access to more than 20,000 instruments and gauges. In addition to specialised and bespoke equipment, the extensive inventory includes track gauges, multi-meters, torque wrenches, crimp tools, verniers, micrometers, and electrical and pressure gauges.

To certify the continued accuracy of LUT’s gauges and instruments, calibration procedures are performed by a team of skilled calibration engineers at LUT’s Lillie Road depot in Fulham. Each calibration staff member has access to a variety of highly accurate, UKAS traceable calibration apparatus, including torque testers, digital height gauges, manometers, plus electrical and pressure test equipment.

It is the calibration department’s job to track the location of these gauges and instruments and to ensure that each piece of equipment remains in calibration. In addition to LUT’s huge gauge and instrument inventory being distributed over multiple locations that have several different departments, items can also be booked-out and used on-site. Given that LUT’s calibration procedures takes place either on a 6 month or 12 month cycle, the status and tracking of 20,000 instruments and gauges has previously presented extremely challenging logistical problems.

LUT’s calibration facility previously operated a business process compliance system, although, as LUT’s gauge and instrument inventory grew, this inflexible software struggled to handle the large volumes of records and the required management tasks.

To help overcome these difficulties a search was made to find a flexible software package that was able to match all of the company’s

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stringent demands, and that would also remain ‘future-proof’ as LUT’s gauge and instrument inventory grew. Having considered several other options, IndySoft was judged to be the most suitable software for both current and future needs.

After LUT purchased its first user licence and following a short training period, staff were immediately able to make use of all basic tasks, then, as IndySoft proved to be intuitive and easy to use, more advanced functions were quickly mastered. Also, all existing gauge data and history was imported directly into the IndySoft program, from LUT’s older application, without any problems.

As LUT’s calibration department have quite specific requirements the help and support provided by IndySoft allowed the software to be configured to suit the department’s own particular needs. Now, as IndySoft introduces additional software features, LUT staff makes use of the company’s readily available support and assistance.

For instance, having recently implemented an IndySoft feature that, at the start of every month, allows the department to automatically email its ‘customers’ with a calibration-due reminder, IndySoft’s UK staff provided help in putting the new system into practice.

Due to the many ‘equipment status’ options available in the software, such as ‘in-use’, ‘external calibration’, ‘archived’, ‘lost’, ‘stolen’ and ‘scrapped’, LUT can now accurately record the exact status of every piece of its equipment.

multiple sites. Although, the use of the flexible software is equally applicable to the management of the gauge stocks of smaller concerns.

Due to the trouble-free communication between many instruments’ commonly used software, the use of IndySoft has allowed LUT to bring previously externally calibrated instruments, such as Multimeters and clamp meters, in-house. This means that, in addition to achieving considerable cost savings, increased in-house work has drastically reduced calibration turnaround times. So successful has the adoption of IndySoft been, LUT has recently added additional licences.

“All users of IndySoft software packages benefit from years of real-world development and testing by true professionals in the field.

An acknowledged innovator, over many years, IndySoft has regularly introduced new products feature that have quickly become established as industry standards. This is a ‘paperless’ system with full audit trails and has recognition of compliance to many quality standards such as AS9100, QS9000, TS16949, ISO9000, FDA 21CFR Part 11 and ISO17025 – to name just a few.”

Jake Bishop, Managing Director, IndySoft Europe enthused. “London Underground’s experience with IndySoft Calibration and Asset Management Software illustrates the system’s unmatched ability to manage complicated gauge inventories, across

“Calibrations can be performed on a pass/ fail basis, test point results or even from embedded Excel or Word documents. Also, a Module is included with the software allowing users to perform studies such as R&R, Linearity, Bias, Stability, Failure Logs etc.

“We attribute much of IndySoft Europe’s current sales success to satisfied customers recommending the software to others.

IndySoft offers the most flexible and easy to use calibration system. ‘Out of the box’, new users are able to calibrate equipment and to quickly generate certificates of calibration.

Through an exclusive process modelling engine, users are able to configure thier own event driven system with checkpoints and rule sets at every point along the equipment path. This ensures that assets are handled according to existing workflow and in-house procedures. Users can track all their equipment as it moves about their business, manage schedules such as Preventative Maintenance, Calibration, Service/Repair and any other schedules they wish to create.”

www.indysoft.com Issue 39 PECM

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CONTROL & AUTOMATION

COMMUNICATION PROTOCOL EU AUTOMATION

OPC UA IN THE SMART FACTORY

The story of the Tower of Babel describes a time where all human beings spoke the same language. When the Babylonians decided to build a tower tall enough to reach heaven, God stepped in and created a multitude of languages so the builders could no longer understand each other. The result? The tower was never completed. Here Sophie Hand, UK country manager at industrial parts supplier EU Automation, explains the universal language of automation equipment - OPC UA. A single, unifying language isn’t just useful when building a tower - it is also beneficial in industrial automation environments.

If equipment in a facility does not use the same communication protocol it can hinder their ability to share information. In the era of the Industrial Internet of Things (IIoT), connectivity is essential to remain competitive, that’s why the Open Platform Communications Foundation developed a cross-platform protocol.

THE SMART FACTORY’S INTERPRETER

The Open Platform Communications Unified Architecture (OPC UA), is a machine-to-

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machine communication protocol for industrial automation. OPC UA is opensource, platform-independent, protocolindependent and comes with a very rich extensible data model. Importantly, OPC UA was designed with cybersecurity in mind — it is secure by design, with validation, encryption and authentication already built in.

Thanks to OPC UA, equipment from different vendors can communicate, solving the interoperability pain-point for manufacturers. As well as vendor-to-vendor connection between programmable logic controllers (PLCs), the protocol can connect supervisory control and data acquisition (SCADA) systems, manufacturing execution systems (MES) and enterprise resource planning (ERP) systems for a vertical view point of the factory. By connecting to the cloud, plant managers can remotely access information to gain an overview of the entire plant in real-time.

OPC UA offers unified connectivity in a cost-effective way, because manufacturers don’t need to alter their existing machines. The OPC server will convert the communication protocol of the PLC or other

piece of equipment into the OPC protocol.

Consequently, even small and medium-sized businesses can now benefit from complete connectivity in their production processes.

Because of its benefits, OPC UA is already used by 50 million machines worldwide.

There are numerous benefits to a factory where all parts and even better, all systems, can communicate. For example, manufacturers with cloud-connected systems can remotely control processes in the plant, which means there is no need to travel to a site for simple fixes. If a component breaks down, the manufacturer could identify this quickly and order a replacement component, limiting expensive downtime.

Communication problems may have prevented the Tower of Babel from going ahead, but it doesn’t have to prevent your smart factory project from being successful.

OPC UA provides an easy and effective way to get your entire factory talking.

For more information, visit www.euautomation.com.

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CONTROL & AUTOMATION

AUTOMATION SOLUTION ADNAMS

HOW TO ORGANISE A PICK-UP IN A BREWERY

While brewing in Britain pre-dates the Roman invasion in 54AD, its evolution has helped to propel the food and beverage industry to become the country’s largest manufacturing sector. As techniques have been honed over the subsequent centuries, numerous breweries have established themselves as household names. Adnams still operates out of its original 18th century site in Southwold, but its commitment to tradition has not stopped it implementing a 21st century end-of-line automation solution.

“Adnams Brewery has been in Southwold since 1872,” begins Fergus Fitzgerald, Head Brewer at Adnams. “We brew mostly cask beer but we have invested in expanding our range over the last few years to include

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a variety of keg beers, as well as a distillery.

It’s quite a changing brewery really.

“We can brew up to 40 different beers over the course of a year – we have our core beers that we do day-in, day-out, but we also have our seasonal beers and one-offs too. We brew about 100,000 barrels a year – although by barrel I mean a brewer’s barrel – which is 163 litres.”

The brewery still operates out of its original site at the heart of Southwold, and produces the equivalent of 1,900 barrels of beer a day. However, fitting a 21st century brewery into a 19th century building has proved to be an on-going challenge for Fergus and his team, as they have looked to keep pace with modern brewing methods

and rapidly expanding consumer demands for a much wider portfolio of beers and spirits.

One area where the brewery has looked to take serious strides forward is the introduction of automation; and more specifically, the use of robotic end-of-line palletising systems to process the beer barrels once they have been filled.

Fergus continues: “While we’ve expanded our portfolio in recent years, cask beer very much remains a core part of the brewery.

At the end of our main cask filling line – where we put the beer into the barrels – we had an old palletiser which took up a lot of space.

Given where the brewery is located, we’ve got a very limited amount of space, so we have to be quite creative when it comes to using it as effectively as possible.

“We had identified a new piece of technology that we wanted to install to allow us to brew a 0.5%-alcohol version of our Ghost Ship Pale Ale, but we had exhausted all available floorspace. However, by upgrading the old palletiser to a more compact automated solution, we figured

we could accommodate everything within the existing brewery site. We actioned this in early 2018 and approached FANUC to design a robotic end-of-line loading system.”

In order to meet the significant load demands of handling metal barrels filled with over 160 litres of beer, FANUC specified its R-200iC/210L 6-axis palletising robot.

With a maximum payload of 210kg, it could comfortably process the full casks at the

required rate of 250-300 barrels an hour, to keep pace with the beer as it came out of the filling line. With a compact footprint of 771mm x 610mm, and a reach of 3100mm, it can easily operate within the confined working environment of the brewery.

Crucially, the robot body is IP54 rated, to protect it from the residual beer found throughout the cask filling line.

However, the R-200iC/210L was not Adnams’ first foray into robotics. Back in 2017, in response to the growing popularity of keg beers, Fergus and his team decided to expand Adnams’ keg programme. Up until then all non-cask beer was sent away for kegging, but the brewery wanted to bring that process in-house at its main site in central Southwold. This involved finding space for conditioning tanks, as well as filtration and kegging equipment. The final piece of the puzzle was the addition of a FANUC R-2000iC/165F robot within the kegger, which was used to lift and stack the newly-filled kegs. While this was on a much smaller scale compared to the brewery’s cask line, its success paved the way for the much larger system which followed on the cask filling line in 2018.

Following the finished installation of the R-200iC/210L in 2018 and the FANUC R-2000iC/165F in 2017, all of the brewery’s cask and keg beers are now handled and loaded by robots.

Fergus continues: “Compared to a manual process, automation is much better.

Issue 39 PECM

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Not only from a consistency and speed perspective – robot loading is twice as fast as manual loading – but for our production team, it takes away all the health and safety issues linked to manual handling out of the equation.”

However, there was another underlying factor which helped tip the balance in favour of a robot loading system, rather than a like-for-like palletiser.

“One of the main reasons we chose the robot system – aside from floorspace – was that we wanted to move away from wooden pallets, which we’d been using for years, and start using plastic locator boards,” says Fergus.

Locator boards are durable plastic interlayer boards which allow barrels to be stacked securely and safely on top one another.

At Adnams’ cask palletising system, the FANUC R-200iC/210L will pick six filled casks off the line and place them on a conveyor in two rows of three. The robot will then select a locator board from a magazine stored within the cell, and place it on top of the six barrels, before collecting the next six barrels from the filling line and stacking them on top. This process is repeated until there are 18 barrels securely stacked, before they are moved to the end of the conveyor where they can be collected by forklift truck and either loaded directly onto a distribution lorry, or stored nearby until ready for collection.

Fergus concludes: “Plastic locator boards are light, they’re cheaper, they last longer; and they also enable you to get more product on a vehicle as you can take some of the weight out. Ultimately there were lots of benefits from moving to locator boards from pallets, however we couldn’t do that on our old palletiser system so, as part of putting the robot in, we moved to locator boards as well.”

For more information on FANUC’s range of palletising robots, please visit: www.fanuc.eu/uk/en/robots.

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PECM Issue 39

CONTROL & AUTOMATION ENHANCED PLC RANGE HELPS SECURE CLOUD-ENABLED APPLICATIONS

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.

To meet the increasing data demands of digital applications, ABB launches new central processing units (CPUs) for its AC500 PLC range which offer enhanced connectivity, performance and speed suitable for industrial, buildings or substation uses.

Users of programmable logic controllers (PLCs) looking to extend connection capabilities to secure their cloud-enabled applications, can benefit from increased security of ABB’s new AC500 V3.

The PLC gives end-users, machine builders and original equipment

manufacturers (OEMs) the freedom to add features to their products or extend applications with cloud connectivity. This allows them to capitalize on the opportunities to communicate with other devices through the Internet of Things (IoT). It achieves this by offering four different Ethernet protocols that provide data connectivity, cloud connectivity, substation communication or intelligent building automation, offering users an easy to integrate and open platform.

For more information, visit www.abb.com/plc.

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.

Assured Automationassuredautomation.com/ FireChek- assuredautomation. com/firechek/

FLUXDATA ANNOUNCED NEW SPECTROPHOTOMETER: SPECTRANOVATM D8-M2, OFFERING HIGH-ACCURACY NON-CONTACT COLOR MEASUREMENTS FluxData Inc., an international leader in industrial in-line color process control and measurement, announced the formal release of a new color measurement system designed for use in challenging industrial settings. The new SpectraNova™ D8-M2 is designed from the ground up with reliability and efficiency in mind. The measurement head is sealed to protect the integrating sphere from the factory environment using a sapphire window, which is easily cleanable in the field. Measurements are reported instantly to your software through a machine-to-machine interface, ensuring

the SpectraNova™ D8-M2, which is designed for industrial applications, is non-contact, rapid, compact and correlates with QC laboratory systems.

accuracy and eliminating the need for a human operator. FluxData’s SpectraNova™ D8-M2 offers seamless integration with existing systems and manufacturing lines and results in dramatic reductions in costs and yield improvements. FluxData offers such benefits to the user by assuring that

FluxData’s latest product, which includes 8° diffuse geometry, offers reflectance and CIE colorimetric data output, rapid measurement cycles of less than 150 milliseconds, and requires minimal maintenance.

Phone: (800) 425-0176 www.fluxdata.com

Issue 39 PECM

67

ELECTRICAL & ELECTRONICS

MAINTAINING EXCELLENCE SPELSBERG

IN-HOUSE MACHINING MEANS CUSTOMISED ENCLOSURES CAN BE DELIVERED OVERNIGHT

Spelsberg UK takes the view that all of its enclosure should be absolutely top quality, whether they are a standard catalogue item or have undergone secondary customisation processing.

There are literally thousands of off-the-shelf designs for electrical enclosures, but there is still a significant need for customised alternatives. Spelsberg UK recognises that requests for special products usually emanate from important projects, so has invested in a centre of machining excellence at its Telford HQ to meet these needs.

Electrical enclosures made of highperformance plastic are available in many sizes and shapes, in multiple configurations for cable entry points, and with many options for switches, lamps and other accessories. But they are used in so many diverse applications that in a lot of cases a standard product that manages to meet all the job’s needs just cannot be found.

Thus there is a significant need for customised solutions - standard products that have had secondary machining to open up cable entry points; cut holes for switches, lamps, sensors and gauges; engrave logos, operating instructions or safety information.

Sometimes customised enclosures are oneoffs, but more often there is a requirement for multiple units, and possible an on-going serial demand.

Importantly, this customisation must be done while maintaining the structural strength and integrity of the enclosure and without detracting from its aesthetic appearance.

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PECM Issue 39

Each of the CNC machines feature interchangeable bed fixtures, which allows any two or more of them to be set up to run the same job. Thus, multiple units can be produced rapidly.

With so many considerations it is not surprising that OEM and end users often choose not to undertake this work themselves, but to outsource it to a third party company. However, involving a third party can create issues itself, in terms of adding extra time for preparing an accurate brief for the service provider, allowing for delivery to and from their machining centre and – initially at least - checking the capabilities of the chosen service provider.

As one of the leading manufacturers and suppliers of plastic enclosures, Spelsberg UK has taken many of these worries out of the process by offering secondary processing as a mainstream service to its customers. It has a well equipped machining facility in its headquarters in Telford and can commit to providing first samples within 24 hours.

The facility is built around four state of the art CNC machines, each with milling, drilling,

countersinking, tapping and engraving capabilities. These are run by highly skilled staff who understand the need for fast turnaround and right-first-time operations.

Furthermore, they fully understand the intricacies of the machine operations, including the need to maintain the correct temperature, tool speed and pressure for optimum cutting.

Each of the CNC machines feature interchangeable bed fixtures, which allows any two or more of them to be set up to run the same job. Thus, multiple units can be produced rapidly.

Complex customisation needs can be met, including non-round holes, counter sinking, chamfering and thread cutting. Logos, diagrams, other graphics and vital safety instructions can be milled permanently into the enclosures, so that they will not fade over time.

Spelsberg UK takes the view that all of its enclosure should be absolutely top quality, whether they are a standard catalogue item or have undergone secondary customisation processing. The same principals are maintained on the customer service side for both standard and custom products, with rapid deliveries and full technical support fundamental parts of the equation. www.spelsberg.co.uk

Industrial Quality Power Supplies

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

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

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

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

TSP Series AC-DC Converters 70 to 600 Watts output power Universal (up to 90W) or auto select AC input 12V, 24V or 48V DC output versions Optional external redundancy modules.

Full safety approvals and ATEX certification for hazardous locations.

TSP Series Function Modules Redundancy Module enables two units to operate in parallel mode.

Buffer Module allows hold up time up to 4 seconds depending on load.

Battery Controller Module enables TSP to be used as AC-DC UPS.

TEX120 Series AC-DC Converter 96 & 120 Watts output power 85-264VAC (85-375VDC) input range 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 Series AC-DC Converters 80 to 480 Watts output power Universal 85-264 VAC input with Power Factor Correction.

12V, 24V or 48V DC output versions.

Full safety approvals and ATEX & UL Hazloc certification.

www.powersolve.co.uk

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

ELECTRICAL & ELECTRONICS

MARKET LEADER DUNKERMOTOREN

a itep W02h/02/2017

BG SERIES OF DUNKERMOTOREN MATCHES PERFECTLY WITH SIMATIC MICRO-DRIVE SERVO DRIVE SYSTEM With the brushless DC motors (24 to 48 volts) of the series BG 45, BG 65(S), BG 75 and BG 95, Dunkermotoren has been the market leader in the 20-1100 Watt power range for years. As part of a product partnership with Siemens, the motors are now also available in specific versions compatible with the new SIMATIC MICRO-DRIVE servo drive system.

The simple integration of the SIMATIC MICRODRIVE servo drive system into the SIMATIC world significantly shortens the engineering time. The integration into Siemens automation technology is possible via the

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PECM Issue 39

TIA portal and simplifies commissioning and service. Communication takes place via PROFINET IRT with PROFIsafe and PROFIdrive profiles. The new Safety Integrated Function SLT (Safely Limited Torque) ensures a limited torque by monitoring the motor current during operation.

A sophisticated modular system allows the motors to be individually adapted: Matching planetary and right-angle gears and brakes complete the comprehensive portfolio.

Smart components in the motor, together with a patented data transmission system, set the controller to a preset state after it is connected to the motor. Cumbersome drive tuning and parameterization of the controller control loops are a thing of the past.

Further information can be found in the product flyer: www. dunkermotoren.com/fileadmin/ files/downloads/Produktkataloge/ Simatic_Micro_Drive_Web.pdf

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ISABELLENHUTTE IVT-S MODULE SERIES Rhopoint Components are proud to present the newest addition to their portfolio, the exciting IVT-S modules with potential to revolutionise a range of industries, combining the highest quality current measurement shunt with digital processing into a compact package for a reliable plugand-play solution.

The key features include: • Accurate measurement of current, voltage (optional), temperature, power (optional), including energy (optional) and current counters • Isolation of up to 1000V • Choice of 5 voltage ranges (100A to 2500A DC)

• Communication via CAN interface • Optional voltage measurement channels and extra CAN channel to enable daisy-chaining available These modules are increasingly becoming popular with critical industries where precision measurement is of paramount importance, such as EV and automotive. They are also suitable for a range of other industries, particularly for inverters, energy storing and other applications.

For more information please contact our sales team at sales@rhopointcomponents.com

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IVT-S: The next generation of current & voltage measurement • Customisable plug-and-play modules suitable for industrial applications • High accuracy measurement up to 2500A • Readings immediately available via CANbus 2.0 interface

01342 330470

rhopointcomponents.com Issue 39 PECM

71

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.

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.

The PSICL is a housed in a low profile V0 flammability rated plastic case measuring 91H x 71W x 57Dmm. The same design

powersolve.co.uk/product-category/ inrush-current-limiters/

BUILDING ENERGY EFFICIENCY FOR THE FUTURE Sandford Electrical Services has been providing BEMS and electrical control panel consultation, design, and manufacturing services since 1989. Everything is done under one roof so things tend to be streamlined, quick, and transparent.

We are also one of the few UK companies to be BS EN 61439 accredited meaning you are ALWAYS safe in our hands!

Sandford is a premium brand. But savvy constructors have worked out that investing in high quality BEMS and electrical control panels adds enduring value (and cache) to their build.

We’ve worked on some of the most iconic and complex building projects in the UK. We can do the same for you.

Contact us on 01628-668-808 www.sandfordelectrical.co.uk

72

PECM Issue 39 Guhring Drill Is The Top Prize For

Electrical & Electronics

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.

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.

Email: hvtest@drallim.com | Tel: 01424 205140 | Web: www.drallim.com

quaterpageadapril18-2.qxp_Layout 1 18/04/2018 10:01 Page 1

KAIZEN TECHNOLOGY You think it, we build it!

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www.kaizentechnology.co.uk

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

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

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

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

Issue 39 PECM

73

ELECTRICAL & ELECTRONICS

POWER CORE PARADIGM SHIFT REO

WHY MODERN ELECTRICAL APPLICATIONS DEMAND NEW CORE MATERIALS Modern electrical systems that use inductors, such as on-site renewable energy generation, rely on efficient electronics for power conversion and switching. Here, Steve Hughes, managing director of power quality specialist REO UK, explains how the choice of electromagnetic core materials — particularly new ones like amorphous cores — can make all the difference to electrical applications.

According to the Fundamentals of Electric Circuits by Charles Alexander and Matthew Sadiku, “An inductor is a passive element designed to store energy in its magnetic field. They are used in power supplies, transformers, radios, TVs, radars and electric motors”.

