Process Engineering Control & Manufacturing - Issue 45 2020 by MH Media Global

Process

MANUFACTURING

Control &

Engineering

ZYGO - 6

CORBETTS - 14

Promoting Manufacturing efficiency through the use of 3D optical metrology

Corbetts remains open for business with vital NHS and utility contracts

PECM

Global Success Through Innovation Issue 45 2020 Â£3.95 www.pecm.co.uk

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Process

MANUFACTURING

Inside... Sections

Control &

Engineering Inside Issue 45

Editors Choice

Boiles & Maintenance

Control & Automation

ZYGO

CORTEC

Promoting Manufacturing Efficiency through the Use of 3D Optical Metrology.

Electronics

UKMFG

EMISSCO

Facilities Management

Fluid Handling

CORBETTS

BLUM-NOVOTEST

Manufacturers unite to target reshoring opportunities and new supply chain capability.

Health & Safety

Corbetts remains open for business with vital NHS and utility contracts.

Hydraulics & Pneumatics

SULZER

Machining & Machinery

Measurement & Monitoring

Cortec® Releases Utilities ‘Survival Guide’ for Extended Shutdown of Commercial and Institutional Facilities. Emissco announces British business success with Premium Partner Yara UK bottling and distribution contract. Blum-Novotest launches virtual showcase to give industry a window to its production metrology.

OIA

Independence from petroleum-based plastics is becoming more achievable, as it develops into an issue of national importance.

News & Events

SURREY UNIVERSITY

Product News

Scientists developing point of care COVID-19 test

‘International Women in Engineering Day’: Siemens at forefront of recruiting women into manufacturing

Storage, Handling & Distribution

MITSUBISHI

Training & Recruitment

Quality assurance detection rate up by x30 for inhaler manufacture.

SIEMENS

Smart factories and the use of AI from an automation perspective.

“The Centre of Excellence for Strainer and Filtraaon Technology”

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

Coalescers & Seperators Pressure Vessels Flame Arresters Sight Glasses Silencers Spools

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

Issue 45 PECM

Hygienic level sensor The latest LR guided-wave radar level sensor features reliable and precise detection of media in hygienic applications. The The probe probe can can be be swapped swapped out out or or cut-to-length, cut-to-length, anywhere anywhere between between 55 and and 200cm, 200cm, reducing reducing inventory. inventory. IO-Link IO-Link enabled. enabled. Fits Fits most most common common process process adaptors. adaptors. Medium Medium temperatures temperatures up up to to 150Â°C 150Â°C

www.ifm.com / uk/ LR ifm Telephone 020 8213 2222

Process

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

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Engineering MANUFACTURING

Control &

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Issue 45 PECM

EDITOR’S CHOICE

METROLOGY SOLUTIONS ZYGO

Promoting Manufacturing Efficiency through the Use of 3D Optical Metrology

Critical dimensional and surface measurement for fuel delivery component

Woodward Inc., with over fifty years heritage in the aerospace industry, is a leader in developing and delivering motion control and integrated propulsion systems. Much of their success can be attributed to their unique approach to applying total system solutions in meeting the needs of their customers and staying at the forefront of the industries they serve. Michael Schmidt, Market Development Manager, Zygo Corporation Woodward Inc. works with leading optical metrology instrument supplier ZYGO to “tune” their manufacturing processes by leveraging precise 3D surface data. In many cases, the insight gained by utilizing 3D optical metrology has improved Woodward’s component design, quality, and overall product performance. Through this technology, Woodward has been able to identify key characteristics of its manufactured surfaces that result in a real differentiator in the markets it serves. We caught up with Jack Clark, who currently leads the ‘Materials and Surface Engineering’ group as a Senior Scientist in the Woodward Technology Development family. Jack’s group focuses on developing surface finishing processes that are specific to the role of a particular component to ensure proper function, reliability, and potential cost savings. Varying materials and machining processes necessitate confirming the inspection of production lot samples quickly and efficiently to confirm that manufactured parts meet or exceed specifications. To accomplish this, the Materials and Surface Engineering Group relies on instrumentation and software which meet their stringent manufacturing demands and deliver the functional measurands necessary to control critical part performance.

3D OPTICAL METROLOGY To meet Woodward’s exacting applications and requirements Clark prefers to use 3D optical metrology instruments. “Many of the advantages of 3D optical metrology start with being able to gauge the

PECM Issue 45

component in all dimensions, and the entire functional area. That is why we refer to 3D optical metrology as ‘areal.’ You are characterizing the entire part or region of interest (ROI), not just segments of it, as you do with 2D (linear measurement) lines. 3D optical metrology enables much faster data acquisition. Data for an entire ROI can be collected simultaneously, instead of one data point at a time. Also, the measurements are more repeatable because users are including so many more data points, allowing the local part

uncertainties to be a smaller percentage of the overall measurement than that of 2D”, Clark explains. Manufacturing processes are multidirectional. A single line profile (2D) ‘sees’ the process from only one direction and cannot visualize the gauge-able process variations in any other dimension. The manufacturing process will vary in many dimensions, and that is why it is essential to capture all the pertinent data through the use of 3D optical metrology.

Metrology for production aerospace applications 3D optical metrology can report form deviation, thickness, parallelism, roughness, leak paths, edge radii, defects, etc. all in the matter of a few seconds, with one instrument, in one set-up. This single instrument can replace two to three alternative gauges that may not necessarily report the same required functional information. Clark continues, “Manufacturing is slow to change, and despite the inherent advantages of 3D optical metrology, there is still some resistance to replace legacy solutions. 2D metrology — especially profilometry and CMM — is the standard throughout manufacturing, and the ISO and ASME GD&T and surface standards were developed around the 2D measurement methods of the day. However, times have changed, and now there are 3D and areal standards to control those measurements and allow designers to put 3D callouts on drawings.” “Effectively, manufacturing’s resistance to this paradigm shift is because of not being familiar with the tremendous advantages of 3D metrology, and a lack of understanding of the ‘function’ of the components they produce and what must be measured to ensure functional parts and assemblies. Therefore, adapting to new manufacturing methods and metrology is sluggish. Engineers and scientists in companies are

ZYGO has been and will continue to be a strategic partner in Woodward’s quest to be an example of the best use of advanced metrology. not being allowed to ‘get out there’ and see the new world that has evolved and is passing them by”, states Clark. Today, integration of 3D optical metrology is well established in research laboratories, shop floor metrology cells, fully-automated manufacturing and assembly lines. Optical metrology is fast, repeatable, and requires little maintenance — allowing it to be used in all phases of manufacturing metrology and process control. There are many aspects of the manufacturing process for which 2D contact gauging may not be the best option. For example, an artifact that occurs randomly would likely be missed by a single line trace but would easily be detected by a 3D instrument that characterizes the entire ROI.

Knowing for sure that the manufacturing process as a whole has been characterized is vital. Not only for adherence to drawing specifications, for example, but detecting manufacturing process issues such as machine tool vibration due to a “bad bearing,” poor tool set-up, or worn cutting inserts. All these can be characterized with 3D optical metrology, and subsequently controlled by the manufacturing team.

METROLOGY AT WOODWARD At Woodward, Clark specifies the use of ZYGO 3D optical metrology instruments in particular. “The criteria for the choice of any metrology instrument is extensive. In terms of reliability and uncertainty, ZYGO instruments are proven to produce less noisy data and are faster in data acquisition and analysis. (Data collection and analysis time is critical in automated applications.) On ZYGO instruments, long-term instrument reliability is outstanding, which results in consistent long-term results. Plus, the software is designed specifically for manufacturing applications and conforms to international standards. ZYGO is also adept at providing ‘special equipment and function’ to accommodate demanding metrological applications, part handling, and varying surfaces that can cause uncertainties in optical measurement. Issue 45 PECM

ZYGO’s instruments are also flexible to change over for the multitude of applications appropriate for this technology.” Woodward uses a range of ZYGO 3D optical profilers, a Verifire™ laser interferometer, and distance measurement systems for a wide variety of applications including: • surface roughness and waviness • flatness and parallelism • height/thickness measurements • edge radii • component wear (life testing) • material porosity • corrosion characterization • material failure analysis • coating thickness • burr characterization • defect detection and classification • GD&T, where applicable

sophisticated customer expectations. Also, ZYGO’s data acquisition speeds outperform the competition, and the company’s data analysis is a crucial differentiator between instrument suppliers. Apart from adhering to the ‘standard’ algorithms to produce ‘standard’ measurements, ZYGO provides tools to segment/parse the data to produce functional results that other suppliers cannot. The metrologist must be aware of the functional characteristics that can be reported via ZYGO software tools and use that knowledge to help decide what instrument to specify for a particular application.” Clark continues, “ZYGO has been and will continue to be a strategic partner in Woodward’s quest to be an example of the best use of advanced metrology. All ‘standard’ and technically demanding non-contact applications are supplied

by ZYGO. We are continuously working with their application engineers to expand the technologies offered. This close relationship allows Woodward to implement the advantages of non-contact, interferometric 3D methods throughout our manufacturing and reap the benefits of improved quality and component performance.” He concludes, “Many times, problemsolving and development does not come at a fast pace. When you have a solid, intimate relationship between companies, great accomplishments are produced in a timely manner to help both companies thrive. We have individuals in both companies that are dedicated to offering feedback and requirements, interacting together and coming to a metrological solution that supports Woodward’s needs and, in many cases, expands the offerings of ZYGO.”

Woodward’s dedication to reliable metrology helps ensure critical parts and assemblies will function as designed with the reliability their customers expect. ZYGO’s 3D optical metrology instruments have also made a significant impact on other aspects of Woodward’s manufacturing operations. For example, the company uses areal measurements to examine and analyze component wear. Combining the 3D data with in-house scanning electron microscopy information, Woodward can determine the root cause of an issue more quickly and more precisely than using either method independently. Also, the company has been able to “tune” its manufacturing processes using the 3D data. In many cases, insights into the surface quality and process control have improved Woodward’s overall product performance. The company has been able to identify key characteristics of its manufactured surfaces that, when monitored by 3D non-contact inspection, result in a real differentiator in the markets served. As for choosing the optimum provider for 3D metrology instruments, Clark explains, “When we finally needed to fix on one supplier for all of our metrology needs, we chose ZYGO because the company supplies specialized optics (and other hardware) to accommodate various areas of interest and resolutions required to gauge the components. ZYGO is [also] an optics manufacturer and therefore, can design and build many instrument components that are specific to the metrological/application task. There are other metrological instrument companies that can integrate components to produce a solution, but ZYGO has capabilities to create new designs to satisfy more

Verifying edge callouts on production fluid flow control components

For further information, please visit www.zygo.com

PECM Issue 45

EDITOR’S CHOICE

Steam Sterilization Valve GEMÜ offers a compact and fast acting workhorse for CIP, SIP, condensate and water applications. The GEMÜ 550 actuated angle seat globe valve has a stainless steel actuator, proven to be reliable throughout a long service life. In a successful application of steam sterilization of solids that deactivate unwanted micro-organisms using a combined effect of steam and pressure, GEMÜ 550 valves are installed in the condensate line, airline and in the refrigerant circuit. The valves are also used for control functions in steam sterilization process, as the GEMÜ 550 is available as a Shut off or control valve. Pharmaceutical companies use steam sterilizers for example, to sterilize nutritive media, but also cages, animal feed and drink solutions within animal sciences. With an all stainless-steel actuator, spindle, body and optional switchbox or positioner, the GEMÜ 550 is ideal for this application as it exactly suits cleanroom and utilities process lines – and perfect for high cycles! Tel: 01925 824044 Email: enquiries@gemu.co.uk www.gemu.co.uk

Steam Sterilization Valve Bonut Engineering Ltd was established in 1966 and is a leading UK manufacturer and supplier to the fastener and general engineering industry. We specialise in the UK manufacture of engineer’s studs, shaft collars, precision turned parts and valves in stainless steel, high grade alloy and non-ferrous metals. Bonut has also acquired the Dereve Safety and Water Valve business as well as the fusible plug business which is now consolidated under the Dereve brand. Our experience of both the fastener and valve manufacturing businesses enables us to support our customers over a wide sector of Industry.

www.bonut.co.uk

Issue 45 PECM

EDITOR’S CHOICE

OFF TO A FLYING START UKMFG

Manufacturers unite to target reshoring opportunities and new supply chain capability

A new initiative designed to build UK industrial capability and increase reshoring has got off to a flying start after £625,000 of orders were placed in the first few weeks. UK Manufacturing Unite (#UkMfgUnite) has been launched in response to the national effort to produce more critical components and essential equipment at home and is the first step in the sector’s fightback against the damaging effects of Covid-19. Created and run by manufacturers for manufacturers, the movement is urging more firms to come together to collaborate, share practice and find practical solutions for developing domestic supply chains.

PECM Issue 45

Over 35 companies - ranging from AW Precision, Brandauer, Bruderer UK and Composite Integration to ENL, Fife Fabrications and Photofab - have already signed up to the online platform that will act as a central place for sourcing supply solutions or getting answers to issues businesses are facing. “We wanted an idea that would bring the manufacturing community together by simply asking, ‘what do you need help with and are you in a position to help others?’ Why? Because as a nation, we need something to happen, right now,” commented Garry Myatt, Collaboration Director at #UkMfgUnite.

“Covid-19 has underlined the need for engineers to pull together, to innovate as allies and to build our networks closer to home so we can mitigate supply chain risk. Ultimately, what we need are collaborating engineers - ‘sharing networks, disciplines and advice’.” He continued: “Collaborationeers, if you like, are a new breed of manufacturer evolving day by day to tackle the critical challenge of helping to care for a nation, to build economic stability, to increase UK productivity, encourage reshoring and ultimately lay down a foundation for future generations to come.”

www.ukmfgunite.co.uk is now live and will be the focal point of the initiative, offering an online directory where companies can find suppliers, opportunities and answers to manufacturing concerns. Each company will have a listing and a description of what they do, with the opportunity to post thought leadership articles and best practice blogs, not to mention provoking conversation with an interactive forum. There will also be a section for videos showcasing collaborations, state-ofthe-art manufacturing facilities and new technologies being developed in the UK.

to join who are passionate about the future of UK manufacturing.

With any new initiative, it’s great to get off to a positive start with a few ‘wins’ #UkMfgUnite is looking to get to 100 members by the end of June. It is open primarily to all manufacturers regardless of size, sector or specialism and there is an additional option for associate supporters

The concept, which is not-for-profit, is hoping to play a central role in bringing work back to this country and building supply chain capability so that we avoid some of the issues seen during the early stages of the Covid-19 pandemic. For further information, please visit www. ukmfgunite.co.uk or follow @ukmfgunite on twitter. You can also use/watch the launch video https://www.youtube.com/ watch?v=a3pWwdtf-mU

“With any new initiative, it’s great to get off to a positive start with a few ‘wins’,” added Garry. “We got this immediately when a request was tabled for a UK manufacturer of cable looms in high volumes to support the Ventilator Challenge UK consortium. PP Control & Automation successfully tendered and is now in the process of manufacturing 50,000 units in just four weeks. “This was quickly followed by two members working together to source and manufacture vital PPE, whilst another six enquiries have been logged this week alone.”

For further information, please visit www.ukmfgunite.co.uk Issue 45 PECM

EDITOR’S CHOICE

Network, Learn, Collaborate – connecting the engineering community

Cistermiser’s new CPD presentation explains the benefits of IoT remote monitoring

The IET’s Online Community is your place to connect with engineers around the world.

Intelligent washroom controls and water efficiency specialist Cistermiser has launched a new CPD learning module entitled: “Using the Internet of Things for Water Temperature Monitoring to Help Reduce Risk of Legionella”.

Stay up to date with current technology and industry developments, access free technical webinars, grow your CPD portfolio, take advantage of peer to peer networking opportunities and help to give back to the profession. With networks spanning technical sectors, geographical areas and special interests, there’s something for everyone. Start making connections today.

theiet.org/communities

PECM Issue 45

This CPD discusses how remote monitoring systems using IoT platforms can deliver significant advantages for management of commercial buildings in the 21st century. 1 hour in duration with a closing Q&A, this CPD learning module from Cistermiser is presented in “short seminar” format and is approved by 3 third party organisations: The CPD Certification Service, RIBA and CIBSE.

www.cistermiser.co.uk

NETZSCH MASTERMIX LTD NETZSCH MasterMix Ltd. is part of the NETZSCH Grinding & Dispersing division of the NETZSCH Group. The family owned Group of companies has a long history, from its inception in 1873, in grinding and dispersing technology. NETZSCH MasterMix Ltd. supplies the entire product line of NETZSCH Grinding & Dispersing from laboratory sized machines through to turnkey production plant. There is also a comprehensive AfterSales support package with UK based service and spares supply. NETZSCH also offer specialised knowledge and expertise from the NETZSCH Process & Plant Engineering team. This global reaching division provides the latest technologies and best in class solutions for all process engineering plant requirements.

