Process Engineering Control & Manufacturing - Issue 48 2021 by MH Media Global

Process

MANUFACTURING

Control &

Engineering

CORBETTS THE GALVANIZERS - 12

WILLIAM WHITELEY & SONS- 20

Record £1m month as historic galvanizer rises to the Covid-19 challenge

Investment gives one of Sheffield's oldest manufacturers a new cutting-edge

PECM

Global Success Through Innovation Issue 48 2021 £3.95 www.pecm.co.uk

BRANDAUER - 74 It's all about the micron as Brandauer set to play key role in £500,000 new electric machine project

Process

MANUFACTURING

Inside... Sections

Control &

Engineering Inside Issue 48

Editors Choice

Boilers & Maintenance

Control & Automation

Electrical & Electronics

Facilities Management

Fluid Handling

CORBETTS THE GALVANISERS

SEMPRE GROUP

MAN GROUP

An industrial necessity for post-Brexit Britain?

Record £1m month as historic galvanizer rises to the Covid-19 challenge

£2m boost as MAN Group looks to recover from Covid-19 disruption

NOVOTEK

Fasteners & Fixings

Gears, Drives & Motors

Making production processes more sustainable

Health & Safety

WILLIAM WHITELEY & SONS

Machining & Machinery

Measurement & Monitoring

News & Events

Packaging

Process Technologies

Pumps

Software & Systems

Storage Handling & Distribution

£2m boost as MAN Group looks to recover from Covid-19 disruption

TR FASTENERS

Improving speed without increasing costs

PORTESCAP

Top motor trends in the continuing evolution of robots

Taking better care of medical manufacturers

SCHNEIDER ELECTRIC

ROCKWELL AUTOMATION

Rockwell Automation Improves Productivity, Drives Profitability and Reduces Risk Across Plant Operations with the Release of PlantPAx 5.0

EMS

How infrared technology brings safety in multiple applications

BRANDAUER

It’s all about the micron as Brandauer set to play key role in £500,000 new electric machine project

SWMAS

Brexit uncertainty weighs heavy on SME manufacturers looking to recover from Covid-19

Issue 48 PECM

New benchmark in thermal flow measurement The The latest latest SA SA flow flow meter meter from from ifm ifm electronic electronic for for liquids liquids and and gases gases also also measures measures temperature. temperature. Fast Fast response. response. Easily Easily readable readable LED LED display display can can be be set set to to change change between between red red and and green green and and the the whole whole unit unit can can be be rotated. rotated. Calibrated Calibrated for for water, water, oils oils and and air. air. A A clever clever solution solution from from ifm ifm

www.ifm.com / uk/ sa 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 48 PECM

EDITOR’S CHOICE

CABLE INNOVATION HEATSENSE CABLES

Specialist High-Performance thermocouple and signal cable manufacturer continues to expand manufacturing capabilities CAPABILITIES Heatsense Cables is the UK’s leading specialist high-performance thermocouple and signal cable manufacturer. The company is a technology leader in fluoropolymer extrusion, high-performance taping and cable wrapping. Related processes include cover sintering, colouring, etching and the application of various specialist coatings. The range covers cables that are resistant to flame, oils and chemicals and which operate in ultra-high vacuum, cryogenic and high radiation environments.

INSULATION & BRAIDING EXPERTS Insulation materials include PFA, FEP, PTFE, ETFE, EFGLAS, SILICONE, PE, PU, PVC, Taped & Sintered PTFE, Polyimide, Aramid, PTFE impregnated yarns and Mica. Braiding materials include glass, quartz & ceramic fibres, other specialist yarns and various metals. The company manufactures thermocouple cables, extension wires, equipment, wires, coaxial cables, multicore cables, microcables and fine wire from is manufacturing plant in Rochdale, Greater Manchester. Markets include, aerospace, nuclear, automotive, medical, R&D, oil & gas and general industry. The company offers a range of approvals which meet internationally recognised specifications. Highly customer focussed, Heatsense offers a bespoke technical design and manufacturing service, rapid response times, short lead times, low MOQ’s and competitive pricing.

EXPANSION Over the course of the last twelve months Heatsense has acquired a specialist thermocouple calibration laboratory. This has enabled the company to test thermocouple and resistance wires used in production and also ensure that all cables are calibration and resistance tested before dispatch. The company continues to upgrade and

purchase additional specialist plant & equipment to further broaden capabilities and efficiencies. Despite the economic impact of COVID-19 Heatsense has added a further 5000sq.ft of manufacturing space taking the total to almost 20,000sq.ft. During this period the company has also continued to purchase specialist plant & equipment, expanded its manufacturing capabilities and taken on additional highly skilled staff.

The company continues to develop its digital strategy encompassing shop floor data capture, ERP, CRM and machine automation. Heatsense is ISO9001:2015 and ISO14001:2015 Accredited and has been awarded F4N Status by the Nuclear Advanced Manufacturing Research Centre. T: +44 (0) 1706 767070 W: www.heatsensecables.co.uk

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

PECM Issue 48

The UK’s leading specialist high-performance thermocouple and signal cable manufacturer The company is a technology leader in fluoropolymer extrusion, high-performance taping and cable wrapping. Related processes include cover sintering, colouring, etching and the application of various specialist coatings. The range covers cables that are resistant to flame, oils and chemicals and which operate in ultra-high vacuum, cryogenic and high radiation environments.

INSULATION & BRAIDING EXPERTS PFA, FEP, PTFE, ETFE, EFGLAS, SILICONE, PE, PU, PVC, Taped & Sintered PTFE, Polyimide & Aramid Yarns, PTFE impregnated yarns and Mica. Braiding materials include glass & ceramic fibres, other specialist yarns and various metals.

MARKET SPECIALISTS

Automotive

Aerospace

Nuclear

Medical

Industrial

PARTNERSHIP BUILDERS Advanced technical design & bespoke manufacturing service • Rapid response times

• Service international partners

• Short lead times

• Competitive pricing

• Based in the UK

• Low MOQ’s

*Registered owner of the world-renowned INTEMP trademark

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

Research

EDITOR’S CHOICE

New benchmark in thermal flow measurement The new benchmark in thermal flow measurement is the SA from ifm electronic. Quite simply the best and easiest to use, the SA is optimised for a range of media including water, oils, glycol and air. Not only will the SA measure the flow rate, but the device will also measure the temperature of the medium. The SA series are equipped with the latest sensing and connection technologies for optimum setting and usage, as well as featuring a very flexible design concept to reduce inventory. The SA features a highly visible four-digit display, which the user can configure to show the flow rate or temperature and to alternate from red to green as required, and the housing can be aligned for optimum readability. Unlike most flowmeters, using an SA does not mean specifying exactly the pipe diameter to find the correct device. The SA consists of a display and evaluation section that sits on the pipe where the display can clearly be seen, and a probe inserted through the pipe wall into the medium. As only a simple probe needs to be inserted into the pipe, the SA is easy to fit and versatile, covering a range of pipe sizes from and internal diameter of just 15mm up to a massive 400mm. Fitting is via a progressive ring compression joint, allowing control of the insertion depth. The user merely selects the probe length from 45mm,

both measurements are registered via a simple three-core cable. Moreover, as IOLink is a stronger digital 24V signal without conversion losses, the data is more reliable than any analogue mA value. IO-Link is a two-way street, giving the user the flexibility of remotely adjusting parameters, too. That means that the user is all set for Industry 4.0.

100mm or 200mm. If there are many different pipe sizes on site, the stock of different flow meters is kept to a minimum. Accuracy and speed of response are vital, and the SA performs on both counts. The SA can react to a change in the medium as quickly as half a second, with an accuracy of ±0.3K for temperature and ±5% for flow. Switching outputs (normally open or normally closed), pulse output, analogue signals and IO-Link provide various options to further process the signals. The IO-Link option has already proved of value to customers who have been able to replace two units with one, and not only that but as the IO-Link signal is transmitted over the normal output connection,

www.ifm.com/gb/en

NEW Jackets, Work Trousers & Topwear in the 2021 Snickers Workwear Catalogue With a focus on comfort, performance and sustainability in its new products, the 2021 digital catalogue has all you need to know about Snickers Workwear, including new products that now use REPREVE, the world’s number one brand of recycled performance fibre. There’s also new AllroundWork Topwear with the cooling 37.5® moisture transportation fabric, as well as upgraded FLEXIWork Stretch Trousers with extra functionality and durability. By popular demand, there’s also a stretchy hi-vis Work Jacket with great comfort and flexibility for high-performance work and high visibility in low-light conditions. Added to which, there’s the most innovative streetsmart stretch fabrics in the ALLROUNDWork clothing range for mobile comfort and a Layered Clothing System that ensures you can choose clothes to suit

PECM Issue 48

the weather on site – rain or shine, wind or snow - plus an extensive range of EN-certified ProtecWork and PPE products. Complimented by Snickers Workwear’s Profiling and Embroidery services and the most extensive range of garment sizes, this clothing system delivers the ultimate solution to make every man and woman’s workday easier and safer.

www.snickersworkwear. com/page/product_guide_ media

Many application are open to the SA units as they are rated up to a maximum pressure of 100bar, and many different media with flow rates of 5 to 300cm/s (liquids) or 200 to 10000cm/s (gases) over temperatures ranging from -20 to +100°C. Construction is up to ifm’s usual high standard, with wetted parts made of high-grade stainless steel and the housing sealed to IP65 / IP67. ifm is committed to working closely with its customers to develop products which precisely match their needs, and the company provides expert, readily accessible technical support to help users maximise the benefits they gain from ifm products. For further information, contact Gemma Anderson, ifm electronic Ltd., efector House, Kingsway Business Park, Oldfield Road, Hampton, Middlesex, TW12 2HD. Telephone: 020 8213-2234. E-mail – gemma.anderson@ ifm.com.

EDITOR’S CHOICE

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 long-term reading assurance • Extensive diagnostics and selfmonitoring, including empty pipe detection Sizes from ½” to 2”. Available for Litre Meter, call 01296 670200, now.

www.litremeter.com

we GEMÜ SUMONDO

Single Use Putting you in control GEMÜ SUMONDO - World’s first Single-Use diaphragm valve • Panel mount actuator & mini positioner • Gamma-sterilizable valve body material • Quick clamp body (Flowpath ready)

www.gemu.co.uk

Issue 48 PECM

EDITOR’S CHOICE

Atom TPM Atom TPM are a multi-disciplined Consulting Engineering & Project Management Practice with the UK Centre of Excellence for Food Manufacturing Factory Design based in Edinburgh, Scotland with other associated offices in Canterbury and Dornoch. They were established in 1995 and have grown to become one of the leading Designers of Food Manufacturing Factories in the UK. This has led to the company uniquely being able to offer a full package of Total Project Management®, specialised in Architectural production layout design and spatial planning, Production Analysis, Project Management, Structural, M&E Engineering, Refrigeration Engineering and Building Consultancy services tailored to suit a Client’s needs and importantly to achieve major Retailer Technical Approval and industry wide standards such as BRC, EFSIS and SALSA accreditation.

The future of desktop manufacturing

Labelzone.co.uk – Your One Stop Label Shop!

Market leaders in 3D printing extrusion systems, E3D-Online have developed a technique of integrating subtractive technologies (on a layer-by-layer basis), into their award-winning, open-source tool changing 3D Printer, built with the best in-class components.

When you need to source labels or label printers, the Labelzone.co.uk website offers big brand labelling solutions at great prices. As a key distributor of Brady, Brother, Zebra, TSC and Dymo labelling products, we can supply a wide range of labels for your existing label printers or help with new labelling projects. Custom labels, including short runs are available with fast turn round times. We specialise in cable marking, asset labelling, barcoding and tagging. Although the range offered on Labelzone.co.uk is vast, our knowledgeable pre-sales team will be pleased to offer advice and help on any aspect of labelling.