An inductor is one of the three types of passive linear elements, along with capacitors and resistors, that make up a circuit. The main difference between a capacitor and an inductor is that, where a capacitor stores charge in an electrical field, an inductor stores the energy in a magnetic field.

Because an inductor opposes any change in the direction of current flowing through it, it is particularly suited to blocking AC current and only letting DC through.

Although any material that conducts electrical current has inductive properties, to produce a practical inductor, a coil of conductive wire is wrapped around a core.

More commonly known as a choke, coil or reactor, an inductor generates a magnetic field to store electrical energy when an electric current flows through it.

Storing energy is necessary in a variety of electrical applications. As the need to produce clean energy becomes increasingly important, high frequency switching and power transformation necessitates the need for energy-efficient components that can switch faster and exhibit fewer conduction losses. Fifty years ago, for example, the high frequency inverters that make renewable generation possible today simply did not exist.

There are a few factors that can affect the strength of the inductive force generated in an inductor. These include the magnetic field flux density and the permeability of the core, which are affected by variables such

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PECM Issue 39

as the number of turns of the coil, the cross sectional core-area covered by the coil, the length of the coil and the core material.

As electric current flows through the inductor’s coil, it generates a magnetic field.

The number of magnetic field lines passing through the surface of the conductive material (the magnetic intensity) affects the density of the resulting field, which is why the geometry and shape of the inductor is important to maximise the flux density.

Steve Hughes - managing director of REO UK

CORE MATERIAL

Once the coil variables have been optimised, the next variable is the permeability of the core. Permeability is the measure of how well a material can support a magnetic field within itself. Using a ferromagnetic core with a high permeability — usually made of iron, but can also be made from nickel, cobalt or other iron alloys — significantly increases inductance compared to using a coil made from air or steel.

While a high permeability is preferable, the core’s material affects its saturation limit.

This is when an increase in the applied magnetic field intensity does not continue to magnetise the core material, leading to flux density levelling off. This effectively means the inductor stops acting as an inductor, potentially leading to excessive current waveforms damaging components such as sensitive semiconductor materials.

Similarly, the construction of the core material can also affect the level of losses the inductor incurs. Choosing the right core material can also impact other crucial factors such as weight, operating temperature and size of the finished inductor. Design engineers must consider these factors when choosing their core material.

FERRITE CORE

One of the most common types of core, ferrite cores are typically made from iron and its alloys. These cores were traditionally created in response to the need for inductors to operate at higher frequencies. However, as applications began to demand frequencies higher than 20 kHz, the traditional laminated core design became less and less effective.

Traditional laminated cores were made using thin sheets of iron coated in an insulating material and stacked together to form a core.

This method provided an effective means of reducing losses such as eddy currents compared to solid cores.

For higher frequency applications, ferrite cores are created using iron powder mixed with an insulator and binder material and compressed under high pressure. The resulting core has a distributed air gap where the energy is stored in tiny air gaps that occur between the small particles of iron in the substrate.

This means that the core delivers a high permeability with a uniform temperature and performance curve. It also means

that the losses are distributed across the material. Producing ferrite cores in this manner is relatively cheap but is reserved for relatively low frequency applications and are only practical to manufacture to a diameter of around 140 mm.

In an amorphous core, the atoms are arranged in a non-uniform manner. For design engineers, amorphous metals offer the best of both worlds, offering very low losses at very high frequencies of 300kHz while retaining a high permeability.

NANOCRYSTALLINE CORE

REO UK has made strides in developing usable inductors and chokes made from both nanocrystalline and amorphous core materials. We’ve made it easier for design engineers by constructing the components to avoid damage to the core or altering its physical structure and achieve superior inductance performance with very low stray values.

Although nanocrystalline cores are ostensibly similar in appearance to ferrite cores, typically taking a donut-shaped form, they are made from thin ribbon-like strips of nanocrystalline material. Although they are still made from iron, the grain size is much smaller, typically 10 nm in size — hence the name, nanocrystalline.

This type of core is annealed during its manufacture, where a heat treatment process is used to achieve a uniform atomic structure and significantly improve the magnetic permeability of the material, usually by a factor of 10–20. However, design engineers should take care with this material because the annealing process can leave the core brittle, so insulators should be used to reinforce the core’s structural strength.

AMORPHOUS CORE

Recent advances in metallurgy have made once exotic core materials more accessible for use in components such as inductors. Also referred to as metallic glass or glassy metal an amorphous core is made by heating and rapidly cooling the ferromagnetic material to produce a thin foil with a non-crystalline structure.

With a background specialising in wound components, REO UK also offers the flexibility of building components with an ingress protection rating of IP66 and watercooling where required.

As clean energy applications begin to take the market by storm, semiconductor materials will continue to get smaller, and operate at higher frequencies. In this environment, it’s important that design engineers continue to keep pace with market requirements by specifying the right material for the job.

For more information visit www.reo.co.uk.

Issue 39 PECM

75

FACILITIES MANAGEMENT

LEADING ELECTROCHLORINATION SYSTEM NOW APPROVED FOR USE ON PUBLIC WATER SUPPLIES technical director, Andrew Gaffey. “There are over 300 Hyprolyser® systems in use on major water treatment applications around the world. These include theme parks, wastewater treatment plants, industrial and food preparation processes, plus highprofile installations such as the Edinburgh Royal Commonwealth Pool, Center Parcs in Woburn Forest and the Logan Solar Water Treatment project in Queensland, Australia.

One of the UK’s leading manufacturers of industrial and commercial water treatment solutions has announced that its electrochlorination system has been approved for use on UK public water supplies. Gaffey Technical Services, which is internationally recognised for its technical expertise and innovative product development, has revealed that its Hyprolyser® 280-2200 system is now approved under Regulation 31 of the Water Supply (Water Quality) Regulations 2000.

This further acknowledges the quality of the Hyprolyser® system which has already found considerable success on various water and general processing applications.

Gaffey Technical Services has announced that its Hyprolyser® electrochlorination system has been approved for use on UK public water supplies. This further acknowledges the quality of the system which has already found considerable success on various water and general processing applications.

The Gaffey Hyprolyser® system has been widely proven in commercial and municipal waste-water, private drinking water supply and swimming pool applications. It uses marketleading technology to generate sodium hypochlorite by applying an electrical current to a water and salt solution. This eliminates the need for chlorine to be stored on site, and so offers a reliable, lowrisk and environmentally-friendly solution for disinfecting water.

“This latest recognition marks a significant achievement and is another step forward in the progress we have been making with the Hyprolyser® product range,” comments

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Industrial Flooring !

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le p m i S e d Ma • • • • • •

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

Call the industrial flooring experts on 01952 740400

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

Accredited Contractor www.chas.co.uk

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PECM Issue 39

“This new compliance level for use in drinking water demonstrates that our Hyprolyser® 280 – 2200 system generates a high-quality product and meets strict standards for chemical impurities and toxicology. This opens up a whole new set of opportunities for the Hyprolyser® system and will allow far more organisations to benefit from the many advantages it offers.”

Since 2014 Gaffey has exported Hyprolyser® products to over 17 different countries including Canada, Australia and the UAE. For more details visit www.gaffey.co.uk, email info@ gaffey.co.uk or call +44(0)1254 350180

SAVE UP TO 90%

ON YOUR ENERGY COSTS.

EVAPORATIVE COOLING • Runs at less than 10% compared to refrigerated air con • Increases productivity, hygiene and condition compliance • No harmful refrigerants - only 100% fresh air • Avoids air recirculation - improves air quality/reduces smells • Energy Efficient Natural Cooling - decreases carbon footprint • New build and retrofit with solutions to fit a range of applications

EcoCooling: the established leaders in evaporative cooling UK-based with over 4500 installations worldwide; with clients including BT, Cummins Diesel, Premier Foods, Marks & Spencer, Net-a-Porter, Cambridge University, Talk Talk and CGG Veritas. Case studies online!

Industrial Cooling: Provides 35kW of cooling for only 1.5kW of electricty. 14,000m3/hr of cool air for less than 12p per hour. ROI in under 3 years.

Large UK wide network of installers ready to quote on a solution to fit your needs.

sales@ecocooling.co.uk | T: 01284 810586 www.ecocooling.co.uk | www.cloudcooler.co.uk

FACILITIES MANAGEMENT

PRECISION EQUIPMENT ULTRAWAVE

MAKING WAVES FOR OVER 28 YEARS Ultrawave have been manufacturing precision ultrasonic cleaning equipment for over 28 years. Our range of ultrasonic systems are all designed, manufactured & tested in house. By ensuring we have complete control of all our processes, we have the flexibility to meet individual customer requirement & provide cleaning solutions to a diverse market.

Ultrawave’s standard industrial ultrasonic cleaners offer excellent performance across a diverse mix of applications. Ranging from 5-125 litres in capacity, these ultrasonic cleaners are designed to be incorporated into manufacturing & routine maintenance programmes where the highest standards are essential. Ultrawave’s ultrasonic cleaners are reliable & will provide consistent cleaning results time after time.

As well as our catalogue of off-the-shelf products, Ultrawave have the experience, knowledge and capabilities to specify, design and manufacture bespoke cleaning systems to meet individual requirements.

Our unique product design process allows us to specify systems tailored to give precise cleaning results, whatever the customer’s needs. In addition we offer a range of submersible transducers & generators to convert existing systems to fully aqueous, environmentally friendly cleaning systems.

Having become preferred suppliers to companies in industries as diverse as medical device manufacture, food and beverage, pharmaceutical, automotive, aerospace and defence, we know the requirements of specific processing applications.

Since our formation in 1990, we have supplied over 60,000 ultrasonic cleaners to a diverse range of industries. Accredited to ISO9001 & ISO13485, we can supply ultrasonic cleaning systems to meet your exact requirements.

NEON SERIES Through innovation and expertise, Ultrawave has developed a multi-stage cleaning, rinse and drying system offering

customers enhanced cleaning capabilities.

Listening to customers’ needs is essential to deliver products that will help them achieve their expectations.

Ultrawave’s Neon Series is the highest quality design, delivers outstanding ultrasonic performance for precision cleaning of instruments and components across a wide range of industries.

The integrated recirculation system minimises fluid contamination, reducing operating costs and improving component cleanliness.

Available in capacities from 35 to 125 Litres, the Neon Series’ clever modular design allows easy retrofitting of additional wash, rinse and drying stages to meet the highest cleaning and processing standards.

The design provides a robust versatile cleaning system incorporating 2mm thick industrial grade 316 stainless steel tank, digital control, and Graphical User Interface with split level program security to set cycle Temperature and Time variables.

This range really offers the flexibility that gives customers the cleaning answer for today and tomorrow. www.ultrawave.co.uk admin@ultrawave.co.uk Tel: +44 (0) 845 330 4236

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PECM Issue 39

FASTENERS & FIXINGS

FASTENING SOLUTIONS STAR FASTENERS

STAR FASTENERS NOT JUST A FASTENER SUPPLIER! As a well-established leader in the global Huck® fastener distribution network Star Fasteners (UK) Ltd, are committed to supplying customers with the most innovative fastening solutions on the market.

Star work closely with Arconic Fastening Systems on designing new products to meet customers’ requirements. “We have been a Huck fastener distributor for over 30 years, Arconic are very proactive and work with us on ideas and product developments. The Huck range has an excellent reputation in the market for their quality and reliability. This is essential knowledge when we are talking to customers about new projects,” explains Daniel Starbuck, Director. “We have been involved in the development of a few new products that Arconic have introduced to the market under the Huck range and we have lots of other ideas that we can see becoming possible in the future. Innovation is key and is an important part of Star Fasteners core values.”

There are numerous reasons why customers should use Huck products. But what make the UK’s largest Huck fastener distributor, Star Fasteners different; what extra services can they offer? Here are some of the value-added advantages of Star Fasteners solutions: Supplying a diverse range of industries, Star Fasteners have many years of technical knowledge and if required offer support from highly qualified and knowledgeable staff. However, Star Fasteners are flexible enough to adapted fastening solutions to the needs of their customers. “Huck fasteners are what we specialise in, we carry extensive stocks so that our customers’ never run out”.

Exclusively from Star Fasteners, the Huck PentaLok® designed specifically for the composite panel market, is an easy to install, 6.4mm diameter, plated steel, peel fastener with superior blind side strength.

Due to its high pull-out strength, PentaLok is suited for use within thin materials or delicate composites, as well as within misaligned, oversized, or slotted holes. Its uniquely engineered peel system installs with ease into shallow panels.

Another joint development by Star Fasteners and Arconic has been the encapsulated headed Hucktainer®, which is available in any colour head. “The encapsulated

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Encapsulated Hucktainers Hucktainer has been available in the market for many years,” reports Daniel. “We had customers contacting us saying that they wanted to use the products directly on truck panels to match the colour of their livery.

Previously they were painting over the grey headed Hucktainer, but if the paint was for some reason damaged it showed the grey colour again. We now have the Hucktainer heads encapsulated to customers colour requirements.” Star Fasteners can offer hundreds of different colours and supply the product across Europe. They can even offer a next day service for special requirements.

“Customers often come to us with challenging projects. We recently developed a countersunk Hucktainer collar for fixing commercial vehicle locking gear and load restraint. Many manufacturers use the same materials suppliers and history showed that these were normally fastened with a standard bolt and nut, but this protruded from the panel and needed a capping strip. The customer wanted to stream-line the vehicles profile. We designed-in the countersunk collar which resulted in a smooth finish and saved weight; a great solution!”

The in-house powder coating service allows any Huck stock item to be coloured to meet customers’ requirements. Customers’ needs vary, some order bespoke colours to match the livery of a contract, but they have also been coloured for health and safety identification purposes. Small order requirements are a bonus and as it’s an in-house service they can generally be despatched at short notice.

“We are also aware of the constantly evolving metal plating industry and try to pre-empt customers requirement for additional corrosion resistance. With

Countersunk Hucktainer Collar this in mind we now stock all Hucktainer pins with J63 Zinc-Nickel and Trivalent Clear Passivation. This finish is free from hexavalent chrome and is compliant with European directive EU 2000/53 Annex 2 in materials and components of vehicles.

Additionally, it also meets the requirements of the Restriction of Hazardous Substances regulations. These new processes and resources will help our customers to address corrosion resistance for many years to come.”

Star Fasteners in-house and onsite tool repairs and servicing keep production lines rolling and fasteners installed correctly. Star Fasteners stock a comprehensive range of new installation tools for every budget, including the new Huck Range Force® battery tool. “We always stock plenty of tooling spares to ensure servicing and repairs can be turned around quickly” adds Dan. If the customers budget does not allow for the purchase of new tooling or the requirement is for a shortterm project Star also offer a long or shortterm hire option.

“Technology is always evolving and we have customers that come to us with specific needs who want to develop projects beyond the ‘norm’ and to push the limits of technology. It is up to us to keep up with new developments and seamlessly integrate these into our product range.

We don’t want to be seen as just a fastener supplier, but as a company that is pro-active and one that offers something different, a solutions provider!”

For further information email sales@starfasteners.co.uk or call us on +44 (0) 115 9324 939

FLUID HANDLING LABTEX

Labtex supplies leading laboratory products including HUBER liquid temperature control systems, DIEHM glass reaction systems to 100 litres,

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.

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.

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.

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.

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

Fluid Carrying

... always an intelligent solution

Flexibility Articulated Torsion Pipework In Hoses Rotating Cylinders

Swivel Joints

COMPRESSION FITTINGS ORIGINAL RANGE Sizes 15 -100mm

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.

QUICK RANGE Sizes 15 -50mm

LEAK SEALING CLAMP Sizes 10 -100mm

Malleable

Tel:

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

+44(0)1663 735003

E-mail:

DZR Brass

TAPPING CLAMP

Malleable

DZR Brass

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

PECM Quarter page, CABCO.indd 1

Issue 39 PECM 81 10:38 10/03/2016

FLUID HANDLING

CLEAN WATER QUALITY BURKERT

SMART CUBES FOR SMARTER WATER NETWORKS Maintaining clean water quality is extremely important for both consumers collecting it from the tap and for manufacturers that rely on it as a key constituent part of a process. Efficient measuring and monitoring of parameters such as pH, iron content and turbidity, is a constant challenge for many water utilities and food & beverage producers. Now there is a flexible, modular system that uses smart cube technology to save space, time and money.

Traditionally, clean water analysis equipment has been bulky and time-consuming to install, not to mention the resource required to monitor and calibrate it regularly. Due to the importance of quality standards and compliance with statutory regulations that are applied for the safety of the general public, these short­comings have been unavoidable -until now.

Experts in flow control technology at Bürkert have been applying some innovation in this field and as a result the company’s Type 8905 Online Analysis System is setting new standards in terms of flexibility, ease of use, installation time and reduced operating costs. As a compact, modular system it is far easier to integrate into an existing control infrastructure than typically in-line alternatives and can be adapted almost instantly for individual applications.

SMART CUBES

The secret to its success is plug-and-play sensor cubes that are capable of measuring pH, reduction potential (ORP), conductivity, free chlorine, chlorine dioxide, iron, and turbidity. Each cube, irrespective of its capabilities, has the same dimensions and connections and can be plugged in, or removed, from the unit while it is operational, thus providing a ‘hot swap’ facility.

Each cube holds all the calibration data and mapping data that is required for it to operate without additional input from the operator. This onboard ‘intelligence’ means that any cube can be installed in a base unit and it will automatically configure itself and make its presence known to the rest of the system.

This benefit is enhanced when it comes to ongoing calibration because now a process that was rather drawn out and timeconsuming, can be completed in a matter of seconds.

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All cubes can be calibrated in a cleaner environment using a laptop and the associated calibration equipment. The ‘hot-swap’ function of the cubes means that an operational cube can be replaced with a recently calibrated cube from another sampling station. This allows a spare cube to be rotated across any number of sampling

stations, all the time carrying its calibration with it.

Looking at the individual sensor cubes and their calibration processes in detail it is possible to gain a better understanding of the advantages they have over more traditional monitoring systems.

Bürkert’s sensors, which operate with much smaller volumes of sample fluid than traditional equipment can offer more accurate data and greater operating life.

TURBIDITY

Traditionally, turbidity sensors are calibrated using formazine, or verified with a verification block and probe. Both have their downsides, formazine is a carcinogen, so in most cases the probe is sent back to the manufacturer to be tested and cleaned.

The verification block and the probe equipment on the other hand is difficult to store and use in the field while maintaining accuracy.

Bürkert has done away with both of these less than ideal methods in favour of repeatable, accurate test processes using a dedicated plug-in calibration tool.

The added difficulty with turbidity calibration is that any bubbles, however small, will interfere with the result. Bürkert’s in-field calibration tool takes account of this and ensures continued accuracy without the need to send sensors back to the manufacturer.

PH

Traditional pH probes should not be allowed to dry out, either during storage or operation, and they have a defined shelf life of approximately one year. With the Bürkert solution, there is no glass component within the cube, so it can be stored indefinitely, and the calibration process is straightforward and quick.

The calibration process for pH, ORP and conductivity cubes uses a hand-held module that connects into the bus network or via a laptop, with the onscreen guide providing step-by-step instructions. The calibration module contains a standard fluid, for example at pH 5 or pH 7, which is drawn into the analysis cube. By following the steps any offset between the standard and the cube reading is addressed, and the process is complete.

CHLORINE

The amperometric chlorine MEMS sensor chip used by Bürkert is not affected by chloramines, providing true chlorine analysis.

Other major benefits are the fact that the sensor cubes are not reagent-based, they do not use an electrolyte or a membrane cap as traditional probes do, neither is there a need to maintain a gold electrode with abrasive paper, so the maintenance requirement for this system is greatly reduced. The calibration process involves taking a reading from the display in parts per million (ppm), and a sample of the water at the same time and using a DPD1 photometer reference test for free chlorine. This is a universal test for chlorine that is used all over the world to quickly establish the offset and recalibrate the cube.

CONNECTIVITY

Each of these cubes can be arranged as required, depending on the application.

Multiple sample lines can be added to one central analysis station, or several remote stations can be connected using any of the common industrial networking communication protocols.

Depending on the needs of the system, the analysis cubes can be connected directly to a PLC, which can perform the datalogging function as well as using the analysis data to make changes in the process. Used in either a compact system or a panel-built system, there is a direct connection between the cube and the output card.

Therefore, if the display or the datalogger fails for any reason, the cube continues to operate and transmit its data to the control network. Each sensor cube has its own output card, so if one fails, all the other cubes continue to operate, while the failed card issues a warning message to allow a repair to be made.

COMPACT SOLUTIONS

This simple solution offers many advantages to the water industry as well as the food and beverage sector. Downtime for calibration is kept to an absolute minimum, site operatives’ safety is assured and the costs for calibration are also minimised. Integration with existing process control systems is relatively straightforward, however Bürkert can provide on-site support ranging from specification advice to a full turnkey installation and commissioning service.

The combination of modular cubes, simple calibration, operational flexibility, reliability and a very compact footprint means that Bürkert’s Type 8905 Online Analysis System is setting the standard for clean water quality analysis. www.burkert.co.uk Issue 39 PECM

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FLUID HANDLING

STEAM GENERATION CYCLE MAGNETROL

ARE SUBTLE INEFFICIENCIES CONDENSING YOUR BOTTOM LINE? In many process industries, as much as 60% of total energy consumption goes to the production of steam. Our newly updated white paper on the steam generation cycle shows how better level instrumentation can improve efficiency, reduce fuel consumption, lower costs, and prevent production downtime.

To identify key areas in the steam generation cycle, condensate recovery system and waste heat recovery process where cost-effective instrumentation solutions offer a tangible return on investment over the short-term. The goal is to reduce heat rate, environmental impact, fuel and water consumption, water treatment and maintenance costs in commercial and heavy industries where steam generation is essential to the production processes.

Although plausible, it is rare to identify a single source of inefficiency related to poor-quality level controls that impact a company’s bottom line in the doubledigit percentile. More so than not, it is these small incremental opportunities for improvement across various aspects of the steam generation cycle, condensate recovery system and waste heat recovery process that ultimately equate to substantial savings.