For more information, please contact 01543 418938 or visit www.netzsch-grinding.com

EDITOR’S CHOICE

INDUSTRIAL PRECISION LASERS LASER TOOLS CO

At the forefront of laser technology development for more than 30 years Laser Tools Co., Inc. has taken the alignment needs of industries around the world into consideration when designing new product lines for the last 25 years. Each tool has been certified for the Mining and Tunneling industries of the United States and Russia. Some of the most sophisticated industries in the world trust Laser Tools to produce adequate and accurate laser alignment tools. Laser Tools’ products are designed specifically for the industries their clients serve. They have Long Distance Alignment Lasers that are precise and visible up to 5,000 feet and Leveling Alignment Laser Systems which include up to three leveling vials for horizontal, vertical and 45-degree alignment. Now sheaves, belts and motors can be positioned faster and with improved accuracy using Laser Tools’ newest LX Series™ Sheave Alignment System and ColorGage™ Targets. ColorGage™ alignment targets are visible indoors and in direct sunlight by using enhanced reflective and fluorescent technology. When visibility is at its best, alignment can be made easier and more precise than ever. This means lower maintenance expenses, reduced downtime and an increase in the life of motorized equipment. Curious how it all works? It starts with the LX85 model sheave alignment tool which is available in three different laser beam colors; Red for short distance and inside use, Green for long distance, outdoors and florescent warehouse lighting and Blue which is brighter and produces a stronger illumination when reflected off the target. Blue also enhances visibility due to color blindness, blurriness or dullness. The LX85 comes with three magnets embedded on one side of the tool’s case and a 40-arc minute leveling vial on outside of case. The LX85 projects a laser light parallel with the faces of the drive and driven sheaves. The ColorGage™ adjustable targets attached to the sheaves, intersect with the laser beam and visually show any misalignment. You can “Positively Track” the direction and amount

of adjustment required to align the sheaves and motor shaft. The LX85 includes one laser alignment tool, three magnetic ColorGage™ targets and one soft shell carrying case with a belt strap for easy carrying. Clients have access to all the combined resources of Laser Tools Co. at

www.lasertoolsco.com. Engineers are on hand for specific tool designs. Technicians ensure exact tolerances and power requirements are achieved and attentive Customer Service Representatives answer the phone on the first ring. So, give us a call today!! Orders can also be placed through our European Representative, Coast Laser, at www.coastlasers.co.uk

For further information, please visit www.coastlasers.com. Issue 45 PECM

EDITOR’S CHOICE

OPEN FOR BUSINESS CORBETTS

Corbetts remains open for business with vital NHS and utility contracts Maintaining supply to critical utilities customers and helping protect vital IT cabling for the NHS has kept the UK’s oldest hot dip galvanizer open for business during the Covid-19 pandemic. Corbetts the Galvanizer has used its 160 years of experience to pivot some of its operations to provide galvanizing services for covers at sewage treatment plants and for cable trays and ladder racking used at the NHS Nightingale Hospitals in Birmingham and Manchester. The company, which has kept more than 50% of its workforce operational, is now planning to ramp up volumes in line with Government guidance on social distancing and increased activity within its other customer markets, including leisure, automotive and trailer manufacturing. “It has been a really challenging period, but

PECM Issue 45

I’m very proud of our outstanding workforce who has enabled us to support existing and new customers supplying services and parts to the frontline,” explained Sophie Williams, Finance Director and General Manager at Corbetts the Galvanizers. “We wanted to keep as much capacity as we feasibly could open, so decided to shut Plant A, whilst moving over some staff to Plant B. This gave us 24-hour coverage, seven days per week and meant we could respond quickly to urgent orders, such as the ones we completed for the NHS.” She continued: “Sales in a number of core markets dropped off the cliff in April after a pretty strong March and, like many firms, we had to react accordingly…using the Government’s furlough scheme to protect some of our workers. “We are expecting some of these markets

to return and volumes to gradually pick-up again, albeit slowly. As this happens, we will look to bring more of our staff back and potentially explore reopening Plant A.” 2020 marks 160 years of Corbetts the Galvanizers supplying world class hot dip galvanizing to thousands of customers across the UK and Europe. The company, which was originally founded by Samuel Corbett, opened its Wellington factory in 1860 and Shropshire has remained its home ever since. However, today’s site on Halesfield, its base since 1999, will be barely recognisable to those that started out all those years ago, with a new water recovery system in place, state-of-the-art kettles installed and a 13-strong fleet of vehicles in the yard acting as the distribution nerve centre for serving its client base.

With Covid-19 causing drops in volume, the firm decided to use some of the downtime to focus on implementing a number of new operational efficiencies, securing an average weight per boom increase of 80% and introducing a new process for yard management to speed up workflow. Sophie continued: “At Corbetts, we want to ensure our key workers, who are committed to producing galvanised streel for critical infrastructure and the transport sectors, are safe.

It has been a really challenging period, but I’m very proud of our outstanding workforce.

“We have increased the levels of deep cleaning in high traffic areas and altered the way we do internal meetings so there are no longer large gatherings in smaller offices. We have PPE in place, but have had to order face masks from China as we are unable to get any stock from the UK.” She concluded: “We are open for business and looking to support our existing and new customers as they safely return to work and start to get the economy moving again.”

For further information, please visit wcorbett.co.uk Issue 45 PECM

EDITOR’S CHOICE

IMPROVED SUSTAINABILITY SULZER

PLA advances are changing the plastics industry Independence from petroleum-based plastics is becoming more achievable, as it develops into an issue of national importance… The recent development of new polymerization methods that allow the economical production of poly lactic acid (PLA) with a higher molecular weight have effectively removed many of the limiting factors on its use, opening-up a greatly expanded application base for the plantbased bioplastic. This is happening just at a time when pressures on extended supply lines for crude oil derived products have increased in many highly industrialized countries due to stay-at-home policies for workers and tighter border controls. Sulzer technology is included in almost all PLA plants worldwide, and while not an instant fix - the timing for Sulzer Chemtech to develop a flexible and robust technology to enable the production of various new PLA grades, could not be more prescient. The company has developed a turnkey process with partners to produce PLA from sugars via lactic acid followed by a downstream dimerization and ring opening polymerization process that has already been installed and is operating in six distinct production facilities worldwide. Improved sustainability and lower energy usage have proved to be a strong driver for the use of PLA in plastic food containers, films, and wraps, whereas high biocompatibility has led to numerous biomedical applications. In the past however, the usage of PLA, or plant-based bioplastic was limited by its mechanical properties in production (technically its viscosity in the melt), and by the thermo-mechanical properties of the finished product. The new processes solve both these issues and as a result extend its economic use to a much wider spread of consumer goods and packaging applications. Benefits such as its low toxicity, along with better sustainability as a result of using renewable resources as raw materials make the new grades of PLA an ideal material for the food packaging and

The ideal biodegradable polymer for use in medicine and pharmacy should also have certain key properties: it must not promote inflammation or cause toxic reactions; it has to be easy to sterilize and after serving its purpose, it needs to be possible to enzymatically biodegrade it using an appropriate metabolic pathway. PLA fulfils all these requirements and therefore is a natural choice for the applications described. consumer product industries. Due to a high level of robustness, biocompatibility and sterilization options they are also suitable for a number of medical applications such as implant devices, tissue scaffolds and internal sutures, plus a wide variety of other pharmaceutical devices and packaging applications. Torsten Wintergerste, Division President from Sulzer Chemtech comments, “It’s evident that going forward nation states can’t operate on a business-as-usual basis. We need a domestic supply chain solution that is more reliant on national resources, with production facilities that are strategically located. When the in-feed materials are based on corn, or other domestically farmed sugars, for example local plants, can be built to produce sustainable plastics for making both essential medical supplies and food packaging by injection molding, 3D printing, film forming and extrusion. The latest grades of PLA are highly flexible and have a much wider scope of useable properties, making them ideal for all these plastics production methods.” In the last few years great strides have been made with commercializing bio-based plastics produced from renewable sugars and starches. More efforts are needed to increase the use of biopolymers such as PLA in substitution of conventional fossilbased and non-biodegradable commodity polyolefins such as polyethylene (PE). PLA is biodegradable under certain conditions and many PLA-based film applications are proven to be industrially compostable according to the recognized standard EN 13432.

HOW THE NEW GRADES OF PLA ARE PRODUCED PLA can be produced starting with hydrolyzed starch or sucrose transformed to lactic acid (2-hydroxy propionic acid) building blocks, which exist in optically active D- or L-enantiomers. Depending on the proportion of the enantiomers, PLA with different properties can be produced. This enables the development of multiple processing methods to produce a wide range of PLA grades with properties suitable to differing applications. The differences are based on molecular weight and content of D-lactic acid units. The molecular weight affects the rheological properties (viscosity in the melt), whereas the content of D-lactic acid units affects thermo-mechanical properties. PLA with a high molecular weight is one of the main drivers for the economical production and consequent expanded use of this polymer. There are two methods to prepare PLA: the condensation of lactic acid and the ring opening polymerization of lactide, however the latter is the one preferred by Sulzer engineers as it provides improved control over quality and more flexibility in terms of the material properties of the end product. Sulzer can design and execute whole projects, from the first concept to an industrial scale plant using in house engineering, equipment, assembly, commissioning, and start-up capabilities. This allows PLA producers to enter into the biopolymer market with the capacity to produce the new formulations at a customizable scale.

For further information, please visit www.sulzer.com

PECM Issue 45

EDITOR’S CHOICE

QUALITY HINGES TALK TO THE EXPERTS.

Driven By Performance Race-Tec are specialists in the design and manufacture of low friction seals and precision elastomeric components

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

Innovative Sealing Solutions race-Tec Sealing Ltd +44 (0)23 8024 6986 www.race-tec.com

Tricor PRO Plus Series

The new Tricor PRO Plus Series of Coriolis Mass Flow Meters is an accurate and highly repeatable meter with the smallest installation length on the market for installation into systems where space is limited. The TCD transmitter offers greater robustness, performance, diagnostics, and connectivity options. With a modern HMI interface and excellent logging functionality, the DSP transmitters provide users with an efficient configuration and analysis tool. PRO Plus Series Features: • High dosing accuracy due to short response time (max. 10 ms)

• 100 Hz refresh rate makes this series suitable for pump monitoring and fast response control • Extremely short installation length makes for an easy fit in most configurations • Excellent zero stability for drift-free accuracy and longterm reading assurance • Extensive diagnostics and self-monitoring, including empty pipe detection Sizes from ½” to 2”. Available for Litre Meter, call 01296 670200, now.

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Issue 45 PECM

EDITOR’S CHOICE

UPSCALING TESTING CAPACITY SURREY UNIVERSITY

Scientists developing point of care COVID-19 test A team of scientists from the University of Surrey, Lancaster University and Brunel University are developing an easy-to-use test that can inform people if they have COVID-19 in just half an hour. The proposed molecular test and smartphone app would let people who are self-isolating test themselves, and allow health care workers test both patients and themselves – helping the UK to dramatically upscale its testing capacity. The battery-operated, hand-held device is simple and straightforward to use: nasal or throat swabs are placed into the device; then, in 30 minutes, it can identify whether the individual has COVID-19. The samples do not need to go to a laboratory and the same device can test six people at once. The science behind the test has been used and evaluated in the Philippines to check chickens for viral and bacterial infections. The UK-based team is adapting the Philippines method to detect COVID-19 in humans and is calling on backers to help them mass-produce the kits. The team is also working on adding a telemedicine functionality to the mobile app that can control the device, track the users’ movements and contact anyone who has had a close interaction with the person diagnosed to suggest steps to take in order to reduce the risk of COVID-19 infection and spread. The estimated cost of the device is approximately £100 each to mass-produce and about £25 to 6 samples. Professor Roberto La Ragione, Deputy Head of the School of Veterinary Medicine at the University of Surrey, said: “We are delighted to be involved in the development of rapid diagnostic tools for Covid-19. With a fast response from manufacturers, we could deliver a point-of-care test kit to support mass-scale testing within the NHS and globally.” Professor Wamadeva Balachandran from Brunel University London said: “Now that

With local hospitals’ help we aim to do a limited amount of testing using positive and negative samples that are currently available. we know multiple genomes of COVID-19, we can develop the molecular test in a week and have it up and running on the device in three or four weeks. We are confident it will perform well and we urgently need industrial partners to come on board. This innovation is set to have a huge impact on society.

“Normally, anything like this would have to undergo extensive clinical trials, but this is not a normal situation. Speed is essential. With local hospitals’ help we aim to do a limited amount of testing using positive and negative samples that are currently available. According to the Imperial College model, this pandemic might last for 18 months -- and cases will rise over the next few months. The new test would be a tremendous help in easing the pressure on the healthcare sector.” Dr Muhammad Munir, Molecular Virologist at Lancaster University, said: “The team strongly believes that with our combined expertise we will be able to make this device and its associated system available for adoption within a few weeks, and take a step closer to beating COVID-19.”

Manufacturers can contact wamadeva.balachandran@brunel.ac.uk

PECM Issue 45

EDITORâ&#x20AC;&#x2122;S CHOICE

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gjw@mcs-corporate.com Issue 45 PECM

EDITOR’S CHOICE

LATEST NEWS FROM ACE COLLINS AEROSPACE

ACE is going for gold with Collins Aerospace

One of Shropshire’s leading manufacturers of precision components has been selected to take part in a prestigious supplier development programme by Collins Aerospace. Advanced Chemical Etching (ACE) is working with the world leader in aerospace and defence technologies on a host of continuous improvement and training activities to help it strengthen its ability to supply group factories across the globe. The company is now setting its sights on securing ‘Gold Supplier’ status, which could be achieved over the next six months if it continues to meet 100% delivery on-time-in-full and stronger collaboration on root cause analysis.

PECM Issue 45

It marks what has been a rapid period of growth for ACE in the aerospace sector, with sales into this industry now accounting for 25% of annual sales. Ian Whateley, Managing Director, commented: “This is a very demanding supplier development programme and very difficult to get on to, so this in itself is testament to the relationship we currently have with Collins Aerospace. “We have taken a top-down approach to our involvement, making sure every member of our 65-strong workforce is on board, understand what is required and how they can play a role in helping us achieve the performance requirements in terms of cost, quality and delivery.”

He continued: “The support we have received to help us on this journey has been world class and it has been a real team approach from both companies to identify areas to work on and new opportunities to pursue. “When we achieve Gold Supplier, we will then appear on Collins Aerospace’s worldwide portal as its preferred etching company. This will be massive for ACE, as it means we could be used by any international division across the group, not to mention the profile it will give us amongst the rest of industry.” Richard Jones, Supplier Development Manager at Collins Aerospace, has been working hand-in-hand with Advanced Chemical Etching.

“It all starts with The Quality Clinic, which provides an insight into investigation, detection, root cause analysis and the implementation of preventative actions to ensure we are delivering the highest standards to our internal and external customers. “Ian and his team are fully engaged with the training I’ve helped provide and

The support we have received to help us on this journey has been world class.

this has ensured the right culture is in place, where a ‘Quality First’ mentality is embraced and driven by every single member of staff.” He concluded: “The company is well on its way to achieving the Gold Supplier status and, importantly, become ‘best in process’ across the etching world.” ACE offers development of prototype components, pre-production and volume fulfilment to customers in aerospace, automotive, electronics, medical, telecoms and renewables. The scope of its activities is far and wide and can include anything from safety critical components for aircraft and F1 cars to meshes and electronic connectors and even frames for designer glasses. All parts are developed and manufactured at its main site in Telford, where it has recently spent £850,000 on pre and post cleaning machines and new auto loaders to support a move to ‘lightsout manufacturing’ in some parts of production.

For further information visit www.ace-uk.net or follow the company @Ace_ChemEtching on twitter. Issue 45 PECM

EDITOR’S CHOICE

PPE FOR EVERYONE TO USE 3D PRINT UK

3DPRINTUK develops the most efficient SLS 3D printed face shield design to help the demand for PPE and releases it for free 3DPRINTUK has partnered with Arts University Bournemouth to manufacture face shields for front-line provision of PPE and has released it for everyone to use. 30 April 2020; London, UK: There has been a large scale response by the 3D printing community to the COVID-19 pandemic, with a giant effort to close the gap between supply and demand for PPE for front-line NHS workers. In recent weeks, some really clever and innovative designs have been released for people to produce but all have been designed and optimised for FDM printers. Nick Allen, MD at 3DPRINTUK says, “From the very beginning of the COVID-19 crisis, in common with numerous other 3D printing companies, we analysed ways in which we could make useful interventions and help the efforts of the NHS. “One thing we noticed was that many of the face shield related designs were perfectly suited for FDM machines, but didn’t work well with the SLS process. As a company, we are intimately associate with SLS, and have printed over 2 million SLS prints, so we began to look at how we could optimise designs for the 3D printing technology that we use every day.” What the team at 3DPRINTUK noticed when they looked, for example, at the amazingly well-designed and groundbreaking Prusa face shield design was that only 14 individual head bands could be printed on the EOS FORMIGA P110 SLS machine at a time. The team focussed on a design that the P110 could accommodate in much larger numbers. By nesting the main peak component inside one another they were able to create one that allowed for 260 to be printed in a single print with a 27-hour build time. Allen continues, “That is 6 minutes per shield, which is a game changer. The design that we created clips together in 10 seconds, uses silicone straps for adjustment, can take an acetate sheet with

equipment for the healthcare sector. Since its campus closure in March, the university’s facilities have become a production line for visors, facemasks, scrubs and gowns, which are being distributed across a range of public healthcare settings, including doctors’ surgeries, care homes, and volunteers providing door-to-door services for the elderly.