They have named this technology ASMBL™ Additive Subtractive Manufacturing by Layer. Implementing an ASMBL toolhead grants users the ability to automate post-processing steps in a wide array of methods; including layer line removal, true square corners, correctly toleranced holes and radii, and even nonplanar surfacing. To enable ASMBL™ E3D have developed a Fusion 360 plug-in which cleverly combines Fusion’s additive paths with subtractive CAM paths, working closely with Autodesk themselves.

www.atom-TPM.com

https://e3d-online.com/products/ toolchanger-motion-system-bundle-tools

Only nature can compete with us

Dr. Shrink, Inc.

SIRE was established in 1987. We have an extensive experience in cooling water systems to all types of industries. Our portfolio includes air-cooled and water-cooled chillers, heat-pumps and chillers with heat-recovery, containerized chiller units for concrete cooling, with capacities ranging from 6kW to 1.5MW+, shell and tube heat exchangers and cooling towers. In addition to these models, we are prepared to respond to the market with special chiller models for saltwater or naval chillers with titanium condensers and evaporators. We also offer chillers with heat pumps for climatization. All equipment is built with anticorrosion materials, enabling the placement of the equipment outdoor, and has a strict quality control, planning, production and finishes, which gives the client a product of guaranteed, excellent quality and reliability.

Dr. Shrink, Inc. is an international shrink wrap supplier of premium shrink wrap and all installation accessories.

Our chillers are submitted to a demanding series of control tests in terms of quality and durability. www.sire.pt

PECM Issue 48

We stock shrink wrap from 12’ to 60’ in width for covering almost any object for protection against weather damage while being transported or stored. Our major industries include marine, construction, industrial manufacturing, aerospace, military, and material handling. Dr. Shrink is noted for innovative products, prompt delivery, competitive pricing, experienced application advice and hands on training. Dr. Shrink, Inc. 315 Washington St Manistee, MI 49660 Phone: 1-231-723-2685 Email: drshrink@dr-shrink.com Website: www.dr-shrink.com

Visit www.labelzone.co.uk or call us on 0800 975 5040 Labelzone.co.uk Advanced Labelling Limited Unit B8 Arena Business Centre Holyrood Close, Poole, Dorset BH17 7FL Tel 0800 975 5040 Sales@labelzone.co.uk

Innovation, best practice and first-class customer service With the introduction of social distancing measures, end-to-end automation to facilitate fewer people along the production line will be the aim for many manufacturers. Extending automation beyond production and into packaging processes will make a print and apply labelling system an appealing option. The benefits of a print and apply solution, of course, pre-date social distancing restrictions. Print and apply labelling systems create the label in real time, on the line, with the security of built-in barcode verification, enabling an efficient workflow and reducing manual labour costs. No errors or security risks from manual application and no waste. Cobalt can supply a case sealing and labelling system in one small footprint that’s ready to run.

01270 539800 sales@cobaltis.co.uk www.cobaltis.co.uk

EDITORâ&#x20AC;&#x2122;S CHOICE

Quantumâ&#x20AC;&#x2122;s Hire Fleet creates improved process, reliability and efficiency at Sugar Facility Its peak season for processing sugar beet and we received a request from a Sugar Company to help create a new system that improves the cleaning pump process and more importantly, the reliability. This new system had to be super silent, efficient and be able to withstand weather conditions of the outdoor site environment. We partnered with a Pump Supply Company to give the best solution to our customer, a new pump system, a 22kW Hire Variable Speed Drive and Generator (both from Quantum Controls extensive hire fleet) were supplied to the customer. This gave the system extra flexibility with variable speed control and pump reliability. Due to the location and such harsh operating conditions, our Unique Weatherproof Variable Speed Drives were the only VSDs on the market for this application. Because this was initially a trial to test the new system, a super silent and efficient generator was also supplied, this was to save on mains modifications in the timescale allowed. The new system was trialled and proved a success, the units will stay on hire for a further 12 weeks while a new permanent system is installed.

Quantum Controls have an extensive range of hire equipment, not only Weatherproof Variable Speed Drives up to 4.5MW power rating, we have a fleet of; electric motors, mains cables, data loggers, flow meters, transformers, generators and harmonic filters. Our hire fleet are available 24/7 through our Quantum Prime service. One call to 0330 9000 247, day or night, and we will have any piece of equipment in transit within 30 minutes of your call.

www.quantum-controls.co.uk

Issue 48 PECM

EDITOR’S CHOICE

LATEST NEWS FROM CORBETTS CORBETTS THE GALVANIZERS

Record £1m month as historic galvanizer rises to the Covid-19 challenge The UK’s oldest hot dip galvanizer is bouncing back from Covid-19 disruption after it processed a record amount of steel from one plant in a single month. Corbetts the Galvanizers used the downtime in the summer to improve productivity and modernise processes and this has paid off with nearly £1m of orders completed in October. Celebrating 160 years in business in 2020, the Telford-based company processed 34% more volume than the same time last year for customers involved in street furniture, transport and construction. With volumes continuing to rise and new contracts being secured, the recently

PECM Issue 48

strengthened management team are now planning to reopen the smaller Plant to increase capacity. “This is a phenomenal achievement by our workforce and highlights growing optimism in our sector,” explained Sophie Williams, Finance Director and General Manager at Corbetts the Galvanizers. “It proves that the manufacturing best practice improvements we have undertaken over the last six months are working, including throughput, how we hang work, process speed and upgrading the pretreatment process. There’s also been considerable investment in upskilling the workforce and bringing in new team leaders.”

She went on add: “All this has led to a record month in terms of volume and sales, but, most importantly, we have done all of this whilst maintaining outstanding quality and 24 to 48 hour turnaround time for existing business and 5-10 days for new clients.” Corbetts the Galvanizers has been supplying world class hot dip galvanizing to thousands of customers across the UK and Europe for 160 years. This process is the most effective and environmentally friendly way to protect steel from the elements and provides a long-term solution to corrosion (rust) and maintenance free protection in excess of 100 years.

This is a phenomenal achievement by our workforce and highlights growing optimism in our sector. From its purpose-built facility in Telford, it operates a number of galvanizing baths that give it the opportunity to process in excess of 50,000 tonnes every year and the ability to double dip material up to a length of 14 metres. Product is then loaded on to the company’s fleet of 13 vehicles that make up to 5000 different journeys every year, with the latest investment meaning that the oldest lorry is less than five-years-old. Sophie, who recently oversaw the appointment of new managers for Sales and Marketing, Procurement and Operations, concluded: “2020 hasn’t been the year we were expecting to celebrate our big birthday, but what it has done is given us time to look at how move forward for the next 160 years. “This means we are now a more efficient operation and we have been looking at new ways in which we can grow the business. One big plan is currently in the final stages of negotiations and, if it comes off, could change the way the galvanizing sector operates forever.” For further information, please visit www.wcorbett.co.uk or follow @wcorbetts on twitter. Issue 48 PECM

EDITOR’S CHOICE

LATEST NEWS FROM PTC PTC

GLORY selects PTC’s ThingWorx for development of its next-generation remote monitoring solution

GLORY, a global leader in cash automation solutions for the financial, retail and gaming industries, has selected PTC’s ThingWorx® Industrial IoT platform and Microsoft Azure to develop and run its new cloud-based remote management solution UbiqularTM Bridge, which enables real-time insights into the performance of its devices. The company’s solutions are deployed by banks and retailers in more than 100 countries around the world to optimise the cost of managing cash and enhance the customer experience - central to this value proposition is maximum uptime of the devices. ThingWorx is designed to accelerate Industrial IoT deployments across the enterprise value chain. The awardwinning platform contains a broad set of features, including multiple connectivity options, application development tools and analytics. It also enables businesses like GLORY to create scalable and secure solutions that provide high levels of return on investment. “GLORY has a rich tradition of placing our customers at the centre of our business

The award-winning platform contains a broad set of features, including multiple connectivity options, application development tools and analytics. strategy and this focus has uncovered an increasing need for advanced remote management capabilities,” said Sion Roberts, EVP of Global Digital Services at GLORY. “To satisfy this demand, we needed the best IoT platform for the job, which led us to replace our legacy IoT platform, Axeda ®, with ThingWorx running on Microsoft Azure.” “Understanding operational efficiency is the key for our customers,” continued Roberts.

“With ThingWorx, we enhanced our cloudbased remote management application, UbiqularTM Bridge, to deliver real-time performance data, allowing key executive insights into the effectiveness of operations. “By driving efficiencies through monitoring, collecting, and analysing data delivered to the GLORY Service Centre, we will be able to better identify and develop service improvements for our connected devices and support new customers who come onboard. Additionally, the transition from Axeda to ThingWorx was managed smoothly and successfully by the service professionals in the PTC Customer Success Team.” “ThingWorx and Microsoft Azure have enabled Glory to rapidly develop and deploy a tailored, scalable, and secure application suite that can provide its customers with real-time operational intelligence,” said Joe Biron, Divisional General Manager, IoT Segment at PTC. “We are pleased Glory selected our technology to ensure its customer-centric strategies succeed and look forward to new projects with this world-class company.”

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

PECM Issue 48

CONTROL & AUTOMATION

Incremental and Absolute Encoder Solutions! When you call BEPC, you talk to engineers and encoder experts who can help you find and spec the right encoder for your application. From compact to heavy-duty stainless steel, thru-bore or shaft, incremental or absolute, we’ve got the encoder you need for motion feedback.

Thru-Bore Encoders – From the compact Model 15T/H, 5T/H, too the the low-profi low-profile Model 26satile Model 25T/H, we’ll help you find the right solution. olution. Tru-Trac Encoders– An Encoder and Wheel solutionn integrated integrat ated ed into int ntoo one one compact comp co mppac actt unit, unititt, un al for countless coun untltles esss applications. appl ap plicicat atio at ions io ns. ns simplifying system design and reducing cost making it ideal

Programmable Encoders – Not sure of the exactct config configguration u attio ur ion you y u need? yo neeed? ed? No ed No pproblem. robl ro bllem m. der and new neew thru-bore tthhhru ru-bbor ru ore ore BEPC’s highly-configurable Model 25SP Size 25 shaft encoder Model 58T to program the electrical specifications on-site.

Absolute Encoders – Mechanically and electronically ally versatile, versat atililile,e, BEPC’s at BEP EPC’ PC’s C’s selection C’ selelelect se c io ion of of absolute abs bsol sol olut lut ute encoders enco en c ders co ders de

is your solution when you need position information after power-off power offff scenarios. scen sc e ar a io ios And Anndd our u NEW NEW W A58E A58 58EE series seerires e of encoders are EtherCAT and Profinet ready!

BEPC’s standard lead time is just 4 - 5 days

Call us today, and we’ll help you find your motion feedback solution.

Web: www.encoder.co.uk Tel: +44(0)1978 262100

Despite the pandemic SP has reached and exceeded its order intake targets. With companies looking to safeguard their future, and optimise production, many are accelerating their automation projects. SP Automation and Robotics design develop, and finally install their bespoke designed automation solutions into a myriad of industries, the spread this year has been across medical device/pharma, food, and the semiconductor industry. Although all completely different

markets, the solutions have one thing in common, improving quality and reducing costs for clients. Just like the variation in project types, the project values also varied, ranging from £250,000 to £1,500,000. Alongside the full SP Automation systems, SP Elements provide collaborative robot solutions to help our customers deploy automation quickly to cater for repetitive tasks. For more information visit us at www.sp-automation.co.uk

Issue 48 PECM

CONTROL & AUTOMATION

UNIVERSAL AUTOMATION SCHNEIDER ELECTRIC

An industrial necessity for post-Brexit Britain?