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

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

Dampfauslass

Swell

Feed water

Normal Water Level Shrink Steam andund Dampfwater mix Wassergemisch

Regardless of the scale of an operation –commercial power generation or small scale boiler system, leveraging the inherent attributes of an instrument’s fundamental technology in both the shortterm (engineering, upfront cost, installation and commissioning) and long- term (maintenance, day-to-day practicality and energy management) present simple and cost-effective approaches to maximizing the return on investment in the system itself.

Estimates of up to 49 percent of the energy can be recovered through the use of flash steam routed to heat exchangers or the deaerator to preheat boiler makeup water or support the deaeration process,

Optimizing boiler, deaerator, heat exchanger/condenser and blowdown usage relative to level control primarily affects fuel economy by better managing the amount of energy required to produce high quality steam for any given task.

Seamless response to changes in demand and reducing maintenance associated with the instrumentation or damage to hardware are residual benefits that have their own financial ramifications; hence, should also be considered when implementing any technology. The return on investment time frame can vary depending on the scale of the operation as well as the time spent maintaining aging instrumentation.

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

Corrosive environments.

Costly blowdowns.

Hidden costs.

Don’t let your efficiency evaporate.

This is why level matters.

Steam production is responsible for up to 60% of your total energy consumption. Which means any inefficiency can cost you a small fortune. That’s why Magnetrol® matters.

We’ll help you identify hidden costs, improve production and reduce downtime. And we have the broadest portfolio of level instruments to optimize your entire steam generation and condensate recovery process. That’s critical. Because at your plant, level matters.

©2019 ©2019 Magnetrol Magnetrol International International

Download the Steam Generation Optimization Kit at steamgen.magnetrol.com Issue 39 PECM

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www.elaflex.de/en/configurators

Many options, fast choice.

ELAFLEX hose assemblies, nozzles, rubber expansion joints and couplings reflect the decision for premium quality. They ensure safe operation and long-term optimisation of the total cost of ownership.

Due to the large number of product options we have complemented our catalogue with online configurators.

These configurators offer a fast and efficient overview or can be used for your enquiries.

nozzleconfigurator.elaflex.de

hoseconfigurator.elaflex.de

ervconfigurator.elaflex.de

manntekconfigurator.elaflex.de

ELAFLEX - Gummi Ehlers GmbH · Schnackenburgallee 121 · 22525 Hamburg, Germany · Tel. + 49 40 540 005-0 · info@elaflex.de · www.elaflex.de/en

FLUID HANDLING

SEEPEX RISES TO THE CHALLENGE OF VISCOUS WASTE AT CIABATTA BREAD FACTORY An on-site trial at a ciabatta bakery has demonstrated that it is possible to pump viscous, sticky dough products, even when mixed with baked bread. SEEPEX UK’s enclosed, automated waste removal solution has optimised the bakery’s waste handling process, reducing labour and improving hygiene levels.

The bakery owners identified the manual removal of waste bread and dough as an inefficient task. When looking for an alternative solution to reduce manpower, improve hygiene standards and optimise the waste removal process, they approached progressive cavity (PC) pump supplier, SEEPEX UK. The challenge was not just that dough is a difficult substance to pump but also, the variety of materials being handled. Dough is highly viscous; fresh bread is light and compressible; and waste bread is hard and non-flowable.

SEEPEX’s solution comprises a BTM open hopper pump with integral static and rotating knives. It also includes an auger that mixes the different products and prevents them from bridging in the

hopper. The product is then transferred through enclosed pipework into removal lorries.

The existing manual system often caused waste product to fall onto the factory floor, creating an unhygienic and hazardous environment. Movement of waste from production areas to the outside of the bakery also presented hygiene problems.

In contrast, the only open part of the new solution is the hopper, meaning there is no need for anyone to enter and exit the

factory. The reduction in spillage keeps the factory floor clean and tidy.

The fully automated solution only requires one person to load product into the hopper, freeing resources for production.

Furthermore, the pump only runs when there is product to handle, making it extremely energy-efficient.

www.seepex.com

HANDLE VISCOUS, STICKY AND NON-FLOWABLE PRODUCTS. SEEPEX’s pumping solutions with open hopper and auger feed screw simplify product transfer and waste removal as well as being safer, more hygienic and cost-efficient than conventional methods such as conveyors, vacuum systems, water flumes and tote bins.  Handle up to 80% solids content  Optimised feed hopper prevents bridging  Modular system enables customisation

 Optional knife system for cutting within the pump  Easy maintenance  Increased productivity

SEEPEX UK Ltd. sales.uk@seepex.com www.seepex.com

Issue 39 PECM

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FLUID HANDLING

SWIVEL JOINT SPECIALISTS ROTAFLOW

DOMESTIC ENGINEERING RESCUES TYNE GANGWAY PROJECT UK Swivel joint specialist Rotaflow recently reminded us why domestic engineering services providers can offer significant advantages over cheaper yet often less reliable non-domestic firms.

The bespoke Tyne Gangway Project hit a stumbling block when a multi-flow swivel joint that had been promised for the project failed to be delivered.

The 210 bar hydraulically operated gangway required an 8 passageway swivel joint at the centre to allow the entire system to rotate as required.

Facing a major delay to the project if the swivel joint wasn’t manufactured and delivered on time, Tyne Gangway reached out to Rotaflow with a desperately short deadline of just two weeks.

For reference, a multi-flow swivel joint would take around 8 weeks to design, approve, manufacture, test and then deliver ready for installation. Facing such desperate circumstances, the Rotaflow team had to work round the clock to get the job done in a quarter of the usual time.

ENGINEERING EFFICIENCY

A significant advantage Rotaflow have is that their design, manufacturing and testing facilities are all on the same site, meaning there are no delays in the process.

The design team work in offices adjacent to the manufacturing plant, so as soon as a design is approved it can be passed

straight to manufacturing for the joint to be produced.

When the joint is finished, Rotaflow’s in house test facilities are used to pressure test it is located at Rotaflow HQ, so the process from start to finish is seamless. There are no lost time delays when joints have to be sent off site to be tested. It’s a major reason than Rotaflow are able to deliver joints with a much shorter lead time than many other engineering firms.

THERE WERE LESSONS LEARNED FROM THE PROJECT…

We like to champion domestic engineering and this project is an example of why it usually makes more sense to shop domestically. This may be an extreme example, but the advantages of using UK based engineering companies include…

• No language barrier – clear communication is vital • No currency fluctuations – agreed prices are set • No time delays – domestically manufactured parts are delivered quickly • No working hours differential – we all work in the same time zone • No export or import issues – delays or taxes at customs

INTEGRATION IS KEY TO SPEED

Integrated engineering solutions once again have come to the forefront. Rotaflow’s ability to design, manufacture, test, paint and ship from the one location means we can cut lead

times down compared to most companies.

This way of working comes into its own when a project requires such a short lead time.

KEEP SUPPLY CHAINS SHORT

Rotaflow operate with a short supply chain – having materials stockpiled means that as soon as a design is approved, manufacturing can get on with producing the swivel joint quickly, without having to wait for materials to be delivered, inspected and checked. If the wrong or poor quality materials are delivered from suppliers, there are more delays that could have been avoided.

USE SPECIALISTS FOR SPECIALIST JOBS

Rotaflow make swivel joints all day, every day. The design team have designed thousands of joints for all kinds of different uses. This experience means they can preempt and avoid potential problems with design because they’ve done it so many times before, cutting down time spent designing a joint.

Manufacturing at Rotaflow is world class – with thousands of swivel joints made, the process and eye for detail needs no training.

The parts are made quickly, accurately and nothing leaves the plant until it has been tested and inspected. Having been through the process so many times, it runs like clockwork. This experience saves a lot of wasted time.

PARTS DELIVERED, PROJECT SAVED

It certainly wasn’t an easy job, but quick and clear communication between Tyne Gangway and Rotaflow means that the swivel joint was designed, approved, manufactured, tested, shipped and installed in just under the 2 week deadline, saving the project from a certain delay which would have cost a lot of time and money.

Thanks to the success of Rotaflow’s intervention, Tyne Gangway have advised they will be looking to Rotaflow to fulfil their future swivel joint requirements. www.rotaflow.com

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PECM Issue 39

GEARS, DRIVES & MOTORS

ULTRA SLIM PERMANENT MAGNET BRAKE SG Transmission has supplied a robotics manufacturer with a new Ø56 diameter x 24.5mm Permanent Magnet Brake. The client, who has applications such as servo motors and cobots, based in Asia with locations across the world, has worked with SG Transmission for a number of years.

Adam Russell, the lead design engineer on the project said, “This is our sixth brake we have designed and manufactured for this successful blue chip electronics Company since we began working with them four years ago.”

SG Transmission customises electromagnetic clutches, brakes and magnets to meet the customer requirements.

Get in touch regarding your application with sales@ sgtransmission.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

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 39 PECM

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GEARS, DRIVES & MOTORS

STAINLESS STEEL BAUER

THE FAVOURED OPTION FOR GEARED MOTORS IN FOOD AND BEVERAGE APPLICATIONS

With lower maintenance requirements and increased durability leading to longevity of FDA conformity, stainless-steel geared motors remain the industry standard.

From conveyors to processing machines, geared motors are utilised across the food and beverage production process. While specialised coatings exist to ensure they offer the cleanly compliance required in this highly regulated industry, specifying stainless steel geared motors has become the industry standard.

Yasar YĂźce, Product Manager at Bauer Gear Motor, a premier brand of Altra Industrial Motion Corp., explores why stainless steel is often considered the best option, but also examines if this is always the case for end users?

The challenges facing motors in the food and beverage industry are many. Rigorous hygiene standards govern all equipment

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PECM Issue 39

on production lines. Washdowns with high pressure water and chemicals happen with regularity, so any device operating in these conditions must offer a high ingress protection to defend a device’s internals from damage. A high IP rating is a must.

These washdowns are employed to limit the spread of contaminates. To further limit this spread, components such as geared motors should offer a smooth design to limit opportunities for contaminates to gain a foothold. This smoothness must also be achieved with durability, as geared motors will be expected to operate to the same hygiene standards for many years without risking the quality of the food or beverages processed on the line. Corrosion poses the

same risks, so a highly resistant exterior is the minimum requirement for any geared motor.

Hygienic standards are dictated by national and federal legislation, so any coatings or materials utilised in a design must match up to these pre-existing regulations.

Organisations such as the FDA and NSF uphold these standards.

Stainless steel geared motors are often selected as they meet all application requirements without the need for further coatings. As a base material, stainless steel is inherently resistant to corrosion and chemicals, ensuring that repeated washdowns do not adversely affect the reliability or FDA compliance of the geared motor.

Stainless steel geared motors are often selected as they meet all application requirements without the need for further coatings.

A stainless steel solution will be easier to maintain than a geared motor that relies on a specialised coating for its hygiene compliance. When stainless steel is scratched, it does not compromise the corrosion or contamination resistance of the geared motor, preserving its FDA conformity. With coatings however, if the top layer is scratched or flakes, it provides an opportunity for contaminates to gain a foothold whilst losing many of its corrosion protection properties. In areas of mechanical risk, where the geared motors are likely to subject to impact damage or excessive maintenance checks, this fragility is less than ideal.

For maintenance engineers working on-site it’s important to consider that any loss of regulatory conformity in a geared motor will result in production downtime as the problem is remedied. In an industry that operates with low margins per unit, protecting uptime is vital to ensuring profitability. So, with lower maintenance requirements and increased durability leading to longevity of FDA conformity, stainless-steel geared motors remain the industry standard.

The beauty of engineering is that every application is varied, so that’s not to say that stainless steel is the optimum solution for every food and beverage production area.

In areas with no impact risk, specialised hygiene coatings can provide an alternative option to plant operators. Bauer Gear Motor recognises this and offers a range of aseptic gear motors with optimised coating systems resistant against near all common

From conveyors to processing machines, geared motors are utilised across the food and beverage production process. industrial cleaners in the range pH2 to pH12 – including an IE4 super-premium efficiency permanent magnet motor solution.

Our engineers help customers to assess their environments and provide expert guidance on what solution is most appropriate. We then work in conjunction with the customer to specify, install and maintain an optimum geared motor solution that will preserve

uptime. In our experience it’s correct that stainless steel has become the industry standard solution in the food and beverage industry – however it’s important to offer customers the solution best suited to their needs.

www.bauergears.com Issue 39 PECM

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GEARS, DRIVES & MOTORS

REPAIR PARTNERS ROTAMEC

ROTAMEC’S PREMIER CUSTOMER SERVICE ENSURES 24-HOUR MOTOR REPAIR TURNAROUND

Rotamec’s round-the-clock maintenance services are performed by qualified and experienced engineers that can handle both electrical and mechanical repairs.

Rotamec Engineering Solutions has launched its Premier Service to support businesses that rely heavily on motors, gearboxes, pumps and fans. The service agreement states that activity will commence upon the client’s instructions and continue to be worked on 24-hours a day until the job is complete.

The service has been created to support customers who can’t afford downtime and need a repair partner who cares as much about their productivity as they do.

Rotamec’s round-the-clock maintenance services are performed by qualified and experienced engineers that can handle both electrical and mechanical repairs.

Extensive expertise, on-site tooling and CNC capabilities and a large stock-holding of transmission components, electric motors and other pieces of equipment are key to achieve fast turnaround times.

Simon Brooks, Managing Director at Rotamec, explains: “Maximising uptime

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is crucial to all of our customers; but for some, every second counts. We believe that our Premier Service is the highest level of customer service possible – we literally will not rest until the work is complete.”

Repairs are conducted through three strategically-located service centres, therefore the company is able to offer the Premier Service Level Agreement nationwide. This localised support is also backed by Rotamec’s extensive network of industry-leading distribution partners across the country. For less urgent repairs, Rotamec also offers a Standard and Superior Service, which offer turnaround on repair inside 72 and 48 hours respectively.

Of course speed isn’t the only important issue to consider when choosing a repair specialist. Rotamec values reliability and durability to maximise cost-efficiency to customers. In order to deliver high-quality solutions that extend the operational

life of motors, gearboxes and drives, Rotamec’s staff always follows strict quality procedures and uses best-in-class facilities.

More precisely, workshops and machine shops are fully equipped with state-ofthe-art facilities, such as dedicated rewind areas, CNC lathes, mills and testing units. In this way, customers can benefit from a onestop-shop for diagnostics, maintenance and quality control.

Simon Brooks comments: “Customer satisfaction is at the heart of our business.

This is why we always go the extra mile to ensure that we are providing highquality repairs in a time- and cost-efficient manner. It’s in this way that we add value to different businesses that use motors, gearboxes and drives.”

www.rotamec.com

Motors | Automation | Energy | Transmission & Distribution | Coatings

WG20

GEAR UP FOR A NEW GENERATION WEG MOTOR SCAN

The monitoring solution for Industry 4.0 - for more information visit www.weg.net/wegmotorscan/en

We present the WG20 product range extension up to 18.000 Nm WG20 is the first geared motor program to be completely developed by WEG. It consists of helical, flat and bevel-helical gearboxes offering high efficiencies throughout the large gear range.

The specification and design of the robust housing is compatible with those already established on the market making the WG20 fully interchangeable with other geared motors in an existing system or production line without delays or conversions.

This flexibility makes the WG20 series of products both versatile and realiable for a wide range of applications.

Learn more about the WG20: www.weg.net/wg20

Transforming energy into solutions.

www.weg.net

HEALTH & SAFETY

COMPREHENSIVE SAFETY REMBE

EXPLOSION ISOLATION WITH Q-FLAP RX™ Explosion Isolation is absolutely necessary for a comprehensive safety concept.

Without explosion isolation, the safety concept is not just insufficient, it also represents wasted money for operators, because: Throughout the industry, vessels, silos and other parts are often connected to each other by pipelines. If a dust explosion occurs in one equipment, this also enhances the risk of flames and pressure propagation to other parts of the plant.

Pre-compression and flame jet ignition exacerbate the explosion severity in interconnected vessels. The result is a series of secondary explosions that may cause even more catastrophic damage.

An explosion isolation system prevents deflagrations from propagating and thus minimises the effects of an explosion.

Adjoining plant components are optimally protected. A distinction is made between active and passive systems: Passive isolation systems such as explosion isolation flap valves make use of the overpressure of the explosion for their operating principle:

PASSIVE EXPLOSION ISOLATION - THIS IS HOW IT WORKS Passive explosion isolation systems respond purely mechanically to the propagation of pressure through its constructive design.

Under normal operation, an explosion valve in a pipeline is kept open by the available flow. When an explosion occurs, the valve is closed by the spreading of the pressure front, thus effectively preventing the pressure and the flames from propagating any further.

ONE FUNCTION, DIFFERENT REQUIREMENTS Even if the function of an explosion isolation flap valve is size-independent, the requirements for a wide variety of processes and industries vary greatly.

While in the pharmaceutical and chemical industries in particular explosion isolation flap valves are typically only installed in nominal pipe sizes up to DN 400, especially on decentralised aspiration systems of the food industry, for example, larger nominal

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pipe sizes between DN 450 and DN 710 for central dust extractors can quickly become necessary. In the grain, wood and heavy industry, nominal pipe sizes from DN 800 to DN 1250 are mainly applied.

OPTIMUM FULFILMENT OF REQUIREMENTS INSTEAD OF ONE-FOR-ALL The standard EN 16447 defines the general requirements for explosion isolation flap valves. Like any standard, it can only provide general recommendations and specifications, but cannot address every application in detail.

Obviously, however, an explosion isolation flap valve DN 250 used in the chemical industry must meet different requirements than its DN 1250 counterpart installed in a grain or wood processing plant.

While the first application above all requires a high-quality design, the operators of grain mills or particleboard plants with their characteristic large pipe diameters want safety devices that are as easy to handle as possible.

The Q-Flap RX™ explosion isolation flap valve, a joint development of the explosion safety specialists REMBE (Germany) and RICO (Switzerland), offers three different design versions. Developed on the basis of many decades of experience the two companies have accrued with regard to the different customer requirements, the nominal pipe sizes from DN 140 to DN 710 feature an inspection flap, the largest nominal pipe sizes (up to DN 1250), on the other hand, have a modular design so that maintenance and servicing can be carried out easily and thoroughly.

Through the swing ´n slide closing principle integrated into the nominal pipe sizes up to DN 710, the valve blade not only rotates into the closed position, but also slides horizontally into the closed position at the same time. This ensures an even more reliable sealing of the entire cross-section.

In addition to the features mentioned above, the Q-Flap RX™ enables high KSt values, flexible installation distances and maximum strengths. www.rembe.de

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

An extensive range of explosion protection equipment.

From supply to full turn-key solutions Visit our new website

Flash 2 Explosion Suppression System The latest version of the industry leading StuvEx Flash suppression system has many advanced features.

* www.stuvexuk.com * Earthing Control

There are two Earthing Monitors within the StuvEx range for Gas and Dust applications.

Gas Version

· Single and multipoint injection suppressors capable of

· · · .

handling 4 ducts from one suppression bottle New Master Control Unit can handle up to 16 Zones.

A range of explosion detectors for various applications.

New Gas Generator - no pressure vessels used.

Atex Certified.

Explosion Isolation Isolating an explosion is vital. There are five different explosion isolation devices in the StuvEx range.

· NOREX valve. Designed for filter inlet ducts, though can be

used elsewhere. · Ventex Valve. For installation to a filter air intake. · Fast Shutting Gate Valve. The most efficient way to isolate an explosion. · Diverter Valve. Used to divert a potential ignition source to a safe area. · Fire Trap Valve. Protects ‘Down-Stream’ machinery in the event of a fire or vexplosion.

· Competitively priced. · Very easy to install. · Failsafe operation – visual confirmation of correct earthing through green/red lights. · Automatically recognises the object to be earthed. · Atex Certified.

Explosion Venting StuvEx supplies a range of explosion venting devices.

· StuvEx Explosion Vent. A 100% efficient vent for silos, bins, filters etc. · StuvEx DQS. A maintenance free, flameless vent for installation to an internally located vessel. · StuvEx Flameless Indoor Vent. Allows an explosion to safely occur inside a building.

StuvEx Safety Systems Ltd, Abbey Studio, Church Walk, Chertsey, Surrey, KT16 8RE - United Kingdom Tel: +44 (0)1932 571303 - Fax +44 (0)1932 570548

Email: info@stuvex.com - www.stuvexuk.com

HYDRAULICS & PNEUMATICS PARO SOFTWARE

Instant tube connection with the Fluidfit range CERTIFICATIONS AND CONFORMITY

HydroSym will enable you to quickly and easily design a wide range of hydraulic systems, from a small power unit to a large hydraulic installation. Get started from just €39 per month.

This includes smart connecting lines with information flow, automatic jumpers, easy positioning of items between the connecting lines, the straightforward changing of solenoid properties, automatically generate Bill of

Materials, and much more. Get your free one month trial: www. paro-nl.com ​ PARO offers the complete hydraulic software package for design and production of hydraulic manifolds with HydroMan 3D design and with HydroCAM automatically program your CNC machine.

PARO Software B.V. www.paro-nl.com

FEATURES ■

■

■

Easy action allows fast connection Made from NSF and ACS approved non-toxic materials Plastic, soft metal and hard metal tube types

The CDC Fluidfit one touch push-in configuration allows instant tubing connection. Smaller fittings feature wider working pressure and temperature ranges for maximum versatility. The CDC Fluidfit range is reliable and adaptable for various uses with air pressure piping.

FLUID TYPES ■ ■

Water Beverages

Sales: 01772 255109 | Online: tom-parker.co.uk Request a catalogue: marketing@tom-parker.co.uk Issue 39 PECM

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MACHINING & MACHINERY

CAPABILITY AND CAPACITY BARNSHAW

IS YOUR METAL SUPPLIER FUTURE-FIT FOR THE AGRICULTURAL INDUSTRY? To satisfy demand for higher productivity and yields, agricultural equipment is becoming more advanced and complex. This extra demand placed on original equipment manufacturers (OEMs) translates directly to the supply chain, especially those providing structural and functional metal components.

Curved metal plate, section and tube is one category where a greater awareness of what advanced suppliers now provide can make a difference.