3 holes, is lightweight at only 42g, and is sterilisable with IPA, autoclave, or ethylene oxide (Et0). All in all, we believe that this is the most efficient visor design to produce via 3D printing available today.” Additional design benefits include a closed peak design for extra protection, the material used (PA2200/Nylon 12) is biologically safe, and the shape has been designed so that it can be flat packed into an A4 envelope for cheap postage and storage. Once the design was proved and validated, 3DPRINTUK had to look for partners to scale up production. In recent weeks, 3DPRINTUK has been directly involved with the UK Cabinet and manufacturers working on a number of large ventilator projects, which has taken up their own printing capacity. Information relating to the design was released, and the first facility to take on the manufacturing role was the Arts University Bournemouth (AUB) which had access to the P110 machine and also had laser cutting capabilities. From the get-go, there was a great connection between the 3DPRINTUK and AUB teams, with AUB producing the initial batch of 5000 units and more thereafter. These shields will be distributed for free to front line key workers. The arts university has been spearheading an effort by educational institutions to manufacture and create vital protective

AUB Vice Chancellor Professor Paul Gough said: “We’re delighted to be involved with this vital project. Many AUB staff members have been involved; from our cutting-edge technical teams to our Innovation and Campus Services teams. AUB is honoured to play a part in the national drive to create and distribute lifesaving apparatus, it’s so important that we’re all able to play our part during this global pandemic. “As a specialist university, we firmly believe in the ways in which research and creativity can greatly improve productivity. In times like these, we’re challenged to rapidly innovate, and at such a crucial time, it’s hugely heartening to see those from across the creative industries maximising PPE production through design and collaboration.” Allen concludes, “We would invite anyone else with the SLS capacity to make the face shield to contact us and we will share the design data with them. This has been a monumental effort from all involved, and I would personally like to thank Tom Preston, Fred Holdsworth, Eden Franham, Rhiannon Evens, Alex Greatwich, Lucy Devall, Paul Johnson, and Tom Marshall from the Arts University Bournemouth, and my colleagues at 3DPRINTUK, Jason Pereira, Joshua Wells, Chris Owen and Kirby Downey. “We’re sad that we will not be able to manufacture many of them in house, but to see the project come to fruition and with such gracious and dedicated work from so many people is truly humbling.”

For full story and video visit https://www.3dprint-uk.co.uk/worlds-most-efficient-sls-face-shield-covid19/

PECM Issue 45

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EDITOR’S CHOICE

THE NEW ‘WORKING NORMAL’ INTOWARE

Wearables on the factory floor Keith Tilley, CEO of Intoware, explains how the pandemic is accelerating the push towards digitisation and wearables as part of the new ‘working normal’. As we are all adopting video conferencing in the office as the new ‘working normal’, on the factory floor increasing digitisation and wearable tech featuring augmented (AR) reality are helping to streamline everything from machinery inspections to avoiding bottlenecks on the assembly line. This is achieved by allowing a remote worker to see the physical world in video and annotate physical objects, using a mobile (Android and IOS), tablet or head mounted device. It enables the worker to capture every step of a production process by creating instructions for others to follow, from a manufacturing plant here or on the other side of the world. Covid-19 has accelerated the push towards the new ‘working normal’ as businesses look to optimise productivity, cost savings and increase remote working to ensure staff safety.

KNOWLEDGE CAPTURE IS THE ‘GAME-CHANGER’ WorkfloPlus developed by Intoware is a workflow automation platform using mobile and AR technology from our partner Realwear which aims to digitise audit, compliance and manufacturing processes. As by switching to digital instructions manufacturers can build a huge bank of data for machine audits and they can also predict when failures in manufacturing or assembly processes may occur. It is the capture and utilisation of this knowledge that is a real ‘game-changer’. By providing real-time analytics, WorkfloPlus is delivering new insights that will help deliver greater efficiencies, reduce costs and drive further innovation. A manufacturer that is taking advantage of these innovative technologies is Bayer Pharmaceutical. It has recently tested

It is the capture and utilisation of this knowledge that is a real ‘game-changer’. and is now deploying WorkfloPlus with Realwear HMT-1 headsets to help manage its production change over process, in what is a highly regulated market. As drug manufacturing requires regular cleaning and change overs between each batch, by using WorkfloPlus it allows this procedure to be taken in a constant and timely manner, to help minimise any “downtime” for greater cost efficiency, while at the same time it provides a thorough audit check that a manual ‘tick-list’ could never deliver. This is just one example of how ‘disruptive’ technologies are creating a safer, more connected ‘working-normal’ to achieve greater operational visibility, productivity and cost savings. Isn’t it time to fall in love with what the tech can do for you, not just the tech itself?

Keith Tilley, CEO of Intoware

For further information, please visit www.Intoware.co.uk or call: 0115 977 8969

PECM Issue 45

BOILERS & MAINTENANCE

Reciprocal agreement with Turkish distributor enhances Lanemark Combustion Engineering capability Process gas burner specialist, Lanemark Combustion Engineering Ltd., is announcing a major agreement with a new distributor in Turkey. The link with YETEN Combustion and Energy Technologies Ltd., based in Istanbul, will create opportunities for both organisations to add each other’s burner equipment to its range – with each enhancing its services to its customer base. “YETEN is very well established in the field of high temperature burners which are used

extensively in areas such as metal processing,” says Adrian Cadman, Sales Manager at Nuneaton-based Lanemark. “Now, by being able to make selected burners from their range available to our own market, we will be able to develop our involvement in areas such as steel and aluminium manufacturing.” With an ongoing focus on research, development and design – including use of state of the art Fluent Computational Fluid Dynamics – and on providing eco-friendlysolutions, YETEN’s reputation reflects the philosophy that has underpinned Lanemark’s own worldwide success for some four decades. “The organisation also offers extensive test facilities which, again, mirrors our own growing capability in this area,” adds Adrian Cadman. The agreement with YETEN is also set to strengthen Lanemark’s own burner sales in the new distributor’s markets. The company’s (FD) forced-draught oven burners, (TX) tank heating burners and its (DB) duct burners – each used extensively in processing and manufacturing operations from aluminium anodising to food processing – will, in turn, all enhance YETEN’s own market strength.

“We are committed to building on the close relationships that we have with distributors around the world and we are, therefore, delighted to be able to add YETEN to this list,” concludes Jeff Foster, Sales Director at Lanemark. “The area within which both companies have developed globally leading reputations is highly specialist so we are confident that the link between us will offer major gains to our respective customers.”

www.lanemark.com

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31/08/2016 09:04

Issue 45 PECM

CONTROL & AUTOMATION

DIGITAL FOOD FOR THOUGHT MITSUBISHI

Smart factories and the use of AI from an automation perspective Factory automation has traditionally provided the food industry with faster, more reliable and cleaner production capacity - however, with the advent of the smart factory and commercial AI the factory of the very near future is starting to make production efficiency improvement decisions itself. The first stage of becoming a smart factory is digital network communication, having the right data infrastructure allows companies to create, move and use that data efficiently. With the swift movement and processing of data comes homogeneous control and fast responsive manufacturing, which in-turn justifies investment in the latest automation technology. Getting the most from a Smart factory is then a case of being aware of the possibilities, this is where using state-of-the-art technology such as AI can already improve the performance and efficiency of factory equipment and human resources.

THE ROLE OF THE INDUSTRIAL INTERNET OF THINGS (IIOT) The role of the IIoT in today’s factory is to connect customer demand to a fast and flexible production facility. Once a purchase decision is made then any increase in the speed of response from the manufacturer is a competitive advantage. If the IIoT offers us one thing, then it is the ability to define customer demand instantly and adapt production to suit. Companies that can be flexible enough to move away from large batch production can also avoid the cost of large stock holding, both at the manufacturer and throughout the distribution chain. Customisation is already a unique selling point for a large number of consumer goods. The food industry is following suit with individual printing and marking options being designed into many new products. Customisation equals profitability in both cases. The transfer of data from a sales operation to a manufacturing site, out to the suppliers and then simultaneously back to the distribution and retail network is the key to responsive, flexible manufacturing. To achieve ‘batch size one’ profitably and efficiently we must have the connectivity that the IIoT offers.

PECM Issue 45

The ability to generate, record, transfer and process a large amount of data reliably and efficiently has other benefits. It enables a higher degree of traceability for example, serialisation is already essential for many food, pharmaceutical and consumer products. Better information also allows for continuous improvement and process optimisations at a micro and macro level, generating multiple opportunities for increased efficiency and cost reduction.

ARTIFICIAL INTELLIGENCE (AI) IN CONTEXT AI is still at the beginning of its journey but we can expect it to have a substantial impact on the industrial environment over the next few years. AI is a perfect fit for manufacturing and leading companies are now integrating various AI functions into factory automation equipment. Advanced Analytics (AA) and Artificial Intelligence (AI) technologies are extending traditional machine control architectures with more advanced data processing, learning and decision-making capacity. The objective is to deliver increased productivity, efficiency, reliability and accuracy, as well as opening up new possibilities for machine control. AI can, for example, be a driver for increased productivity. Today, most machines are still built to work within defined margins of capability – perhaps to allow for different

loads or speeds or safety ranges. AI technology using deep learning algorithms within the control system enables machines to be driven right up to and even beyond today’s margins, significantly boosting productivity without compromising reliability and quality. Applying AI principles to individual machine processes can already help to reduce autoadjustment times, synchronise increasingly complex systems and offer helpful suggestions to operators. It can even enable autonomous decisions to be made based on measured data in real-time, further optimising the process. Making reliable predictions based on experience, evidence and guidelines is a fundamental function of human intelligence. AI is no different in this respect, it can contribute toward more effective predictive maintenance, monitoring the condition of components to enable replacement before damage occurs, so preventing unplanned downtime. We see this already but deep learning algorithms are pushing the boundaries further, calculating with more accuracy how long a component can run before replacement. Maybe even compensating for delivery times on replacement parts by slowing the machine down slightly to increase longevity rather than stopping the production line completely.

Similarly, the combination for AA and AI can be a driver for increased efficiencies right across the production environment and here we get into the realm of Big Data Analysis. AA and AI technologies enable different machine states to be recorded and analysed in real time to recognise the current machine status, detect potential faults on the horizon and immediately offer recommendations for actions to the machine operator or autonomously initiate remedial actions. Reaping the maximum benefit from this development will depend on control systems that not only embed these technologies but which also provide higher levels of connectivity. If the full spectrum of data sources on the plant floor can be connected to Edge Computing platforms for efficient processing for example and on to MIS/ MES and ERP systems, then the full benefits of AA and AI are realised. This level of integration enables a far greater range of KPIs to be analysed and so can be used to drive improvements in overall equipment effectiveness (OEE). What we see then, with control systems built around AA and AI technologies, are machines that are self-learning and selfoptimising. The importance of Artificial Intelligence to the machine control market cannot be overstated. In addition to developing products that incorporate a connection to cloud based AI as a service, IBM’s Watson for example, Mitsubishi Electric for one has developed several in-house AI algorithms and services and is positioning its developments in AI technologies under its own brand to reflect its growing importance.

compatibility to data security. On the other hand, edge computing systems can be easily interconnected with cloud services to provide scalable data storage and management solutions. In this way users have all the benefits of IT systems, without storage issues or being influenced by potential threats.

LOOKING AFTER YOUR ASSETS Against the backdrop of a desire to increase OEE by means of digitalisation, there is a high demand for analysis of extracted data (data mining) from production. The condition and operating profile of plant automation devices and machines for example like a production robot’s components such as servo drives can be recorded. This provides valuable information for example the status of wear parts and any contamination. The resulting database information then enables predictive maintenance strategies with a significant saving potential in maintenance costs. To improve these strategies further, edge computing technology [as described earlier] is being used to leverage the value of manufacturer’s data using advanced analytic algorithms executed on the Edge of the shop floor. Another important category of process data is the one that is used for traceability

and consumer information, especially in the food sector. This can be employed, for example, to prove compliance with the cold chain or to attach origin information to food packaging that can be called up via a QR code. Data collected from PLCs, controls and drives centrally and processed locally using edge computing reduces the bill for storage space in the cloud in addition to delivering many other advantages for faster production control and monitoring.

PREDICTING THE FUTURE AI is certainly playing a key role in manufacturing, moving from vision recognition to skill learning and predictive maintenance for failure prevention, however it has further scope for providing operational benefits and efficiencies. When detecting impending faults and informing operators how to fix problems for example we see AI again coming to the fore. AI is being used to increase the effectiveness of predictive maintenance for plant automation assets. Cloud-based solutions using AI platforms analyse operational data and can optimise maintenance regimes based on actual usage and wear characteristics. Predictive maintenance for plant automation assets can of course reduce operational costs, increase asset productivity and improve process efficiency.

PROCESSING AT THE EDGE Managing the crossover between Information Technology (IT) and Operational Technology (OT) is the next major challenge. The successful merge of these worlds needs to address the skills gap that has traditionally existed between FA experts and IT departments. Historically the OT layer is managed by automation engineers who do not necessarily have extensive IT skills, while programmers and IT system architects may not completely understand the automation world. It is worth it though – the most recent technology developments are based on edge computing, which provides the answer by bridging the gap between IT systems and plant level automation. Edge devices can collect and analyse data from neighbouring automation systems and make decisions in real time to influence the production process. Using this technology effectively can provide a huge competitive advantage. It also creates new challenges: from system For further information, please visit gb.mitsubishielectric.com/en/ Issue 45 PECM

CONTROL & AUTOMATION

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PECM Issue 45

Reduce unscheduled shut downs, reduce maintenance costs and improve plant safety with our Valvescan Diagnostic Monitoring System. Our revolutionary system is an end-to-end solution that captures data from every valve operation, analyses it and provides targeted alerts on the valve health without any requirement for involvement from plant personnel or any potential impact on the asset real-time control integrity. It is a true IIoT solution for automated valves. This system is not only a pioneering development in valve monitoring, it is also; ● Cost effective and easy to install ● Works with all existing valve systems ● Enables data retrieval and transmission to the cloud ● Provides a ‘real time health’ check on the valve and alerts when performance drop off is detected

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CONTROL & AUTOMATION

THE OPTIMUM SOLUTION TF AUTOMATION

TF Automation focuses on robotic handling, testing and process automation solutions TF Automation design, engineer and manufacture process automation solutions, supporting a wide range of manufacturing industries from, aerospace and automotive through to medical, food, printing and packaging. Investment in the latest automated manufacturing technologies is a key issue for many of our customers who see it as a viable strategy to tackle skills shortages while maintaining the agility to stay competitive in a global market and we work closely with them to ensure cost effective and efficient solutions. Projects range from product identity and traceability as well as units with vision inspection. We automate intricate operations with pick and place and product assembly systems incorporating robotics as well as designing numerous work-stations for product testing. This has meant our continued involvement in the supply chain for the automotive and aerospace industries as well as heating/plumbing products, personal protection and medical. The need to improve process and productivity is a constant challenge for all our customers. Our focus is on providing solutions to reduce the risk of human error in tasks that are constant, predictable and repetitive. We engineer and program our machines to perform tasks over and over again, offering accuracy and repeatability far superior to the same task carried out manually, thus ensuring increased output and efficiency. With over 40 yearsâ&#x20AC;&#x2122; experience, our strength is in our assessment and understanding of the requirements of each project, end user and operative. We take the time to consider all possible solutions for clients, ensuring that both their expectations and their clientsâ&#x20AC;&#x2122; are met and the optimum solution provided. To find out more or to discuss your next automation project with our design team, contact us on 01274 308005, email us at info@tfautomation.co.uk or visit our website www.tfautomation.co.uk. For further information, please visit www.tfautomation.co.uk

PECM Issue 45

Specialists in the engineering and manufacture of process automation solutions to improve efficiencies, output and support continuous improvement programs.

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ELECTRONICS

CAREFUL INVESTMENT PTC

Digital technologies hold the key to developing the UK’s long-term reshoring strategy Embracing digital technologies will need to be a key component of any UK reshoring strategy warns one of the world’s leading industrial innovation technology specialists. Paul Haimes, European Vice President of Technical Sales for Farnborough-based PTC, believes the new-found desire to manufacture more in the UK will have to be supported by a willingness from industry to further invest in automation and adopt the digital technologies which underpin the Industrial Internet of Things. He feels that for domestic production to continue its increasing parity with traditionally low-cost counties, there will need to be careful investment to improve productivity throughout the full product lifecycle, including the connected factory and product in the field.

based on digital technologies that leverage our proven strengths as a global base of manufacturing skills and talent.”

This means aiming for greater manufacturing operational intelligence by capturing and analysing data from machines, processes and factories to reduce lead times, shrink costs and boost product throughput.

The company has used its Vuforia Expert Capture Augmented Reality (AR) technology and Microsoft’s HoloLens to create a virtual guide to building the different models and is transferring it to the factories of consortium partners through the power of AR glasses and tablets. This is helping increase capacity, whilst at the same time minimising the risk of the virus spreading among consortium partners.