By Mark Yeeles, VP of Industrial Automation at Schneider Electric

digital technologies, will challenge the status quo.

The tumult of 2020 has underscored the importance of contingency planning. With Covid-19, countries have revealed their unpreparedness when managing novel scenarios.

The double-edged sword of Brexit means UK manufacturers will have more visibility – and more competition – on the global stage. For our industry to succeed, agility, sustainability, productivity and profitability must be the standard. In 2021, the reality of Brexit’s effect on the cost of business operations, the optimum locations for plants and factories, as well as the retention of staff and resources will be revealed.

With the reality of Brexit now upon us, UK industry, particularly manufacturers, need to act fast to minimise long term impact. Early 2021 will see British manufacturers begin to action specific strategies. It will be the first opportunity to assess the true impact of Brexit on production and supply chains. In the wake of a pandemic, and in the face of political uncertainty, how can the industry adapt, survive and thrive?

HOW THE INDUSTRY WILL BE IMPACTED 2021 will see a levelling of the playing field. Even established manufacturers, historically immune to market fluctuations and supply chain disruptions, will suffer the impact of uncertainty. New global dynamics and fully digital newcomers, poised to embrace

PECM Issue 48

As Britain’s trade deal with the EU takes a different direction, our success will actually be more reliant on an extended ecosystem of partners. 2021 will see workforce management become critical to operations. There will now be a pressing need for businesses to find alternative ways of performing tasks for which they have a shortage of either staff or resources, to guarantee that their business continues to thrive. This is where automation comes in. After January 1st, businesses will have a clearer understanding of which operations need automation, the level of automation required, and which technologies should be prioritised for success.

Introducing and adopting next-generation industrial automation will make this possible, ensuring interoperability and breaking free from the propriety locked-in model currently in place. Manufacturers will need to welcome a new era of universal automation with open arms, moving the industry from a hardware-centric to software-centric model to succeed in these turbulent times.

LOOKING AHEAD Reshaping post-Brexit Britain will deliver huge benefits if it’s coupled with greater ambition from industry. While manufacturers may find this challenging, it’s the perfect environment for universal automation to come to the fore and prove critical for those willing to adopt it. Universal automation describes the adoption of a common standard for all automation systems, making them easy to pick up, implement and share. It removes the dependence that many manufacturers currently have on a one vendor system, OEMs and integrators, enabling end users to build the architecture they need with the best ‘plug and produce’ solutions from multiple providers.

To fully realise the next generation industries alongside the new challenges that Brexit will bring, manufacturers need to fundamentally change their technology model. The adoption of universal automation will enable manufacturers to create a step-change in operational improvements capable of keeping up with the speed of doing business and remaining competitive in the global market.

automation systems will increase. New business models will be enabled, new customers reached, and new markets served, reshaping post-Brexit, postpandemic Britain for the better. This approach will bring changes across the entire operational lifecycle of industrial enterprises and will ultimately leverage digitalisation to fully realize the potential of Industry 4.0.

With manufacturers facing ongoing changes as a result of political uncertainties and constantly shifting consumer needs in the wake of Brexit and the 2020 pandemic, the adoption of universal automation will provide safety and certainty to the sector. Industry siloes and vendor lock-in must be eliminated, with equipment interoperability and data-driven insight boosting the industryâ&#x20AC;&#x2122;s agility, profitability and resilience. At a time when the manufacturing industry is in desperate need of future proofing, resilience building technologies, industrial automation offers a much-needed solution.

READINESS THROUGH INNOVATION After the year weâ&#x20AC;&#x2122;ve had, many of us are eager to see the back of 2020

and welcome 2021. However, with the uncertainties that the next year brings, it could be a daunting time for industry. We have little control over the implications of Brexit and other crises, nor can we predict what the next challenge may be. However, the opportunity to prepare and build resilience is very much in our control and has the power to make or break us. By moving the industry from a hardwarecentric to software-centric model, universal automation will usher in a new dawn for industrial automation. With challenge comes innovation and with innovation comes new opportunity.

Over the course of 2021, as we see more businesses move from a proprietary world to universal automation, the benefits will be far reaching. It wonâ&#x20AC;&#x2122;t just be end users who reap the rewards of an automated approach - it will give an edge to all who are willing to transform and embrace the value of software innovation. As automation systems become more flexible and capable of providing end user value, we will see the beginnings of a virtual circle where investment in For further information, please visit www.se.com/uk/en Issue 48 PECM

CONTROL & AUTOMATION

OVER 40 YEARS’ EXPERIENCE TF AUTOMATION

Providing automation solutions to improve productivity TF Automation have over 40 years’ experience in the design, engineering and manufacturing of process automation solutions, supporting a wide range of manufacturing industries and have just completed another successful year. It has been an interesting and challenging year for all and at TF Automation, we are no exception. We remained fully open during lockdown to support our varied customer base working in critical industries, both with bespoke machine build projects and the supply of pneumatics and industrial components. Our testing and manual workstation projects have continued at a pace this year, supporting our Tier 1 and 2 suppliers to the automotive industry. We have also engineered machines for clients in the textile, aerospace, motor sport and industrial sectors, with laser marking, pickand-place, product testing, hot air welding and plasma treatment machines. Plasma treatment is new technology for TF Automation and we were commissioned by Kostal, with whom we have a very long-standing partnership, to design and build two plasma treat machines to address the increase in demand for cleaning new automotive switch products. The company has also made some significant investment this year taking delivery of a new 3- Axis CNC Milling Machine to add additional capacity to production and enable the 3-dimensional machining increasingly required by its customer base. The new machine ensures that our machining capabilities are more innovative, versatile and flexible, enabling us to support customers with their ongoing requirements. TF Automation plays a vital role in supporting its local student community in Bradford and took part in Bradford Manufacturing Weeks again this year. This innovative initiative was set up by the Chamber of Commerce to engage local schools with local manufacturers

to showcase both manufacturing and engineering as valid careers. We are also working closely with The University of Bradford supporting MSc Marketing Communication students for the second year with a live project to create a marketing campaign. We were delighted to receive the “Highly Commended” Award for Outstanding Business Contribution in the Careers and Technical Education (CTE) Partnership Awards 2020, having been nominated by Hanson School, Bradford. CTE is a pioneering way in which young people can gain skills and experiences planned around the requirements of local employers. The need to improve process and productivity is a constant challenge for all our customers and our focus is on providing solutions to reduce the risk of human error in tasks that are constant, predictable and repetitive. To find out more or to discuss your next automation project with our design team,

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

PECM Issue 48

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

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T: 01274 308005 E: info@tfautomation.co.uk Hillam Road, Bradford, West Yorkshire BD2 1QN

CONTROL & AUTOMATION

UNLOCKING VALUE ROCKWELL AUTOMATION

Rockwell Automation Improves Productivity, Drives Profitability and Reduces Risk Across Plant Operations with the Release of PlantPAx 5.0 Rockwell Automation (NYSE: ROK) today released the PlantPAx® 5.0 distributed control system (DCS). This latest DCS version from Rockwell Automation helps industrial producers positively impact the lifecycle of their plant operations with plantwide and scalable systems to drive digital transformation and operational excellence. New system capabilities help digitally transform operations by introducing process functionality native to the controller, improving the availability of system assets driving compliance in regulated industries, while enabling the adoption of analytics at all levels of the enterprise. Intuitive workflows and the use of industry-leading cybersecurity standards will help teams design, deploy, and support a DCS infrastructure which reduces time-to-market and helps plants realize profit at a faster rate. “We’re excited to bring PlantPAx DCS 5.0 to our customers,” said Jim Winter, Global Process Director, Rockwell Automation. “New

PECM Issue 48

system features are step changes in helping our customers lower the overall costs to design and commission. The functionality improves the overall effort to integrate the process control layer to the enterprise. By reducing the lifecycle cost of the system and lowering operational risks, we are continuing to find innovative ways to bring more value to end users.” Process end users desire a system that offers the benefits of a modern experience without the burdens that come with a traditional DCS. The new 5.0 release innovates the modern DCS in the following areas:

REDUCED FOOTPRINT This release introduces new process controllers and extends the Logix family with cutting-edge processing power and capacity to reduce the complexity of PlantPAx architectures. This footprint reduction reduces total cost of ownership of the system throughout the lifecycle.

PROJECT CONSISTENCY With native process instructions embedded in the controller firmware, project teams can adopt approaches to control strategies that drive consistency for individual projects or multi-site deployments. Consistency simplifies the lifecycle management of deployed systems as teams modernize their automation infrastructure. Consistency lowers total cost of ownership (TCO).

STREAMLINED WORKFLOWS PlantPAx 5.0 provides improved design and operational user experiences. Development teams will realize savings in the configuration of instrumentation, alarms and diagnostic system elements. Operators will have the extended ability to view underlying control logic in a safe and secured manner. Maintenance will have controlled view access for troubleshooting.

TĂ&#x153;V -CERTIFIED FOR CYBERSECURITY To operate at peak performance and minimize cybersecurity threats, PlantPAx 5.0 system architectures are TĂ&#x153;V certified to the international standard ISA-99/IEC 62443-3-3 which provides guidance on the implementation of an electronically secured system.

ANALYTICS ENABLED

applications such as soft sensors, anomaly detection, or model predictive control.

The functionality improves the overall effort to integrate the process control layer to the enterprise.

As producers continue their digital transformation journey, the advances from this system release will help them unlock value and reduce overall costs at all phases of the plant lifecycle. For more information about PlantPAx DCS 5.0, please visit rok.auto/plantpax.

Process end users recognize the value of analytics as an essential strategy to realize profit in their process operations. The PlantPAx 5.0 release has purpose-built frameworks that easily connect live and historical data from the DCS into reporting and analytical tools. Enables extended experiences, such as Augmented Reality, using workflows aligned with process strategies controlling plant operations. Allows extensible scalable analytic packages leveraging predictive and prescriptive models for process Issue 48 PECM