Stuart Anderson, Sales Manager at Barnshaws Section Benders, regarded as one of the world’s most capable metal bending companies, explains why capability and capacity is the new king in future-proofing the metal supply chain.

One of the most important aspects of a reliable, lean supply chain is its flexibility i.e. its ability to respond to spikes or falls in demand. While this is important for many suppliers to the agricultural industry, when it comes to commodities such as metal components, it is even more so.

Even for a specialist service, such as metal bending, continual investment by the supplier is incredibly important. Press braked steel, for example, is often used to manufacture the chassis for powered agricultural equipment. Barnshaws offers the capability to form sheet metal at 12 metres long using multiple press machines up to 1000 tonnes.

Chutes, pipes, arms and chassis members on towed equipment can all be formed from tube that has undergone mandrel or

Chutes, pipes, arms and chassis members on towed equipment can all be formed from tube that has undergone induction bending to improve the shape or performance.

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To ensure the flexibility needed to meet the demands of future production operations, suppliers of metal fabrications need to be investing in both capacity and personnel.

(Source: Istock Copyright: GordanD ID: 174243147) induction bending to improve the shape or performance. By investing in more of these bending machines, suppliers can again grow with the increased demands of the OEMs. For example, Barnshaws has invested in the capability to precision curve pipes up to 32� in diameter, which is much larger than anything currently seen in the agricultural sector.

A knock-on effect of this improved capacity is increased speed of delivery. With a capable supplier, not only is machine capacity soaking up fluctuations in the supply chain, it also means reduced lead times. More machines in-house translate to increased fabrication speed, which provides a fast supply response and is extremely important in meeting the requirements of just in time (JIT) manufacturing. When combined with a metal bending process that already saves time when compared to welding, this reduced lead time is compounded.

A wider view The production volumes of agricultural vehicles and equipment pale in comparison to the volumes associated with passenger vehicles for example, however, as demand for food rises, so naturally will the amount

of powered and towed equipment being produced by the OEMs. To be successful with any large-scale machinery production activity, it must be supported by a lean, efficient supply chain, providing innovative materials that allow design developments to be realised.

To ensure the flexibility needed to meet the demands of future production operations, suppliers of metal fabrications need to be investing in both capacity and personnel.

When it comes to selecting suppliers for metal fabrications as an OEM, choosing a business that continues to invest in its machine capacity ensures that growth in demand can be adequately met. This can provide the extra security required to grow production activities, while avoiding any potential bottlenecks and risks to production uptime.

Barnshaws Steel Bending Group : Matthew Pritchard Tel: 0121 557 8261 Web: www.barnshaws.com Email: matthew.pritchard@ barnshaws.com

MACHINING & MACHINERY

CNC ROUTERS & LASER CUTTERS Now with Touch Screen Control

CNC Routers

• Affordable, high quality build • Over 25 years experience in supply and installation of CNC Routers • Excellent technical support and back up

CNC Laser Cutters • Models for both metalic and non-metalic materials • 150w laser tubes

ATACAM ALM1390 ATACAM AL1390 Call for more information or a demonstration, or visit www.atacam.co.uk ATA Engineering Processes Ltd ATA House, Unit B, Boundary Way, Hemel Hempstead, Herts, HP2 7SS t: 01442 264411 e: sales@ataeng.com www.ataeng.com

Leading pressure vessel manufacturer gains from Westermans International service “Our work with Westermans International enables us to integrate new technology into the manufacture of our full range of pressure vessels in a very cost effective way – enhancing the performance and value of our service to customers.” Henry Price, Managing Director of Nottinghamshire-based Abbott & Co. (Newark) Ltd., is clear about the value of the refurbished welding and machining equipment available from Westermans International. Abbott & Co has worked closely with Westermans International since the Leicester-based company started offering refurbished equipment in the early 1960’s. Throughout this time, the organisation has grown its range of pressure vessels – including air receivers and surge vessels alongside other equipment such as heat exchangers.

Full details of Westermans International’s services can be found at www.westermans.com

Hallamshire Engineering Services Hallamshire Engineering Services is a leading manufacturer of materials handling equipment, such as pulleys, rollers and conveyors for industries that include mining, quarrying, agriculture and recycling.

PUWER inspections by machinery safety experts

Roltech Mechanical chose to work with Hallamshire Engineering Services as it was looking for a company that could provide high service levels and technical expertise in conveying systems.

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.

Hallamshire Engineering Services is part of Group Rhodes, one of the largest Original Equipment Manufacturers in its field.

If requested, advice and support can be provided to help make machines PUWERcompliant. www.machinesafety/puwer

The company goes from strength to strength and has recently won a major contract to supply pulleys for conveyors to Roltech Mechanical Ltd as part of a new 2000 TPH ballast washing system for a major UK quarrying company.

www.grouprhodes.co.uk Tel: 0 (44) 1924 37 11 61 Issue 39 PECM

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MORE THAN 75 YEARS COBORN ENGINEERING

A SUCCESS STORY IN PRECISION ENGINEERING Established in 1941 by Sam Innocent, Coborn Engineering initially manufactured high precision spindles and balancing systems and its name rapidly became associated with the diamond industry. Coborn’s expertise in spindle design and dynamic balancing is still of upmost importance in scaife benches for polishing high value gem diamonds and this remains one of the company’s core strengths. However, meeting the specific customer needs of the ever-growing industrial diamond market has become the greatest factor in the continuing success of the company.

guarantee performance and keep production targets.

Above, PG4. Below, RG9AR

“Coborn is the only global company that is totally focused on grinding and polishing all types of diamonds. Coborn is a vital part of the diamond industry’s value chain.

The partnership with relayr is a unique opportunity to provide engineered solutions, both technical and commercial, to support the continued growth of the industry by predictive maintenance, controlled machine downtime and ultimately, process optimisation. It will enable our customers to realise the full potential value from our machines,” explains Steve Westlake, Managing Director of Coborn.

Coborn has a unique, global position supplying specialised, high-precision equipment to the polycrystalline diamond industry and the gemstone and natural diamond tooling industries, with over 90% of machines being exported throughout the world. Coborn constantly strives to improve its range of products, services and solutions which is one of the many reasons the company is globally recognised as a provider of precision engineering excellence.

Today Coborn offers a wide range of machines and accessories for all facets of the diamond industry including the latest-generation PG4 and RG9A grinding machines with full CNC control which are used extensively in the production of diamond cutting tools to meet the specific demands of modern machine shops/ manufacturers. Optional extras are available for Coborn’s machines providing a tailormade solution for the specific requirements of each customer.

COBORN CUSTOMER CARE Customer care is paramount to Coborn’s company ethos and working closely with its customers and building long-term relationships contribute greatly to the ability to offer bespoke engineered solutions, product development and performance enhancement. Coborn uses the latest machine tool technology, combining in-house hardware and software design with the best equipment available from around the world. The experience gained from producing machines for over 75 years, puts Coborn in an excellent position to advise and assist its customers with the subtleties of Polycrystalline Diamond (PCD)/ Polycrystalline Cubic Boron Nitride (PcBN) and Single Crystal Diamond (SCD) tooling

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Partnering with relayr will enable Coborn to deliver Industry 4.0 business solutions to its customers through a unique blend of technology, finance and insurance offerings.

This unrivalled approach will provide a distinct level of customised customer support and services whilst guaranteeing the uptime of Coborn Intelligent Machines.

In turn, Coborn customers will be able to increase their productivity and receive the exact services they need.

RG9A MULTI-FUNCTIONAL CAPABILITIES

where machine set-up and preparation are critical in the production of complex tool geometries.

PARTNERSHIP - INNOVATING THE DIAMOND INDUSTRY As testament to Coborn’s commitment to its customers and the development of the diamond industry, the company has entered into a long-term partnership with relayr, a specialist in industrial solutions in the field of Internet of Things (IoT). The purpose of this long-term partnership is to develop Coborn diamond grinding machines into smart equipment by introducing digital services in Coborn products. Thanks to anomaly detection through relayr’s AI-based analytics, data collected from these machines will allow Coborn to deliver pre-emptive service to each customer, enabling Coborn to offer machines with improved diagnostics to

The RG9A is a fully automatic, high precision grinding machine designed to meet the sophisticated demands of toolmakers working with both hard and ultra-hard materials, such as PCD, PcBN, carbides and ceramics. From simple, single point shank tools to helical/radius multipoint rotary tools, the RG9A has all the characteristics, functions and capabilities needed to minimize tool production costs.

The RG9A is ideal for tool manufacturers making both small and large batch sizes.

Individual tool set up times are quick and the machine is supplied “robot ready” and the optional Stäubli 6 axis robot can be added to the machine to facilitate fully autonomous “lights out” production of tools.

The RG9A’s construction ensures fast grinding times and repeatable accuracy to 2µm tolerances and the Coborn designed and manufactured wheel spindle is dynamically balanced to ensure minimal edge chipping of brittle and delicate tool materials.

Programming is rapid, menu driven and straightforward for the operator and the ultra-fast vision system, with closed loop feedback, ensures minimum cycle times and maximum rates of throughput.

The PG4 uses high quality air bearings for both wheel spindle and the pivot which are essential pre-requisites for controlled and low waviness SCD tools. Programming is extremely simple and minimal

The Coborn RG9A Laser Measuring System is an optional extra which can be purchased at point of sale or as an add-on, retro-fit kit at a later date. This sophisticated laser-beam measuring system can be used to accurately reposition the RM Rotary axis, in order to eliminate loading and brazing errors giving you the exact geometry you want. The laser uses a triangulation system with aid from the camera to measure the beam’s position and alter the machine’s axis positions giving a high degree of accuracy and precision, significantly improving grinding results.

training is required. It is an ideal machine for SCD tool manufacturers who are looking to minimise production costs and use their skilled operators in more demanding areas.

PG4 ULTRA-HIGH PRECISION SCD GRINDING The PG4 is an automatic, ultra-high precision grinding machine designed to meet the most advanced requirements of toolmakers working with natural or synthetic single crystal diamond (SCD), manufactured by either high pressure high temperature (HPHT) or chemical vapour deposition (CVD). The machine enables many of the laborious and time consuming processes, such as blocking out, to be fully automated and the subsequent final radius polishing to be completed without human intervention.

GLOBAL PARTNERS Coborn works closely with its international network of partners and agents to provide the best engineered solutions for the global diamond industry. In Germany, Austria, Czech Republic, Slovenia, Croatia and France, TECNO.team is the long-term partner.

TECNO.team is recognised as a specialist in complete solutions for high-precision cutting and grinding machines and also offers service solutions from its headquarters in Stuttgart. For the past 30 years, Chase Diamond Tools International, based in Corby, England has been one of Coborn’s most valued partners in the SCD tooling market.

The partnership with Fuel Instruments & Engineers (FIE), India, is another example of Coborn enabling growth by partnership. FIE will manufacture Coborn Scaife Spindles for gem polishing to Coborn quality standards for sale on the Indian market. This market is the largest in the world for polishing gems.

FIE has already successfully manufactured the first batch of Coborn Scaife Spindles and Coborn India will also be established, which

will enable local service and support for company sales in India.

COBORN SUPPORT/SERVICE Coborn machines are designed to be future proofed, so that the option to upgrade existing equipment to the latest technology is ongoing and at the forefront of its development.

Coborn Customer Support provides a wide array of support services and the service team guarantees customer service worldwide. The Coborn engineers are able to complete diagnoses online, thereby solving problems quickly and giving considerable peace of mind. Spare parts can be supplied quickly and will continue to be available and training programmes are offered to ensure the products Coborn supplies are used to their full potential.

ENGINEERED SOLUTIONS TO THE DIAMOND INDUSTRY Coborn continues to work closely with its global customer base and with industry partners and academic partners to ensure that the necessary machine developments and innovations are being addressed.

Coborn’s aim is to provide ‘Engineered Solutions to the Diamond Industry’.

coborn.com Issue 39 PECM

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MACHINING & MACHINERY

SPECIALISTS IN TOOLS & GAUGES WISEMAN THREADING TOOLS LTD

WISEMAN THREADING TOOLS LTD SPECIALISTS IN TOOLS & GAUGES FOR SCREW THREADS We have been supplying threading tools and gauges since 1987.

Together with supplying plain plug and ring gauges this is all that we do, we therefore consider ourselves to be specialists in this field.

We supply worldwide.

We hold extensive ready stocks that include all of the standard stuff that others offer, but also includes taps, dies, die nuts, die head chasers, thread rolls and gauging for threads not normally available 'off the shelf '.

Our real time stocks can be checked and purchased online at www.threadtools. com Just enter the thread details into the search box on the home page.

You will be directed to the item, if stocked, or to our specials, (custom manufacture), sales team. who will quote to supply at competitive rates, in good time.

As an account holder you can also order online from our listed in stock items, at your normal terms. We realise that you need the right item at the right price and quality, and in a reasonable time frame.

We are geared to provide that.

We can ship stocked items same day.

Our experienced sales staff can assist and advise you on any technical issues.

We welcome enquiries from resellers and can offer terms to suit.

WISEMAN THREADING TOOLS LTD

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

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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 All types; Spiral flute and point, Fluteless, Left Hand, etc, etc.

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

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

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

Custom manufacture our speciality!

MACHINING & MACHINERY

MOLDMAKING UNISIG

MULTITASKING MACHINING CENTERS DOUBLE THROUGHPUT, CUT COSTS Concours Mold Inc. (Lakeshore, Ontario, Canada) makes it a priority to keep its machinery and equipment up to date to ensure competitiveness. From its enterprise resource planning (ERP) system and advanced scheduling system, to its radio frequency identification (RFID) tool management system, to rigorous qualitycheck procedures, not to mention five-axis machining centers, the company does whatever it can to continually improve its processes. In fact, the company recently invested millions of dollars in new equipment, but one machine, the UNISIG USC-M, has so improved Concours’ machining processes that, according to Ed Ergun, corporate sales manager, it has been a game changer.

CONCOURS MOLD INC. Problem: The efficiencies in standard machining processes at Canada facility due to multiple setups required on each of two machines (boring mills and gundrills) necessitated more outsourcing of work to keep up with deliveries.

Solution: Addition of a UNISIG USC-M50 and two UNISIG USC-M38 multitasking machining centers.

Results: Significant reduction in setups, virtually eliminating down time between setups. Faster machining, better accuracy and fewer mistakes reduced lead times, allowed first-time quality and enabled more time to handle more work coming through the machines.

Concours specializes in building small to very large injection, compression and hydroforming molds as a primarily TierOne supplier to the automotive industry and has additional locations in Cullman, Alabama, and Puebla, Mexico. All locations run 24/7. Molds built for interior automotive parts produce instrument panels, door assemblies, A, B, C and D pillars/assemblies and much more, while molds for exterior parts produce such items as fascias, grilles, spoilers and rockers. The balance of the company’s business encompasses building molds for heavy-truck parts and consumer products.

Still, it is the automotive OEMs that dominate Concours’ customer list and, as

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Increase your mold manufacturing versatility using the power of gundrilling with the leaders in deep hole drilling, UNISIG. Offering complete solutions for everything from simple to complex mold components, UNISIG machines help moldmakers improve efficiency, throughput and precision with outstanding part-processing versatility at an exceptional value. anyone who has experience with serving Ergun says. “The USC-M Series machine is TAKEindustry YOUR MOLDMAKING much a multitasker and has reduced the automotive knows, high quality veryOPERATIONS our lead times by roughly 30 percent.” is expected, and mold deliveries are tight.

FURTHER WITHsaid UNISIG “As our company announcement when TODAY. we launched our third UNISIG USC-M in IT’S ABOUT REDUCING COSTS February 2018, the USC-M series brings Concours regards the time spent setting unmatched capabilities in a single, gameup jobs as throw-away costs. “There are so changing machine,” Ergun says. “This is our Find out more at www.UNISIG.com many setups involved on just a boring mill tomorrow.” alone, it adds up to costs that we have to absorb, plus a crane and any employees IT’S ABOUT THROUGHPUT required to work on it,” Ergun says. For GAINED example, to set up a block in the boring mill, he says it would take half an hour to an Boring Mill. Gundrill. Before purchasing its hour, depending on the setup, to bore/drill third UNISIG in February 2018, Concours five holes, then lay it down and set it up to utilized these machines every day, complete another series of holes and so on. repeatedly, during the mold building process. “Anything that came into our OUR SETUP TIME HAS facility basically hit these machines at one DECREASED BY MORE THAN 50 time or another,” Ergun says. He adds that PERCENT. each machine would need to be reserved in the schedule as needed to complete that “Now we have the five-axis positioning portion of the build, to keep blocks and components moving and on schedule. If any capability of the Unisigs and FCS clamping systems along with automatic pallet issues arose that prevented movement of changers on each machine, which is a the workpiece, then the scheduling would 100 percent time-saver when it comes to be off, and machining delayed till the next switching a tool from one setup to the next,” available slot opened up. It was a constant Ergun says. struggle to update and revise the schedule to remain current.

THIS IS OUR TOMORROW. “Now, instead of reserving a boring mill for three days, and then the gundrill another three days, we can take care of all the boring and high-speed gundrilling on the UNISIG,”

Further information on all machines of the B series and the complete UNISIG machine program is available at: www.unisig.com or follow the company on LinkedIn and Twitter (@ UNISIG).

UNISIG.COM

UNISIG TAKES YOUR GUNDRILLING PRODUCTION FURTHER

Gundrilling and BTA deep hole drilling for highly productive shops.

Whether your shop needs on-center or off-center holes, specialized job shop work or fully automated production, UNISIG has a deep hole drilling solution with the accuracy and performance you need.

Take your shop’s production further - learn more at UNISIG.COM.

The world of metalworking - UNISIG Hall 15 D34 UNISIG machines, engineered and manufactured in the USA

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TEMPERATURE SENSORS LABFACILITY

TEMPERATURE AND PROCESS TECHNOLOGY

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.

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.

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.

IR INFRARED THERMOMETERS

STAINLESS STEEL BOURDON TUBE PRESSURE GAUGE

Stainless Steel pressure gauges with a large range of pressure ranges to suit your required application. Standard bourdon tubed, glycerine filled and low-pressure industrial capsule versions available.

Commonly used for chemical, petrochemical, power stations, mining, off-shore, environmental technology, machine building and plant construction.

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Infrared thermometers are used for measuring the temperature of the object’s surface, which is applicable for various hot, hazardous or hardto-touch objects without contact safely and quickly.

THERMOCOUPLE CABLE / WIRE

We offer a wide range of thermocouple, PRT and extension cable / wire in stock for immediate despatch. Thermocouple cables are available in IEC or ANSI Colour codes.

Insulation types include PFA, PTFE, PVC & Fiberglass.

CUSTOM BUILT SENSORS & GAUGE CONFIGURATORS

Labfacility are specialists in the design and manufacture of custom-built temperature sensors. Just fill in one of our custom build configurators and you will be contacted by a member of our experienced sales team with a quote.

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

In addition to stocked items, 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 For all other sales enquiries please contact us as follows: Email: sales@labfacility.com Tel: +44 (0) 1243 871280

PRODUCT SHOWCASE – ON THE SHELF Stock items available immediately

Tempmaster PRO Precision Thermometer The Tempmaster PRO from Labfacility provides very high precision temperature measurement with Pt100 sensors. www.labfacility.com

L300 8 Zone Temperature Alarm / Controller with Pt or TC inputs The Labfacility L300 Pt100 and TC temperature alarm / on-off controller can be used in conjunction with a PC to provide accurate monitoring and alarm or on-off control of up to 8- zones simultaneously www.labfacility.com

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. www.labfacility.com

Labcal PRO Precision Thermometer The Labcal PRO from Labfacility is fully characterised for Pt100 sensors and all major thermocouples. www.labfacility.com

Bognor Regis 01243 871280 | Sheffield 01909 569446 sales@labfacility.com

www.labfacility.com

MEASUREMENT & MONITORING

WHAT IS PLUG & INSPECT™?

INSPEKTO

THE TECHNOLOGY THAT PROMISES TO MAKE SYSTEMS INTEGRATORS OBSOLETE Traditionally, machine vision solutions are developed and installed by a systems integrator, a professional who researches the specific Quality Assurance (QA) needs of a production line and designs a tailored solution. This process is expensive and timeconsuming, but the advent of Autonomous Machine Vision is revolutionising the scene, making huge investments and long downtime a thing of the past. Here Yonatan Hyatt, CTO of Autonomous Machine Vision expert Inspekto, introduces the technology that makes it possible.

In the cinematic classic Modern Times Charlie Chaplin interprets Charlot, a distressed factory worker whose only task is tightening bolts at an ever-increasing pace on an assembly line. Driven insane by this tedious and alienating job, he is eventually sent to a hospital to recover from a serious nervous breakdown.

Machine vision solutions were initially developed to liberate QA managers from the most Chaplin-like aspects of their jobs, monotonous and repetitive tasks that did not actively add value to the production line. Unfortunately, these traditional machine vision solutions come with many disadvantages: they have to be designed and installed by an external integrator, are expensive, and take a long time to create.

Luckily, Autonomous Machine Vision (AMV) offers a revolutionary approach to QA, allowing manufacturers to have access to less expensive and user-friendly technology that does not require the intervention of any external expert.

THE NEW ALTERNATIVE

The technology that makes it possible is Plug & Inspect™, which has been developed by Inspekto, a German industrial company with Israeli DNA. It combines computer vision, deep learning and realtime software optimization technologies for a ground-breaking QA experience.

Its operating principle is simple: given a sample of good products—20 to 30, depending on their complexity—the system will learn the characteristics of a perfect item and signal any abnormality.

The system takes into consideration different positioning of the item, light changes and other environmental variables and is able to discern between them and actual defects. Furthermore, the system keeps learning and improving itself: if it flags a product as defective but an operator deems it as good, the same variation will not be considered again in the future.

Unlike traditional machine vision solutions, Plug & Inspect™ powered systems don’t need to learn how to recognize a faulty part. This is usually a time-consuming process that requires a certain number of items with various abnormalities, which the manufacturer may not have. On the contrary, Plug & Inspect™ learns based on good products.