“The coronavirus outbreak, after all, has highlighted the fragility of outsourcing to offshore locations,” explained Paul, who was central to PTC’s involvement in the VentilatorChallengeUK consortium. “While many UK manufacturers had already experienced quality issues and rising transport costs associated with outsourcing, the virus has wreaked havoc on extended supply chains. As a result, the risks of over-reliance on overseas supply of strategically critical components and parts have come into sharp focus.” He continued: “The challenge now, as I see it, is for manufacturing companies to figure out how to turn reshoring into a long-lasting and sustainable trend. In preparation for a post-Covid world, companies need to start planning for a fundamental shift in industrial production,

PTC is playing a significant role in the successful ramp-up of Smiths and Penlon ventilators for use by the NHS.

Whilst many manufacturing leaders will no doubt worry that this reinvention will involve huge investment at a time when preserving capital is paramount, Paul believes this approach shows how you can achieve operational intelligence on an incremental basis. He also underlines how through the introduction of low-cost sensors - deployed in limited sprints for example – small wins can be generated that build into real savings. Smart use of intelligent robotics could also help factories redeploy a limited workforce on higher-value activities. Paul went on to add: “In the current crisis, there are valuable lessons to be learned.

Over recent months, many manufacturers have found themselves struggling to respond to the changing situation, with demand patterns and materials availability thrown into disruption. “However, if the Industry 4.0 trend is about anything, it’s about moving away from a traditional reactive state to a more predictive one, which anticipates the availability of materials, people and assets and constantly reassesses and reschedules production plans accordingly. “As our involvement in the VentilatorChallengeUK consortium has amply demonstrated, a willingness to experiment with digital technologies, combined with the best of our nation’s manufacturing skills and talent, can be a powerful combination. “It’s a lesson that will hopefully be remembered as we move towards a postCovid world, one in which the UK is able to take full advantage of its innate strengths and reinforce its domestic capabilities for future resilience.” PTC employs 163 people across its UK and Ireland operations and provides a host of technology solutions to help industrial companies create value for themselves and the rest of the world. This is achieved through a combination of Augmented Reality, Industrial IoT, Product Lifecycle Management and CAD solutions.

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

PECM Issue 45

ELECTRONICS

Don’t be held back by a part number With an impressive selection of over 25 industry-leading brands and several new product ranges added to Rhopoint Components’ portfolio in 2019, they have taken steps towards serving the ever-growing demand for customised solutions in the electronics industry. Off-the-shelf products no longer sufficient and using a close-enough part often means a compromise elsewhere. Rhopoint Components represent carefully selected manufacturers who can satisfy this market shift, while continuing to serve the industries where the flexibility and high quality have always been important. Whether an

unusual package, resistance value, tolerance beyond the datasheet values or specialist terminations, Rhopoint Components offer customisation on the vast majority of their range of passive and active electronic components as well as pressure, temperature and liquid level sensors. Custom components can be surprisingly cost effective – often in line with the standard models, in addition to saving cost elsewhere in form of saved board space or eliminated need for an additional component. To see how Rhopoint can help equip your design with the right components, contact their technical sales team or visit their website.

www.rhopointcomponents.com

• Resistance value • Tolerances • TCR • Package • Terminations • Lead lengths and more....

Custom ise solutio d ns

Fully customisable electronic components and sensors with low MOQ Call 01342 330 470 to discuss your requirement today sales@rhopointcomponents.com www.rhopointcomponents.com

Compact, multi-wavelength LED solar simulation The Model 6000B-100 from Innovations in Optics, Inc. is a compact, multi-wavelength LED solar simulator for PV manufacturers meeting IEC 60904-9 Class AAA requirements for spectral match, non-uniformity of irradiance and temporal stability. The 6000B-100 includes a digital driver/controller with MODBUS protocol. Embedded chip-scale spectral sensors provide feedback monitoring to stabilize source irradiance. The field of illumination is 50 x 50 mm at a working distance of 155 mm. The compact and lightweight design supports a diversity of system integration concepts. Consuming only 15W of input power to produce 1 Sun of irradiance, the 6000B100 is energy efficient and simplifies any thermal interface or active cooling scheme. The product is intended for industrial use by qualified system integrators. T: 781-933-4477 kevinc@innovationsinoptics.com www.innovationsinoptics.com

Whippendell Whippendell specialises in providing electrical solutions for harsh environments such as the Rail, Naval and Commercial Marine Industrial Sectors. This includes design, manufacture, in-service support and maintenance. For example, the company has been supporting the Royal Navy since the 1930s, with equipment on all current surface ships and submarines. We offer a range of electrical panels, motor starters, control systems, power conversion equipment and aircraft ground power support systems. Many of our solutions arise from a reverse engineering task to replace obsolete systems with modern alternatives. Typical applications include high pressure air control systems, pumps, steering gear, stabilisers, lifts, winches, mechanical handling equipment and HVAC systems. Solutions can be designed around Whippendell components or to customer preferred requirements and components – use of COTS and PLC technology is standard. www.whippendell-marine.co.uk

New safety lock out for mains cut outs Now available from Martindale Electric – leaders in safe isolation and electrical safety – is the new LOK6W, a simple and effective locking off device for Henley and Lucy mains supply cut outs. Designed to restrict finger access to live contacts and prevent the reinsertion of a fuse whilst maintenance is in progress, the LOK6W is an essential accessory to keep electricians, installation teams and their customers safe in accordance with Electricity at Work Regulations. In common with the LOK6, the new LOK6W features an extendable design which also makes it suitable for larger Red Spot type fuse holders rated at 63A and 100A For more information, please contact Martindale Electric on 01923 441717 or visit: www.martindale-electric.co.uk Issue 45 PECM

FACILITIES MANAGEMENT

PROTECTION SOLUTIONS CORTEC

Cortec® Releases Utilities ‘Survival Guide’ for Extended Shutdown of Commercial and Institutional Facilities As the reopening of some commercial and institutional facilities gives a glimmer of hope for more normal days ahead, other facilities remain closed and uncertain on when or if they will open again. Over the last several months, these hotels, resorts, restaurants, theme parks, convention centers, school districts, university campuses, and air and ship terminals have faced new challenges as unprecedented public safety measures have reduced or shut down operations completely. Many facility managers who never had to even consider a preservation plan have been left with a major project to tackle. Among other tasks, corrosion prevention on core utilities such as boilers, cooling water systems, and closed loops is a top priority, since corrosion on idle equipment can result in • Premature equipment failure • Unnecessary and non-budgeted repair/ replacement costs • Further delays to equipment startups

PECM Issue 45

To help commercial and institutional facility managers avoid these negative repercussions, Cortec® Corporation has released a detailed white paper on simple and effective strategies for the layup of boilers, closed loops, and cooling water systems at commercial and institutional facilities. These strategies provide excellent protection with minimal effort and easy startup. Helpful reference charts identify the best water treatments to apply based on system type, component, size, and dry or wet-dry layup method. The guide offers invaluable direction for those still in the middle of a shutdown crisis, as well as for those who are reopening but can still benefit from corrosion solutions for temporary preservation of boilers or cooling systems entering seasonal layup. The white paper also includes solutions for cleaning; odor control; and drain, septic, and grease trap maintenance using biologicals from Cortec’s biotechnology subsidiary, Bionetix® International. These products contain beneficial microorganisms

The guide offers invaluable direction for those still in the middle of a shutdown crisis. that continue biodegrading waste and soils even after initial application. This ongoing biological activity makes shutdown an ideal time for treatment because it gives the microorganisms plenty of opportunity to work without disruption while drains are not being used. Shutdown is also an excellent time to perform concrete repair and maintenance tasks without getting in the way of customers, tourists, or students who

would normally be on site. To maximize the durability of these projects and structural components, the white paper identifies several MCI® materials to mitigate corrosion: MCI® repair mortar, surface applied Migrating Corrosion Inhibitors (with or without a combination water repellent), and a water-based coating to protect rebar from corrosion in outdoor storage. It is easy to guess that the need for simple, effective protection of basic utilities has reached an all-time high this year. Fortunately, this white paper gives facility managers an excellent preservation plan to guide them through a time of uncertainty toward the hope of a good future startup— minus the problems of corrosion. Read the new white paper on “Protecting Commercial and Institutional Facilities During Extended Shutdowns” here: https:// www.cortecvci.com/protecting-commercialand-institutional-facilities-during-extendedshutdowns/

Contact Cortec® today for further assistance: www.cortecvci.com Issue 45 PECM

FLUID HANDLING

BRITISH SUCCESS STORY EMISSCO

Emissco announces British business success with Premium Partner Yara UK bottling and distribution contract Emissco has won an Premium Partner contract with Yara, the world’s largest manufacturer of AdBlue®, to bottle and distribute its product for the UK and Ireland. Carrying out the bottling in-house, Emissco will deliver AdBlue® to retailers, garage forecourts, motor factors and repair shops. AdBlue® is a fluid that is injected into the exhaust gas stream, helping to turn harmful NOx emissions into nitrogen and oxygen. It is designed for diesel vehicles, from large commercial trucks to passenger cars. Yara is the world’s largest manufacturer of AdBlue®, with 17,000 employees and operations in over 60 countries turning over more than £10 billion.

Yara has selected the expertise of Emissco, a leading manufacturer of fluids and aerosols, due to its filling machine and logistics capabilities in the UK. The business offers the capacity to produce 16-20 million litres of fluids a year, ideal for meeting the supply needs of the consumer market.

centres and point of purchase across the UK and Ireland. A dedicated fleet of delivery vans ensures reduced lead times and fast reactions for stock resupply enabling customers to also operate with more efficient inventory and working capital.

Utilising its filling machines, Emissco will bottle Yara AdBlue® into millions of 10 litre branded containers during 2020. Emissco has developed its filling machines in-house, constructing them to clinical standards. Hoses and nozzles have been designed to operate reliably during the handling of the crystalline fluid.

Mark Brickhill, CEO of Emissco, said: “We are delighted to be a premium bottling and distribution partner for Yara in the UK and Ireland. To be working with the world’s number one producer of AdBlue® really displays our capabilities in terms of filling machine capacity and logistical expertise. We have geared our business to provide contract services to leading fluid producers, as well as formulate and deliver our own products to the consumer market.

Using its pre-existing supply chain, Emissco will deliver AdBlue to both distribution

Emissco has won an Premium Partner contract with Yara, the world’s largest manufacturer of AdBlue®, to bottle and distribute its product for the UK and Ireland.

PECM Issue 45

Yara is the world’s largest manufacturer of AdBlue®.

Virtually every new diesel car from September 2019 requires AdBlue to meet the new, stringent environmental regulations. It’s both great to be announcing a British business success story, particularly in these challenging times, and to find a further way to support our customers including those in the emergency services. “It’s a fabulous and essential product,” Brickhill adds enthusiastically, “Enabling ultra clean emissions from the most modern diesel cars, improving air quality and producing 15-20% less CO2 greenhouse gas emissions than petrol engines. Virtually every new diesel car from September 2019 requires AdBlue to meet the new, stringent environmental regulations.” Emissco is brand within the Klarius Group

Utilising its filling machines, Emissco will bottle Yara AdBlue® into millions of 10 litre branded containers during 2020. of Companies, which also includes Klarius Products Ltd. Klarius offers same day supply of exhaust pipes, mufflers, diesel particle filters and catalysts to more than 600 delivery points in the UK and mainland Europe. “With storage for receiving multiple tanker loads and production lines for the filling of many millions of litres of packed AdBlue® into our Cheadle site near Stoke, we complement our emissions

control portfolio. In Yara we have the most reputable partner”, Brickhill continues. “We’re proud to be bringing a great service to our customers with such a positive product for the environment, whilst also securing further manufacturing and logistics employment locally in our site’s 50th anniversary year.” At the Klarius Group of Companies, we are striving to offer you the best possible service during the COVID-19 outbreak.

For further information, please visit www.emissco.co.uk Issue 45 PECM

FLUID HANDLING

Looking at Rotaflow’s Repair, Reuse and Recycle Approach

Fluid Carrying

In an age where greener work practices and recycling is being brought to the forefront of our collective attention, Derbyshire based swivel joint specialists, Rotaflow, are doing their bit to repair, reuse and recycle wherever possible. There’s a triple benefit here – first of all there’s a reduction in the amount of perfectly good parts that need to be disposed of, potentially contributing to the rising pressure on landfill sites. Secondly, there’s a much faster turnaround for the customer. Stripping, cleaning and refurbishing parts is typically significantly faster than the design and manufacture of new parts. This allows a job to be completed quickly, allowing the business to move on to other projects. The third benefit is cost – Rotaflow always advise if it is not cost effective to repair a swivel joint over the price

Flexibility Articulated Torsion Pipework In Hoses

of a replacement. If it can be refurbished then as a customer you’d always pays less for the job, which allows the savings to be passed down the line.

Rotating Cylinders

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

Another, perhaps more subtle benefit is the reputation boost for you as a business. If you’re honest enough to suggest a parts repair and refurbishment rather than a more costly full replacement, you’ll save your customer money and would be more likely to secure repeat business from them in the future.

www.rotaflow.com

Swivel Joints

Tel:

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

+44(0)1663 735003

E-mail:

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

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

safety and efficiency in their production processes. We share Prominent’s commitment to environmentally sound, sustainable and costeffective 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

PECM Issue 45

FLUID HANDLING

New couplings & accessories catalogue now available Dixon Europe are driven to provide ‘the right connection’ in meeting specific hose and coupling requirements across all industries. Their strength in service, technical support, training and advice ensure the correct specification of bespoke hose assemblies and couplings. Our latest couplings & accessories catalogue is now available to download from www. dixoneurope.co.uk or in hard copy.

Dixon has been building a credible reputation for over 100 years, demonstrating that it’s a responsible manufacturer producing and supplying safe, reliable and long lasting products. Open communication with customers and following through with solutions strengthens trust as a supplier of both current and future products. Dixon products can be relied upon, as quality control starts at the innovative design stage,

and is further supported with technologically advanced engineering and manufacturing processes. Dixon will not compromise on high quality control, utilising assurance standards and inspection procedures at each critical step of the production process To find out more about how Dixon can help you make the right connection and the Dixon range head to dixoneurope.co.uk or contact our customer sales department on 01772 323529

www.dixoneurope.co.uk

Dixon Petrochemical Products

Fluid transfer products for upstream, downstream and refining Products:

• Hoses and hose assemblies • Hose & pipe fittings • No-spill couplings • Safety breakaway fittings • Blow-Out prevention couplings

• Hydraulic Fracturing: Low Pressure Systems • Loading arms • Liquid level sensing • Zero emission valves

Services:

• Global inventory and locations • Sales and technical support worldwide • In-house engineering & design • ISO 9001 accredited • Pressure Equipment Directive (2014/68/EU)

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

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

Issue 45 PECM

SAFETY & CONTROL

PRESSURE RELIEF REMBE

ÂRupture disc for applications with strict hygiene requirements There are two main challenges for aseptic processes: firstly, sterility is not guaranteed with DIN or EN flanges, and secondly, existing system parts must be modified to integrate these flanges, which create undesirable dead spaces. Cutting pipes, attaching new flange connections, flanging pipe sections with an integrated rupture disc and correcting suspensions if necessary - the to-do list of fitters is extensive. The REMBE rupture disc KUB clean with sanitary gaskets provides help. If a process is to be secured (retrospectively), an existing tri-clamp connection can be replaced by a KUB clean rupture disc without modifying the existing pipework. Fitters no longer need to do the tasks

The integrated gasket in the rupture disc assembly is also particularly robust and corrosion-resistant. described above. The KUB clean enables fast, simple and reliable process safety. The secret lies in the combination of a highquality reverse acting rupture disc and a special gasket, which is characterized by durability and resistance. The integrated gasket in the rupture disc assembly is also

particularly robust and corrosion-resistant. If necessary, the tri-clamp connection can be opened and the rupture disc and gasket can be easily removed. The KUB clean is unique in the fact that it can be supplied with integrated signalling to provide constant monitoring of the rupture disc and reliable notification of disc burst when connected into a process control system - all from one installation point, and as a single device! Fulfilling the hygienic standards and FDA requirements, the KUB clean with its integrated signalling is quick and simple to install. Providing a completely leak-tight seal, the KUB clean with its integrated signalling offers the most reliable burst notification under stringent, hygienic operating conditions.

Rupture disc KUB clean with integrated signalling

Rupture disc KUB clean â&#x20AC;&#x201C; for applications with strict hygiene requirements

For further information, please visit www.rembe.com

PECM Issue 45

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

Made in Germany

Your Specialist for

PRESSURE RELIEF and

EXPLOSION SAFETY

Consulting. Engineering. Products. Service.