CONTROL & AUTOMATION

RETHINKING AUTOMATION NOVOTEK

Using automation obsolescence as an opportunity for innovation The global demand for pharmaceutical products has grown consistently since the turn of the century. Despite the growth in demand and market value, pharmaceutical manufacturing has by and large neglected many of the productivity and efficiency benefits presented by automation systems. Here, George Walker, managing director of pharmaceutical automation specialist Novotek UK and Ireland, explains how pharmaceutical manufacturers can find greater value in their automation layer. Even prior to 2020’s COVID-19 outbreak and global pandemic, the pharmaceutical industry was one with climbing demand. According to Statista, the global revenues for pharmaceutical companies totalled $1.25 trillion in 2019 — an increase of $46 billion from 2018. Although specific demand figures are difficult to gauge, it’s reasonable to surmise that they would be increasing in line with revenue. Although revenue has increased threefold since 2001, many of the automated processes and approaches implemented by pharmaceutical manufacturers have remained the same. In 2001, the US Food and Drink Administration (FDA) and the EU worked closely together to develop the 2001/83/EC Directive for good manufacturing practice (GMP) and good automated manufacturing practice (GAMP) in the production of pharmaceutical products. A core part of this directive was to ensure safety in drugs by outlining a need for extensive validation and documentation of manufacturing processes and setpoints. Pharmaceutical manufacturing is a careful and complex series of processes. Once an initial formulation for a product is proven, proportions of biological agents or chemicals must then be correct at scale to preserve the efficacy of the drug as designed, without risks such as adulteration. This involves meticulous control of variables such as ambient temperatures, characteristics of incoming raw materials and dosing levels, as well as conducting routine temperature checks

and providing staff with effective protective equipment. To follow GAMP and comply with the EU Directive, pharmaceutical manufacturers are required to not only validate their processes, but also extensively document the rules around setpoints — such as sensor data, ambient conditions and programmable logic controller (PLC) settings — and evidence that checks are routinely undertaken. If any changes are made to processes or systems that can affect product quality, manufacturers must go through the costly process of re-validating and re-documenting their production. For many automation engineers, it seems intuitive that these requirements readily lend themselves to digitisation using automation systems such as manufacturing execution systems (MESs) to monitor and control processes. However, many manufacturers misinterpreted the need for repeat validation and documentation as extending to all changes in the control system, not just the ones directly related to production quality. This means even component or equipment health indicators, such as motor speed or temperature, would not be controlled; effectively meaning that automation systems were not used to their fullest. This was further compounded by misinterpretation around electronic batch record (EBR) guidelines. As part of the EU guidelines, auto-generated data from automation software systems can be

used in EBRs, but only if pharmaceutical manufacturers can demonstrate that the data management system is being managed safely and securely. Effective management can include ensuring that the system is tamper-proof to avoid manipulation of sensor data, locking the server to all but authorised personnel and introducing extensive change control practices that cover all underlying automation systems. The reality is this is an overcomplication of the EU guidelines that led to many pharmaceutical businesses introducing paper on glass MESs. These systems are effectively MESs without the execution functionality; they are simply a way of digitally recording precisely what was formerly handwritten. Yet because of the expense incurred in introducing these systems, combined with the perceived cost of re-documentation, they are still commonplace. Today, the EU Directive is better understood and pharmaceutical manufacturers have a clearer idea of what can be done within the guidelines. And due to the amount of years that have elapsed since the introduction of the guidelines, many of the systems are likely to be nearing obsolescence in the coming years. As such, now is the ideal time for manufacturers to look at how they can not only replace their systems, but also improve their capabilities.

For further information, please visit www.novotek.com/uk

PECM Issue 48

ELECTRICAL & ELECTRONICS

Introducing the New and Improved Range of AS Modular Floor Standing Cabinets with more sizes and accessories to suit your needs...

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PanelPilotACE Do you need to find a way to fast-track the development of touchscreen interfaces for critical equipment projects? What if you discovered there was no need for you and your team to grapple with hardware selection, driver integration or interface layout design?Â What if you didnâ&#x20AC;&#x2122;t even need to write any code at all? PanelPilotACE, nominated by the British Engineering Excellence Awards 2020 for Electronic Product of the Year, is an integrated

hardware solution that, combined with our unique and free Design Studio software, lets you create full colour HMIs in a fraction of the normal time. Powerful features for process control include a logic builder, maths functions, PWM output and many more. The PanelPilotACE is a game-changer for busy development engineers! https://www.lascarelectronics.com/ applications/plc-hmi-data-acquisition

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Issue 48 PECM

Power Control

Scient Instrumen

ELECTRICAL & ELECTRONICS

THE F-TECH RANGE WILKINSON STAR

More new fume extraction systems meeting latest HSE welding requirements New from Wilkinson Star, one the of the UKâ&#x20AC;&#x2122;s largest independent distributors of Welding and Industrial Equipment, is the F-Tech Fume technology product range of high vacuum fume extraction systems and welding torches. Welders and operatives can be exposed to welding fumes, grinding dust and oil mist in the working environment. It is therefore obligatory for employers to create safe and healthy working conditions for operatives by reducing these health risks. The F-Tech Armur is a high vacuum dust extraction system offering a mobile solution to extract dust from manual welding and grinding processes. The Armur unit features a high performance German motor and a choice of 3 mtr suction Armoflex or Armotech

cantilever arm and a user friendly digital panel with hour meter, clogged filter alarm. This unit offers E12 99.5% filter efficiency and comes with a 5 year warranty on both 110V and 230 V models. The F-Tech Pocket is a portable extraction unit designed to extract and filter fumes from welding processes, micro dust, vapours and odours. At only 20kg, it is a robust unit with a practical long handle perfect for site work and those difficult to reach areas. This unit has a 2mtr hose fitted with a plastic extraction nozzle.

The Pocket also has a filter efficiency of E12 99.5% and comes with a 2 year warranty. Additional features include a hourmeter and it is available in 110 and 230 Volt. The F-Tech Fox is a high vacuum dust extraction system offering a portable solution to extract dust from manual welding and grinding processes. Offering a 5 year warranty the Fox unit offers automatic cleaning of the filters which are manufactured in Europe and offer a long service life. The robust tandem motors offer pure efficiency in providing a vacuum over 20,000 Pa to extract and filter harmful welding and grinding dust. An auto start/ stop unit is also available to reduce noise levels and energy consumption when the unit is not running. The Fox will also run two welding torches simultaneously. The F-Tech range of fume extraction MIG welding torches are of Swiss manufacture. They offer the user more extraction efficiency at the welding source. Available in 300, 400 and 500A air/water cooled versions in 3, 4 and 5 mtr euro fittings. Also added to the range are the Down and Draught extraction benches, the heavy duty Armur-Force for manual plasma cutting and grinding dusts. Also new is the F-TECH ICAP; a wall mounted welding fume extraction system with self supporting HD cantilevered 3 mtr arm. The F-Tech range is available through Wilkinson Starâ&#x20AC;&#x2122;s extensive distributor network. For further details please contact Wilkinson Star on 0161 728 7900 or visit wilkinsonstar247.com.

For further information, please visit www.wilkinsonstar247.com

PECM Issue 48

NEW

Welding is all about harnessing the power of electric arc. When it comes to pulse welding, we understand the importance of generating consistent and precise arc for achieving optimal results. The key lies in merging inverter welding technology with advance MCU circuitry. With this in mind, we give you the JASIC MIG300P and MIG500P. The duo comes with high-precision waveform management, delivering high-quality pulse and consistent droplet formation. With the addition of CANbus and expert synergic welding, these 2 models give you full control for your welding tasks.

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@wilkinsonstaruk

Issue 48 PECM

ELECTRICAL & ELECTRONICS

STEGO’S NEW IIOT PLATFORM STEGO

Cloud service for IO-Link-based Industry 4.0 applications STEGO CONNECT is the latest contribution to the Industry 4.0 technology. The new Software-as-a-Service provides userfriendly access to network and control sensors and actuators based on the IOLink protocol. Data storage and software functionality are centrally organised in the STEGO CONNECT cloud. Freely configurable dashboards, alerts and workflows give users full control of their digitalisation projects. At the end of 2020, (scheduled launch date: 24 November 2020) STEGO is launching its new IIoT platform: STEGO CONNECT. The cloud service is a springboard into Industry 4.0 for small- and medium-sized enterprises (SMEs). The IIoT-based solution lowers the barrier to entry for individual digitalisation projects, particularly for SMEs. STEGO, based in Schwaebisch Hall/ Germany, enhances IO-Link technology with its STEGO CONNECT software layer to achieve this.

DIGITALISATION-AS-A-SERVICE When it comes to IT infrastructure, even companies open to digitalisation face challenges. STEGO CONNECT is positioned as a solution ready for immediate use. Users pay a monthly “rental” subscription to access the STEGO CONNECT cloud and get started with their own Industry 4.0 project with a fully-established IIoT platform. There is no need for any time-consuming, expensive set-up. Users can focus entirely on their projects.

EASY SET-UP AND NETWORKING STEGO CONNECT makes initial set-up easy for users. Plug & Connect is the motto for the effortless integration of any IO-Link device into the STEGO CONNECT IIoT platform. Connected devices are automatically detected, without any user intervention, and included in the central device management module.

and processed in real time on the edge computer in the STEGO CONNECT system platform. Users receive an immediate virtual image of their actual application as a decision-making tool for automations and alerts. Thus, data is used as a basis for fault detection, fault correction and optimisation. Condition monitoring and remote access are achievable objectives, which are easy to accomplish using the STEGO CONNECT control functions.

ACTUATOR CONTROL FROM THE CLOUD A unique feature of STEGO CONNECT is its ability to not only gather IO-Link data, but to also use it to specifically and automatically control IO-Link actuators. All parameters for this can be configured at edge computing level from the cloud.

WORKFLOWS VIA DRAG & DROP

KNOWLEDGE ACQUISITION FROM DATA A continuous stream of data is collected

It is easy to create workflows with STEGO CONNECT using the intuitive drag & drop

editor. Even users without any programming knowledge can set up complex processes that trigger control commands and alerts based on sensor data or processed data. The combination of resources in STEGO CONNECT is unlimited. Every connected sensor and actuator is automatable from the cloud with full flexibility. And in addition, manual override of the hardware is also possible from inside the cloud.

INTUITIVE, CROSSMANUFACTURER IIOT ECOSYSTEM In summary, STEGO CONNECT is a new, smart ecosystem in the form of an IIoT platform solution. The crucial advantage lies in it being independent from any manufacturer. IO-Link sensors and actuators from any manufacturer are reliably integrated by STEGO CONNECT into an intuitive automation system. STEGO is offering a subscription package for its cloud service to mark the launch of its IIoT platform solution. The business model is priced at a monthly fee of € 99 for each edge box installed in the system.

For further information, please visit www.stego-connect.com/en

PECM Issue 48

FACILITIES MANAGEMENT

Why leasing makes sense when cashflow is tight How do you invest in the equipment your business needs during uncertain times? With affordable fixed monthly payments and no deposit, finance leasing allows any business to improve cashflow, complete projects with immediate effect and provide high-quality modern equipment for your staff. 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. Plus, leasing payments are tax deductible, so it saves your business money no matter your financial circumstances.AJ Products offers leasing for all your workplace furniture and equipment requirements. From pallet racking and materials handling solutions to office furniture and breakout spaces, AJ Products has the solutions to help your business improve workplace productivity and employee wellbeing. info@ajproducts.co.uk 01252 359760 ajproducts.co.uk

NEW ProxATEX™ Digital Temperature Controller for Hazardous Areas This brand-new temperature and power controller brings a host of ‘world-firsts’ to the table, for design-in use as a digital controller fully adjustable within potentially explosive atmospheres. Built for worldwide “Ex” use with ATEX/IECEx and UL/CSA standard certifications, its high current 25A design is the perfect match for our legendary THERMOSAFE® induction drum heater, but is also ideal for control of “Ex” rated industrial ovens and process plant trace heating projects. Secure NFC programming cards add a new dimension to application security, with up to 15 parameter settings. Zones 1, 2, 21 & 22. T3 155°C / T4 135°C Rugged and reliable with IP66 all-weather protection for use in demanding environments UK, European, USA worldwide patents. lmkthermosafe.co.uk

CE and UCKA Marking Now that the UK has left the EU single market, the UKCA mark is being phased in from 1st January 2021 to replace the CE mark within the UK. Conformance has led the field in CE marking for over 20 years and is perfectly positioned to guide you through the CE marking and UKCA process. Our sister company Authorised Representative Service is also available to help you place your products on the EU market if you do not have a physical presence within the EU. With our Dublin office, we can support manufacturers to place their products legally on the market by becoming the responsible economic operator.

Learn more here: https://www.conformance.co.uk/ourservices/authorised-representative-services

Energy harvesting sensors provide immediate benefits Sensors are a key component to overseeing facilities. However, many sensing options generate installation and maintenance challenges that weigh against their benefits. DCO Systems offer affordable, simple to use energy harvesting sensors that provide immediate benefits and solve many issues faced on sites today. During lockdowns, facilities managers without remote monitoring found it more difficult to detect failures or diagnose faults. Scheduling an electrical engineer to wire in sensors also became much more difficult. At the same, those with battery-powered sensors found them constrained by infrequent updates, giving them only snapshots and partial sets the data they needed. To solve these issues, DCO Systems have created energy harvesting sensors. They are easy to install, ready for immediate use and provide an always-on, real-time connection of equipment and assets. Furthermore, self-powered sensors are ideal for remote monitoring in hard to access locations and sites with limited existing infrastructure. With continuous monitoring, energy harvesting sensors provide facility managers with a high-definition picture of their equipment and operations.