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SIMPLER, INEXPENSIVE, FASTER

Plug & Inspect™ can be installed in 30 to 45 minutes, more than 1000 times faster than traditional machine vision solutions, whose design and installation usually takes from six weeks to a year. Moreover, any employer on the plant can easily set up and run the system independently, without the help of any external expert.

The technology is self-handling and selfadapting, meaning that the manager can decide to move it to other areas of the production line at any time, and thanks to its deep learning capabilities the system will adjust to suit the QA requirements of that particular junction. To top it off, the production line can keep running during set up, installation and change-over, eliminating the problem of downtime completely.

In Modern Times, Charlot prefers jail to his repetitive tasks at the factory, but thanks to this new technology, the tedious aspects of visual manual QA are indeed a thing of the past. Plug & Inspect™ combines ground breaking technology with the most userfriendly interface, to make QA managers love their jobs.

www.inspekto.com

MEASUREMENT & MONITORING

ADVANCED ELBOW SCANNER ADDED TO RENTAL FLEET

WASTEWATER METER WWM™

CHALLENGE NON-RETURN TO SEWER ALLOWANCES!

Ashtead Technology has added the Olympus FlexoFORM™ pipe elbow scanner to its rental fleet of Non Destructive Testing equipment. “This is part of a major investment in our NDT fleet,” says NDT Market Manager Steve Drake. “The FlexoFORM is an extremely important addition because it complements our other pipe inspection equipment and provides a solution for many particularly challenging applications.

accelerated corrosion (FAC), but they can be difficult to inspect because their shape changes from convex to concave, and of course pipe diameters vary widely.”

The scanner can be used with an OmniScan® MX2 or SX instrument to measure remaining wall thickness, and detect corrosion pitting and mid-wall laminations or inclusions. www.ashtead-technology.com

“Pipe elbows are susceptible to damage from issues such as flow-

The WasteWater Meter WWM from Micronics is a cost effective and reliable solution for measuring the flow in waste water pipes, to challenge non-return to sewer allowances and comply with Effluent discharge licence requirements. A unique British product that provides accurate waste water metering through non-intrusive microwave technology and measures flow in pipes containing clean or dirty water on gravity systems. No V Notch Weir required! ™

The meter has a local volumetric display and a R.A.S. (Remote Access Service) logger, which provides real-time monitoring via a mobile data network and a comprehensive web dashboard. And blocked or partially blocked pipe alarms are also available.

By measuring the input water supply and then the outflow with the WWM™ end-users can see a true reflection of the water used in their particular process, including a real outflow value for accurate billing.

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.

The WWM™ is CE Approved with MCERTS and suitable for a wide range of applications including: Waste water outflow, Effluent discharge licence compliance and Blue & Grey water measurement.

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.

Our purpose is to harness the Industrial Internet of Things to help power your business For further information call us on

+44 (0)1628 810456 or email sales@micronicsltd.co.uk

www.captiondata.com solutions@captiondata.com

www.micronicsflowmeters.com

1230-Micronics WasteWater Meter WWM 90 x 277mm Ad June 2018 v1.indd 1

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MEASUREMENT & MONITORING

INNOVATIVE TECHNOLOGY KEWTECH

PAT TO THE FUTURE! Kewtech are an industry leading manufacturer of electrical test equipment designed specifically for the UK. The innovative technology in Kewtech’s next generation PAT tester’s sets the bar in both speed of testing and quality of reporting.

THE IMPORTANCE OF PAT TESTING The testing of portable appliances is essential as it is the responsibility of employers and landlords to ensure the safety of their staff and occupants. More people sustain injuries through problems with faulty portable appliances every year than they do fixed installations and with insurance companies looking for any way not to pay out on claims, there is no question of the importance of PAT testing our appliances.

HOW CAN KEWTECH HELP YOUR BUSINESS? Kewtech’s new PAT system allows those testing to get through their work load faster than ever before. The simplicity of their system has prompted many facilities managers to bring their testing in house, saving businesses thousands of pounds on unnecessary PAT testing bills every year.

From electricians and PAT testing companies to charity shops, school maintenance teams and business facilities managers, Kewtech have provided the simple, cost-effective solution that works for all needs.

THE FREE KEWPAT APP KEWPAT, designed in conjunction with SimplyPats, is the most advanced PAT testing app on the market, allowing you to capture and record data, risk assessments, visual inspections and results. You can even email professional reports straight to your customer! The App also works manually with the EZYPAT, EZYPAT PLUS and SMARTPAT and is free to download on Android and iOS devices.

And there is no more need for written pass labels either! Kewtech’s portable

Bluetooth printer, the KEW80L, connects to the KEWPAT to produce professional and bespoke labels for your business in seconds.

Kewtech’s revolutionary new PAT system provides the simplest and most efficient way to test yet by combining the highest quality engineering with the latest smartphone technology. With a PAT to suit all testing needs, free data recording software, and the KEW80L Bluetooth printer, Kewtech have provided the fastest and most cost-effective system that’s simple to use and free from written data logging.

TEST SMARTER, SAVE TIME AND MONEY Kewtech’s lightweight, battery-operated range have been specifically designed to be as user friendly and efficient as possible. The range has large easy-to-read display screens, with a clear green for PASS and red for FAIL. The EZYPAT is ideal for testing in office environments, with the comprehensive EZYPAT PLUS also allowing for run tests on 110V appliances.

Kewtech’s top of the range SMARTPAT is the UK’s first Wi-Fi enabled tester to be remotely controlled from your smart phone or tablet, including automatic data logging direct to the FREE KEWPAT App! No more written or manual data collection, truly SMART!

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Kewtechcorp.com info@kewtechcorp.com 01494792212

JOIN THE SMART GENERATION

The new EZYPAT/SMARTPAT range brings you the world’s fastest PAT testing solution.

Test smarter, save time and money.

Email: info@kewtechcorp.com for latest offers and info or call: 01494 792 212.

THE KEWPAT APP. FAST. EASY. FREE! + Data Collection + Risk Assessment + Test Lead Resistance + Email / Backup Facility + Controls SMARTPAT DOWNLOAD FOR FREE TODAY!

KEWTECH - INNOVATION AND SUPPORT YOU CAN RELY ON

MEASUREMENT & MONITORING

PUMP LIFE EXPECTANCY SULZER

ENSURING FEEDWATER PUMP RELIABILITY THROUGH PROACTIVE SITE PERFORMANCE TESTING Chris Muscavage, Field Technical Service Engineer, at Sulzer, looks at the importance of pump performance testing and how it can improve plant reliability.

Fossil fuels continue to be the primary source fuel for power generation which, according to the U.S. Energy Information Administration in 2017, accounted for 62.7% of capacity with nuclear capacity accounting for an additional 20%. This equates to nearly 83% of U.S. power being wholly or partially reliant upon steam generation utilizing feedwater pumps.

Deregulation has given rise to an open market where pump “design point” and actual “operating point” may no longer be equivalent and may vary significantly. Such market-driven conditions primarily affect combined-cycle, coal, and biomass-fueled generators during Independent System Operator (ISO) dispatch control. Where is my pump operating? Which pump should take overhaul priority? These are certainly valid questions regarding asset availability, reliability and the associated financial consequences of “abnormal operation”.

Where is my pump operating?

In the following example, one boiler feedwater pump (BFP) was selected from a group of eight where proactive field performance testing was accomplished.

Performance testing was employed to provide the owner/operator with quantifiable pump condition data to aid in prioritizing unit overhaul schedules. This particular generation facility is configured with six separate combined-cycle units employing 12 feed water pumps. The example pump is one of eight axial-split, multi-stage, ring-section pumps. At the time of field performance testing, gross facility generation was limited by ISO dispatch to 60 percent of full generator / heat recovery steam generator (HRSG) load.

indicating satisfactory performance, subject pump hydraulic results show operation at 58% of BEP. This is a surprisingly common situation in the current generation market.

In addition, in cases where the pump’s NPSHr curve rises with a reduction in capacity, the NPSHa may be insufficient to overcome the on-set of cavitation. Operation at lower than recommended BEP flows can result in pump inlet flow recirculation leading to increased vibration, wear and reduction in mean-timebetween-repairs (MTBR).

[FIGURE 3]

Pump mechanical integrity is also evaluated in addition to hydraulic testing with realtime vibration data being captured and analyzed. BFP C1 vibration response showed clear indication recirculation at the suction side and BFP C2 exhibited similar response to a lesser degree. Vibration data were consistent with pump hydraulic results and leak-off rates. The facility prioritized overhaul scheduling accordingly.

Which pump should take overhaul priority?

Example 2 considers the same group of eight pumps as considered in example one. By prioritizing time-based overhaul scheduling founded on actual unit performance, the owner/operator can maximize unit reliability and availability.

Further mechanical evaluation is accomplished using infrared thermal imaging, visual inspection of pump, seals, lube oil system, coolers, baseplate, foundation, and grouting.

[FIGURE 2]

Figure 2 shows boiler feedwater pump (BFP) C1 hydraulic performance results which are indicative of degraded or less than optimal internal clearances. Note that results fall below the OEM test curve indicating unsatisfactory performance and that flow capacity is limited to 51% of BEP. Balance line leak-off rate is an excellent and well-documented indicator of internal wear.

Figure 3 graphically tabulates leak-off rates of the eight subject pumps and, as expected, the largest flow rate recorded was at BFP C1.

In taking this comprehensive approach to pump performance testing from both the hydraulic and mechanical perspectives, an experienced field engineer is able to then provide the end user with detailed analyses and recommendations relative to in-service pump performance.

Field performance testing of critical feedwater pumps provides the owner/operator with quantifiable results and recommendations for their pump(s) in service at plant generation conditions. Proactive periodic testing raises the reliability bar another notch by establishing a benchmark for comparison which removes any question of pump condition. Annual or bi-annual performance testing of a facility’s heart is highly recommended.

[FIGURE 1]

Figure 1 shows pump hydraulic performance “as found”. Note how far to the left of best efficiency point (BEP), shown in blue, test results, shown in red, fall on the original equipment manufacturer (OEM) test curve.

Critical pump operation is expected to fall within 70-120% of BEP. In this case, although test results fall directly on the test curve

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Sulzer Turbo Services Houston Inc. : Jennifer Cardillo, Marketing and Communications Manager, Americas Rotating Equipment Services Tel: +1 713 567 2706 Web: www.sulzer.com Email: jennifer.cardillo@sulzer.com

MEASUREMENT & MONITORING

IOT MADE EASY CAPTION DATA

INTRODUCING THE NANOULTRA RANGE! Our hardware products service a wide range of applications and offer you the chance to immediately access the Industrial Internet of Things to power your business.

They all seamlessly link to the CDLSmartHub™ where you can configure and manage assets, set alarms, view audit trails, integrate and export data, view trends and visualise data.

Investing in the NanoULTRA and CDLSmartHub™ gives you access to a fully integrated end-to-end IoT solution to effectively manage your assets.

The products within our range all log data and transfer it securely to our IoT asset management platform, the CDLSmartHub™, where the raw data can be turned into actionable insights, delivering you a quick return on investment Our unique position of having application specialists, hardware, software and firmware engineers in house allows us to go a step further and custom build our standard range to ensure our customers get exactly what they need.

NANOULTRA – MATRIX

NANOULTRA – SHOCK

The NanoULTRA – Matrix allows you to connect multiple wireless sensors to a single base station allowing measurement of temperature, humidity, CO2, WME and more.

The analogue input wireless sensor option allows not only connectivity to our sensors but opens up the ability to connect with 1000s of available ‘off the shelf’ sensors, which creates infinite options for accessing the Internet of Things within your sensor networks.

Managing the tracking and condition of assets on the move has never been easier.

NanoULTRA – Shock is a battery powered, web based, real time monitoring system that tells you where your shipment is whilst in transit, and what shock loadings and environmental conditions your goods are subjected to.

Previously known as the Shocktrail, this product is designed to meet our customers’ logistical tracking needs.

Our internally made, battery-powered wireless sensors incorporate state-of-the-art sensing technology to accurately measure and monitor data, before transmitting to the NanoULTRA – Matrix base station. The data is then transmitted via mobile phone networks to our secure cloud platform, the CDLSmartHub™, where raw data can be turned into actionable insights.

Previously known as the RDL//1000 and the Nano//1000, we plan to build on this product’s capability.

NANOULTRA – ATOM

NANOULTRA – VIBE NANOULTRA – EDGE Managing a network of field assets has never been easier with the NanoULTRA – Edge. It has the flexibility of up to 16 I/Os, integrated SD card and communication via mobile phone networks. Its high-resolution data transfer happens seamlessly and securely from multiple assets to our secure cloud platform, the CDLSmartHub™.

Monitoring the levels of vibration in a static environment has never been easier with the event based NanoULTRA – Vibe. It has been carefully designed to be robust for use in harsh environments such as construction sites, yet simple to use and sensitive enough to capture low frequency vibrations providing you with valuable data on events as they happen. Formerly known ad the RDL//Vibe, this unit will continue to be a leader in event-based monitoring for the construction industry.

Deploying remote environmental sensors has never been quicker and easier. The NanoULTRA - Atom is a self-contained, battery powered temperature humidity & WME data logger that seamlessly communicates its values to the CDLSmartHub™. This compact unit quickly addresses your environmental needs.

Investing in hardware from the NanoULTRA range and CDLSmartHub™, gives you access to a fully integrated end-to-end IoT solution to effectively manage your IIoT needs.

info@captiondata.com +44 (0) 1905 754078 www.captiondata.com Issue 39 PECM

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MMS® INSPECTION SERIES FISCHER INSTRUMENTATION

NACE: CORROSION COSTS $2.5 TRILLION ANNUALLY Every year, corrosion causes an economic damage of more than $ 2.5 trillion worldwide. Therefore, the prevention of corrosion, is an issue that plays an im­portant role in many areas. The new MMS® Inspection series that is optimized for corrosion protection reli­ably supports the inspector in assessing corrosion-ex­posed components and in jobs that involve checking of corrosion protection.

Corrosion is the deterioration of a metal as a result of chemical reactions between it and the surrounding en­vironment. This leads to a functional impairment of the metallic component over time. Accordingly, rust forma­tion on a railroad track is not harmful, since the function of the rail is not diminished. However, a pipe which has become leaky due to pitting corrosion is clearly defective, since the safe transport of liquids is no longer guaran­teed. The same applies to the maritime sector, where material surfaces attacked by corrosion on ship walls can quickly become a safety risk.

There are serious con­sequences caused by corrosion in engineering structures such as bridges. If the steel structure corrodes without any control, a bridge can quickly become a threat to those who move on it.

Furthermore, there are economic advantages to implementing proper corrosion prevention methods.

In order to protect metallic materials against environ­mental influences and thus corrosion, in most cases coating with suitable corrosion protection material is sufficient. The expense for this – passive – corrosion pro­tection is relatively low in relation to the costs caused by corrosion such as loss of value, downtime, dismantling, etc. For companies and institutions saving on corrosion protection, it usually becomes expensive to repair the damages afterwards. This is especially so for structures that are very difficult to access after installation, such as offshore wind turbines. Corrosion protection involves regular inspection and checks for proper functioning. This means that inspectors and service personnel need to use targeted measurements to inspect if the quality of the corrosion protection coatings still meet specified standards.

With regard to coating thickness gauges used here, both magnetic induction method and eddy-current testing have established themselves as standards worldwide.

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MMS® Inspection DPM (Dew Point Meter)

MMS® Inspection SPG (Surface Profile Gauge)

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

Magnetic induction is the method of choice The MMS series offered as a of set non-magnetic of three to enable for measur­ ing theisthickness better corrosion protection. They are the only device layersonon baseIPmaterials, themagnetic market that meet 65 protectione.g. requirements includeplastic, dust protection and water layerswhich of paint, galvanized orproof. hot-dip galvanized on offers steelone-handed and iron.operation The eddy The MMSlayers Inspection and provides immediate feedbackfor by means of light, vicur­rent method is suitable electrically bration and sound. The auto rotate function allows the non-conductive layers on non-ferrous corrosion inspector to view measurement results at all metals, such as e.g. paint, lacquer or plastic important angles. on aluminium.

Depending on the version, modern gauges such as the newly developed MMS® Inspection series from Helmut Fischer offer both measuring methods.

Helmut Fischer has made every effort to ensure the con­venience of the user. For this reason, international mea­surement standards such as SSPC PA2 (Level 1-5), IMO PSPC, ISO 19840, Australian AS 3894.3-2002 or Swedish IS 1841 60 are firmly integrated as pre-configured batches or measurement specifications via the software. The dew point measuring device MMS® Inspection DPM, which belongs to the same series, measures the dew point before the corrosion protection paint is applied. This helps to ensure that the coating is applied under proper environmental conditions. If the conditions are not suitable, premature corrosion may occur or the paint may peel off as a result of poor adhesion.

MMS® Inspection DFT (Dry Film Thickness)

Inspection SPG. This gauge measures A big advantage of the MMS® Inspection series is the according the “Peak Valley” intuitive usertointerface for allto systems.

Themethod, software guides theASTM user step step through meameeting D by 4417-B and the USindividual Navy NSI suring programs and shows him how to proceed with 009-32 standards.

The surface profile depth each measurement. Thus, the devices can be handled influences amount of paint needed. If the reliably eventhe by untrained personnel. peak to valley distance is too big, the applied Helmut Fischer has designed this series of gauges to paint may not beinspection thick enough on easthe makelayer corrosion protection considerably ier. ThisAdditionally, enables many companies the world tothe peaks. the pro­around file infuences avoid corrosion damage andon thethe resulting loss of value. adhesion of the paint surface.

The MMS series is offered as a set of three to enable better corrosion protection. They are the only device on the market that meet IP 65 protection requirements which include dust protection and water proof.

The MMS Inspection offers one-handed operation and provides immediate feedback by means of light, vi­bration and sound. The auto rotate function allows the corrosion inspector to view measurement results at all important angles.

Intuitive user interface for all systems.

The software guides the user step by step through the individual mea­suring programs and shows him how to proceed with each measurement. Thus, the devices can be handled reliably even by untrained personnel.

Helmut Fischer has designed this series of gauges to make corrosion protection inspection considerably eas­ier. This enables many companies around the world to avoid corrosion damage and the resulting loss of value. www.fischergb.co.uk

Absolutely reliable.

Even under harsh conditions.

THE NEW MMS® INSPECTION SERIES

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

MEASUREMENT & MONITORING

CHALLENGING THE STATUS QUO BELL FLOW SYSTEMS

MFGD GAS FLOW METERS MERGE CURRENT TECHNOLOGIES WITH TRADITIONAL METERING

Turbine, rotary piston and diaphragm gas flow meters have traditionally dominated the UK gas metering marketplace, however new digital technologies including Ultrasonic and Thermal Mass flow measurement are challenging this status quo.

The MFGD Thermal Mass meter manufactured by Siargo – California, is one such design and incorporates proprietary MEMS sensor intelligence powered by a replaceable three year battery, showing flow rate and total flow displayed on the integrated LCD readout.

Featuring increased accuracy and significantly lower installed pressure losses, the MFGD range offers inherent advantages over existing traditional technologies and is available exclusively in the UK via Bell Flow Systems in Buckingham.

Specially designed for natural gas metering, the MFGD is able to reduce traditional un-corrected accuracy losses caused by temperature and pressure variations as these models compensate electronically for the volumetric expansion of gas using patented, advanced MEMS technology.

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WHAT IS THERMAL MASS? In the example below, the MFGD - MEMS (CMOS) type Thermal Mass flow meter senses flow via the convective heat transfer, flow measurement principle. A micro-heater is placed in the middle of two temperature sensors symmetrically positioned at upstream and downstream points. The cavity below the micro-heater and sensors plays the role of thermal isolation as it is filled with the gas. When the flow passes through the micro-heater, heat is carried away by the flowing medium, with the temperature differences measured by the up and downstream temperature sensors being directly proportional to the mass flow of the gas being measured.

WHY THERMAL MASS? There are many advantages to this method of air flow measurement. These type of sensors feature zero moving parts in a nearly unobstructed straight through flow path, which facilitates extremely low pressure drop measurement. Maintenance costs are low and this type of meter is very sensitive at low flow rates, which allows for a high turn-down ratio whilst remaining accurate over a wide measuring range.

Insertion style models can also be used

in larger pipe sizes, with the option to install via a Hot-tap kit under full system pressure. We recommend placing thermal mass flow meters in dry gas downstream of all treatment filters to prevent sensor degradation.

The MFGD models provide a pulse output and RS232 for remote data logging capabilities and BMS integration. The large integrated data logging memory allows for easy historical download and subsequent analysis. This range is constructed of Aluminium with stainless steel options and features BSP threaded connections as standard, available in sizes DN32 to DN80 with a flow range of 0.1 to 500 Nm3/hr, ideal for light industrial gas measurement applications.

www.bellflowsystems.co.uk

SENSORS

PRECISION SENSOR MICRO-EPSILON

INLINE AND ROBOT-MOUNTED 3D INSPECTION SYSTEM ENABLES FAST, RELIABLE DEFECT DETECTION ON NON-REFLECTING SURFACES

Precision sensor manufacturer MicroEpsilon has launched a 3D non-contact surface inspection system for defect detection and for inspecting the aesthetic appearance of non-reflecting (matt, unpainted, plastic and bare metal) surfaces. The turnkey system enables fast, reliable 100% surface inspection and can be integrated directly into processing/ assembly lines or on robots.

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The new surfaceCONTROL system from Micro-Epsilon system is based on the principles of deflectometry and fringe projection, which enables even the smallest of surface defects to be recognised reliably, as well as the inspection of surface aesthetics. surfaceCONTROL complements the company’s existing reflectCONTROL 3D surface inspection system, which is already being used by automotive vehicle manufacturers worldwide including

the likes of Daimler, BMW and Honda.

Whereas reflectCONTROL is designed for the inspection of shiny, reflective, painted surfaces only, surfaceCONTROL measures against non-reflective surfaces such as matt, plastic, unpainted and bare metal surfaces, making it suitable for automotive press shop and body-in-white inspection.

However, other industries where high quality surface finish and consistency are important such as aerospace manufacturing will also benefit from the system.

surfaceCONTROL is designed for the inspection of diffuse surfaces such as metallic surfaces (e.g. uncoated, electroplated, EPD), plastic surfaces and ceramics. The sensor, which is based on the fringe projection principle, scans the surface and generates a 3D point cloud.