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

HEALTH & SAFETY

LATEST NEWS FROM SDI SDI

SDi’s new hygiene solutions in demand as Boots, M&S and Tesco race to protect staff and customers Urgent demand to keep employees and customers safe in the wake of Covid-19 has seen a Leicestershire point of sale and visual merchandising display specialist pivot its operations to deliver a range of end-to-end hygiene products and services. SDi, which employs 113 people at its stateof-the-facility in Loughborough, has taken just three weeks to develop protective face guards for employees, pharmacy/checkout screens and anti-bacterial wipes/sanitiser hand stations. There is an urgent demand to get these made and in stores as soon as possible, with 260,000 face guards manufactured already, over 10,000 pharmacy and checkout screens delivered to Boots and M&S, whilst 1500 sanitiser hand stations are currently in production for Tesco, Dixons Carphone and other retail partners. In a further step to protect people, an official collaboration with Addmaster has been signed that will give SDi the capability to embed Biomaster technology into all of its products, providing an additional ‘antimicrobial’ barrier to prevent bacteria and viruses growing on surfaces.

We’re talking volumes in the tens of thousands, maybe eventually hundreds of thousands.

increase, a number of manufacturing jobs could be created shortly.

“These products will help to protect people and potentially save lives, so, put simply, retailers couldn’t wait six weeks for them to come from overseas suppliers.”

Matt continued: “There is definitely a feeling that more businesses are starting to make plans about how they reopen when the lockdown eventually eases and hygiene will be at the forefront of their thoughts.”

SDi, which is also in the process of supplying 1.6million visors for the NHS, has more than 40 years’ experience of creating, making and fitting point of sale and visual merchandising displays.

He concluded: “The products we are supplying to retailers can be used by companies in all sectors, whether you are manufacturing, operating trade counters or working in contact centres.

“Our specialist designers and production experts came up with a range of hygiene products that could solve some of these challenges, starting with protective face guards and then quickly evolving into pharmacy/check-out screens and sanitiser hand stations.”

Its established single-source solution covers the new hygiene range, with the company able to design, manufacture and install all of the new products, including vital stocks of sanitiser that is in huge demand at the moment.

“We are already having discussions with some restaurants about making partition dividers to help with social distancing and speaking to firms about how they can clearly communicate safety measures in the workplace.”

He continued: “Manufacturing lines were adapted to ensure we could provide a single-source solution from start to finish.

Pivoting to this new approach has meant that all production staff have been kept in full-time work and, if volumes continue to

For further information, please visit www. sdidisplays.co.uk/ppe or follow @sdidisplays on twitter and SDI-Displays on LinkedIn.

“We have always been a close partner to the retail sector and have been in constant discussions with them during the pandemic. The conversations were mainly focused around protecting staff and customers who are working and shopping, so we immediately sprang into action to meet this challenge,” explained Matt Evans, Retail Sales Director of SDi.

For further information, please visit www.sdidisplays.co.uk/ppe

PECM Issue 45

HEALTH & SAFETY

INTRODUCING GRECON GRECON LTD

How GreCon can help you return towards a new normal GreCon makes people and places safer and enables the ‘smart factory’ as the leading provider of innovative industrial fire prevention and process measurement solutions. GreCon Limited is located just outside of Newcastle upon Tyne and is a member of the Fagus-GreCon Group. With a wealth of experience as a global market leader, GreCon demonstrates a strong understanding of customer needs and provides turnkey solutions for a wide variety of industries including wood manufacturing, recycling, biomass, pharmaceutical, food, hygiene and more.

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

PREPARING FOR A RETURN TOWARDS A NEW NORMAL GreCon has helped businesses across multiple industries as many return towards a new normal. The pandemic has meant that companies have taken advantage of shut-down periods to optimise production processes, and GreCon has been on hand to deal with enquiries and make improvements. Managing Director Jonathan Hamill commented, “We’re available for exploratory discussions and happy to conduct no-obligation surveys. Utilising our know-how, we believe we can play a vital role in helping industry tackle the current challenge, to emerge stronger and more resilient.”

FIRE PREVENTION OR FIRE PROTECTION? The adage, ‘prevention is better than cure’ rings true. GreCon believes that early detection of ignition sources is critically important. Once a fire starts, the results can be catastrophic. When companies are not aware of GreCon’s technologies, they rely on more conventional fire protection systems, which do not always provide the best defence. Customers are particularly interested in the recently introduced DLD 1/9, which is a highly sensitive spark, ember and hot particle detector for protection against fire and explosion in industrial processes. Intelligent Detection Technology IDT® provides optimal detection performance for all ignition sources in any environment and enables the detector to distinguish between dangerous sparks and harmless ambient light.

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

CALL GRECON TODAY Today customers all over the world rely on GreCon. Please contact us and discuss how we can help: Email: sales@grecon.co.uk T: 0191 414 7200

For further information, please visit www.grecon.co.uk Issue 44 PECM

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PRODUCT LABELS

HEALTH & SAFETY

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A full range o plastic & me f tal

PRODUCT LABELS

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Legionella – Innovative Testing Methods from TME

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

The measurement and monitoring of stored and circulating hot and cold water temperatures continues to be the primary preventative measure for Legionella control. Testing protocols focus on pipe surfaces, running water and immersion. Achieving reliable measurements can be complex due to variables like the size, shape and accessibility of each water asset. TME’s Legionella Temperature Range feature KS20-S dual surface immersion probes which ‘double up’ for pipe surfaces and running water together with the ground-breaking MM2008 legionella thermometer with in-built timer for running water tests, speed up and simplify repetitive testing. KA01 fine wire thermocouple sensors for pipe surfaces and KM07 immersion probes for water tanks can be left in situ and connected to TME’s innovative TC Wall Ports (miniature wall-mounted

PECM Issue 45

thermocouple sockets sited up to 20 metres away) - a practical, low cost method of testing hardto-reach assets like concealed pipes, high level water tanks and crowded calorifiers. The MM7000-2D Bluetooth Barcode Thermometer is a unique paperless recording solution which delivers instant handheld data logging including the unique identity of every water asset right down to the last tap or TMV.

TM Electronics UK Ltd (TME) sales@tmethermometers.com +44 (0)1903 700651

www.tmethermometers.com

HYDRAULICS & PNEUMATICS

Highest flow on the coupling market

Stable, quality performance from E.MC cylinders Pneumatics and hydraulics specialists Tom Parker Ltd are UK exclusive distributors for pneumatics products by E.MC. Established in 1986, E.MC possess over 50 patents and provide pneumatic solutions for over 50 industries. E.MC products offer production efficiency with precision, low consumption pneumatics. Their worldclass manufacturing and test facilities are in response to industry demand for greater streamlined performance, combined with durability. E.MC provides a wide range of pneumatic cylinders for the automation industry. With bore sizes ranging from 10 mm to 125 mm in the range available from Tom Parker Ltd, each element of the cylinder series has been engineered to produce superior performance and reliability. Cylinders are machined by high precision American and Japanese CNC robots and are automatically assembled and tested. Automated machining ensures bores are precisely cut; extending the life cycle of devices. Cylinder styles available from Tom Parker Ltd include the ISO 15552/ VDMA standard and profile cylinders, compact cylinders, the ISO 21287 compact cylinder, and guided cylinders, many available with a range of accessories, and backed by E.MC product specialist knowledge from experts at Tom Parker Ltd. E.MC products are already the first choice for many leading companies around the world. For more information, please contact Tom Parker Ltd, telephone 01772 255109 or visit tom-parker.co.uk.

www.tom-parker.co.uk

Safety has been CEJNâ&#x20AC;&#x2122;s top priority for many years, which led them to develop eSafe: a compact one hand operated, high flow coupling that vents downstream air before disconnection, eliminating the risk of hose whip. eSafe is an innovative and patented safety coupling offering the highest flow on the coupling market, combined with a low pressure drop. A low connecting force and easy to grip design makes eSafe the natural choice when choosing a safety product with top of the line features. Contact Tom Parker Ltd for more information on the eSafe range.

Sales: 01772 255109 | Online: tom-parker.co.uk

Request a catalogue: marketing@tom-parker.co.uk

Issue 45 PECM

MACHINING & MACHINERY

MAXIMISING DOWNTIME BLUM-NOVOTEST

Blum-Novotest launches virtual showcase to give industry a window to its production metrology One of the UK’s leading providers of production metrology is going online to help it deliver product awareness and technical application sessions during Covid-19. Blum-Novotest is looking to maximise any industrial downtime by offering new and existing customers the opportunity to take part in 60 to 90-minute sessions that will give them the chance to learn about the latest products and how they can be used to save time and improve accuracy. The company, which delivers its solutions to some of the world’s largest aerospace primes, car manufacturers and a host of CNC machine tool suppliers, is showcasing its DIGILOG touch probes/laser control and

PECM Issue 45

roughness gauges, as well as the latest LC-Vision software to boost machining performance. Six clients have already taken part as a way of finding out more about the Blum-Novotest portfolio, the benefits they provide and how technical experts can get the most out of the technology. “Whilst there’s nothing like visiting customers face-to-face and getting to the bottom of their needs, the virtual approach is certainly proving a very worthwhile exercise and is receiving significant interest from machine dealers and sub-contractors,” explained David Mold, Managing Director of Blum-Novotest in the UK.

“We have a lot of solutions that cover measuring components, measuring machines and test engineering, but some parts of industry will only know us for certain products. The online sessions give us a great opportunity to talk to and virtually demo all of our solutions, taking questions on application, installation and trailing new products that will be launched later this year.” He continued: “The feedback has been really good and we certainly believe that virtual sessions could remain part of our marketing mix alongside more conventional face-to-face meetings. It’s certainly going to be a major benefit for us with a lot of UK and international trade shows cancelled or delayed as a result of the pandemic.”

The feedback has been really good and we certainly believe that virtual sessions could remain part of our marketing mix

“We have only just started working with Blum-Novotest on a number of potential projects in the medical sector and my initial interest was focused on its roughness surface gauge. Taking part in this virtual session gave us all a much better understanding of the complete range and we’ve already identified a number of technologies that could support our customers.”

Premier Machine Tools (PMT), a specialist supplier of CNC machine tools and carbide cutting tools to the metal cutting sector in Ireland, has already taken advantage of the new Blum-Novotest online workshops. Six of its staff - from across all areas of the Kildare-based business - completed an introductory session to the range, exploring tool setting, workpiece and DIGILOG touch probes, including the recently launched LC50 that promises to be 60% quicker than conventional in-machine measuring. Dennis Ross, Key Account Sales Manager

for PMT, added his support: “Covid-19 has had a dramatic effect on the machine tools sector and the imposed lockdown has given us more time to understand technology that could support our ability to offer the best possible turnkey offer.

He concluded: “Our relationship with principals, such as Matsuura, Seco and Tornos, are built on years of trust and understanding and this is something that we are looking to build with David and his team. There’s lots of mutual synergies that will benefit our clients going forward and the next online session is already scheduled for a few weeks’ time.”

For further information, please visit www.blum-novotest.com or follow @Blumnovotestuk on twitter. Issue 45 PECM

MACHINING & MACHINERY

SPECIALISTS IN TOOLS & GAUGES WISEMAN THREADING TOOLS LTD

WISEMAN THREADING TOOLS LTD Specialists in Tools & Gauges for Screw Threads We have been supplying threading tools and gauges since 1987. Together with supplying plain plug and ring gauges this is all that we do, we therefore consider ourselves to be specialists in this field. We supply worldwide. We hold extensive ready stocks that include all of the standard stuff that others offer, but also includes taps, dies, die nuts, die head chasers, thread rolls and gauging for threads not normally available 'off the shelf '. Our real time stocks can be checked and purchased online at www.threadtools. com Just enter the thread details into the search box on the home page. You will be directed to the item, if stocked, or to our specials, (custom manufacture), sales team. who will quote to supply at competitive rates, in good time. As an account holder you can also order online from our listed in stock items, at your normal terms. We realise that you need the right item at the right price and quality, and in a reasonable time frame. We are geared to provide that. We can ship stocked items same day. Our experienced sales staff can assist and advise you on any technical issues. We welcome enquiries from resellers and can offer terms to suit. WISEMAN THREADING TOOLS LTD 11 Padgets Lane South Moons Moat Redditch B98 0RA UK 0044(1527)520580 sales@threadtools.com www.threadtools.com

For further information, please visit www.threadtools.com

PECM Issue 45

Threading Tool Specialists

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

THREAD CUTTING AND ROLLING HEADS and parts and repair service

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

HSS TAPS Huge Stocks for all Standard threads CUSTOM MADE taps our SPECIALITY! We stock taps for many non standard (SPECIAL) threads

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

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

All types; Spiral flute and point, Fluteless, Left Hand, etc, etc.

Wiseman Threading Tools Ltd 11 Padgets Lane, South Moons Moat. Redditch B98 0RA Worcs UK 004(0)1527520580 sales@threadtools.com www.threadtools.com Issue 45 PECM

MACHINING & MACHINERY

AUTOMATION WITH DRIVE KEB AUTOMATION

Machines & Controls Ltd chooses KEB drives and controllers for special purpose stone and slate cutting machines KEB Automation has supplied a variety of drives and control equipment to a UKbased machine builder for use on special purpose cutting machines for stone tiles and roof slates. KEB provided a complete solution from a single source and provided engineering support all the way through the machine design and build process.

conveyors pass over two cutter blades, which cut (‘hammer’) the slate to size. KEB COMBIVERT S6 drives control the position of the upper cutting blades, with two KEB servo motors driving the cutter heads. All controls for the two machines are housed in a single control cabinet with operator control joysticks

Based in Bridgnorth, Shropshire, Machines & Controls Ltd is a small, privately owned business that designs and manufactures special purpose machines. Established in 2018, the business specialises in the design and build of special purpose machines, including robotics and associated controls.

Wilson concludes: “On both machine projects, I was particularly impressed with KEB in terms of their technical capabilities and engineering support. They have been very helpful and have always responded promptly when I’ve needed support on resolving any issues. I look forward to working with KEB on future machine projects.”

Alex Wilson, Managing Director at Machines & Controls Ltd, states: “In 2018, we received an order for a stone façade cutting machine. The machine is a 5-axis CNC sawing machine that cuts stone tiles and cladding for buildings. Around the same time, we also received an order from another customer for two special purpose cutting machines for roof slates.” Both types of machine required a range of drives and control equipment and so Alex Wilson conducted a thorough supplier evaluation process. “In the end, I chose KEB Automation, as they were able to provide all the drives, controllers, gear motors and HMIs from a single source and were willing to provide engineering support through the machine design and build phases, which you don’t always get from other suppliers,” adds Wilson.

THE STONE FACADE CUTTING MACHINE For the 5-axis stone facade cutting machine, KEB supplied four COMBIVERT S6 drives, four servo motors, two gear motors and a COMBIVERT F5 inverter. All the control equipment is housed in a control cabinet which has an integrated HMI touchscreen display from KEB. With dimensions of approximately 3m

square by 2m in height, the machine comprises two conveyor bands with a bridge over and two 4kW powered saw blades in the X-Y axis. As the stone is moved down the conveyor, the saw blades can be programmed to add chamfers and slots in the stone. Each saw blade has two axes of motion (up and down/in and out). The machine is fairly low speed (up to 1.5 metres per minute), but is precise and accurate. Two KEB gear motors drive the conveyor bands. Four KEB servo motors (two per head) move the cutting heads. A KEB COMBIVERT F5 inverter controls the two geared motors for the conveyors. The machine is totally enclosed by protective guarding. All control equipment is housed in a control cabinet with KEB touchscreen HMI. As Wilson explains: “All the control programs were written by KEB using its COMBIVIS software. This meant we had KEB’s support through the design and build stages of the project, which was really crucial for us. We delivered the machine to the customer in February 2019, who is extremely happy with it. Since installing the machine, the customer has reported no issues at all.”

THE TWO SLATE CUTTING MACHINES The two identical slate cutting machines, which have dimensions of around 2m x 1m square, are inclined at 30 degrees and comprise of a pair of conveyors, each driven by a KEB servo gear motor. The

DRIVES, CONTROLLERS AND GEAR MOTORS Compact, flexible and powerful, the COMBIVERT S6 range of servo drives is suitable for a wide range of highly dynamic servo applications, including highly automated, safety-oriented machines. The drives provide optimal motor control in real time, integrated safety functionality and are designed in a compact, space-saving bookstyle format for easier mounting in control cabinets where space can be limited. The COMBIVERT S6 range is 100% in-house designed and built by KEB. The drives are available in two different enclosure sizes across motor power sizes from 0.75kW up to 5.5kW or electrical currents from 2.6A to 12.0A, with overload to 250%. The drives can be customised with a variety of design options to suit the specific application. Safety functionality can be selected from three modules to suit the requirements of the machine. In combination with its control systems and drive controllers, KEB also offers a wide range of servo motors and geared motors, including three-phase motors, servo motors, helical geared motors, shaft mounted helical geared motors, helical worm geared motors and helical bevel geared motors.

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

PECM Issue 45

MEASUREMENT & MONITORING

Epsilon Engineering can significantly improve your manufacturing productivity... Our core strengths are analysis and creating a design to solve your production or process problems – helping your organisation to become more profitable! Our customers usually need ‘bespoke’ solutions. We study the requirement in detail, and discuss with you the customer the most appropriate way of upgrading a manufacturing, packaging or safety process. We have been acquiring a wealth of experience since 1989. We have modified existing machinery, built new machinery, re-tooled or reconfiguring production lines and upgraded machinery safety systems to meet current standards. We have also built palletising, and special purpose handling robotic systems using Kawasaki, ABB and Kuka robots. We fit in as an extension of your engineering department, and without the day to day distractions that they face, we can move forward swiftly with solutions that pay for themselves quickly. We use Solidworks for our CAD and simulation and we can also provide CAD drafting at competitive rates, either from our offices or on-site.