DCO Systems’ sensors for specific applications are already available with extensive customisation through options to fit different processes and needs. Equally important is that all sensors can easily be installed by the customer. To simplify, DCO have included coordinated connectors, adapters and fittings for many different requirements, with

installation videos that lend additional support. The ease of installation and use means that these energy harvesting sensors can be up and running immediately. To read the full article on DCO’s energy harvesting sensors, go to https://dcosystems. co.uk/mailing/pecm-jan21/.

For energy harvesting solutions, go to dcosystems.co.uk Issue 48 PECM

FACILITIES MANAGEMENT

THE SHIFT TO REMOTE SUPPORT GLOBAL HEAT TRANSFER

Is it time thermal fluid systems joined the fourth industrial revolution? The first company to provide remote consultations with doctors launched in 2013. Fast forward to 2020, and the pandemic has meant the entire NHS has switched to remote consultations. In industry, advances in sensor technology and manufacturing software have seen remote monitoring become more prominent. But will maintenance professionals, like doctors, be able diagnose problems online? Here, Clive Jones managing director of thermal fluid supplier Global Heat Transfer, discusses whether the pandemic could kickstart the digital revolution of thermal fluid monitoring. Because thermal fluids degrade over time, regular thermal fluid analysis is a vital part of maintenance in facilities that use heat transfer systems. Traditionally, carrying out sampling, analysis and maintenance requires on-site support from a thermal fluid expert, who is usually a third-party. As manufacturing facilities implement new procedures to meet social distancing recommendations, it could become more difficult for external engineers to regularly visit sites.

PECM Issue 48

Pandemic or not, thermal fluid analysis is not something that can be put off â&#x20AC;&#x201D; it helps ensure compliance with The Dangerous Substances and Explosive Atmospheres Regulations (DSEAR) of 2002 and the Explosive Atmosphere Directive (ATEX 137). These regulations set the minimum requirements for protection against risk of fire, explosions and similar events that can occur when there are dangerous substances in the workplace. In addition, failing to sample fluid regularly could lead to extensive downtime if issues go undetected â&#x20AC;&#x201D; it is a matter of safety, productivity and profitability. Over time, operating thermal fluids at the high temperatures required for process applications can lead to the build-up of contaminants, such as carbon, in the system. Carbon is a natural insulator so can cause a lack of flow that will lead to uneven heat transfer and a system that cannot reach and maintain required temperatures. This will begin to negatively impact product quality and increase energy costs, and

could result in costly maintenance and downtime.

DISTANCED DIAGNOSIS The new guidelines for businesses returning to work will change how manufacturers interact with suppliers and other third parties. For some outsourced maintenance activities, audio or video calls will allow the engineer to understand the situation and offer support without visiting the site. However, effective thermal fluid management and maintenance requires external specialists to visit a site to collect a sample and perform maintenance on system components. A thermal fluid expert must take a closed sample while the system is hot and circulating, to gain an accurate representation of fluid condition. Though visiting the facility is therefore still essential, good communication can help to reduce time on site.

For example, manufacturers can send external maintenance engineers previous reports or any relevant production information ahead of a visit for sampling. If the company experiences a drop in heat transfer efficiency or an unexplained increase in energy costs, it could help the engineer to get a clearer picture of why this is occurring, and where the problem is. After the sample has been taken, the engineer will send it to a laboratory for testing and analysis to determine fluid condition. To further limit unnecessary visits to site, engineers can deliver the analysis report virtually, explaining the status of the fluid and offering recommendations on how to maintain or extend the lifespan of the heat transfer fluid. If required, facilities managers and external engineers can also plan any maintenance accordingly so that they can maintain social distancing and hygiene measures.

CONTINUOUS MONITORING Embracing digital technologies is one of the ways that businesses are improving productivity with fewer people in a facility. The heat transfer market has been slow to reap the benefits of digitalisation, but the pandemic could be the catalyst for change.

Regular thermal fluid analysis is a vital part of maintenance in facilities that use heat transfer systems. Condition monitoring technology could revolutionise how businesses complete accurate thermal fluid management in the future, by both bringing it into the digital age, and by reducing time on site. Until recently, there has been no way of knowing thermal fluid condition without an engineer visiting a site and taking a sample. However, the introduction of ThermocareÂŽ 24/7 Live Condition Monitoring cloudbased remote monitoring system changes everything. While facilities should continue regular sampling using traditional methods, a monitoring system can detect potential issues earlier, reducing the risk of costly downtime in the future. The system continually monitors fluid condition, sharing

real-time data with the cloud that engineers can access from any location. The platform can determine the presence of degradation factors and warn maintenance personnel with an alert to smart devices if it detects an anomaly. Installing a remote condition monitoring system allows engineers to monitor and access accurate data about fluid condition without affecting the flow of the liquid. Investing in this equipment as part of a proactive maintenance programme for thermal fluid management will help to keep heat transfer systems running efficiently. It can also reduce the need for external engineers to visit the site regularly, because they can react to alerts on the remote condition monitoring system and assist when required. While sampling will still be an important part of maintenance, bringing thermal fluid management into the fourth industrial revolution can greatly benefit productivity, particularly as remote working and virtual communication becomes the norm. The ability to access real-time information about fluid condition from any location will reduce unplanned site visits while still effectively sustaining thermal fluid and system life span.

To discuss the benefits of a remote preventative maintenance plan with a thermal fluid expert, visit www.globalhtf.com Issue 48 PECM

FACILITIES MANAGEMENT

A ONE STOP SHOP THE PREPARATION GROUP

The Preparation Group celebrates being granted Made in Britain membership The Preparation Group led by Founder & Managing Director Tracey Glew, is committed to provide environmentally friendly, clean, easy to use and low maintenance equipment with professional guidance and training for efficient sustainable results in surface preparation. Their contracting division PPC (UK) Ltd prepares thousands of square metres of concrete every month in readiness for final applications to be laid. Preparing subfloors and screeds, for epoxy resins, coatings and many other resilient floor finishes we provide 24hr support for our contractors and our operatives ensuring all eventualities are covered. We carry out 98% dust free operations in hundreds of different types of situations. We provide services for the removal of laitance, adhesives and bitumen using different equipment as necessary, alongside having the ability to clean, refurbish and renovate many different types of resilient flooring. Our teams are all trained to NVQ level for preparing and profiling substrates and have continual professional development provided in our own training school. Trading since 1991, celebrating our 30th Anniversary in 2021, we continue to invest in R&D and training to deliver our customers the honest cost effective solutions. Our focus is to provide a One Stop Shop for environmentally friendly solutions for all types of surface preparation.

Preparing, Polishing & Cleaning

PECM Issue 48

Sales & Hire of Equipment Training Accessories Repairs & Maintenance

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Manufacturing machines and equipment in our workshop for our contracting division gives us the confidence to recommend the correct machines and processes required for all your flooring solutions and dust collection needs. We carry large stocks of a huge range of diamond tooling and other surface preparation consumables, alongside spares and component parts for man makes of equipment, all available for next day delivery. The Preparation Group has recently been accredited as a member of Made in Britain. The Preparation Groupâ&#x20AC;&#x2DC;s adoption of the official, protected mark will help buyers recognise its products as good quality, great value and British-made. We are extremely proud to be able to Fly the Flag and contribute to the re-growth of the UK economy and encourage buyers to get behind the country and buy British wherever possible. For further information on all our products and services please contact us on 01522 561460. For further information, please visit www.ppcgroup.co.uk

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Issue 48 PECM

FACILITIES MANAGEMENT

INDUSTRIAL DOOR SOLUTIONS ASSA ABLOY ENTRANCE SYSTEMS

ASSA ABLOY Industrial doors boost productivity and safety in the workplace pharmaceutical, chemical, electronics and micro-mechanics industries.

High speed doors for the food industry meet the highest hygiene requirements High speed doors for the food industry are designed for where high hygiene standards must be observed. These doors are easy to clean and disinfect and are resistant to aggressive cleaning agents. The combination of high speed and perfect sealing protects against drafts and moisture, keeping dirt particles out of production. Our high speed doors are HACCP certified, rendering them suitable for food processing applications.

Roller Shutters Gain an advantage in manufacturing with ASSA ABLOY Entrance Systems. Our automated door systems offer efficient and dependable solutions for your facility. Utilising Assa Abloy’s proven solutions considerably increases efficiency, moving people, goods and equipment seamlessly, creating separate clean environments, maintaining required temperatures, and increasing usable floor space whilst boosting production output. At the pinnacle for safety, security and convenience we design, build, install and service every door we make to ensure they’re a perfect fit.

Heavy-duty doors for intelligent manufacturing Assa Abloy machine protection doors are ideal for material processing, separating robots, machines and employees within seconds, offering safety, speed and reliability. The doors allow short cycle times and significantly reduce the footprint of the work station area, replacing guards which require greater distance between machine and operator.

High speed entrances for controlled manufacturing of pharmaceuticals Fast opening and closing speed helps control air exchange and reduce contaminants. A break away system ensures maximum safety for personnel and equipment. Assa Abloy cleanroom high speed doors feature an almost airtight seal minimising pressure drop and protecting against drafts, humidity, dust and dirt. Fully compliant with international cleanroom standards and certified by the Fraunhofer Institute. Ideal for cleanroom applications in

Machine protection doors are ideal for material processing, separating robots, machines and employees within seconds

Assa Abloy offer a complete portfolio of high quality roller shutters for industrial and commercial applications designed and manufactured in our state of the art facility in the UK to EN 13241-1 & EN 12604 safety regulations. Our range includes thermally insulated shutters, electric or manual fire shutters fully tested and certified to the latest BS EN 1634-1:2014 + A1:2018 fire regulations. The service you deserve Maintenance of automated entrances is essential in maximising lifespan, efficiency & operational reliability. Assa Abloy Entrance Systems have the UK’s largest network of highly trained Industrial Door Technicians on call 24/7, 365 days of the year, spanning the whole of the UK and are proud to serve many of the UK’s largest manufacturing and distribution companies. Service and maintenance programmes devised by ASSA ABLOY Entrance Systems cover all maintenance requirements for ours and competitors industrial doors, roller shutters, dock levellers, shelters, high speed doors and fabric hangar doors.

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

PECM Issue 48

Industrial and High Speed Doors for every application: • Machine Protection

• Material Handling

• Process, Printing & Packaging

• Waste & Recycling

• Cleanrooms

• Warehousing

• Food & Beverage

• Distribution & Logistics

• Service and Maintenance

• Automotive Manufacturing

assaabloyentrance.co.uk

Experience a safer and more open world

FLUID HANDLING

MAK CHEM International The MAK CHEM brand is a range of premium performance maintenance chemicals for cleaning & maintenance including degreasers, NSF Registered & specialised solutions – part of A&S International Ltd. With over 40 years experience in maintenance chemicals and lubricants we deliver products and services that provide game-changing solutions for UK maintenance teams. Our talented & reliable team help our clients & distributors to achieve, and in many cases even exceed, all their key goal requirements… • Expensive machine downtime minimised • Prolonged service life of critical components • Reduced maintenance costs • Approved performance in food processing equipment

Palamatic Vacuum Tube Lifters solve manual handling of door cores, for Leading Fire Door Manufacturer

Thermal Fluid Solutions – pioneers in thermal fluid management

We are actively looking to appoint a network of UK resellers to market & sell our quality maintenance chemicals. Contact us to find out more about this profitable opportunity.