This point cloud is subsequently evaluated using specially developed tools in order to recognise extremely small defects and discontinuities on the surface. Sensors

with different measuring ranges, areas and resolutions are available to suit any application.

DIGITAL STONE surfaceCONTROL scans the surface of the car body components with a 3D sensor in a few seconds and offers the detection and evaluation of local defects. A digital stone, for example, is used for the analysis.

This block is moved over the 3D-data of the surface like a physical block. The length and direction of the block is adjusted according to the shape of the surface. The result is the DefectMap – a graphical representation of the defect with precise information about the height and depth. The determined values can be used for an automatic ‘OK/ NOK’ quality control decision. surfaceCONTROL comprises a 3D smart sensor and two optional software packages.

The new 3D sensor achieves significantly higher inspection speeds, together with increased measurement accuracy by using a fast projection unit and new cameras.

The modular design of surfaceCONTROL enables the system to be installed both offline (fixed mount) and as an in-process inspection (robot-mounted) system.

The technology is already being used by automotive companies to inspect internal vehicle components such as airbags, dashboard consoles and instrument panels.

The sensors are available for measurement areas of 290 x 210mm2 up to 570 x 430mm2. The sensors detect a surface within typically 0.5 seconds per measurement area. The achievable lateral resolution is between 0.25mm for small areas and 0.5mm for the largest area. This means that surface deviations from 5µm in height can be detected reliably. The depth of the measurement area of between 150mm and 300mm also enables reliable detection of zones with a strong curvature.

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By using planning software based on CAD data, larger test objects are separated into several measuring positions that are approached one after another. The system is designed in such a way that several robots can operate in one cell on the same test object in order to adapt inspection times to suit production cycle times.

dimensions are up to approx. 200mm x 300mm. The sensor system is integrated into a protective enclosure/cabinet.

The components to be inspected are introduced to manually or automatically into the system. surfaceCONTROL Compact is ideal for inline inspection of injection moulded or die cast components.

INSPECTION OF LARGE COMPONENTS

A CHALLENGE FOR MANY INDUSTRIES

Three different versions of surfaceCONTROL are available. surfaceCONTROL Robotic is for the inspection of large components. By mounting the sensor head to a robot arm, the system can be adapted very quickly to different inspection applications. All six degrees of freedom of the robot are available. Depending on the requirements, a robot with a specific radius can be selected.

If the component is also positioned on a rotary table (i.e. as the seventh axis) it can be turned towards the sensor in such a way that the projection of the robot can be reduced. With surfaceCONTROL Robotic, the complete inspection of large components using only one sensor is possible.

MOBILE INSPECTION SYSTEM

surfaceCONTROL Mobile is the ideal solution for surface inspection of components in different locations. This portable system, which comprises of a laptop and a sensor mounted on a tripod, can be safely transported to its destination in a carrying case. The standard measuring surface is approx. 410mm x 300mm.

INSPECTION OF SMALL TEST PIECES

surfaceCONTROL Compact is available for the inspection of small test pieces whose

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The perceived quality of smooth, defectfree surfaces is determined by the look and feel, colour and shape consistency of the surface. High quality finished surfaces are therefore a challenge for many industries, not just automotive. Aerospace components, domestic appliances, entertainment devices and consumer electronics also require high quality finished surfaces.

Although inspectors are able to recognise a high proportion of surface defects reliably and quickly, visual evaluation is often subjective and depends heavily on several factors, including tiredness, lack of concentration and varying light conditions.

The aim of surface inspection is to achieve an objective, reproducible evaluation of surface deviations in order to quickly and reliably make decisions with respect to component tolerances.

tests. Furthermore, flush rivet heads and the smallest possible rivet indentations in the outer skin of the aircraft are technically and aesthetically critical. In addition to versatile applications on the outer skin of an aircraft, the interior also offers a variety of potential applications including the inspection of flaps on hand luggage compartments, armrests and wall coverings.

CONSUMER ELECTRONICS

Sophisticated smartphones, tablets and notebooks not only stand out as versatile, technical equipment but also due to their high quality housings and finish. In order to reduce weight and materials, the wall thickness is often reduced to a minimum.

This could cause slight sink marks and other discontinuities on the surface, which become visible under certain lighting conditions.

DOMESTIC APPLIANCES

An increasing number of sophisticated household appliances are now designed and equipped with high quality surfaces.

For example, freestanding refrigerators are often a decorative eye-catcher in a modern kitchen. Washing machines also match modern interior designs with their flawless, attractive appearance. This is why an immaculate surface for domestic devices is becoming increasingly important.

AEROSPACE

Flawless surfaces with a uniform appearance are equally important in the aerospace industry. World-class inspection services are therefore needed, whereby small bumps and dents caused during fuselage mounting are only recognisable after the painting process and often lead to complaints during customer acceptance

For more information on the surfaceCONTROL system, please call the Micro-Epsilon sales department on 0151 355 6070 or email info@ micro-epsilon.co.uk

MEASUREMENT & MONITORING

Sensor for testing DC motors The company PCE Process Control Electronic GmbH has developed a sensor for non-contact testing of DC motors.

The residual magnetic field of the pole housing is detected and evaluated. During start-up, the direction of rotation is determined, which is difficult with DC motors without contact to the axis. The direction of rotation can depend both on the polarity of the power supply and on the stator magnetic field.

After the run-up, the idle speed is measured.

The system also checks for armature faults such as lamella closure and interruption. The results can be read out via an RS 485 interface (I/O standard). An adaptation to further interfaces is planned. www.pce-systems.com

HBM Introduces Latest Addition to CFT Piezoelectric Range For applications that require the coverage of a wide measuring range, such as presses with a large force measurement range, HBM – a market leader in the field of test and measurement – has introduced the new CFTplus force transducer, which features improved accuracy and calibration in three measuring ranges.

Designed for industrial applications, particularly within the manufacturing sector, the new CFTplus series is calibrated for the measuring ranges; 1%, 10% and 100%, and can be used immediately on installation. Featuring a high degree of rigidity and a rugged design, the latest series is particularly useful for use in adverse environments. Elimination of drift, which is often seen as a frustrating effect, is also dramatically reduced, providing the user with more accurate results.

For further information, please contact HBM on +44 (0) 1525 304980 or via email: info@uk.hbm.com or visit the HBM website at www.hbm.com

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NEWMAX PRECISION aim to stay technically ahead with the 5-Axis multi-pallet Matsuura

HBM data acquisition amplifier module operates under harsh conditions

The MX-330, 90 tool unmanned cell machining center and the hyperMILL programming cam system allows us to meet our main objectives to continuously satisfy customer requirements.

Test and measurement expert HBM has expanded its range of data acquisition modules with the SomatXR MX1609TB-R. This amplifier is part of the industry standard’s SomatXR family, and provides engineers with a reliable and flexible solution to measuring temperature, particularly in harsh operating conditions.

With 16 channels and a sample rate of up to 100 kS/s per channel, the MX1609TB-R is shock resistant with an IP54/IP67 degree of protection, which makes it ideal for use in measurement tasks within a wide range of applications, such as mobile measurement and tests with off-highway vehicles, stationary measurements, tests on infrastructures and field tests in harsh environments.

Our MD, Adrian Bundy says; “Since acquiring our Matsuura the appetite that it has for machined parts is amazing, incorporating multiple operations in one footprint making us more cost effective and saving our customers money”.

We utilize the 10-pallet system to give us flexibility and increased unmanned capacity, which allows us to give our customers the best price, delivery and quality.

If you would like to try us out, visit Newmax Precision’s web site (www.newmax.co.uk ) and upload a drawing for us to quote.

For further information, please contact HBM on +44 (0) 1525 304980 or via email: info@ uk.hbm.com or visit the HBM website at www.hbm.com

Techsil’s Form-in-Place Foam Gasket Service Expands Capacity by 25%

DIN11864 and DIN 11853 Aseptic Unions for Orbital Welding

To meet the growing demand for their contract Form-in-Place Foam Gasketing (FIPFG) service, Techsil are pleased to announce a 25% increase in production capacity. This has been achieved at the UK manufacturing site with the addition of a 4th production cell.

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.

Using an innovative single-component liquid polyurethane foam sealing system and machine technology Techsil’s bespoke FIPG contracting service is the economical and reliable solution for replacing labour intensive peel and stick gasket applications.

For further information on Techsil’s FIPG contracting service please contact our technical specialists on technical@techsil. co.uk or go to www.techsil.co.uk/resourcecentre/form-in-place-foam-gasket-service/

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

MEASUREMENT & MONITORING Improve asset reliability with an innovative all-in-one CBM Solution

...it’s in our DNA

Incorporating ADA™ Fault Diagnosis * Supported Labs only

Eliminate the need for expensive data acquisition systems and highly trained reliability engineers with a cost effective ATEX and IECEx certified condition monitoring system.

New from Niton UK

www.machinesentry.com

XL2 Plus

Verify metals more easily in the dust and wet. www.nitonuk.co.uk 01256 397860 info@nitonuk.co.uk Issue 39 PECM SepOct2018_Advert_PECM.indd 1

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NEWS & EVENTS

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 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.

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

Dublin’s New Central Plaza Conversion Uses Denso Protection The old Central Bank Building in Dame Street, Dublin, is currently being redeveloped and will reopen as the Central Plaza consisting of offices, shops and restaurants. Winn & Coales (Denso) Ltd are supplying corrosion prevention coatings for major structural sections and also an outer wrap prior to fire protection. The building was originally constructed in the 1970’s and the design was based on suspending each floor from two large concrete cores. Each floor level was then constructed at ground level and hoisted into place and then supported by Macalloy tension bars.

DBFL Consulting Engineers in discussion with Winn & Coales decided to remove the existing wrap and apply Denso Tape™ to 2500m of 40mm Macalloy bars, thus providing long term corrosion prevention. Denso Self Adhesive PVC Tape™ was then used as an outer wrap before fire protection and cladding was applied. www.denso.net

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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

DensostripTM Protection at Bridlington Omnia Bridge

Dawson Shanahan invests in new machines to meet demand

One of the earlier Omnia Bridge Deck Units in use is that forming part of the Bridlington Integrated Transport Plan. PBS Construction Ltd from Hull were awarded the contract to construct the road bridge now in use over the Gypsey Race at Beck Hill.

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.

Omnia Bridge Deck Units were used in the design of the bridge deck and Winn & Coales (Denso) Ltd supplied DensostripTM and Densostrip PrimerTM to seal between the supporting steel beams and the Omnia Bridge deck planks. Denso Primer DTM and Densopol 60TM Tape were then used to seal the joints between the precast concrete planks.

The use of these materials prevented any grout loss when the in-situ concrete was poured to form the bridge deck. www.denso.net

www.dawson-shanahan.co.uk.

NEWS & EVENTS

BIOQUELL PROTEQ BIOQUELL

BIOQUELL LAUNCHES HIGH PERFORMANCE MOBILE ROOM BIO-DECONTAMINATION SYSTEM Bioquell - a leading global expert in reducing the risk of biocontamination in the pharmaceutical, life science and healthcare markets - has launched the cost effective and high performance Bioquell ProteQ mobile room bio-decontamination system. Utilising the company’s 35% hydrogen peroxide vapour and boasting a modular, upgradeable design for a more configurable pricing structure, the Bioquell ProteQ is suited to a wide range of critical areas, including biopharmaceutical manufacturing facilities, GMP/ GLP and bio-safety laboratories, animal facilities and cleanrooms.

Developed as the next generation of the company’s previous mobile room decontamination offering, the Bioquell Z-2, the rigorously tested Bioquell ProteQ incorporates powerful distribution technology for reduced cycle times with more efficient use of Bioquell’s approved 35% hydrogen peroxide vapour and less need for additional standalone distribution fans. It offers new wireless functionality which can network multiple units, improving set up times and making it ideal for areas of any size.

For GMP applications or frequently decontaminated areas, the Bioquell ProteQ carries out an automated decontamination cycle to parameters defined during a documented gas cycle development.

For non-GMP areas and emergency deployment, an updated algorithm delivers an automated 6-log decontamination cycle based on inputted room volume and monitored environmental conditions.

The Bioquell ProteQ offers built-in aeration, but cycle times can be optimised further with optional wirelessly controlled aeration units stored directly in the system’s frame. It easily delivers decontamination of every exposed surface in a single cycle for a validated 6-log sporicidial bioburden reduction.

The Bioquell ProteQ features a mobile and compact design and provides fully automated room and zone bio-decontamination in a facility or even throughout a campus. It can be despatched quickly and completely on a single trip by one person. The system boasts a small footprint occupying less valuable storage space whilst providing robust capabilities.

Running a cycle is simple, whether timed or parametric, as the Bioquell ProteQ offers wireless networking for rapid set up, less downtime and multi-system functionality. There is no need for additional fans or standalone aeration units found in other systems as all required components are stored within its frame.

Thermal printouts and PDF cycle reports helps ensure adherence with GMP regulations. Audit trail software is available to assist in compliance with 21 CFR Part 11. For added assurance, the Bioquell ProteQ can also be integrated with Building Management Systems (BMS) to easily automate HVAC control.

The Bioquell ProteQ offers hydrogen peroxide vapour dispersal and distribution for rooms up to 250m³ per unit. However, the system’s capacity can be easily expanded to up to 400m³ or more for a single system with Bioquell validation. The built-in aeration comes as standard in every Bioquell ProteQ but optional additional aeration

and distribution units with storage space integrated in its frame provide quick setup.

The dual bottle module with RFID reading facilitates safe loading, large volume decontamination, key data collection and traceability.

It is operated via a wireless lectern with thermal printer and a colour touchscreen with pictorial interfacing. The lectern communicates wirelessly with the generator and any aeration units in the room. An easy to interpret LED light strip gives an indication of cycle progress.

Bioquell ProteQ can be upgraded with a variety of features, including process monitoring sensor package, 21 CFR Part 11 electronic compliance package including audit trail, low level hydrogen peroxide safety sensor and laser room dimension measuring device.

Guy Turner, Director Global Product Management at Bioquell comments: “We are confident that people working in small production areas or laboratories will find the Bioquell ProteQ easy to use, fast, reliable and compliant, making it the ultimate mobile room decontamination system on the market.” www.bioquell.com Issue 39 PECM

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NEWS & EVENTS

Alloy Heat Treatment Alloy Heat Treatment is the UK’s only specialist in the heat treatment of aluminium alloys.

With more than 40 years’ experience as a subcontractor, the company is focused solely on heat treating aluminium products, rather than other metals. It offers a range of treatments to change the internal properties and strengthen the aluminium product.

Dudley-based Alloy Heat Treatment works with a diverse range of customers, mainly Tier 2 and 3 companies in the aerospace and automotive industries. The company holds NADCAP, AS 9100 accreditation, and preferred supplier status to many companies such as helicopter manufacturer Leonardo. www.alloyheat.co.uk

High quality build of this rental PRS allows repeated use

The NEW ProtecWork Protective Clothing From Snickers Workwear

The pressure reducing station pictured was an exhibit on our stand at UWL recently. It attracted a huge amount of positive comments and sales enquiries, and even more so when we revealed that it is, in fact, a rental unit which has been out on site, uncovered during winter, for 8 months.

ProtecWork is a new collection of protective working clothes and accessories from Snickers Workwear, which has developed out of over 40 years leading the workwear industry - and through close consultation with users and employers in the railway and energy sectors around Europe. The market-leading riskprotection properties of the clothing are integral components of the extensive range of Base-, Mid- and Top-Layer garments for men and women that combine well with the Snickers Workwear hallmarks of best-in-class durability, comfort, ergonomics and fit. Fully accredited as appropriate to a variety of risk and weather conditions such as heat and flame, electrostatic, chemical and bad weather working environments, all the garments are manufactured from tailor-made fabrics designed to respond to the demands and risk factors of the conditions in which they’re worn.

This pays tribute to our coating and assembly regime. This particular skid will be deployed anywhere in Europe over 10 times in its life. It features our GASCAT regulators which can have integral slam shuts fitted and these, combined with our 3D design service, reduce the footprint of gas stations, making them smaller and more efficient. www.ftpipelinesystems.co.uk Tel: +44 (0)1543 416024 enquiries@ftpipelinesystems.co.uk

www.snickersworkwear.co.uk

Nelson Automotive rebrands as Avistud Global automotive stud welding leader Nelson Automotive has announced a complete rebrand of its business to customers, stakeholders and industry peers. The newly launched brand, AVISTUD, reflects the total separation of the Nelson Automotive business from the brand of its former industrial parent Nelson Stud Welding. Nelson Automotive was initially created as a standalone automotive company following the sale of Nelson Stud Welding from Doncasters to Stanley Black & Decker in April 2018.

Henning Stams, chief executive of AVISTUD, said: “The automotive industry is demanding more speed and flexibility from its manufacturing processes than ever before.

We have adapted our business to meet the automotive sector’s requirement for more lightweight, high-strength materials, electric vehicles and faster manufacturing processes.” www.avistud.com

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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

Horne Engineering

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.

The SWM1 produces temperature controlled hot water to a maximum flow rate of 50 L/ min and is unrivalled in both its safety and temperature control. Uniquely, it is both thermostatic and pressure balanced and, without cold water flow, steam cannot enter the valve, ensuring user safety. A real-time video demonstrates its remarkable performance under varying and challenging inlet conditions: goo.gl/sqp9f3

To contact Henry Howard Finance please contact 01633 415222, www. henryhowardfinance.co.uk

Instantaneous hot water - for rapid tank and vat filling or wash-down purposes across a variety of food and beverage, chemical and pharmaceutical industries can be easily and safely achieved using Horne Engineering’s Steam and Water Mixing Valve.

www.horne.co.uk

PUMPS

NEW FACILITY ERIKS UK

LEICESTER TECHNOLOGY CENTRE SET TO BOOST ERIKS’ CAPABILITIES IN FLOW CONTROL ENGINEERING ERIKS UK has opened a new facility within its Flow Control Technology Centre in Leicester, which brings together specialist knowledge and components in all aspects of industrial flow control systems under one roof. The centre employs 34 people, and comprises of a workshop for repairing, designing, and upgrading pumps and valves, as well as an ‘Automation Cell’ where ERIKS develops and builds complete flow control solutions.

The facility is staffed by engineers from a wide range of disciplines who collaborate to deliver turnkey flow control solutions such as in-line blending and formulating, automatic dosing, dilution, filling, batching, filtration and clean-in-place systems.

By basing the team at the Leicester site, every stage of the design and production process can be carried out in one place. This includes the assembly of bare shaft pumps, testing and certification of valves and actuators, and mounting whole solutions onto skids ready to integrate with whatever direct control system the end user operates.

Andy Silver, ERIKS’ Flow Control Director, says, “Developing specialist flow control and dosing systems demands specialist knowledge, a comprehensive understanding of a wide range of components and access to these parts at competitive prices. By bringing all the expertise and production capabilities together, we can deliver tailored solutions that help customers reduce production downtime, improve health and safety, and increase the reliability of their processes and assets.”

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CELEBRATING ACHIEVEMENT BPMA

EXCELLENCE REWARDED AT PUMP INDUSTRY AWARDS

The Pump Industry Awards is now recognised as one of the leading award ceremonies within the industrial arena.

Founded by the British Pump Manufacturers Association in 2000, the awards celebrate the achievements of pump companies and individuals who strive to go the extra mile.

The annual awards dinner celebrates the industry’s best and brightest with the bonus of excellent networking opportunities, fantastic hospitality and great entertainment.

awards evening was attended by some 200 pump industry professionals who in addition to enjoying the awards presentations, raised over £4000.00 for WaterAid, the BPMA’s chosen Charity, through a Raffle and impromptu Auction.

The BPMA once again partnered with leading brands in the pumps sector to bring the 2019 awards programme to market, including ABB, John Crane, Process Engineering, Siemens, SPP Pumps, Tapflo, Tomlinson Hall, WEG, Wilo, World Pumps and Xylem Water Solutions.

Speaking after the awards, Steve Schofield, Director and CEO at the BPMA commented, “We are delighted that the Pump Industry Awards are so valued by our industry, and that each year we are able to recognise and reward the excellent work that it undertakes on behalf of pump users across the world.

Honouring the people, products, projects and companies who’s engineering acumen

Held at the Heythrop Park Resort in Oxfordshire on Thursday 21st March the

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The evening encouraged a great deal of networking in a competitive but friendly atmosphere, during which the 2019 winners were revealed by celebrity compère, television and radio presenter, Penny Smith.

continues to propel the sector forward is fundamental to the ethos of the BPMA, and once again the judging panel had a really challenging task, given that all the entries were of such a high calibre. So, our sincere congratulations go to all the winners, who’s credentials really were tested against the industry’s best.”

This sentiment was echoed by Wayne Rose, who accepted the ‘Environmental Contribution of the Year’ Award on behalf of Armstrong Fluid Technology. He said, “These awards are particularly important to our industry because, focusing entirely on pump technology, they celebrate the achievements of the world’s very best fluid technology design engineers. We are extremely proud that our Tango Parallel Pumping solution has been selected to receive this award, from a shortlist of outstanding examples of new product design.”

Environmental Contribution of the Year Sponsored by: SPP Pumps Presented by: Richard Wingate, Operations Director, SPP Pumps Winner: Armstrong Fluid Technology for the Armstrong Tango Parallel Pumping Solution Manufacturer of the Year Sponsored by: Siemens Presented by: Julijana Ristov, Global Account Manager, Siemens Winner: Wilo UK Distributor of the Year Sponsored by: WEG Presented by: Patrick O’Neill, Managing Director, WEG UK Winner: Tomlinson Hall & Co Supplier of the Year Sponsored by: Xylem Water Solutions Presented by: Jason Howlett, Managing Director, Xylem Water Solutions Winner: John Crane UK Engineer of the Year Sponsored by: World Pumps Presented by: Alan Burrows, Editor, World Pumps Winner: Reuben D’Orton-Gibson, SPP Pumps

Reuben D’Orton-Gibson of SPP Pumps, who took home the coveted ‘Engineer of the Year’ Award, commented, “The 2019 Pump Industry Awards was a very enjoyable evening and a great opportunity to make and maintain connections across the industry. I was delighted to be awarded ‘Engineer of the Year’ and proud that SPP Pumps was a Finalist in the ‘Manufacturer of the Year’ category.”