We have worked with customers at their sites and with their suppliers across Europe … our customers include Cadburys, Knauf UK, Northern Foods, and Lavazza Professional.

For further information visit our web site epsilon-engineering.uk or call us on 01732 760066 or 07802 204421. We are ISO9001:2015 registered.

For further information visit our web site epsilon-engineering.uk

Manes Controls Ltd Manes Controls Ltd have a long-established reputation and expertise in control system design and manufacture, we now bring all this experience to our range of standard inverter drive products. Please have a look at our full range of motor speed control panels now available to purchase online with 3-5-day delivery times.

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

These panels can be used for various applications such as conveyor belts, fans, centrifugal pumps, hoists, mixers, grinding machines and many more………….

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

www.manescontrolsltd.co.uk

Issue 45 PECM

HIGH PERFORMANCE DIFFERENTIAL PRESSURE TRANSMITTERS The Kobold PAD differential pressure transmitter is a microprocessor based high performance transmitter, featuring flexible pressure calibration and output with automatic compensation of ambient temperature and process variables; configuration of parameters communicated via HART®

Superior Performance & Reliability • High Reference Accuracy: ±0.075% of calibrated span • (optional: ±0.04% of calibrated span) • Long Term Stability: 0.125 % URL, with capacitive or piezoresistive sensors • High Rangeability • Data configuration with HART® configurator, • push buttons, or factory • Zero Point Adjustment • Continuous self-diagnostic function • Automatic ambient temperature compensation • EPROM write protection • Fail-mode process function • CE EMC conformity standards (EN 50081-2, EN 50082-2) • ATEX Exd Flameproof • ATEX Exia Intrinsically Safe • With individual diaphragm seals fitted, applicable for steam, gases, liquids, and for critical media

precise - multifunctional - reliable – proven For your FREE Product Summary Brochure

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

DON...LCD Low & High Viscous Liquids

• • • • •

• • • •

Petroleum High Viscose Resins Inks Pastes

DON--M Mechanical Counter

OVZ Non-Metallic Rotors

DON/OVZ

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

Lubrication Hydraulics Oil Grease Diesel Fuel

For Application examples:

DON-H HIgh Pressure

Producing one of the most comprehensive ranges of flowmeters for the measurement and flow control of viscose liquids

POSITIVE DISPLACEMENT FLOWMETERS Manufactured by Kobold

Quality Engineered Instruments

MEASUREMENT & MONITORING

Gas Flow Meter Calibration

Thermocouple Cables / Wire

Air and gas flow laboratory offering three UKAS accredited flow calibration rigs for the calibration of mass flowmeters, flow controllers, thermal, laminar, coriolis, turbine, vortex differential pressure sensors and variable area flow meters across 1 cc/min to 4500 m3/hr and to a 300 mm diameter line size.

Labfacility offer a wide range of thermocouple, PRT and extension cables / wire in stock for immediate despatch.

Ability to flow calibrate in suction and blown methods for differing meter types.

We also offer retractable curly leads and extension leads.

Thermocouple cables are available in IEC or ANSI colour codes. Insulation types include PFA, PTFE, PVC & Fibreglass.

For smaller bore flow meters and lower flows, flow meters can be calibrated on inert gases traceable to national standards.

Young Calibration Ltd 5 Cecil Pashley Way Shoreham by Sea West Sussex, BN43 5FF Email: ay@youngcalibration.co.uk Tel: 01273 455572 Web: www.youngcalibration.co.uk/ calibration/airflow-calibration

T860 EN 180x132.indd 1 56 PECM Issue 45

www.labfacility.com/thermocouple-cableswires.html

New PhoenixTM ATEX Certified Finishing System PhoenixTM has complemented its range of ‘Thru-process’ Finishing temperature profiling systems with the new FIS04 ATEX system. Developed for automotive paint plants, where paint engineers face demanding challenges of ATEX classification requirements, for safe operation of monitoring systems. At the heart of the PhoenixTM FIS04 ATEX system, the Intrinsically Safe PTM1410 Epsilon-x data logger certified to Group II Category 3G allowing safe operation in Zone 2 ATEX classified areas (eg: paint booth, flash off zone and cure oven). Providing up to 10 points of measurement, paint processes can be monitored accurately and effectively. Thermal View Finishing software provides graphical cure analysis tools for verifying process compliance with ease. Tel: 01353 223100 sales@phoenixtm.com www.phoenixtm.com

29/04/2020 15:19

MEASUREMENT & MONITORING

FROM SIMPLE TO COMPLEX VEGA

New sensors and switches portfolio for food, beverage and automation With the launch of its new low cost high specification VEGABAR pressure switch/ sensor and VEGAPOINT level switches, it enables VEGA to help customers in even more areas in the food and beverage production processes. This brand new compact instrument series is perfectly tailored to the standard applications that still require high quality and strict hygiene. The new level and pressure devices have a universal adapter system of process fittings that provide the flexibility needed to keep installation and spares inventory costs low. A unique ultra-bright, eyecatching, 360° illuminated status display ring ensures visibility, safety and process reliability. Its status colours can be customselected easily seen from any direction – even in bright daylight. Some of the new pressure switch/sensors feature displays and keypads with dual easy-read text and VDMA menu, ensuring the right set up every time and easy understanding of pressure measurement or switch status. Another prominent feature of the instruments is their communication capabilities. They feature Bluetooth wireless, which offers another option for safe remote and easy set up or function check of devices without the need for a PC, cables or connectors. Just download the free, simple (and award-winning) VEGATOOLS App. Also available is the IOLink protocol, this ensures compatibility, intelligent data transfer and simple, fast system integration.

The new VEGABAR compact pressure switch/sensors and VEGAPOINT compact capacitive level switches. They feature a super-bright 360° status display, selected from 256 different colours, easily seen from any direction.

A unique ultra-bright, eyecatching, 360° illuminated status display ring ensures visibility, safety and process reliability. More information available at www.vega.com

PECM Issue 45

RADAR IS THE BETTER

ULTRASONIC

Compact 80 GHz level sensor with in-head display

Â£646 VEGAPULS VEGAPULS 31 31

All All advantages advantages of of the the radar radar technology: technology:

www.vega.com/vegapuls

NEWS & EVENTS

AUTOMATED QUALITY CONTROL OIA

Quality assurance detection rate up by x30 for inhaler manufacture The leak detection rate for in-line pharmaceutical gas analysis during inhaler production has increased by 30 times following the introduction of a new automated quality control solution. The robotised system for Metered Dose Inhaler (MDI) manufacture built by Optimal Industrial Automation means significantly reduced cost and wastage in quality control for MDI manufacture. It’s essential that MDI canisters, typically used in asthma type inhalers, are produced with an optimum level of gas propellant, but effective leak testing has traditionally been problematic. The MDI manufacturer’s objective was to implement 100% quality assurance of all cans while reducing cost and wastage. The company selected Optimal Industrial Automation to design a system based on its 30-year plus

experience integrating high-speed and high accuracy quality control equipment. Optimal’s track record in resolving complex challenges with a range of high-profile brands within the pharmaceutical, chemical and food and beverage industries provided the confidence that an ideal solution could be found. Manufactured in vast volumes, MDI canisters are traditionally batch tested. The challenge for the manufacturer is that if a single canister is defective, the entire batch may be scrapped. This means potentially high wastage, increased cost and reduced efficiency of production. Instead, the manufacturer’s objective was to achieve testing of 100 per cent of canisters, meaning scrappage of only individually rejected MDIs. This was achieved thanks to Optimal’s design of a puck, robot and conveyor

system with an integrated gas analyser. The pick and place action and synchronisation was provided by SCARA robots, a PLC and SCADA software from Mitsubishi Electric. “The application demands a high degree of accuracy to achieve the synchronisation required for a throughput of 180 cans per minute,” says Martin Gadsby, Director, Optimal Industrial Automation. “Reliability has been confirmed through extensive testing and we are now able to identify and reject individual canisters in a continuous process situation. This means significantly less wastage in manufacture and ultimately a reduced cost of production.” Optimal’s system runs on its own communication sub-net but communicates process flow signals both up and downstream.

By leveraging an innovative automated quality control solution, which uses pucks, robot and conveyor systems with an integrated gas analyser, a meter dose inhaler (MDI) manufacturer increased the leak detection rate for in-line pharmaceutical gas analysis by 30 times.

PECM Issue 45

Reliability has been confirmed through extensive testing and we are now able to identify and reject individual canisters in a continuous process situation. around the MDI cannister is purged, with the pucks then individually sealed. The location of the individual MDI canister is identified before the gas analyser removes a sample from the puck to measure any propellant gas leakage. Extremely low gas leak rates have been proven to be reliably detected. Speed and accuracy of integrated communication is vital, where the result is communicated by dedicated active digital signal to an industrial PC running Mitsubishi Electric’s MAPS SCADA software, which analyses the data. The status of the individual MDI test is logged by the PLC. The MDIs are then removed from the pucks by the robot to a constant speed outfeed conveyor, with their location tracked. Exacting synchronisation by the robot is necessary to ensure accurate placement of the MDIs, but in the unlikely event, fallen canister detection also features. MDIs with identified leakage are removed at a reject station on the outfeed conveyor and collected in a reject bin with level detection. The volume of canisters which ‘pass’ is monitored as well as the number of rejects, with an alarm in the event of an excessive reject quantity.

The carousel conveyor transports the pucks through a gas analyser system tunnel, containing a gas leak detector. MDIs with identified leakage are removed at a reject station on the outfeed conveyor and collected in a reject bin with level detection. Taking MDI canisters from an upstream external conveyor, it moves them onto an infeed conveyor with upstream machine monitoring and queue control ensuring synchronisation. MDIs are then picked and placed into individual pucks, six at a time and transported on a constant speed carousel conveyor, with queue control maintaining back pressure to prevent misfeeds. If required, fallen canister detection will signal an alarm for operator intervention. Accuracy and repeatability are critical to ensure speed and reliability of operation, carried out by two, four-axis Mitsubishi

Electric’s RH6 SCARA pick and place robots; one operating infeed of the puck contained MDIs, the other the outfeed. The robots are controlled by a high-end Mitsubishi Electric’s Q Series PLC. Steve Kirby, Key Account Manager at Mitsubishi Electric, adds: “To meet the high levels of accuracy required by the system, we put together a highly integrated suite of highperformance components.” The carousel conveyor transports the pucks through a gas analyser system tunnel, containing a Cascade CT300 gas leak detector, also controlled by the PLC. Immediately before entering the tunnel, air

Full downstream machine monitoring enables smooth flow of returning MDIs, with optional downstream queue switch to prevent build-back onto the production conveyor. Controls for temporary buffer storage via a rotary table are also available. The resulting throughput is 180 canisters per minute. Mitsubishi Electric’s MAPS also produces an exportable report of canister analytical data for each batch, stored in an SQL database, accessed via the IPC’s touchscreen display. Extensive tests of Optimal’s system have been carried out, combining high detection rates with speed, accuracy and repeatability. The machine is now available as a standard proven design, meeting pharmaceutical regulations FDA 21 CFR Part 210/211 - Pharmaceutical Industry GMPs, and FDA 21 CFR Part 11 – Electronic Records and Signatures.

For further information, please visit www.optimal-ltd.co.uk Issue 45 PECM

NEWS & EVENTS

A VIRTUAL SOLUTION V-EX

Iconic exhibition venues to build digital twins

Some of the world’s most iconic exhibition venues now have the impetus to construct digital versions of their physical halls and buildings. Some of the world’s most iconic exhibition venues now have the impetus to construct digital versions of their physical halls and buildings. Using virtual exhibition platforms such as V-Ex, which already hosts full-scale digital exhibitions such as IndustryExpo.online, traditional venue owners can now rely on rendering physically accurate trade shows using real-world lighting, materials and dimensions to recreate virtual twins. The ‘virtual’ halls can look visually identical to the bricks and mortar versions and host most of the same trade shows. V-Ex Director of Marketing, David Bedford, comments, “We have been building virtual environments and the content management platform that supports them for over ten years and we know what works. Most trade

shows that deal with services, physical products or software transfer very easily to a digital format. “Machines, technology, components, toys, planes, trains and automobiles all work well - live animals and arena events not so much! Seminars, presentations and conferences are great as we can prerecord or live steam those events; it’s like Netflix, but much more interactive.” The visitor experience at an online event is different to a live show, but it has its advantages in terms of 24/7 accessibility and longer show durations. A well-known venue such as the NEC in Birmingham with multiple halls could easily offer the same floor space digitally. Visitor numbers will also be higher, as transport, scheduling and health concerns are no longer an

issue. Recreating an iconic show venue like Olympia for example would have the same attraction to exhibition organisers as the real thing. “It remains to see which venue owners and operators will embrace the opportunities that virtual exhibition venues offer. Those that do will be providing their customers with a flexible solution that includes a physical show and a digital online virtual equivalent. Recent events and a general trend toward online solutions for everything from shopping to healthcare and gaming would suggest that the early adopters will have an advantage.” The V-Ex virtual exhibition platform can be used to recreate any physical venue and offer traditional exhibition organisers a whole new world of opportunities.

For further information, please visit www.V-Ex.com

PECM Issue 45

NEWS & EVENTS

Specialist Funding Support to Business Is your company one of the 97% of businesses that incorrectly assume they can’t apply for funding to support their innovative work? MCS Corporate Strategies Ltd provide specialist funding support to businesses, with a core focus on cost recovery. As an independent consultancy, we help businesses and institutions to access the government grants and incentives they’re entitled to. This includes Research & Development, RDEC and Patent Box. Research & Development Tax Credits form a key part of Government strategy to boost innovation in business. This tax relief scheme reduces the real cost of investment in improving products and processes and remains one of the largest single Government funding mechanisms available for business. We make the whole identification and application process quick and simple. 1. We identify your eligibility and take the difficulty and stress out of making a R&D claim. 2. We work with you to gather the details and then prepare all submission documents. 3. We liaise with your accountants and HMRC to submit and process your claim. 4. We handle the entire claim process, from initial assessment to completion.

The single key criteria for qualification is that you be registered as a UK corporate entity. Claims are retrospective (two years) and intended to be claimed year-on-year. SME’s and large companies qualify. Manufacturing, engineering and all disciplines, activities, parts, products, prototypes; IT software and first-of-class items are examples of what is included as items for research and development. The CIRD definition of R&D is wide and inclusive of very broad activities.

We work on a success fee basis only so there’s no initial cost – you’ve nothing to lose. Telephone: 01926 512475 e-mail: charlotte@mcs-corporate.com

www.mcs-corporate.com

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

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

Using a blend of live, online classes, one-to-one sessions with expert tutors, and e-learning, enhanced by a mentor’s support and guidance, EEMUA’s Mechanical Integrity Practitioner Certificate course delivers in-depth training to engineers where they work – to give professionals the flexibility to learn on-site or on-call. The next EEMUA MIPC® course: Learning starts in September. Enrolment to suit your schedule July – September. For more information please contact EEMUA online-learning@eemua.org +44 (0)20 7488 0801 www.eemua.org

Issue 45 PECM

NEWS & EVENTS

A WORLD OF OPPORTUNITIES SIEMENS

‘International Women in Engineering Day’: Siemens at forefront of recruiting women into manufacturing Sarah Black-Smith from the Siemens Congleton factory says engineering has opened a world of opportunities for women Manufacturing has been a male bastion for centuries. Over the years this has changed and although there is still a long way to go women are now represented in many manufacturing disciplines. Siemens is constantly striving to build an innovative and diverse culture. With a 78 per cent male employee base in the UK there is still an urgent need to attract women to the company and to engineering and manufacturing in general. Brian Holliday, Managing Director Siemens Digital Industries, said: “The digital revolution in industry is an opportunity to build better balance. Although figures are improving, the UK still languishes amongst the lowest when it comes to the percentage of female engineering professionals in Europe1, yet our industry needs more than ever, the talent, skills and experience of women to create competitive advantage.” As the world marks the ‘International Women in Engineering Day’ on June 23, Siemens is working hard to ensure that more women join the manufacturing sector. The company has taken concrete steps to proactively make its job adverts more gender neutral, supported them with videos giving applicants an insight into the workplace, to bust a few myths about the manufacturing environment. Siemens hired 40 per cent female graduates in 2019, compared to 29 per cent in 2018. In January 2020 from a total of 555 apprentices across all Siemens businesses in the UK, 96 were female, around 17 per cent, a slight reduction from previous years but a realistic indicator for the 2020/21 academic year. It is trailblazers like Sarah Black-Smith who help demonstrate that women are equally capable of leading in the manufacturing profession. She is now the Head of factory operations at Siemens’ award-winning factory in Congleton which produces one million drives and controls per year and

PECM Issue 45

employs 300 people using the latest digital tools and automation.

trying to save costs, but most importantly, working with diverse sets of factory teams.