Palamatic are the leading supplier of Vacuum Tube Lifting Systems for handling products up to 350kg to to all manufacturing industries. With 35 years’ experience, thousands of our solutions are in use on a daily basis. Our long standing customer, Ahmarra Door solutions has over 10 Palamatic vacuum lifters on site for handling boards and doors up to 120kg. They are one of the UK’s leading fire door manufacturers and have been manufacturing door sets for over 25 years. Vicky Boulton Marketing and Compliance Manager, explained how the Palamatic lifting equipment assists their operators. ‘‘The vacuum lifters make moving heavy door cores easier and quicker. It’s also beneficial from a health and safety perspective, as it helps prevent our staff from the risks of repetitive strain and back injuries’’.

For more than 20 years, we’ve been finding ways to ensure thermal fluids can be safely used for longer, helping manufacturing and process businesses cut operational costs, improve workplace safety and reduce their impact on the environment. We’ve used our expertise and experience to develop safe, efficient, cost-effective ways to recondition thermal oils instead of changing them, which means our customers benefit from: • Fluid life extended by 10 times or more • Reduced system downtime • Reduced operating costs • Reduced risk of fire and explosion • Reduced environmental impact • Increased productivity • Increased system efficiency • Legislative compliance • Senior service technicians available worldwide

0118 930 4321 www.mak-chem.org

T: 01246 452054 | E: sales@palamatic.com www.palamatic.com

For further details, please visit www.thermalfluidsolutions.com

Fluid Carrying

... always an intelligent solution

Flexibility Articulated Torsion Pipework In Hoses Rotating Cylinders

Swivel Joints

COMPRESSION FITTINGS ORIGINAL RANGE Sizes 15 -100mm

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

QUICK RANGE Sizes 15 -50mm

LEAK SEALING CLAMP Sizes 10 -100mm

Malleable

Tel:

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

PECM Issue 48

+44(0)1663 735003

E-mail:

DZR Brass

TAPPING CLAMP

Malleable

DZR Brass

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

PECM Quarter page, CABCO.indd 1

10/03/2016 10:38

HOW PROPER LEVEL INSTRUMENTATION CAN ALLEVIATE FOAM HEADACHES

Despite causing difficulties for many common technologies, the potential impact of foam is often ignored when choosing a level technology. Eclipse GWR transmitters have the highest SNR in the market, making it easier to measure and detect liquid levels through the foam or the actual foam layer itself. Access our FOAM IN THE FIELD white paper and learn how proper level instrumentation can alleviate foam headaches.

Magnetrol International, Inc.

Connect with the level measurement experts at magnetrol.com

FASTENERS & FIXINGS

THE HUCK® MAGNA-GRIP® STAR FASTENERS

Permanent Mechanical LockBolt therefore offers a more secure fastening solution and eliminates the requirement of re-checking.

Like all Huck engineered fasteners, Magna-Grip offers a high level of vibration resistance to deal with the effects of fastening dynamic loads and is used in many harsh environments such as agricultural equipment, specialist structures, commercial vehicles and trailers, in fact wherever there is a need for a fastening solution as an alternative to welding. In applications where a wide grip range is required and a flush pin break to the collar is beneficial, Huck Magna-Grip is the ideal fastener for the job. Magna-Grip can replace up to four traditional LockBolts. During installation the collar is swaged onto the Magna-Grip ‘pin’ and forms a permanent connection which consistently provides high, uniform installed values.

WHAT ARE THE BENEFITS OF USING A HUCK MAGNA-GRIP FASTENER? • Unmatched installation speed – fastener than standard structural bolting assemblies and no re-torque is required. • Low overall installed cost. • Vibration resistance - forms a permanent, vibration-proof connection that promotes increased customer satisfaction and reduced warranty claims. • Wide grip range: reduces inventory requirements and accommodates variations in joint thickness, 14.3/23.9mm. • One pin and one collar cover a wide variety of applications: reducing the risk of incorrect fastener selection. • Eliminates need for secondary operations and hole preparation isn’t critical. • Built-in system values yield high consistent clamp loads and gap removal. • No special training or skills required for operators. • Flush pin-break: no catching on clothes, skin or goods. Available Sizes: 3/16”, 1/4”, 5/16”, 3/8” Materials: Steel, Aluminium

PECM Issue 48

For over 30 years, the Huck brand has set the standard for joining technology with a range of vibration-resistant, maintenance-free fastener options. The Magna-Grip is a permanent Lockbolt and is therefore an ideal fastening solution for tough engineering environments and areas where security is a requirement. One such environment is the conveyor industry. Screw conveyors, feeders and dischargers based on Archimedean screw principles are an essential part of many storage and processing systems dealing with a wide variety of products including powdered, granular and even wet materials. They are used in a diverse range of industries from grain processing, feeds and foods to oilseeds, biomass, waste and minerals. In this high vibration and abrasive environment nuts and bolts might come loose and contaminate the product, this fastening method also needs ongoing maintenance and checks. The Magna-Grip is swaged and

For over 30 years, the Huck brand has set the standard for joining technology with a range of vibration-resistant, maintenancefree fastener options. The Magna-Grip is commonly used in the commercial vehicle bodybuilding industry and is installed in wide variety of applications such as roof supports to roof rails, sider-raves to cross-bearer’s and then cross-bearers to chassis cleats. In these examples it has replaced the need for welding and nuts and bolts. For trailers, Huck fasteners offers a broad range of fasteners including HuckBolts and both structural and non-structural blind fasteners for the assembly of subframes, kick rails, various panels, roof assemblies, and floors. Each of these fasteners delivers an impressive combination of clamp, tensile strength, and zero-maintenance performance. Huck fasteners provide the industry’s most advanced fastening solutions, they are 100% maintenance-free. No re-checking. No re-torquing. No re-tightening. So, a truck or trailer that is assembled using Huck fasteners represents a better value; delivers better life cycle value through, reduced warranty claims, and longer life. Specialists in the supply of Huck Fasteners, Star Fasteners are proud to be the UK’s largest Huck fastener distributor. Working with a diverse range of end users and distributors from across a number of industries including general engineering, rail, solar, wind power automotive, marine and all of the structural construction markets. In fact, they are widely used in any industry where a quality, strong and dependable fastener is a required… application possibilities are endless! Star Fasteners are also an accredited Huck tool service and repair centre; expert technical knowledge and a large tool hire fleet complements the service. For more information about Star Fasteners unique value-added services have a look on starfasteners.co.uk or contact us on the following: Tel: +44 (0)115 9324939 email: sales@starfasteners.co.uk www.starfasteners.co.uk

Huck Magna-Grip Installation Sequence Truss Head MGPT Button Head MGPB Installation Huck Magna-Grip Installation Sequence Huck Magna-Grip Sequence

2. Collar

1. Insert fastener though a prepared hole. The precision collar is placed over the other end.

Broad Collar

2. The Huck installation tool is applied and engages the pin. When the tool is activated, it pulls the pin in a straight line while pushing down on the collar.

Truss Head MGP30

Collar

The tool moves forward over the collar, molding the collar material into the grooves of the pin. This process called swaging, causes a precise stretching out the pin and collar, developing the fasteners clamping force.

When swaging is complete the pintail is automatically tensioned off, flush with the end of the collar. The result is a permanent, mechanically locked fastener.

90째 Flush Head MGP90

Magna-Grip Pin Head S

The tool moves The Huck installation When swaging is Insert fastener forward over the tool is applied and complete the though a prepared collar, molding the The tool moves engages the The pin. hole. The precision Huck installation swaging Insert fastener When swaging is is The tool moves forward pintail is When The When Huck installation tool Truss Head Insert fastener through MGPT Button Head MGPB Stainless Encapsulated collar material into forward over the the tool is activated, it automatically collar is placed over complete the pintail over the collar, molding is applied and engages a prepared hole. The tool is applied and complete theis though a prepared Head MGPTC of the automatically collar molding material intothe the pin. When the the tool isgrooves the precision collar is placed pulls the pin in a collar, tensioned off, flush the otherhole. end. The engages the pin. When pintailtensioned is precision off, flush with the the grooves of the pin. activated, it pulls the pin This process over the other end. pin. straight line while with the end of the collar material into the tool is activated, it automatically collar is placed over end of the collar. The This process called in a straight line while called swaging, pushing down pulls on the collar. the grooves of the The result result is a permanent, swaging, causes a precise pushing down the pinoninthea tensioned off, flush the other end. causes a precise Rivet MGP98T mechanically locked collar. stretching out the pin isand aHead permanent, pin. This process MGP90 Broad Truss Head collar. MGP30 straight line while90째 Flush Head with the end of the stretching out thedeveloping collar, the fastener. mechanically called swaging, pushing down onpin theand collar, collar. The result fasteners clamping force. locked fastener. causes a precise collar. developing is a permanent, Magna-Grip Pin Head Styles the stretching out the mechanically fasteners clamping pin and collar, locked fastener. Magna-Grip Pin Headforce. Styles developing the fasteners clamping force. Truss Head MGPT MGPT

Button Button Head Head MGPB MHPB

Truss Head MGPT

Button Head MGPB

Magna-Grip Collar Styles Broad Truss Head Broad Truss Head MGP30 MGP30

StainlessEncapsulated Encapsulated Stainless HeadMGPTC MGPTC Head

900 Flush Head MGP30 90째 Flush Head MGP90

Stainless Encapsulated Head MGPTC

RivetHead HeadMGP98T MGP8T Rivet

Magna-Grip Collar Styles

Rivet Head MGP98T Magna-Grip Pin Head Styles 90째 Flush Head MGP90 Magna-Grip Colar Styles Magna-Grip Pin Head Styles Standard Flange Collar

Medium Flange Collar

MGC Broad Truss Head MGP30MGCS

Standard Flange Collar Standard Flange Collar Magna-Grip MGC Collar MGC

Wide Flange Collar MGCW

Medium Flange Collar

Styles Medium Flange Collar MGCS MGCS

Wide Flange Collar MGCW

Magna-Grip two-piece Wide Flange Collar Pin and Collar fastener MGCW Magna-Grip two-piece Pin and Collar fastener

further information, Magna-Grip For Collar Stylesplease visit www.starfasteners.co.uk Standard Flange Collar MGC

Medium Flange Collar MGCS

Wide Flange Collar MGCW

Issue 48 PECM

GEARS, DRIVES & MOTORS

Graphalloy_Extremes_88mmx132mm.qxp_Layout 1 10/21/20 1:06 PM Page

GRAPHALLOY® Bearings... We Go to Extremes

Handle High Temperatures and Harsh Operating Conditions with Ease. • Survives when others fail • Run hot, cold, wet or dry • Corrosion resistant • Self-lubricating • Low maintenance • -400˚F to 1000˚F (-240˚C to 535˚C) Yonkers, NY USA • Ovens, furnaces, conveyors, mixers, dampers

Yonkers, NY USA

+1.914.968.8400

•

www.GRAPHALLOY.com

Cross+Morse Power Transmission Manufacturing Specialists

Since 1984

◊ Manufacturing up to 1450mm diameter ◊ Turning - CNC lathes, Vertical Machining Centre ◊ Gear Cutting - Hobbing, Planing, Shaping Gears ◊ Bevel Gears, Helical, External & Internal cut Gears ◊ Rack Shaping, Broaching, Keywaying ◊ Vertical Boring, Centreless & Rotary Grinding ◊ Bore Honing ◊ Induction Hardening

◊ Drilling & Tapping ◊ Large stocks of Transmission Drive components ◊ CAD - CAM Design & Development ◊ ISO 9001 : 2015

Yes we can make it.