Jason Howlett, Managing Director at Xylem Water Solutions UK added, “It was a pleasure to attend this year’s Pump Industry Awards, the whole team thoroughly enjoyed themselves. We were proud to support the 2019 event and delighted to take away the ‘Product of the Year’ award for our innovative Flygt Concertor.”

Sharon George of Stuart Turner Ltd, concluded, “The Pump Industry Awards provide a great platform to celebrate innovation and excellence across the industry and we were delighted to be recognised as Finalists.

The 2019 Category Winners The 2019 awards categories focused on key areas of manufacture and supply, including innovation and achievement, energy saving, engineering excellence, customer care and employee motivation.

On the night, seven companies and two individuals were awarded, as follows: Product of the Year Sponsored by: Process Engineering Presented by: Mike Turner, Commercial Director, Process Engineering Winner: Xylem Water Solutions’ Flygt Concertor XPC Project of the Year Sponsored by: Wilo Presented by: Simon Oakes, Sales Director, Water Management & Industry, Wilo UK Winner: Campion Pumps and Irish Water for the Inniscarra Dam Project

Judges Special Award Sponsored by: Tomlinson Hall & Co Presented by: Colin Simpson, Business Development Director, Tomlinson Hall & Co Winner: Siemens Lifetime Achievement Award Sponsored by: BPMA Presented by: Richard Harden, President, BPMA Winner: Tony Keville, Managing Director of Tomlinson Hall & Co

For further information about the 2019 Pump Industry Awards, and to view the photo gallery please visit the website at pumpindustryawards.com.

If you are interested in sponsoring, nominating and/or attending the 2020 event please contact Andrew Castle at andrew@touchwavemedia. co.uk.

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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 Exhibiting at Engineering Live - 19th September

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PECM Issue 39

Induction Heater Hire

Why use Induction Heating?

BETEX 24RLDi Turbo – The Portable Heater for use in workshops and on site.

Induction heating is a swift,

•

controlled and superior method of

Minimum Inside Diameter: 10 / 100mm Maximum Outside Diameter: 380mm

heating. It is a safe and

Maximum Width: 135mm

•

environmentally-friendly

Automatic Demagnetisation.

Automatic Power Reduction

alternative to traditional heating

Choice of 5 Yokes (Included)

methods such as ovens, oil baths or

•

blow torches. These methods

Maximum Bearing weight: 50Kg Maximum weight of other parts: 30Kg

cause smoke, fumes and oil waste

•

which are hazardous for personal

Suitable for Technical services / Facilities management and MRO Organisations.

health and safety.

Not just for Bearings!

Highly versatile, BETEX® induction heaters can be used in conjunction with many assemblies including gear wheels, bushes and couplings.

BETEX 40RSDm Turbo – The Mobile Heater that can tackle almost any job.

•

Using Best Practice mounting

Minimum Inside Diameter: 30 / 160mm Maximum Outside Diameter: 790mm

methods extends bearing life, whilst

Maximum Width: 315mm

balanced and consistent heating

•

prevents any damage and allows

Automatic Demagnetisation.

Automatic Power Reduction

retention of the original lubricant.

Choice of 5 Yokes

•

High levels of Energy

Maximum Bearing weight: 350Kg Maximum weight of other parts: 250Kg

Efficiency.

•

Induction heating is a far more

Suitable for all areas of Industry;

energy efficient process than the older traditional methods and all BETEX® induction heaters will deliver substantial energy savings.

The advantage of the TURBO series over the Standard series is that larger components can be heated in a relatively short time without any increase in energy consumption.

o

Steel / Paper Mills

o

Petro / Chemical

o

Gearbox Manufacturing

o

Construction & Transport

o

OEM and MRO

Hire Rates & Options

• • • •

Induction Heater Hire rates are per day / 24hrs.

Rates vary depending on Heater model and Yokes required.

Hire Periods of 5 days or more attract a 20% discount.

Customers who hire an Induction Heater for a period of 20 working days or more have the ‘Option to Purchase’ for 20% of the RRP.

Signet Industrial Distribution Ltd | Unit 3 Bullrush Business Park | Bullrush Grove | Doncaster | South Yorkshire | DN4 8SJ Tel: 0845 124 7344 | sales@signetid.co.uk | www.signetid.co.uk

PROCESS TECHNOLOGIES

LEADING CODING SOLUTIONS LINX PRINTING

LINX BUILDS NORTH AMERICAN DISTRIBUTION FOR ITS RANGE OF CODING AND MARKING PRINTERS

Coding and marking specialist Linx Printing Technologies has appointed a number of new channel partners in North America to expand support for its product portfolio.

variety of market sectors and will help deliver the support and service end-user customers demand from their coding and marking printer suppliers.

Diagraph, Linx’s long-term exclusive channel partner for Linx’s continuous ink jet products in the US and Mexico, will continue to focus on that industry leading platform, while the new partners help to expand into other product offerings and support for the US market.

“We are expanding our product range in North America and entering new markets by engaging additional channel partners to sell our Linx 10, Laser and Thermal Transfer printers,” explains Greg Treanor, Regional Sales Manager North America.

Five new distributors have been announced in the US, including Technopack Corporation, Florida, Colorado Scale Center, Colorado and Tourmaline Enterprises Inc, AWLSS Inc., and F.J. Smith Sales Co. in California.

As well as providing greater geographical coverage in this important territory, the new distributors offer expertise across a wide

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PECM Issue 39

Linx’s range of Laser and Thermal Transfer printers, along with the Linx 10 Continuous Ink Jet printer, will be available through the new distributors, meeting the demands for professional coding and marking across both low and high-volume producers.

From the Linx 10 for smaller businesses with its highly compact footprint, easy to use interface and proven technology, through to Linx’s laser coding and marking

machines delivering high print volumes and permanent traceability with no consumable costs, Linx products provide solutions for many different coding and marking requirements.

“We are committed to offering our customers the highest levels of support to ensure they can maximize the benefits of our class-leading coding solutions,” explains Greg. “We are delighted to welcome our new partners and we are sure that their experience in coding and marking and their ability to provide a fast and effective service, will mean we are ideally placed to grow Linx’s presence across North America.”

For more information on Linx’s products and services, visit www.linxglobal.com

一伀

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眀眀眀⸀昀椀氀琀攀爀猀⸀挀漀⸀甀欀

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

K

ecol ecol Pumping Pumping Systems Systems Ltd Ltd are are manufacturers manufacturers of of Air Air driven, driven, Positive Positive Displacement Displacement Piston Piston Pumps Pumps and and Priming Priming Devices Devices in in polished polished stainless stainless steel steel or or carbon carbon steel, steel, for for transferring transferring high high viscosity viscosity nonnonflowable flowable products products from from drums drums and and containers containers as as used used in in the the cosmetic, cosmetic, food, food, pharmaceutical, pharmaceutical, chemical chemical and and general general industries. industries.

Products Products in in drums drums or or similar similar sized sized vessels vessels that that normally normally need need to to be be heated heated in in order order to to reduce reduce the the viscosity viscosity -- can can be be transferred transferred cold. cold. Products Products with with aa viscosity viscosity up up to to 10,000 10,000 Poise Poise can can be be transferred transferred (cold) (cold) using using the the Kecol Kecol Maxiprime Maxiprime Pump Pump and and follower follower plate plate system system and and is is also also used used to to transfer transfer pastes pastes and and products products that that stick stick to to the the inside inside of of an an open open top top drum, drum, wiping wiping the the inside inside of of the the drum drum or or vessel, vessel, eliminateliminating ing product product waste. waste.

Kecol Kecol Air Air Powered Powered Drum Drum Pumps Pumps and and transfer transfer systems systems are are suitable suitable for for all all standard standard size size closed closed top top or or open open top top drums drums and and can can be be adapted adapted to to suit suit open open top top containers containers with with an an internal internal diameter diameter up up to to 1200mm.

1200mm.

Non Non contact contact parts parts as as well well as as concontact tact parts parts are are available available in in polished polished stainless stainless steel, steel, clamp clamp -- type type conconstruction struction is is also also available available for for hygienic hygienic applications. applications.

Typical Typical applications applications in in the the food food industry industry include include transferring transferring tomato tomato

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

puree, puree, concentrated concentrated fruit fruit juice, juice, honey, honey, fruit fruit pastes, pastes, biscuit biscuit creams, creams, jams, jams, butter, butter, margarine, margarine, sweet sweet mince mince meat, meat, sausage sausage meat meat and and meat meat pie pie fillings fillings with with cooked cooked vegetables. vegetables.

Applications Applications in in the the pharpharmaceutical maceutical and and cosmetic cosmetic industries industries include include transfertransferring ring mascara, mascara, petroleum petroleum jelly, jelly, face face creams, creams, base base creams, creams, magnesium magnesium hydroxide, hydroxide, alualuminium minium hydroxide, hydroxide, toothtoothpaste, paste, lip-gloss lip-gloss waxes waxes and and suntan suntan lotions. lotions.

Kecol’s Kecol’s articulated articulated pump pump systems systems

Kecol’s Kecol’s articulated articulated pump pump systems systems

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

Applications Applications in in the the chemical chemical and and general general industries industries include include the the transfer transfer of of paints, paints, resins, resins, adhesives, adhesives, polymers, polymers, latex, latex, high high viscosity viscosity grease, grease, mastic’s mastic’s and and inks inks –– all all pumped pumped cold cold without without pre-heating pre-heating the the products. products.

As As manufacturers, manufacturers, Kecol Kecol Pumping Pumping Systems Systems can can offer offer solutions solutions to to your your particular particular product product transfer transfer problem, problem, by by offering offering aa bespoke bespoke system system designed designed to to exceed exceed your your particular particular production production requirements requirements for for single single drum/vessel drum/vessel use use or or multi multi drum drum use. use.

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

THE HOME OF VISCOUS PUMPING SOLUTIONS

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

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

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

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

PROCESS TECHNOLOGIES

UVC STERILISATION - CLEAN, DRY & EFFECTIVE SANITISING Cutting Edge Services are proud to work in partnership with SterilAir, the world-leading manufacturer of revolutionary UVC sanitising technology for the food industry. SterilAir’s UVC sanitisers are HACCP and FDA compliant solutions, providing clean, safe, chemical-free disinfection with minimal costs and energy usage.

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 exclusive range includes evaporator disinfection systems to directly target any type of surface, air recirculation systems for rooms with low convection,

SterilAir UVC solutions are available now exclusively from Cutting Edge. www.cuttingedgeservices.co.uk 01772956249

Sepura Inside ad 132x180L_Whats Inside advert 28/03/2018 16:53 Page 1

Our expert team of specialists and field service engineers provide full installation and servicing to meet your exact requirements.

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

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PECM Issue 39

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

PROCESS TECHNOLOGIES

HILLTOP HONEY THINK AXIUM’S FILTERS ARE THE BEES KNEES

SecureChem™ SecureChem™ Level Control for chemical IBC’s Benefits

Standard Specification

Eliminates wastage, reducing OPEX.  Minimises chemical handling risks  24/7 availability  Pre-assembled & tested, quickly installed  Robust and modular

uPVC or ABS pipework  Control panel with plc

Features

Axium Process recently supplied a number of 316L stainless steel Pure-Screen filters to award winning honey producer, Hilltop Honey, who are buzzing with success, distributing their products in swarms throughout the UK’s major supermarkets, independent farm shops and delicatessens.

Founded in 2011 by young beekeeper, Scott Davies, Hilltop Honey has a passion for delivering the most exceptional tasting honey from all corners of the world. The recent implementation of Axium’s wedge wire filters is to remove hive debris, which includes wort and fragments of wax, that occur naturally during the extraction process.

WH

“Axium’s Pure-Screen Filter is ideal for viscous products and offers a large surface area that results in lower frequency cleaning“ states Hilltop Honey’s General Manager, “a Technical Sales Engineer helped us select the best option for our application from a wide range of stainless steel filters and they have proved very effective in operation.

The filter is adaptable allowing the use of interchangeable elements with different micron ratings, making it a very flexible solution for a number of operations throughout our process. The use of Axium’s filters ensures that we can effectively remove any debris whilst retaining the worldrenowned properties that naturally occurs within honey”.

Options Available  Various

Pump Types / Standby pumps  Enclosures  Other materials of construction  Frost protection   Site installation

1st alarm at low level  2nd alarm when IBC is empty  Optional automatic changeover  Pump protection  Configurable for your needs

 Duty

SecureChem ™ Auto Dosing system

We also supply bespoke systems for water & wastewater treatment.

E: sales@he-water.co.uk

Tel: +44 1403 272772

Website: www.he-water.co.uk

Head Office: H+E UK Ltd., Field Place Estate, Broadbridge Heath, Horsham RH12 3PB, UK

www.axiumprocess.com

William Hughes Group

Bespoke Springs & Wire Forms

Secondary processes and finishing

William Hughes makes everything possible We’ve been making springs and bending wire for over 200 years. Compression, tension and torsion springs - wire bending, forming and assembly - if something can be made out of wire, we’re just the people to make it.

• • • • • • • • • • • •

• • • •

In-house design Rapid prototyping Short & long runs State-of-the-art production facilities

• • • •

Nadcap accreditation UK and Bulgarian factories Bespoke labelling & packaging All automated delivery systems

Welding Painting Plastic coating Threading Pointing Nibbing Clip application Electrophoretic Paint Line Delta®-Tone Finishing Delta®-Seal Injection Overmoulding

To discuss all things wire, Call now on 01963 363 377

WILLIAM HUGHES Ltd Station Road, Stalbridge, Dorset DT10 2RZ. t: 01963 363377 f: 01963 363640 e: sales@wmhughes.co.uk w: www.wmhughes.co.uk

Issue 39 PECM

141

PRODUCT NEWS

NEW ONE TOUCH 20 BAR FITTINGS FROM CDC Fluid power specialists Tom Parker Ltd have introduced a new line to their extensive range of CDC one touch fittings: a one touch 20 bar version for high pressure applications.

Designed for use with polyurethane and nylon tube, the one touch 20 bar range features a push to connect configuration to permit instant tubing connection. A smaller body size and wider temperature range of -20ºC to 80ºC make it a versatile choice.

The main body of the PL and PT versions rotate to provide better accessibility and comprise O-ring or Teflon coated sections. The new lines include: swivel male elbow, swivel branch tee, straight union, union elbow, and union tee. Available in white with sizes ranging from 4 mm to 12 mm. CDC Pneumatics is a leading global manufacturer recognised for quality, service and value. CDC one touch 20 bar fittings are available from Tom Parker Ltd.

Visit tom-parker.co.uk

NEW UV-CURABLE EPOXIES FOR DAM & FILL APPLICATIONS IN THE INDUSTRIAL SECTORS John P Kummer, a leading supplier of high-performance speciality adhesives, is today launching new UV-curable epoxies for dam and fill processes in the UK industrial sectors.

The “dam & fill” process with two materials is mainly used in cases where a component needs to be protected with either an opticallytransparent or opaque encapsulant or if a conventional glob-top material is too viscous to flow around and underneath fine wires.

Optically transparent encapsulants usually have a low viscosity. A dam is therefore applied around the component first to prevent the potting material from flowing over the substrate.

Epo-Tek OG116-31 is a UV-curable epoxy. Due to its thixotropic1 nature it is often used as a dam.

It can be cured with UV-light in a very short time. Afterwards the encapsulant – either also a UV-cure or a thermoset material - can be applied. Whilst OG142-

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PECM Issue 39

87 is typically use for a UV fill, both products have a high glass transition temperature (Tg >100°C).

As most UV-cure epoxies, both OG116-31 and OG14287 are cationic products. Ionic polymerization is initiated by photo-generated ions. The cure process continues until all polymers are consumed. Generally, cationic products have the benefits of less shrinkage and higher adhesion over free radical cured systems and are not adversely impacted by an oxygen rich curing environment.

Rob Church of JP Kummer said: “The dam and fill process is often a tricky operation. However, these two new UV-curable epoxies make it more straight-forward, with more consistent applications. We are really pleased to make these available.”

www.jpkummer.com

PRODUCT NEWS

VISUAL VERIFICATION STAR FASTENERS

NEW INNOVATION FOR LOCKBOLTS

Star Fasteners has developed a clever colour changing indicator that visually verifies that Lockbolts have been installed correctly.

The new red coating helps to improve final product quality checks, crucially making pre-assembled, uninstalled fasteners much easier to identify. Dan Starbuck, Director at Star Fasteners explains “we were asked by a customer to remove welding from their production process in a safety critical application. We worked with them to specify in a Lockbolt pin and collar fastener. They were so pleased with the outcome as manufacture time was halved and health and safety issues associated with welding were completely removed.

There was just one concern and that was at the final quality inspection stage (PDI).

Their question of how can we tell that a Lockbolt has been installed completely needed to be addressed. To a trained eye this is simple, but the customer wanted further assurance. We developed the Lockbolt colour changing collar coating to give a clear visual warning; if the collar is red it is an instant indication that the fastener hasn’t been correctly installed or fully swaged” The Lockbolt fastener is a is a two-part fastening system that consists of a pin and collar, “Lockbolts are installed using a direct tension technique in which the pin is pulled and the collar is simultaneously

swaged into the locking grooves of the pin. The material is clamped together, which creates structure and strength.”

In most cases, Lockbolts can replace welding. They are faster, safer, more productive and an environmentally friendly alternative method of joining. Advanced, two-piece fasteners are installed using a torque-free, direct-tension, swaged-on method, providing for a reliable installation.

This method of joining ensures a consistent clamp which is the key to a strong, reliable hold – so users know that the joint is permanent and vibration-resistant.

The patent pending colour changing Lockbolt collar coating is applied by Star Fasteners. A visible change occurs when the collar is swaged, in this case from red (uninstalled) to silver (installed). The firm explains: “It’s a definite visual that the fastener has been installed correctly. The bright red colouring, which you can see when the collar has not been swaged is very easy to see. If for example a fastener has been accidentally missed in the production process, the nose assembly is damaged or is becoming worn, or a collar has only been part swaged, then the red coating can be used as a precursory visual indicator, great for quality control purposes.

Some Lockbolt collars have swage bumps or bar indicators on the flange, these are partially flattened on installation, but

cannot necessarily be easily seen from a distance or in low light. Operators and quality managers have to be fully aware of their correct installation and if necessary, carry out additional checks using a swage gauge to identify fasteners that have not been correctly installed. The advantage of Star Fasteners’ method means operators do not require that level of familiarity. All they need to know is that a red collar has not yet been installed”.

While a new development, the colour changing Lockbolt collar has proved to be popular and is already in use with a number of chassis builders. With the implications of product recalls in terms of time, monetary cost and brand reputation, this innovation appears likely to be a requirement in automotive production and safety critical applications.

In fact, potential applications for the colour changing Lockbolt collar are as varied as they are for a standard Lockbolt, including solar and wind power, agricultural and commercial vehicles and machinery, rail, bridge building, screening equipment, portable / steel framed buildings and other industrial applications.

Find out more email sales@starfasteners.co.uk or call +44(0)1159324 939 Issue 39 PECM

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PRODUCT NEWS

REFRIGERATION SOLUTIONS CARTER THERMAL INDUSTRIES GROUP LTD

PROUDLY BRITISH AND FAMILY OWNED

When it comes to energy efficient, sustainable Refrigeration solutions, the Carter Thermal Industries Group provides a wide range of services, products and systems to help your business.

Carter Refrigeration was initially established

by Mr John Carter back in November 1945, with their headquarters in Birmingham.

By 1959, Carter Thermal Industries Group was born and today, they are an industry renowned name with a number of different subsidiaries, including: Carter Retail Equipment, Cater Synergy, KB Refrigeration, Carter Environmental Engineering, CPC UK, and Franklin Hodge Industries. The group also has locations in London, Hereford, Liverpool and Glasgow.

Proudly British and family owned, the commitment of the various group companies to providing sustainable and efficient solutions is clear to all. Through a commitment to constant innovation combined with a reputation for listening to their key customers the group continues to lead in the development of highly efficient solutions.

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PECM Issue 39

One of the group subsidiaries, Carter Retail Equipment are specialists in the manufacturer of refrigerated display solutions. They have worked with clients around the globe and are consistently seen as one of the world’s leading suppliers of retail refrigeration display equipment.

From their factory in Birmingham, CRE manufacturers and supplies refrigerated display cabinets for some of the world’s largest & most prestigious retailers. Their diverse range includes Hydrocarbon, water cooled and Co2 based cabinets. Their quality and superior design have seen their cabinets installed across Europe, North America, Asia and Australia.

Their wide range of display cabinets are built to last and specially designed for impressive energy efficiencies.

Another subsidiary is Carter Synergy Ltd, which provides refrigeration, mechanical, and electrical services across a wide variety of markets in the United Kingdom.

The specialist contractor works with clients from retail, commercial, corporate and government sectors, to design, install, commission and take the lead on projects of any size. Their commitment to sustainable and energy efficient solutions has made Carter Synergy an industry leader in the sale, installation and support of a large number of Co2 based refrigeration installations. They are also well recognised for their excellent commitment to health and safety and are 8 time winners of the highly regarded ROSPA Gold award.

Among their latest ventures, Carter Thermal Industries Group and their subsidiaries have made huge strides in providing sustainable refrigeration solutions, providing over 200 green, energy efficient Co2 solutions for Refrigeration and Air Conditioning systems across the United Kingdom. As a whole, Carter Thermal Industries have seen significant success over the many decades, and have now expanded into both North America, and Australia.

KEY GROUP SOLUTIONS Wide range of highly efficient, industry leading refrigerant leak detection systems to reduce the environmental impact from any system leaks.

Small charge Hydrocarbon refrigerant integral display cabinets for retail / commercial sector.

Manufacturer of a range of highly energy efficient water cooling systems for commercial and industrial process cooling.

Small charge Integral cabinets with integrated Plate Heat Exchangers for connection to either dry air coolers or Chilled water loop systems.