Graduating from Loughborough University in 2004 with a BEng in Manufacturing Engineering and Management, Sarah went on to complete a Masters in Operations Excellence and worked on her placement year for Alstom in Lincoln.

“I moved through the ranks quite quickly, going from Cell Manager to Manufacturing Manager looking after teams of 30 people on the shop floor. I was quite young, but it gave me a great footing in a factory environment. After a few years in Lincoln, a Production Manager role came up at our site in Congleton. I jumped at the chance, my husband and I had already decided we were ready to move back to the North West to be closer to family.

“It was quite lucky really that six months into my placement at Alstom, the site was sold to Siemens in 2003. I was then sponsored through my final year and taken on by Siemens as a graduate. I joined at the age of 22 as a Lean Implementer.” The role was within Assembly and Test, meaning that once the gas turbines were assembled, they were put into the test bays and run up to speed. Core to this early role was identifying process improvements and

“I was promoted to the role of Head of Factory Operations, which is what I’m doing now. I am responsible for all of production, the engineering teams including maintenance test engineering, product and process engineering, and I lead the Lean Operations.”

As the world marks the ‘International Women in Engineering Day’ on June 23, Siemens is working hard to ensure that more women join the manufacturing sector Sarah and many other female colleagues have demonstrated that women can excel and flourish in the manufacturing sector. “The world of manufacturing and engineering has opened up huge opportunities for women,” says Sarah Black-Smith. “We have seen a significant increase in the number of women joining the manufacturing sector but more needs to be done. “What needs to change is the mind-set of women and those working in factories. “The options in engineering are wide and varied, from mechanical and electrical and now there is convergence of internet technology and operational technology. Students aspiring to be engineers already come with knowledge of computing from school and this is an added bonus in the world of engineering.”

Sarah has recruited and mentored many graduates, interns and apprentices over the years and since the launch of the Congleton Junior Factory in 2014 she takes a lot of them under her wing. An example is 25-year-old Ashleigh Sumner. In 2014, after getting good A-levels in maths, physics and product design, she was not so keen to take the university route and applied for apprenticeships in engineering. She joined the Siemens apprentice programme as part of its first cohort of trainees at the Congleton Junior Factory. While there, she completed her Higher National Certificate and then achieved a first-class honours degree in Control and Automation Engineering from Salford University in 2018. Six years on she is a product manufacturing engineer at Congleton. “It has been a wonderful journey and intense learning experience for me at Siemens,” says Ashleigh. “I am well accepted by my colleagues and they respect me. I love my job. I am always pushing myself to do better and to go the extra mile. This is the best thing that has happened to me. I can’t imagine a different path for myself.” Ashleigh’s ambition is to get into management and head the department as a next step. Ashleigh sees Sarah as her idol and remembers advice she gave her as an apprentice, “If you’re presented with an opportunity, no matter how small, and your initial instinct it to run in the opposite direction because it scares you, that’s a sign

for you to jump at it as it will definitely open new doors”. Siemens is constantly looking at new ways to encourage women into the engineering field. It has invested in initiatives like ‘Future Females’ which sponsors engineering scholarships and bursaries through The Institution of Engineering and Technology’s Horizons bursary programme. Siemens continues its push with grass roots level initiatives, which include ‘SeeWomen’ an interactive show helping schoolgirls think seriously about careers in engineering. In 2019, the programme was attended by 1,000 schoolgirls across the country and 2,400 teachers accessed the supporting downloadable resources. For 2020 the programme has been re-branded to ‘SeeMe’ with a view to reaching diverse groups and encourage careers in STEM. The company also has many dedicated employees who go into local schools to inspire young people to consider STEM careers. Holliday says: “I see huge potential for women to succeed in engineering and technology companies, in every kind of role from management and manufacturing, to projects as well as sales and service and Sarah and Ashleigh are great examples. At Siemens, we actively build inclusion into our thinking to see that people’s talent shines through. The International Women in Engineering Day is a potent reminder that now is the time to ensure women are able to excel in workplaces across industry. Siemens supports this stance wholeheartedly.”

For further information, please visit www.siemenc.co.uk/diversity Issue 45 PECM

NEWS & EVENTS

MARKET LEADERS PROFIBUS & PROFINET INTERNATIONAL

Practical Aspects of PROFINET, PROFIBUS and IO-Link Long before the advent of the Industrial Internet of Things, Industry 4.0 and “Smart Manufacturing” a group of leading equipment manufacturers and technical universities came together with the goal of helping German industry automate and standardise as many production processes as possible and link them effectively to IT management systems. This was the beginning of PROFIBUS, closely followed by PROFINET and IO-Link. Now with nearly 80 million nodes installed worldwide, PROFINET, PROFIBUS and IO-Link are truly market leaders, providing state of the art digital communications addressing all the needs of manufacturing and process industries, significantly lowering capital expenditure on installation, commissioning and maintenance.

LEARN MORE ABOUT PROFINET, PROFIBUS AND IO-LINK PI UK is organising a number of free-toattend training opportunities in Birmingham (April 28), Scotland (May 27) and Belfast (June 23). These events are designed to address the opportunities and key practical issues arising from the use of PROFINET, PROFIBUS and IO-Link digital communications technologies in automated manufacturing and process industry applications, paying particular attention to Industry 4.0 and the Industrial Internet of Things (IIoT). Supported by an exhibition with demonstrations of actual tools used in configuration and maintenance, these events will cover key application areas

such as control systems and energy management, pulp & paper, chemical, utilities, pharmaceutical, mechanical handling and logistics, robotics, automotive engineering, electrical and electronics assembly, packaging and printing, from system design and safety & security considerations through to fault-finding and maintenance.

to IoT technologies using OPC-UA. This presentation, including live demonstrations, will take a “how it’s done” approach using products from several well-known manufacturers and will include:

WHO SHOULD ATTEND?

• Profinet - IO-Link

The seminar and exhibition will be of great value to Designers, Production/ System Engineers, Instrument Technicians/ Engineers and C&I Engineers involved in the design, operation and maintenance of modern automated factories and process plant.

ABSTRACTS FROM THE SEMINAR PRESENTATIONS INTRODUCTION TO PI GROUP – INCLUDING HIGHLIGHTS OF NEW SUPPORTED TECHNOLOGIES An overview of the Group’s structure and global representation, taking a look at the protocol basics and their differences, plus showing the progress of the number of installed devices from the group’s supported technologies and relating these figures to their market share.

NETWORK GATEWAY TECHNOLOGY A vendor-independent overview of how to connect PROFINET networks to existing fieldbuses and expose the data

• Profinet - Profibus DP • Profinet - Profibus PA • Profinet - CANOpen • Profinet - OPC UA

PROFINET NETWORK DESIGN It is widely accepted that the most important decisions are made at the design stage of a project. This presentation examines the fundamental principles of good network design for PROFINET systems, although many of the ideas are applicable to PROFIBUS and other networking systems. The presentation will discuss the main factors that must be considered at the design stage of an automation system. Practical examples will show how facilities for health checking, fault-finding and maintenance can have a crucial impact on plant availability. The presentation will also examine how properly thought out network monitoring and redundancy can drastically affect plant up-time and thus profitability.

INDUSTRIAL NETWORK COMMISSIONING & TESTING Take a walk through the process of certifying a new PROFINET (or any other industrial Ethernet) product against the standards and see how easy it can be, then look at a few gotchas that can easily be avoided by careful planning. Learn how to simplify the process of testing both cabling and networks in Industrial Ethernet networks that utilise the PROFINET protocol, how to prevent network failures and resolve cable and network issues faster.

PROFIBUS AND PROFINET DEVICE CONFIGURATION TOOLS. A look at the available device configuration tools and their development including the move to unify the different types into one format – FDI.

PECM Issue 45

PROFINET, PROFIBUS and IO-Link Training Opportunities Learn more about PROFINET, PROFIBUS and IO-Link PI UK is organising a number of freeto-attend training events across the UK designed to answer your questions and show you how to address key practical issues in automated manufacturing and process industry applications. Paying particular attention to Industry 4.0 and the Industrial Internet of Things (IIoT), they will cover key application areas such as control systems and energy management in chemical, utilities, pharmaceutical, logistics, robotics, automotive engineering, electrical and electronics assembly, packaging, printing, pulp & paper - from system design and safety & security considerations through to fault-finding and maintenance. Topics will include: • Introduction to PI Group – including highlights of new supported technologies - An overview of the Group’s structure and global representation, taking a look at the protocol basics and their benefits to UK industry. • PROFINET network design - The fundamental principles of good network design and the main factors that must be considered at the design stage of an automation system. • Network gateway technology - Presentation and demonstration of network gateway technology,

PROFINET to Profibus DP, PA, IO-Link and OPC UA • Industrial network commissioning and testing - Learn how to simplify the process of testing, how to prevent network failures and resolve cable and network issues faster. • PROFIBUS and PROFINET device configuration tools - A look at the available tools and FDI with a live demonstration of PROFIBUS and PROFINET device configuration. • Industrial networks safety & security - The basics of legislation and responsibilities for cybersecurity,

More information and online Registration: Birmingham, April 28 - http://bit.ly/PUK28April Glasgow, May 27 - http://bit.ly/PIUKScotland Belfast, June 23 - http://bit.ly/PIUKBelfast

• Update on Industry 4.0, IIoT, TSN and APL - Explanation of IIoT, IND4.0 and Big Data, and how PROFINET is placed as the ideal network to fulfil the above. Who should attend? Supported by an exhibition with demonstrations of actual tools used in configuration and maintenance, these seminars will be of great value to Designers, Production/System Engineers, Instrument Technicians/Engineers and C&I Engineers involved in the design, operation and maintenance of modern automated factories and process plant.

Contact PROFIBUS & PROFINET International - PI UK: Tel: 02081 449 597 Email: uk@profibus.com Web: profibusgroup.com you expect to be seeing from PI in the not too distant future. We will also consider the impact of open architectures/systems, common technology, international standards and last but not least trust in technology.

This will be followed by a live demonstration of PROFIBUS and PROFINET device configuration using an existing open platform and web browser option.

INDUSTRIAL NETWORKS SAFETY & SECURITY The concept of Industry 4.0 and Smart Manufacturing has gained plenty of traction in the marketplace. What does this greater acceptance of Industry 4.0 mean for Functional Safety and Cybersecurity in Industrial Automation and Control Systems (IACS)? In this presentation we will quickly discuss the basics of Functional Safety and Cybersecurity for PROFI based

safety and functional safety for Industrial Automation.

INDUSTRY 4.0 AND THE INDUSTRIAL INTERNET OF THINGS (IIOT)

applications and then we will consider the impact on these areas from Industry 4.0 in the short and medium term. What should System Integrators and Product Manufacturers be doing now and what can

A short journey to explain IIoT, The Industrial Internet of things, IND4.0 from IND1.0 and Big Data. How PROFINET is placed as the ideal Industrial Fieldbus to fulfil the above, how it is implemented and why you should consider it. Some of the myths explained.

For further information, please visit uk.profibus.com and profibusgroup.com Issue 45 PECM

NEWS & EVENTS

BMPA WEBSITE REFRESH BPMA

BPMA Relaunches Skills Development Websites

The British Pump Manufacturers Association (BPMA) – the organisation which represents the business interests of UK and Irish suppliers of liquid pumps and related pumping equipment - has refreshed and relaunched two of its dedicated skills development websites. In line with recommendations presented to the BPMA Council, and following full acceptance of those proposals, the BPMA’s E-Learning and Certified Pump Systems Auditors (CPSA) websites have been updated and brought into line with the main BPMA website. The changes include easier access for users, a simpler, more intuitive

online experience and greater synergy with the BPMA’s overall corporate identity. These updates have now been completed and can be viewed and enjoyed by following the links shown below:

the BPMA’s E-Learning and Certified Pump Systems Auditors (CPSA) websites have been updated and brought into line with the main BPMA website.

Main BPMA Website www.bpma.org.uk | CPSA Website www.bpma-cpsa.co.uk | E-learning Website www.bpma-elearning.co.uk

PECM Issue 45

NEWS & EVENTS

Fabricator completes £1.3 million investment SevenHills Fabrication, one of the Steetley Corner Group of companies, has completed an investment programme worth more than £1.3 million.

“Our plan is to continue expanding our operations following a decade of growth and having the technology, equipment and skills to run a manufacturing operation which continually adapts and improves is the future for this company. This approach should be the standard for British manufacturers.”

The Sheffield company, which has demonstrated 31 per cent year-on-year growth with a turnover of 3.5 million GBP, has completed its investment drive with the installation of a £200,000 press brake and a £150,000 robot welder. The latest investments have been supported by the Sheffield City Region Business Investment Fund and enable SevenHills Fabrication, a specialist fabrication and laser cutting business based at the city’s Holbrook Industrial Estate, to continue its transition into Industry 4.0 operations. Managing director of SevenHills, James Harding-Terry, said: “The company’s transition to industry 4.0 is essential for future-proofing the business. “Over the past three years, SevenHills has installed a £550,000 Bystronic fibre laser cutting machine, a £60,000 electric tubebending machine and a £250,000 computer system for full mapping of production, accounting, purchasing and distribution. “The new machines complete a substantial

investment programme for us that really sets this company apart from traditional fabrication businesses as we take on increasingly complex and challenging projects across a range of sectors.” SevenHillls, which can trace its history back to 1926, has completed other investments, including £50,000 on improved extraction facilities, LED lighting throughout its operations and measures to improve the company’s energy consumption, waste material ratios, local environment and staff working conditions. James added: “Operating in conjunction with new machines such as the tube bender, press brake and our robot welder, the computer system will help to up-skill our workforce so that they are able to adapt to Industry 4.0 methods.

SevenHills’ growth contributes to Steetley Corner Group’s £8.9 million turnover, growing at 23 per cent. James Harding-Terry added: “Aside from the challenges and opportunities presented to industry through Brexit, the UK has to achieve manufacturing stability, growth and global excellence so that domestic businesses like ours may succeed. We must compete at the highest level, adopting the best resources available.” SevenHills Fabrication supplies high technology solutions to aerospace, defence, hygiene, medical, oil and gas and agricultural sectors and its output covers bespoke single items through to large batch production. Steetley Corner Group incorporates IT consultancy company, Acuma Technology, towbar specialist PCT Automotive and SevenHills Fabrication, based at Sheffield’s Holbrook Industrial Estate.

www.sevenhillsfabrication.com

WES Ltd. appoints new Sales and Marketing Director

Babcock Wanson appoints new managing director

WES Ltd., the leading UK manufacturer of chemical dosing systems, is delighted to announce the appointment of Graham Ward as Sales and Marketing Director. Graham’s extensive experience includes a number of senior roles working for various SMEs and large organisations in the water, power generation, petrochemical, marine and food & beverage industries. As a qualified marine engineer, Graham has established his career in Sales and Business Development both in UK and overseas markets, with a strong emphasis on water and gas treatment, as well as fluid handling.

Industrial boilers and process heating equipment specialist Babcock Wanson is pleased to announce the appointment of David Hatswell as its new UK Managing Director.

Kevin Wheeler, Managing Director says: “Graham has the right skills and experience to deliver further growth as we gear up to support customers in AMP7 and maximise opportunities throughout industry. We’re delighted to have him on board!” For further information on WES products and services, visit www.wes.ltd.uk.