Cross + Morse. Shady Lane, Great Barr. Birmingham. B44 9EU sales@crossmorse.com Tel: +44 (0)121 360 0155 Fax: +44 (0)121 325 1079 www.CrossMorse.com

PECM Issue 48

GEARS, DRIVES & MOTORS

LABINOX bespoke stainless steel vessel, filter and furniture manufacture LABTEX, the Huddersfield based laboratory and scale up chemistry equipment specialist, has introduced LABINOX as sub-brand offering off the shelf & bespoke fabrications in metals.

Stainless Steel Laboratory Furniture

Sourced in the UK, the EU and the USA LABINOX offers plain and jacketed vessels and filters and furniture to customer specifications. Our work ranges from simple fabrications and machining to high specification bespoke projects for the pharmaceutical, food processing, water, paper and chemical industries. Working in conjunction with skilled fabricators and finishers, LABINOX ensures that work is completed to the highest standard and is in accordance with relevant EU directives. In particular the pressure equipment, ATEX and machinery directives.

LABINOX will project manage manufacture and installation of assemblies, ensuring that not only stainless steel equipment but also associated equipment is procured and scheduled to meet your requirements. Services include: Draughting, Design, Quotation and Feasibility Studies, Fabrication Supply and Project Management. 01484 600200”

Labtex.co.uk

forteq UK located in Huddersfield produce high volume injection moulded technical plastic components. They are a wellestablished supplier into the automotive and Industrial product sectors. Applications such as door latch housings, engine mount assemblies, air suspension, geared-actuators, timing tensioners, seating, filtration, HVAC

and fluid delivery bowls are some automotive components produced. Forteq are also specialists at industrial product plastics such as gas and water meter housings, valves and internal functional components, including twin shot moulding. During 2020 forteq have been busy engineering suites of tools for car seating mechanisms, air suspension pistons

and truck filtration assemblies that commence production in 2021. forteq UK have capacity to engineer new projects, please get in touch with Steve Roberts on 01484 483516 – steve. roberts@forteq-group.com to discuss any upcoming projects. www.forteq-group.com

Issue 48 PECM

HEALTH & SAFETY

THE HEAT IS ON EMS

How infrared technology brings safety in multiple applications Infrared temperature guns have become a commonplace safety precaution, with 37 degrees Celsius acting as the entrance pass to many offices, shops and airports. This is just one application where infrared technology provides important safety information. Here Dave Walsha, commercial development officer at precision drive system supplier, Electromechanical Systems (EMS), looks at the applications of infrared technology and the motor technologies advancing them. Temperature guns are one method used to detect if someone is exhibiting Covid-19 symptoms. The guns quickly determine if someone has an elevated skin temperature and should therefore isolate and receive a test. This promptly separates the potentially infected individual from others. However, fever temperature screening is not the only application where infrared technology helps bring safety. Infrared detection systems, such as temperature guns, use sensors to pick up radiation in the infrared region of the electromagnetic spectrum. Although infrared cameras use this same technology, they are much more complex. They convert the thermal energy being detected into an electrical signal, which can then be processed to produce an image. The image varies in colour, such as red for hot and blue for cold, depending on the amount of infrared radiation being detected.

FROM LOST TO FOUND Infrared cameras provide critical information in the emergency services. Someone is reported missing in the UK every 90 seconds, so search and rescue services must act quickly to ensure the highest possibility of finding the missing person safe and well. However, manually searching dense areas with little visibility, such as forests and rural areas, can be labour intensive. When time is precious, infrared devices can help searchers quickly scan over large areas. Search and rescue service teams typically comprise of searchers on the ground and

PECM Issue 48

in the skies. From an arial view, searchers in helicopters can use an attached infrared camera to quickly scan the large area. A missing person will have a much stronger infrared signal than their cool surroundings, so will show up as an easily distinguishable colour on the screen. The coordinates of the missing person can then be reported to the ground team, who can quickly access the area on foot.

The ability to identify the location of an individual using infrared technology is not only used for missing and endangered people. Infrared cameras are also used in the police force to track down suspects. If suspects of a crime recognise that the police are tracking them, they may hide in unusual places, such as on a roof or inside a container. Infrared cameras, along with sniffer dogs, can be used to track down suspects before they escape.

RESOLVING EQUIPMENT FAILURE The emergency services use infrared technology to keep citizens safe, but it can also be applied in industrial settings to safeguard equipment. Industrial equipment must carry out intensive processes, such as cutting and lifting, for a long period of time ― particularly with the increased adoption of continuous automation. Uninterrupted production can cause unwelcomed machine faults to arise and industrial equipment to overheat. Overheating can lead to electrical faults or even fire, risking the safety of both the production line and nearby workers. To ensure overheating equipment remains intact, it must be shutdown and the problem rectified. This can involve painstakingly taking apart the machine and conducting several tests until the problem is located. Instead, an infrared camera can identify the component that’s causing the machine to overheat, which can then be fixed or replaced quickly. This ensures the production line is back up and running as quickly as possible to minimise lost time and maximise productivity.

GETTING THE RIGHT GEAR Cameras viewing objects at varying distances need precision zoom and focus

functions that are controlled by lenses, which can be precisely adjusted by motors. Motors also control the camera aperture, which is an opening in the lens that controls how much light passes through and falls on the image sensor. Infrared cameras also require motors for calibration in non-uniformity correction. This is a process where a black shutter is moved across the lens and the camera takes an image. From this image the camera can measure the heat it is producing itself, and so process its own thermal signature out of future photos, as to not interfere with the thermal image of the subject.

TICKING THE BOXES Motors used in infrared cameras must meet certain performance requirements. In applications where the camera is handheld, the motor must be lightweight so that the device can be easily carried by the user. In critical applications, such as search and rescue, it is vital that the motors used are reliable and repeatable, as a breakdown could have fatal consequences. Similarly, the motor must be efficient with a low power consumption, to ensure the camera can be used for a long period of time without running out of power. EMS is the sole UK supplier of FAULHABER

The emergency services use infrared technology to keep citizens safe, but it can also be applied in industrial settings to safeguard equipment. motors, which are renowned for a superior power density and high performance. FAULHABER motors are made in a high precision manufacturing process, with accuracy that makes them highly reliable and repeatable. In particular, FAULHABER’s flat 1512 DC gearmotor series delivers continuous torque up to 30 millinewton meters (mNm) while having a diameter of just 15 millimetres (mm). Temperature guns have become a common safety procedure to prevent the spread of Covid-19, but there are many other applications where infrared technology is important. From finding the lost to identifying equipment faults, infrared cameras bring us valuable information that goes beyond the human eye.

For further information, please visit https://www.ems-limited.co.uk/ Issue 48 PECM

HEALTH & SAFETY

REMBE IQ SAFETY COCKPIT REMBE

Smart home for factories Visualisation of safety-relevant faults in the control room is only half the battle. In order to appropriately react to such faults, pre-defined counter measures have to be initiated â&#x20AC;&#x201C; what sounds simple is a true challenge for plant operators in practice. Given the risk of human error, the REMBE iQ Safety Cockpit was developed and launched: Similar to a process control system, the REMBE iQ Safety Cockpit offers an overview of all relevant protective and equipment system status, which can also be monitored in real time from any location remotely via smart phone. However, in addition to the PLC, detailed and automatic and semiautomatic action plans can be linked and initiated: In case of an event in a certain area, sending an email or an SMS to a predefined distribution group can be automated to bring the incident to their attention. Such a scenario could for example be, that in the event of an explosion the responsible safety officer might be informed by text message via his service phone, the surveillance cameras in the affected area could be activated or set to a different mode and the management would receive an email. Nevertheless, more importantly, the REMBE iQ Safety Cockpit guides the logged in user through the pre-defined plan of action.

Forced guidance thereby would ensure that all desired and necessary process steps are followed in the event of a disruption. Those applications and process scenarios of the REMBE iQ Safety Cockpit can be individually configured for each plant; both analog and digital signals can be processed. In addition to the REMBE autonomous protective systems, GreCon spark extinguishing systems, camera systems or even fire detectors and other plant components can be combined and connected to the REMBE iQ Safety Cockpit. Learnings from incidents and systematic root cause analysis are subject to be implemented in improved safety concepts. REMBE iQ Safety Cockpit supports as all data recorded during the emergency plan are compiled and archived in a comprehensive log. This data can be practically expended or adjusted via the various end devices. When the location of the accident is inspected, photos can be conveniently taken and loaded into the log (via app) for subsequent evaluation. In the end, this means, that all conventional autonomous protective systems from REMBE have become smarter without sacrificing their actual strength, the fast and reliable function.

In the age of digitisation, it is just as important to ensure a fast response time and the resulting high availability. The REMBE iQ Safety Cockpit also enables optimal integration of other interfaces through the individually coordinated visualization of each process. Faults or, in the worst case, explosions not only require a regulated emergency plan, but also a predictive maintenance that is not only possible through the pure workforce of the employee on site. By detecting the operationally relevant components such as explosion vents, quench valves for explosion protection or pyrolysis gas and fire detectors or grounding systems for explosion prevention, all these can be registered and connected to a material management system. In a nutshell: REMBE iQ Safety Cockpit is nothing else than a smart home control or driver assistance system in the automotive industry. Those are used to improve the efficiency and safety of driving a car and enable, in the right mix of auxiliary sensors and smart detectors, autonomous driving. Staying in that picture, simply spoken, REMBE iQ Safety Cockpit, such as an driver assistance system for plants will allow autonomous operation and push safety and efficiency to the highest possible level in the industry 4.0.

Fig. 1: Example of individually configured application and process scenarios.

For further information, please visit www.rembe.de

PECM Issue 48

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

The eSUPPRESSOR™

New Sharklet Germ Control film

Short Cuts May Cut A Life Short!

The eSUPPRESSOR™ from IEP Technologies is the most technologically advanced explosion protection suppressor in the industry today. Effective and reliable protection is provided by the eSUPPRESSOR™ with the following features: • Monitoring of all safety functions • SIL2 compliant design and pending 3rd Party Certification • Integrated Lock out/Tag Out • No Pyrotechnic Actuator

Sharklet’s micropattern is the world’s first technology to control microbes through surface texture alone.

Safety Signs Manufacturer and Safety Products Supplier Spectrum Industrial have launched a guide to help industries implement a LOTOTO process within their facilities.

IEP Technologies is the worldwide leader in providing explosion protection systems and services. For over 60 years we have offered protection solutions that can suppress, isolate and vent combustible dust or vapor explosions in process industries.

+1-855-793-8407 • info.IEPTechnologies.com IEPTechnologies.com

Lightning Warning System Global Partners and Systems Integrators wanted Biral invites interested technical resellers and systems integrators to join its team of distribution partners. The BTD-200 is an innovative lightning detection and warning system, developed from professional aviation grade lightning detection systems. Its proven technology reliably detects all forms of lightning out to a range of 35km (22 miles) from the sensor. It is a modular system, designed to operate out-of-the-box, but is also expandable as requirements change. The system comprises of a lightning detector placed outside, either on its tripod mount or permanently installed and a PC indoors running the supplied Lightning Works software. The system includes a power supply and (optionally) cabling to connect to the power and host PC. +44 (0)1275 847 787 info@lightningearlywarning.com www.lightningearlywarning.com

PECM Issue 48

Sharklet departs from traditional antimicrobial technologies by not using any additives to kill microorganisms, but instead creates a non-toxic topography that decreases surface energy. Chemical additions can contribute to resistant strains of germs and may be hazardous in applications such as hospitals, children, and the elderly. The new Sharklet Germ Control Film includes Sharklet micropattern that is comprised of millions of microscopic features arranged in a repeating diamond pattern. Sharklet is engineered to produce an anti-fouling effect through enhancing the surface energy of common materials, similar to how it works on actual sharks. Effective against many viruses and bacteria. Film is available at shop.sharklet.com.