Air quality, Noise as well as fume / dust testing, extraction and monitoring solutions for ensuring workplace air quality standards are maintained.

Site assembled Water storage solutions for efficient management of drinking water, fire suppression systems and other bulk liquid storage requirements.

Food security solutions with bulk grain storage and handling systems.

Industry leading provider of preventative maintenance, reactive service and installation of energy efficient technologies in refrigeration, air conditioning, process cooling and heating solutions.

If you would like to find out more about Carter Thermal Industries, then be sure to get in contact using the details below. Alternatively, you can find out more information by checking out the website.

T: 0121 250 1000 sales@cti-ltd.co.uk www.cti-ltd.co.uk

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PRODUCT NEWS

POWER SUPPLY PULS POWER

PULS DIN-RAIL POWER SUPPLY WITH IO-LINK PORT IS INDUSTRY 4.0 READY

PULS Power, the specialist manufacturer of high reliability DIN-Rail power supplies, introduces their first power supply providing systems designers real-time information on power, temperature and status data, supplied directly from the power supply via their proprietary IO-Link port.

“A power supply is situated at a central nodal point in any system, “comments Marco van der Linden, UK Country manager for PULS.” There is more than just output current flowing, a power supply can be used to record a significant amount of real-time information that is of particular interest to the end user as well as the system manufacturer.”

This data can help increase system availability and reduce maintenance and operating costs. An IO-Link connected power supply has the potential – in parallel with its function as a converter – to also act as a sensor node and make a significant contribution to the Industrial Internet of Things (IIoT).

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The DIMENSION QT40.241-B2 from PULS brings to market the first 3-phase DIN rail power supply (24V / 40A) that makes this system data available to users via an I/O port.

The PULS QT40.241-B2 provides a trusted power supply technology combined with the new IO-Link feature. Key specifications include 3-phase, 960W, 24V @ 40A, 95.3% efficiency, +50% BonusPower for 5s, 100A for 10ms to trip circuit breakers, Active PFC (harmonic correction) and full power over the temperature range -25°C and +60°C in just a 110mm wide DIN-Rail enclosure.

The new PULS IO-Link v1.1 (IEC 61131-9) networking function features a 4-pole M12 plug connector, transmission speed: COM 3, (< 230.4 kBaud) and integrated non-volatile memory.

Marco van der Linden continues, ”Our IO-Link device was award-winning even before its market launch. The Manufacturing Leadership Council of consulting firm Frost & Sullivan looks for innovations that

contribute to digitalisation in the production industry. We submitted the QT40.241-B2 to the panel in the first quarter of 2018.

The panel members conducted intensive tests to examine the added value that the power supply offers production companies and were impressed by the user-oriented strategy of PULS. The result was the QT40.241-B2 being awarded the respected Manufacturing Leadership Award even before its official market launch.”

Typical applications for PULS DIN-Rail power supplies include, industrial and process control, building automation, panel-building, test and measurement, instrumentation and communications systems. Versions are available approved for railway systems and ruggedised for harsh environments.

For more information on PULS DINRail power supplies call +44 1525 841001, email sales@puls.co.uk or visit www.pulspower.com

SOFTWARE & SYSTEMS

Axiomtek UK

Dosch Design

Axiomtek - a manufacture of innovative and reliable industrial computer products of high efficiency – is proud to launch the eBOX671521-FL its latest fanless embedded system. It is specifically designed for applications related to graphics computing, artificial intelligence, and machine vision in automation manufactory.It is built to withstand harsh operating environments with extended operating temperatures and vibration endurance.

Main Features: • 8th gen Intel® Core™ i7/i5/i3 & Celeron® with Intel® Q370 chipset (Coffee Lake-S) • 4-CH PoE (IEEE802.3at compliance) • Dual swappable 2.5” SATA HDD drive bay with RAID 0 &1 • Supports MXM 3.1 type A graphics module (optional) • DVI-I, HDMI, and DisplayPort with triple-view supported • AXView 3.0 intelligent remote monitoring software for IIoT

Since 1995 DOSCH DESIGN has been a fixture in quality CG products by staying on the cutting edge in 3D-design, animation, architectural visualizations, print publishing or motion design. With its well-diversified product range DOSCH DESIGN supports CG artists in their daily work.

Especially in the field of Mechanical Engineering, tool making or the automotive industry, 3D-Design has become an indispensable element. DOSCH DESIGN has developed a lot of helpful tools that make life easier for designers and have become an integral part of many users’ creative arsenal.

The Company offers an extensive product range in 3D-Models, Textures, HDRIs, Viz Images or Audio Products. These tools are an important part of marketing for supply companies or manufacturers who want to visualize processes for publications, animations or instruction manuals.

www.axiomtek.co.uk

www.doschdesign.com

PORT introduce a new SoM (System on Module) industrial real time communication board Based on a RIN32M3EC CPU in combination with GOAL technology from PORT, this SoM offers PROFINET, EtherNetIP, EtherCAT and CANopen on board. Simply connect via the SPI of your host controller - and your applications are already multi-protocol capable. One Hardware, many real time solutions. The SoM - RIN32M3 module offers you a cost effective and easy to integrate communication solution. With just one module you have the for market leading real-time communication systems.

The open interfaces allow you to react flexibly in the connector area. RJ45, M12, M8 or Mini I/O - no problem. An extensive tool offer for management and integration makes the design very efficient. With the integrated update service, you are always up to date.

More information you will find here: www.port-automation.com/en/products/ som-module-embedded/som-iot-based-onrenesas-rin32m3.html

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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 connection

Manufacture

Why not call us today....

Call: 01489 780144 Web: www.bvm.co.uk Email: info@bvmltd.co.uk

f

Weatherproo chassis

STORAGE, HANDLING & DISTRIBUTION

MAXIMUM RELIABILITY NORD

DRIVE SOLUTIONS FOR CONTINUOUS CONVEYORS NORD DRIVESYSTEMS offers powerful drive systems for transporting bulk materials that are characterised by maximum reliability, safety and robustness and ensure smooth operation even under the toughest environmental conditions.

Bulk material handling makes great demands on conveyor belts and their drive technology. Different conveyors are required according to the direction of transport, volume flow, conveyor length and construction. Reliable and robust NORD drive units ensure uninterrupted flow of materials. They ensure a precise, dynamic flow of materials which can be individually controlled.

Belt conveyors are conveyor systems which are used for continuous transport of general and bulk materials, for example in mining, mechanical engineering or in the field of plastic and paper recycling.

Especially large conveyor lengths, quantities and speeds can be implemented.

Belt conveyors feature a continuous rubber or plastic belt as well as tensile elements for strength. The conveyor belt passes over at least two drums, whereby at least one drum is powered and moves the belt through wrapping friction.

INDUSTRIAL GEAR UNITS FOR SPECIAL REQUIREMENTS

Durable and low maintenance MAXXDRIVE industrial gear units in which the bearing points and sealing surfaces of the UNICASE housing are produced in a single operation are ideal for large belt conveyors with high capacity. The latest generation MAXXDRIVEÂŽ XT has been supplemented with an application-optimised two-stage helical bevel gear unit â&#x20AC;&#x201C; ideal for belt conveyor systems in the bulk materials and mineral industries. The power and speed range has been specially adapted to the needs of the target industries.

Thanks to their two versions, helical or bevel gear units with flange mounted or pushon housings can be mounted parallel or at right angles to the axis in conveyor systems.

They can be combined with a foot-mounted, high efficiency IE3 motor on a motor rocker or frame and are connected to the motor via a hydraulic coupling. As most bucket conveyor applications involve production of dust, there is a risk of explosion if the dust is flammable. In this case, motors

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and geared motors with customised explosion protection are used, which NORD assembles from its modular range according to individual requirements. The practical maintenance package from NORD - a combination of protective measures and monitoring systems - ensures that the investment functions even under harsh ambient conditions such as continuous operation, dust and the effects of weather. www.nord.com

STORGAE, HANDLING & DISTRIBUTION

Konecranes Demag UK partners with WES

Demag KBK extending cranes for optimum use of workspace

Nickel alloys cut three times faster

Lifting equipment manufacturer and service provider, Konecranes Demag UK Limited, has reaffirmed its commitment to providing equal employment opportunities by entering into partnership with the WES. The move is consistent with the company’s objective of promoting the engineering sector to women and recruiting female employees to establish a more diverse workforce. Konecranes Demag is taking an active role within the WES, attending the organisation’s events and adopting best practice procedures. The company will also advertise technical vacancies on the WES website, job boards and newsletters to make job opportunities more accessible to female engineers. Konecranes UK HR Director, Karen Winfield, stated: “This is an issue about which I am passionate and I am delighted that Konecranes Demag is working with the WES to inspire and support women in engineering careers.”

Demag Cranes & Components has added overhung and extending configurations to its KBK Aluline light crane system. Such solutions are designed for applications where there is a requirement to move loads beyond the crane runway span dimension. They enable operators to perform lifting and positioning tasks between pillars and columns or deposit loads in aisles and free areas between assembly zones and lines.

Depending on the load capacity, design and profile section size, the range can be extended by up to 3,100 mm. Crane extensions to either side of the track runway span dimension may also be specified, creating an even greater range of crane coverage. Compared with Demag’s conventional KBK crane kit, this configuration has a lower headroom dimension, allowing users to benefit from 120 to 220 mm more hook path, dependent on profile size, for improved utilisation of space below the crane girders.

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.

www.konecranes.co.uk

www.demagcranes.co.uk

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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TRAINING & RECRUITMENT

SYSTEMIC APPROACH TEC TRANSNATIONAL

COMBATTING HUMAN ERRORS IN MANUFACTURING

By Dr David Scrimshire – MD of TEC Transnational

TEC Transnational’s 2-day course is unique and covers in detail everything that is needed to develop, document and implement the management processes to address human factors in the manufacturing environment.

We’ve all heard the excuse: “it’s down to human error” with the assumption that there’s nothing we can do about it. However, when any type of quality issue is caused by a person doing something incorrectly there will be a deeper root cause of the incident.

In any situation there are likely to be many factors that can lead to a human error, and these precursors or preconditions are referred to as human factors.

The study of human factors is about people in their working environments, and it is also about their relationship with equipment and procedures. Just as importantly, it is about their relationships with other people – their co-workers and managers. Its objectives can be seen as: safety, efficiency and effectiveness.

Human factors answer the question: “Why do smart people sometimes do stupid and/ or dangerous things?

HUMAN ERRORS ARE CAUSED

BY HUMAN FACTORS Combatting human errors requires a systemic approach that ideally prevents

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their occurrence in the first place or mitigates the severity of their consequences if they happen, and then puts in place a countermeasure to ensure they never reoccur.

There are many factors that can cause a situation where a human error can occur, and these precursors or preconditions are referred to as ‘human factors’. Information relating to human factors in aircraft maintenance is widely available, but little exists for the manufacturing sector. Dr David Scrimshire (MD of TEC) stated: “this prompted me to design a short course specifically for manufacturing organizations, that design-and-manufacture or just maketo-print”.

The course commences with an explanation and examples of why human errors occur in manufacturing operations and their consequences. Guidance is provided on selecting the appropriate ‘models’ to search for, and prove, the root causes. The models are augmented with Why Trees and Boolean logic to enhance the search. Attention then switched to devising and implement effective controls (barriers) to prevent or mitigate the consequences of human errors to downstream operations or the customer.

I’ve also added a session to show how to use practical psychology to help motivate staff.

The course is highly interactive and includes many individual and team exercises, Case Studies and quizzes.

The full course syllabus is available at our web page: (tectransnational.com).

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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

X

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

INDUSTRY 4.0 NIMS

NIMS AND FESTO DIDACTIC TO DEVELOP INDUSTRY 4.0 SKILLS STANDARDS AND CERTIFIED TRAINING PROGRAM

The National Institute for Metalworking Skills (NIMS), in partnership with Festo Didactic, will establish industry-recognized skills standards and ultimately credentials for jobs related to Industry 4.0. In light of the significant trend in digitalization of manufacturing through technology advancements such as Industrial Internet of Things (IoT), training in these skills is vitally needed now. With NIMS’ emphasis on manufacturing skills training, credentialing, and standards, plus Festo’s complete Industry 4.0 learning Factories, courseware and eLearning integration, the two organizations are well poised to provide the training programs for Industry 4.0.

There are so many interdependent functions and abilities surrounding Industry 4.0 that this effort will help to bring clarity to the proficiencies required, train people extremely well, and validate their expertise.”

Montez King, executive director of NIMS, made the announcement and said, “This is an exciting development for manufacturers and educators as it directly addresses both the data-driven revolution happening in manufacturing today and the skills gap.

Mr. Thomas Lichtenberger, CEO of Festo Didactic said, “As the production line become ‘smarter’ – collecting data to change processes and create efficiencies – workers and students will be expected to adapt in the same way. Bringing NIMS, Festo, and other

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The emergence of Industry 4.0 is new territory for most in manufacturing. As such, among the first tasks to be accomplished is to conduct research to discover and verify exactly what those competencies must be.

Then, the training protocols and credentials will be created. “We are hopeful to have the standards identified and the training program in place by the end of 2019,” Mr. King said.

industry partners together, we look forward to a collaboration that leads to world class industry standards and learning systems programs.”

During the development of the new Industry 4.0 skills standards, NIMS will ascertain the credentials in its existing programs that support the various Industry 4.0 functions and target new credentials for development.

The training outcome is to provide employees in or entering a manufacturing workplace with an understanding of Industry 4.0 concepts and impart certifiable skills as companies increasingly adopt automation and data gathering and management functions in their manufacturing operations.

For more information, contact NIMS at (703) 352-4971 www.nims-skills.org.

VALVES & FLOW CONTROL

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

Oliver Twinsafe

Malaysian refinery trusts Rotork Client Support Programme for tailored valve actuation management

Oliver Twinsafe continues to grow through product development in the valve industry aimed at international oil and gas companies.

They have recently completed an API Annex F PR2 qualification on their metal seated 1-13/16” 10,000psi double block and bleed valve. The qualification included 200 cycles at a temperature range of -46 to +144 deg C. Oliver Twinsafe completed the qualification with third party witness and zero through seat leakage.

Malaysian refinery trusts Rotork Client Support Programme for tailored valve actuation management The Rotork Client Support Programme (CSP) has been chosen by the Hengyuan Refining Company Berhad for the asset management of Rotork valve actuation equipment at its Port Dickson refinery.

The CSP is designed to meet the company’s specific needs, encompassing 157 Rotork electric actuators, a Rotork Master Station and Pakscan control loop testing facility. The Rotork CSP can increase reliability and availability of actuator and control products via predictive maintenance and asset management. This includes equipment checks, replacement of worn components and partial or complete overhauls at specific periods.

CSP clients have 24/7 access to Rotork Support Centres, with prioritised technical assistance backed by comprehensive resources.

The potential for this development, which will probably be patented, is huge, particularly in the Far and Middle East sectors where Oliver Valves has its own sales organisations.

For more information on our company and its products please visit our website www.valves. co.uk or contact our Deputy Chairman, Mark Oliver on 01565 632636.

www.rotork.com/en

74 Manchester Road Congleton Cheshire CW12 2HT Phone: +44 1260 277025

Process Valves & Instrumentation Ltd are proud to be the exclusive stockist and distributor for the WEIR BDK range of Plug, Lined ball & Diaphragm valves in the UK. In the past 12 months we have supplied in excess of £300K of there sleeved plug valves delivering every order on time and showing considerable cost saving to our clients. We are doubling our stock holding in the new year providing an even better service.

WWW.PVILTD.CO.UK Issue 39 PECM

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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

TRUSTED SUPPLIER BONUT ENGINEERING LTD

SUPPORTING CUSTOMERS OVER A WIDE SECTOR OF INDUSTRY

Bonut Engineering Ltd has been manufacturing engineering components in the UK since 1966. We are a well-known and trusted supplier to the fastener and general engineering industry of bolts and nuts, engineers studs, shaft collars, parallel keys, gib head keys, precision turned parts in stainless steel, high grade alloys and nonferrous metals and also Dereve brand safety and pressure reducing valves in plastic, brass and stainless steel. Our experience of both the fastener and valve manufacturing businesses enables us to support our customers over a wide sector of Industry.

We are an independent privately owned business, based in Stockport, Cheshire. We have an integrated manufacturing and sales organisation which is focused on competitive friendly customer service and UK manufacturing capability which enables us to offer bespoke products at short notice.

Our product accreditations and operational framework are based on: • ISO9001 Quality Management System • Valves approved to EU Pressure Equipment Directives • WRAS water valve approval • Achilles approved supplier registration • Ex stock availability on standard products • Member of the British Valve and Actuator Manufacturers Association (BVAA) Our Dereve brand Pressure Reducing Valves are principally designed for use on WATER installations up to a capacity of 23 LPM (5GPM), and can also be used as AIR regulators. Our data sheet, which can be downloaded from the web site, contains full details of the products and the specifications we can supply to.

Dereve Safety Valves are certified to the requirements of Module D (Quality Assurance for Production, Final Inspection and Testing)

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of the Pressure Equipment Directive (97/23/EC) with Module B EC Type-Examination. The range covers DN06 to DN25 sizes with set pressures from 0.5 Bar to 56.8 Bar. Dereve Valves are supplied to the required set pressures, pre-set and individually tested with test certificates. The valves are made from Brass or Stainless Steel and are soft seated type. See our data sheet for further details. Please contact our sales team for current availability. Dereve Fusible Plugs are made to BS 1123: 2006 and are manufactured to traditional drawings and specifications which are now the property of Bonut Engineering Ltd. We recommend calling our sales team to check availability as we can provide most standard items and many special products on very short lead times. Most of the popular products are available on same day despatch.

Air Safety Valves DF range of safety valves available from 1/4” - 1” BSPT inlets.

Atmospheric discharge or side outlet available Brass or stainless steel body

Certificate Number 9027 ISO 9001:2015

Pressure Reducing Valves

Water or Air - multi application Available from 1/4”-3/4” inlets with a variety of connections

Air Fusible Plugs The Original “National” Design Designed to protect internally fired steam boilers Gunmetal body construction Fig 5, Fig 8 and 9 Fusible Plugs Fig 17H and 22/22H Fusible Plugs for Air

Engineering Fasteners Gib Head Keys-In EN8 and other alloys Shaft Collars-solid or split, available in EN1A & Stainless Studs-Metric and Imperial, EN1A from stock, specials to order

We also manufacture special parts to drawings and stock a wide range of keysteel and engineers keys

Unit 12, Latham Close Bredbury Industrial Park Stockport SK6 2SD UNITED KINGDOM

Tel: +44 (0)161 430 4000 Fax: +44 (0)161 494 1461

www.bonut.co.uk

sales@bonut.co.uk

VALVES & FLOW CONTROL

VALVE SPECIALISTS ARI-ARMATUREN

ALTERNATIVE SOLUTIONS FOR ENERGY EFFICIENT PROCESS HEATING AND HOT WATER Companies from various industries are utilising ARI-Armaturen’s impressive range of engineered systems. ENCOsys® plate heat exchangers have been a major solution for companies seeking a proficient heating and hot water system that will ensure a secure and economical future for their site.

With so much pressure to reduce spend and improve energy efficiency measures, many have been forced to adopt demanding targets to cut greenhouse gas emissions and are consequently looking for alternative solutions to update energy and heating systems.

Offering reliable and resourceful systems with considerable savings in energy and cost (compared to traditional systems like shell and tube calorifiers), ARI-Armaturen’s ENCOsys® is a compact, low maintenance steam-to-water plate heat exchanger.

Suitable for various applications including domestic hot water, low temperature hot water and process heating, these innovative units are currently operating on many largescale sites across the UK including hospitals, universities and food & drink processing plants.

Designed to provide hot water instantaneously whatever the load conditions up-to 2100kW, a water storage vessel is not required therefore eliminating a potential breeding place for bacteria’s, reducing the requirement for regular inspections.

Advantageously, the ENCOsys® does not need to be stripped down for insurance inspections allowing for significant cost savings, reduced downtime and dramatically improved health and safety risks associated.

Sites with ENCOsys® units installed benefit from reduced heat loss, improved temperature control and better thermal efficiency, allowing for vast improvements to operation efficiency and energy savings.

This system is more responsive to changes in secondary operating conditions, achieving far tighter temperature control. Generally, the water temperature leaving shell and tube heat exchangers tend to cycle in a pattern similar to a sine wave, meaning the temperature set point may have to be set higher to ensure the unit meets the required load at all times. By using ARI-ENCOsys®,

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temperature control is considerably improved, providing an estimated 3% energy saving and 7% more energy efficiency.

Extremely compact, the ENCOsys® heating system ranges from the largest occupying around 3m3 to the smallest occupying less than 1.5m3, producing a smaller footprint than many alternatives on the market.

ARI-Armaturen UK Ltd Sales Director, Nicholas Davies, commented, “By heating the secondary water and sub-cooling the condensate in the same plate heat exchanger, substantial energy savings can be achieved and the cost of ownership is further reduced because improved energy efficiency means lower fuel bills and low CO2 emissions”.

This range of well-engineered, packaged solutions from valve specialists ARIArmaturen UK Ltd come fully assembled to specific requirements and tested ready for connection.

See how ARI-Armaturen can help you cope with rising energy costs – contact the UK sales office on 01684 275 752 or email enquiries@uk.ari-armaturen.com

Portable Confined Space Ventilators & Air Blowers Fume & Dust Extractors Where fumes, smells or dust occur, the Miniveyor Air VAF fans can move contaminated air out of a confined space or building.

They effectively exhaust fumes, ventilate confined spaces, and increase the flow of fresh air.

The Miniveyor Air range are tough! The rugged VAF ventilators easily withstand blows without denting, giving less downtime and greater productivity and come with an industry leading 10 year warranty on the body.

The vane axial fans work on positive and negative airflow and are at home either extracting dust and fumes or blowing clean air into a confined workspace. In fact whatever the industry you work in, from marine, construction, mining, telecoms, fabrication or maintenance services, our VAF series fans will take whatever is thrown at them.

VAF-200 (8”)

VAF-400 (16”)

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

VAF-300 (12”) Pneumatic

www.vaf-air.com

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