The first five years at Babcock Wanson saw David learning the ropes as a Service Engineer, moving on to Commissioning Engineer before taking on the role of Field Service Manager at the company’s headquarters in Borehamwood, Hertfordshire. In 2016 David was promoted to Service Division Manager and this year takes over the reins from Chris Horsley as the Company’s new Managing Director. Chris, who is now Process Engineering Director, will support David in his new role over the coming months. For more information, please contact Babcock Wanson on 020 8953 7111 or info@babcock-wanson.co.uk or go to www.babcock-wanson.co.uk

BOGE’s total compressor rental service guarantees industry the air to work BOGE, a leading manufacturer of compressed air systems, is helping businesses across industry to cost effectively meet both short- and long-term demand for compressed air through its total compressor rental service. The highly affordable service offers businesses an alternative to owning and maintaining their own compressors. BOGE and its network of experienced distribution partners specify compressed air systems based on the needs of each business, ensuring customers are consistently supplied with the correct volume of compressed air required. Skilled engineers oversee a fast installation and commissioning process and provide 24/7 nationwide service and maintenance support as part of the monthly fee. Further information on the compressor rental service is available at www.boge.co.uk. Issue 45 PECM

PRODUCT NEWS

Ecoseal Ecoseal is approved to Gas Industry Standard (GIS) Leakage Control (LC) 25. It is the only product on the market to have achieved the specification set out in GIS LC25. The specification sets out the requirements for flexible joint penetrating sealant repair systems for external application to ferrous distribution pipes with either lead/yarn or mechanical type joints. The maximum operating pressure must be equal to or less than 2 bar, in areas where pipe movement might be experienced. There are three viscosities of Ecoseal, thick, thin and ultra-thin. Each variety is designed to repair a different leaking, corroded or damaged joint. This includes mechanical, lead yarn and tightly packed joints. Ecoseal is a two-part Polyurethane resin. This means a chemical reaction takes place when the two parts meet and combine. The process is user and environmentally friendly as no toxic fumes or chemicals are released. Ecoseal provides an alternative to encapsulation repair systems. It is time-saving and costsaving because it eliminates the need for site assessments and measuring for encapsulation muffs. It provides an option to inject through the socket or directly through the lead joint face. Ecoseal can be used on spigots, mechanical joints, socket joints, and valves. It can be used on a range of pipes up to 2 bar pressure.

admin@mwpolymers.co.uk | 01332 835001 | www.mwpolymers.co.uk

A full range of bespoke industrial graphics products MTM Products have been established for over 40 years and manufacture and supply industrial graphics products including selfadhesive labels, metal nameplates, graphic overlays, engraved labels and vinyl cut decals. We recently supplied over 10,000 front fascia for nurse call handsets for the emergency Nightingale Hospitals set up throughout the UK. As well as supplying original equipment manufacturers in the medical sector, we are also a leading supplier to the automotive, industrial, electrical, rail, construction and life safety sectors. MTM Products has remained open for business throughout the COVID-19 pandemic and have maintained a capability to produce a full range of bespoke industrial graphics products for both existing customers and new customers whose existing suppliers have not been operating. Contact us at sales@mtmproducts.co.uk or www.mtmproducts.co.uk

PECM Issue 45

RRC Live Online Courses • RRC have created a new course delivery option that blends the dynamic of classroom based learning with RRC’s highly regarded Online Learning. RRC are now offering Live Online courses for: • NEBOSH National General Certificate in Occupational Health and Safety • NEBOSH International General Certificate in Occupational Health & Safety • NEBOSH HSE Certificate in Process Safety Management • IOSH Managing Safely

ESAB’s Dual Shield® Prime lowhydrogen fcaw wires feature laser-welded seams to combat moisture absorption

With work underway to offer this method of learning for our NEBOSH Diploma courses in the next few months. Live Online courses run on scheduled dates just like a classroom course. Everything required to study is accessed and launched through our easy to use Learning Centre. There are specific study schedules for each day as well as all the resources needed to successfully study the course.

ESAB’s Dual Shield® Prime is a family of seamless, low-hydrogen (H4) non-coppercoated flux cored wires that combat moisture absorption in humid environments, delivering impact toughness down to -60 oC. Tests performed in accordance with AWS standards show an initial level of 2.17 ml of diffusible hydrogen per 100 g of deposited weld metal; after one week of exposure with a 90% RH at 30 oC, Dual Shield Prime demonstrated just 2.35 ml of diffusible hydrogen. “We laser seal the seams, so there’s no chance of Dual Shield Prime picking up moisture,” says Neil L Farrow, Global Product Manager, Flux Cored Wires, ESAB. “Even after extended storage and exposure, these H4 wires retain their low hydrogen properties. Where procedures allow, Dual Shield Prime’s low diffusible hydrogen may eliminate or reduce preheat requirements.”

Web: www.rrc.co.uk | Email: info@rrc.co.uk

www.esab.com

MANUFACTURERS OF HIGH QUALITY HIGH PERFORMANCE INDUSTRIAL INSTRUMENTS

Exhibitors at CHEM UK, WWEM & HANNOVER MESSE Rearranged exhibition dates will be advised, when confirmed.

Calibration and On-site Commissioning

Light instrument system panel builds, including: Data Loggers & HMI’s

For your FREE Product Summary Brochure

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

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STORAGE, HANDLING & DISTRIBUTION

ADJUSTING TO NEW NORMAL MAHLE AFTERMARKET UK

Mahle supports distribution network during pandemic crisis MAHLE Aftermarket UK is adjusting to the new ‘normal’ to sustain critical activities and support their wide customer base of distributors and independent garages. OEM production has experienced unprecedented levels of factory shutdown, with new vehicle sales not possible in many areas and demand at an all-time low. In the UK aftermarket, due to closure of many distributors and garages, the market has fallen considerably. But despite this, many opportunities still exist, says MAHLE and the company is working with customers to take full advantage. While regular service products such as filtration are in decline, sales of distress parts including rotating electrics and engine components continue at almost normal levels. It is clear that demand is still present to keep vehicles on the road for essential journeys, even in light of the MOT extension period. In support, the MAHLE reduction in minimum order values to qualify for free next day carriage has been extended into May. The MAHLE supply chain is also as strong as ever, with hundreds of pallets arriving

into Bilston every week from European distribution hubs as normal.

social distancing through the warehouse management system.

In accordance with social distancing measures and government guidelines, colleagues are fully protected with PPE and strict one-way routes through the warehouse. Due to the advanced Pick by Voice solution, it is also possible to enforce

As with many other businesses, the current situation has presented an ideal opportunity to push forward with digitalisation plans. All office staff now have the ability to work completely from home, and the Customer Care call centre functions as normal with the team connecting remotely. Most administration tasks have already changed to fully digital or are in the process of going paperless. Hundreds of customers have now been set up on the MAHLE eCommerce portal, allowing them to check pricing and stock availability, or even request returns from any device with a web browser. Jonathan Walker, Managing Director MAHLE Aftermarket Ltd, said: “The MAHLE Aftermarket UK team have performed admirably adjusting to the new normal and we are working around the clock to support customers’ changing requirements. MAHLE Aftermarket UK is fully open for business and we’ve enhanced the support customers receive through greater investment in digital connectivity and ecommerce solutions.”

For further information, please visit www.mahle-aftermarket.com/eu/en/

PECM Issue 45

STORAGE, HANDLING AND DISTRIBUTION

ADDING GENUINE VALUE CROCODILE

Designing bespoke packaging solutions to perfectly fulfil clients’ needs Crocodile began as a family company back in 1991 in response to a growing demand for innovative and versatile industrial packaging solutions. To this day Crocodile remains entirely family owned and run and the goal of providing high quality sophisticated packaging solutions that add genuine value to clients has not changed. Crocodile has a truly global outreach, with manufacturing partners in China, Germany and the USA. But the key to Crocodile’s success is it’s commitment to quality, which is why all aspects of the business from design to manufacturing, right through to delivery of the product is managed under the same roof in Swindon. By controlling every aspect of the business Crocodile ensures that only the best product and customer service is delivered. Crocodile does not sell from a catalogue, but custom designs bespoke packaging solutions to perfectly fulfil clients’ needs. We visit prospective customers and listen to them in order to ascertain as much information as we can about exactly what they want and need from their packaging. Our team of CAD Engineers will then design a packaging solution based around these needs, which we will then present to clients for approval or feedback. Crocodile’s unique clip system means that packaging can be flat packed and reused, which dramatically cuts customers’ total costs and provides a sustainable, environmentally friendly way to ship goods. In 2006 Crocodile opened a Timber Frame Division in order to provide economical timber products to the growing timber frames industry in the UK. For the last 12 years Crocodile Timber Frames has been manufacturing high quality products for use in schools and homes across the UK. Our aim is to win customers by delivering a first class but cost effective solution and performance. We then passionately wish from then onwards to continue supplying the customer every time they need

packaging. This only happens if service is of the highest quality. We aim to provide this as a minimum requirement, every time and to never lose a customer. This can only happen if a company is made up of

individuals that share this goal. Crocodile is very proud to have such staff.

01793821555 ISPM 15 COMPLIANT

For further information, please visit www.crocodile.uk.com Issue 45 PECM

STORAGE, HANDLING & DISTRIBUTION

ALWAYS AN EDGE AHEAD DAIFUKU

Daifuku to construct highly resilient AS/RS

Daifuku, the Japanese materials handling specialist who were announced recently as the World’s largest automated materials handling company in 2020 (Source: Modern Materials Handling), have signed a contract with a Tier 1 automotive supplier to construct a highly resilient AS/RS. The AS/RS will act as a buffer between the Tier 1 supplier’s manufacturing cell and the automotive manufacturer’s assembly line. Parts will be stored in the AS/RS until demanded by the production schedule and must be delivered to a trailer loading system in strict build sequence order. Every part is treated as a unique SKU (Stock Keeping Unit) and no substitution is possible. Therefore, it is of paramount importance to ensure that any part can be accessed by the automated storage

system when called for by the production schedule. To make sure this demand can always be achieved, Daifuku has designed a system that features a spare crane that can be deployed into any of the storage aisles at short notice in the event of a malfunction of any of the “regular” cranes. The spare crane has its own parking bay to the side of the racking and in the event of a failure that cannot be resolved within a very short period of time, the faulty crane is taken out of the aisle using a transfer car and put into a separate maintenance area whilst the spare crane is transferred into the aisle to carry on with the production schedule whilst the defective machine is repaired.

Whilst the MTBF (Mean Time Between Failures) for automated stacker cranes is generally quite long, and the MTTR (Mean Time to Repair) is normally quite short, the risk of stopping the client’s assembly line was considered too great and hence this extra resilience is required. An added benefit of this solution is a reduction in the spare parts holding on site, as the spare crane provides an immediate availability of parts and therefore reduces what can otherwise be a significant investment in critical spare parts. The AS/RS will be installed at the Tier 1 supplier’s UK manufacturing facility during 2020 and will be ready for SOP (Start of Production) of the new model early in 2021.

For further information please contact Robert Wood at Daifuku on 01908 288790 or at robert_wood.europe@ha.daifuku.co.jp

PECM Issue 45

ALWAYS AN EDGE AHEAD We offer efficient automatic logistics solutions for production and distribution. Contact us.

DAIFUKU CO., LTD. Tel. +44 (0) 1908 288 780 www.daifukueurope.com

TRAINING & RECRUITMENT

BRIDGING THE SKILLS GAP TRAINING AND MANUFACTURING GROUP

Training and Manufacturing Group launches technical courses for furloughed apprentices and employees

Furloughed apprentices and employees are being given the opportunity to learn new skills thanks to a new package of support from the Training and Manufacturing Group (TMG). The not-for-profit organisation is working with its technical partners to deliver a suite of world class technology courses to its members, which will help bridge the skills gap, increase R&D and help support the post Covid-19 recovery. Industry experts Bauromat, Guhring, ETG, Hexagon MI and Ceratizit WNT and business specialists BDO, FBC Manby Bowdler and In-Comm Training have agreed to host the interactive sessions completely free of charge and will cover crucial topics ranging from automation, robot/CNC programming and cutting tools to arc/resistance welding, PLC programming and pneumatics.

PECM Issue 45

They will initially be delivered through short webinars or one-to-one sessions at partner sites, adhering to social distancing rules at all times. “As lockdown eases and businesses reopen, the TMG are keen to support the UK manufacturing sector through the recovery period ahead,” explained Cassie Grillo, Business Development Executive at the Training & Manufacturing Group. “With a reduction in productivity during the lockdown period and the subsequent financial impact many have experienced, there is a real opportunity to look at updating your processes or broadening the skills of your workforce. “This got us thinking and, after detailed conversations with our technical partners and our member companies, we have developed a number of upskilling options they can use for apprentices and

employees who are currently furloughed.” She continued: “Getting the most out of automation, robotics and CNC machining can help to boot productivity and this will be crucial as firms look to recover and lay foundations for getting back on track.” John D’Angelillo, Managing Director of Bauromat, is one of the driving forces behind the initiative: “A lot of companies, who have had to furlough staff, are looking at ways where they can boost their own business during a time when demand for services and products are not at their highest. “The job retention scheme allows employees to train and upskill whilst being furloughed, so the TMG technical partners decided that it would be a good idea to give members a flavour of what you can do and how you can increase efficiencies by being more flexible with skills.

The Training and Manufacturing Group is a consortium of like-minded businesses bound together by a common vision to improve skills and productivity in the UK. It has varying levels of membership ensuring that the group is open to all, from small businesses just starting out, through to multi-national companies with multiple facilities across the world. Our 150 members cover a wide range of engineering and manufacturing sectors from automotive and aerospace to oil and gas and nuclear, with the most recent additions, including Central Fabrications, Gleeson Recruitment, Met Recruitment, MyWorkwear and Select Hardware. “The idea is to give a taste of other skill bases that could benefit their manufacturing processes, upskill their know-how, or even allow them to consider the benefits of apprenticeships. “It’s not to provide in-depth training as this can be done through our training centres, but instead provoke conversation about training and guidance that can then be developed further.”

There is a real opportunity to look at updating your processes or broadening the skills of your workforce.

The free training is part of a range of benefits available through the TMG Membership. For just £150 per year, companies can access benefits including grants and funding opportunities, a full free legal review, regular newsletters and support with apprenticeship recruitment. To find out more about the Training and Manufacturing Group please visit www.incomm-tmg.co.uk or follow @InCommTMG on twitter.

For further information, please visit www.in-comm-tmg.co.uk Issue 45 PECM

WORKPLACE

INVESTING IN THE FUTURE AJ PRODUCTS

How leasing supports business development when cashflow is tight How do you invest in the equipment your business needs during uncertain times? Finance leasing from AJ Products can provide the answer. Even when cashflow is tight, businesses need to be able to invest in the future by having the right equipment to maintain safe and efficient work practices throughout the company. With affordable fixed monthly payments and no deposit, finance leasing allows any business to improve cashflow, complete financially-phased projects with immediate effect and provide high-quality modern equipment for your staff when you cannot afford to make the full investment upfront. Leasing is an effective way to spread costs over a period of up to five years to ease the financial burden and drive your business forward. Furthermore, as all leasing payments are tax deductible, it is a solution that will save the business money and is, thus, beneficial no matter your financial circumstances. By maintaining your cashflow, you don’t have to make a choice between the shortand long-term goals of your business. You can spread the cost of your development project across your chosen term as a fixed payment that won’t change throughout the duration of the lease, allowing you to manage your budget effectively. In the meantime, you will have the cash available to invest in other key areas of your business and safeguard essential outgoings, such as staff costs and rental payments. Launched in January 2020, AJ Products now offers a leasing solution for all your workplace furniture and equipment requirements. From office furniture, breakout spaces and conference furniture to pallet racking and materials handling solutions, AJ Products has the solutions to help your business improve workplace productivity and employee wellbeing. We can lend to businesses of all types including start-ups and sole traders for projects from £1000 to £1,000,000. For your peace of mind, security is levied on the equipment rather than your property, minimising the

AJ Products now offers a leasing solution for all your workplace furniture and equipment requirements. risk to your business if your circumstances change. At the end of the lease the products, you can keep, return or upgrade the products as suits your needs. Contact AJ Products to find out how you can arrange to lease the furniture or equipment your business needs. Email: info@ajproducts.co.uk Tel: 01252 359760

For further information, please visit ajproducts.co.uk

PECM Issue 45

INDUSTRIAL INNOVATION

POWER OF COLLABORATION PTC

PTC extends alliance with Rockwell Automation and Microsoft to launch ‘Factory Insights as a Service’ Three of the world’s leading specialists on industrial innovation have joined forces to launch a new solution that will help manufacturers achieve a 90% reduction in development time and increased speed to market. PTC, Microsoft and Rockwell Automation unveiled ‘Factory Insights as a Service’ in front of tens of thousands of delegates at the virtual LiveWorx® 2020 digital transformation, with the promise of giving companies unprecedented impact, speed and scale with their digital transformation initiatives. The turnkey cloud solution harnesses FactoryTalk® InnovationSuite, ThingWorx®, Kepware®, and Vuforia® technology, whilst also leveraging Microsoft’s cloud, industrial IoT and edge services, including Azure IoT Hub and Azure IoT Edge. This enables manufacturers - across a variety of sectors - to rapidly connect individual sites and implement projects across their enterprise network, covering real-time production performance monitoring, asset monitoring and utilisation, connected work cells and digital and augmented work instructions.

“‘Factory Insights as a Service’ builds on the breakthrough capabilities of FactoryTalk InnovationSuite to quickly operationalise some of the most critical use cases improving production, asset and workforce efficiency, while future-proofing our customers’ digital transformation roadmap.”

“‘Factory Insights as a Service’ offers our industrial customers a leaner, accelerated approach to digital transformation,” said Jim Heppelmann, President and CEO of PTC. “The offering reduces reliance on IT and Operational Technologies resources, and, most importantly, takes a value-first approach allowing customers to save time and money by reducing the complexity they would typically undertake as part of an industrial internet of things (IIoT) implementation and digital transformation effort.”

With ‘Factory Insights as a Service’, manufacturers can achieve a 90% reduction in development time and cost and as much as 90% faster time-to-value for the most critical high-value use cases underpinning industrial digital transformation.

In today’s digital-first environment, manufacturers require solutions that solve complex infrastructure issues, data accessibility challenges and reduced resources.

“Simplifying and accelerating digital transformation initiatives for our clients is a fundamental driver for our alliances with PTC and Microsoft,” said Blake Moret, Chairman and CEO of Rockwell Automation.

Jason Zander, Executive Vice President Microsoft Azure at Microsoft, concluded: “We believe in the power of collaborations to help manufacturing companies accelerate the delivery of value to their customers and unlock new business opportunities. “By teaming up with PTC and Rockwell Automation to converge IT and Operational Technologies excellence, we empower businesses to rapidly deploy their relevant use cases at scale - from asset, workforce, and production floor performance to accelerate impact across the global production network.”

To learn more visit www.ptc.com/en/resources/manufacturing/webcast/factory-insight-as-a-service

PECM Issue 45

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”)

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