The NEW FlexiWork Neon Jackets and Fleeces While Fabric, Functionality and Fit are hallmarks of Snickers Workwear, it’s the innovation and fabric technology in the design of the new FlexiWork Neon Fleece Hoodie, Jacket and Gilet that really set these new garments apart. They’re great for working outdoors in the colder months. Delivering superior flexibility and comfort, these lightweight 4-way stretch garments come in a body-mapping design and are made from an Elastane/Polyester fabric with a water-and wind-repellent finish for comfort and durability when you need it most. As well as being street-smart and visibly striking with Neon panels and reflective details for enhanced visibility they’re designed for the fast-paced professional who’s always on the go and delivering top class work on site. For professionals who rely on their gear in demanding environments, they’re a must for those who want to be visibly ahead of the rest on site this winter. www.snickersworkwear.co.uk

Lockout Tagout Try Out (LOTOTO) is the correct method for isolating machinery to ensure that when repairs, maintenance, cleaning or inspections of equipment is undertaken, it is done so safely. Spectrum Industrial have built this guide to raise awareness, promote best practice and to help increase safety across high risk establishments where harm can be caused from machinery. The guide will show you the step by step procedures that should be followed to complete a successful isolation and will help you to create your own LOTOTO process. You can download a copy of the guide or for more information or to view Spectrum’s product range visit www.spectrum-industrial.co.uk

MasterCheck app provides the paperless solution to mandatory forklift inspections The new MasterCheck app automates the inspection process and provides the supervisor with important operational analytics and management tools on the web-based Supervisor Dashboard. Operators complete forklift inspections, repair reports, accident reports and near-miss reports including photos, quickly on a mobile device or tablet and simply click “send” to have the inspection sent to their supervisor and saved in the cloud. No more looking for lost paper reports – everything is automated! MasterCheck is currently being used by companies throughout the world, and at $19.99USD per year versus as much as $120.00USD per year with traditional paper booklets, the decision to go automate and go paperless is an easy one. www.mastercheckapp.com

NO LIGHT. TWILIGHT. DAYLIGHT. SUNLIGHT. Buckz Viz hi-viz styles bring crucial see and be seen safety to the workplace round the clock and in all weathers. Theyâ&#x20AC;&#x2122;re waterproof too for the odd time it rains.

Call 01382 82 82 00 or email info@buckbootz.com

HEALTH & SAFETY

DAILY-DISPOSABLE LENSES DAYSOFT

Process technology inspired by Mother Nature … for a greener world … half the price … half the plastic

You would not be surprised to be told that your banana was ‘made’ entirely in its skin! Mother-nature is a very efficient process engineer and would not consider growing a banana, then a skin, then placing the banana in the skin and then ‘zipping’ it up.

producers the world over do; they form a lens between two precision optical moulds, remove it from this assembly, discard the optical-moulds before carefully transferring the lens into a third moulding then filling this with saline and shipping it to customers.

But that’s what we human engineers do … we make a product then decide how to wrap it up wasting time and materials doing that. To be more precise, that’s what contact lens

Mother Nature was not impressed. “Three plastic moulds to make one wee contact lens … you must be joking!” The challenge was massive because modern soft contact lenses are extremely fragile, being more than 50% water. The centre thickness is less than a human hair. The diameter is 140 times this thickness. The contour shape has to provide precise power-correction within tight limits and it has to be strong enough to support its weight in air even when fully hydrated with water. It has to be crystal clear, without imperfections so as to sit comfortably on the human eye. But the Daysoft Engineering Team got to work and invented a completely new process they named INPAC®. This eliminates making millions of mouldings each month

then lifting wet fragile lenses into these. Now the lens is formed, hydrated, sealed and sterilized-in its originating mould. INPAC® process technology already has patent protections in US, Canada, Europe (UK, Ireland, Germany, France), Hong Kong, China, Japan. Manufacturing site capacity has been increased to over 100 million lenses per year. Mother Nature was consulted. “Supplying the lens in the mould you made it in … now that’s impressive.”

For further information, please visit www.daysoft.com

PECM Issue 40 48

Half the price, half the plastic Mother Nature CEng – Inpac® Process approved

£5.99

32 Lenses per Box minimum purchase 2 boxes, £0.70/Box post and packing Today orders are taken from around the world, picked and packed within 8 hours and posted direct to wearer homes or office right from the end of the new INPAC® production lines. Over 650,000,000 sold direct world-wide Daysoft® process engineering: • Half the plastic, half the process transfers • Half the shipping stages • Half the price • Designed and made in the UK.

DAYSOFT.COM DAILY-DISPOSABLE CONTACT LENSES FOR A GREENER WORLD

DAYSOFT.COM

HEALTH & SAFETY

Forerunner Yesterday. Today. Tomorrow. The Sensor People have been setting technological standards in industrial automation for more than 50 years. In the field of safety at work, we convince right from the start with trend-setting inventions, such as the development of the first protective sensor ever, to our latest safety innovation, “Smart Process Gating” – the space-saving solution for access guarding on conveyor lines. This is how we ensure the success of our customers in an industry that is ever evolving.

www.leuze.co.uk

PECM Issue 48

MACHINING & MACHINERY

Automations role in the race to develop the COVID-19 vaccine In addition to supplying high quality components, Versatile Controls Limited’s automation department design and manufacture electrical, pneumatic and hydraulic control systems to the highest quality. The company has maintained a full workforce throughout the Covid-19 pandemic supplying the world’s leading pharmaceutical companies with bespoke automation systems to assist in the race to develop the Covid-19 vaccine. William Slim, Director explains, ‘A particularly challenging aspect

to developing such critical systems during the pandemic is the extremely tight deadlines involved. We are proud to have delivered several critical projects on time and to specification’. The company primarily serves pharmaceutical, medical, automotive and petrochemical industries. Extensive experience in electrical circuit design and software development means Versatile can offer a complete automation package.

www.versatilecontrols.co.uk

CNC ROUTERS & LASER CUTTERS Introducing the NEW Fibre Laser Marker

Features • High-speed galvanometer • Compact and light weight • Low power consumption, less than 500W • Air-cooled • The machine can increase production and reduce costs Typical Applications Industry: Gold and silver jewellery, sanitary ware, food and beverage packaging, pharmaceutical packaging, medical devices, eyeglasses, clocks, automotive parts and electronic hardware. Materials: Gold, silver, stainless steel, ceramic, plastic, glass, stone, leather, fabric, wood etc.

Introducing the NEW CNC Laser Cutters The NEW ATACAM range of Laser Cutters includes models for both metalic and non-metalic materials. They are equiped with co2 laser tubes, which can be used for cutting metalsheet such as carbon steel, stainless steel and non-metalic materials such as acrylic, MDF, plywood, etc. Model AL1390 (pictured) for Non Metalic cutting and Model ALM1390 for Metalic and Non Metalic cutting. Call for more information or a demonstration, or visit www.atacam.co.uk ATA Engineering Processes Ltd ATA House, Unit B, Boundary Way, Hemel Hempstead, Herts, HP2 7SS t: 01442 264411 e: sales@ataeng.com www.ataeng.com

Issue 48 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 48

Threading Tool Specialists

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

THREAD CUTTING AND ROLLING HEADS and parts and repair service

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

HSS TAPS Huge Stocks for all Standard threads CUSTOM MADE taps our SPECIALITY! We stock taps for many non standard (SPECIAL) threads All types; Spiral flute and point, Fluteless, Left Hand, etc, etc.

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

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

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

MACHINING & MACHINERY

TOTAL SUPPLY PACKAGE JOHN KING GROUP

Material processing solutions since 1926 John King is a family-owned manufacturing company founded in 1926. The fifth generation of the family are now working in the business; both qualified and committed to take it forward and achieve greater success. The enterprise began by producing plain pedestal bearings for coal mining pit tubs. Expansion came with the rapid mechanisation of the collieries and an increasing demand for chain conveying equipment. In the early days it was supply to one industry in one region of the United Kingdom. The Company has enjoyed unrivalled success and expansion in the last decade. Today exporting mechanical handling equipment to over 60 countries. This achievement was recognised in 2020 when the Company won the Queens Awards for Enterprise –International Trade

PRESENT DAY FOCUS

The business is now focused on provision of a total supply package for materials handling; comprising chains and sprockets to conveyor systems and their eventual installation and maintenance. John King Laser was established in 2007 primarily to service the mechanical handling division. It was well understood that the available capacity surpassed that of in-house requirements and the business model from the outset was to sell laser cut and fabricated parts to customers producing a wide range of machinery and equipment. More recently the division has been able to support John King’s site service division

John King main factory in Yorkshire with an original pit tub in the foreground. Above left, Installation of new laser – to be commissioned in January 2021 where bespoke fabrications have been required .A good recent example would be the survey, technical drawing, production and installation of major fabricated structures within an EFW plant (Energy from waste). The laser division has remained autonomous from the start in having to achieve individual levels of sales and profitability whilst critically benefitting as part of a Group structure in investing in new technology to give the division a distinct advantage in efficiency and quality of products produced. The current installation of the newest and probably best laser capacity in the country is testament to that particularly in considering the present challenges within the economy as a result of the pandemic .It is our strong opinion that in 2021 John King Laser will be perfectly prepared to deliver as the economy emerges from a challenging period.

MANUFACTURING CAPABILITIES

The 2020s business is a lean and profitable enterprise working from a modern manufacturing facility employing best production techniques Fibre laser technology , plasma for thicker material sections , CNC machining and Robotics. Group structure

provides the internal resource to implement production management systems that ensures highest quality, consistent and competitive products produced in a safe environment. All manufacturing is conducted within the dictates of ISO9000 to the latest 2015 standard to ensure quality objectives are monitored and maintained.

OUR PEOPLE

Our people are at the heart of the Kingdom, constantly driving the business forward whilst showing unrivalled commitment to make us the success we are. Together we search for continuous improvement and product innovation. As a family enterprise we are proud of what we have achieved .To be working and succeeding in manufacturing is a privilege. To operate in a process led sector where we turn raw material into a wide variety of products by using machinery and manpower is challenging and eminently rewarding. As a result of unceasing advances in technology and machinery Engineering is one of the fastest developing sectors internationally. The UK engineering sector generates more than 27% of the UK’s GDP and it is clear that the industry is driving productivity whilst having a positive impact on other areas of the UK economy. For every new job in engineering, two more are created outside of the sector. The UKs Engineering sector is the real wealth creator and it is my hope that post Brexit the Government will realise the opportunity we have to put UK Engineering at the forefront. David Wadsworth Managing Director

For further information, please visit www.johnkingchains.com

PECM Issue 48

Laser Cutting, Plasma Cutting & Flame Cutting

The undisputed Kings of Laser proﬁling and fabrication

To add to our existing armoury of cutting equipment we are pleased to announce the installation of the newest and best laser technology available Nationwide.

Trulaser 3040 Fibre 4000×2000 bed with integrated lift master and plate storage tower for unrivalled efficiency in parts production. • Group strength to support ongoing investment in best manufacturing, • Maximum cutting availability with automated plate storage and handling, • Dramatic increase in available processing capacity, • Full range of supplementary manufacturing processes, • Bespoke manufacturing service – design, manufacture, install, • Quality management in accordance with Company MQS ISO 9001:2015 the latest standard.

Press braking – 200 tons 4000 mm

Robot welding

Design capability

In house material Analysis

Machining

Powder coating

All Enquires please contact Email: sales@johnkinglaser.co.uk

or Call Us by Phone

+44 1977 686 570

John King Laser Limited New Climax Works, Lancaster Business Park, Sherburn-in-Elmet LS25 6NS UK www.johnkinglaser.co.uk

MACHINING & MACHINERY