Process Engineering Control & Manufacturing - Issue 49 2021 by MH Media Global

Process

MANUFACTURING

Control &

Engineering

SIEMENS - 6

WARNER ELECTRIC - 30

UK manufacturers must step-up energy resilience planning to meet the challenges of tomorrow

Warner Electric XS & WR Series brakes reduce footprint of six-axis robot

PECM

Global Success Through Innovation Issue 49 2021 £3.95 www.pecm.co.uk

SULZER - 58 Sulzer creates a hybrid additive manufacturing process to minimize lead time on components for Chevron

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Process

MANUFACTURING

Inside... Sections

Control &

Engineering Inside Issue 49

Editors Choice

Boilers & Maintenance

Control & Automation

Electrical & Electronics

Facilities Management

Fasteners & Fixings

Fluid Handling

Gears, Drives & Motors

Health & Safety

Machining & Machinery

Measurement & Monitoring

News & Events

Industry News

Packaging

Process Technologies

Software & Systems

Tools, Plant & Equipment

Training & Recruitment

Valves & Flow Control

SIEMENS

WARNER ELECTRIC

BENTLEY

FANUC

UK manufacturers must step-up energy resilience planning to meet the challenges of tomorrow Bentley extends covid safety and wellbeing colleague measures – increases community support programme

CLPA

4 ways TSN can boost productivity in manufacturing

BAROMETER

Brexit challenges threaten to slow SME manufacturing comeback, reveals latest Barometer

WATSON MARLOW

PTC technology accelerates WatsonMarlow’s digital transformation plans

BARA

RMGroup becomes the UK’s first certified robot integrator

Warner Electric XS & WR Series brakes reduce footprint of six-axis robot Injecting innovation into Northern Irish manufacturing

RAPIDDS

Overcoming the Challenges to Automate Manufacturing

SULZER

Sulzer creates a hybrid additive manufacturing process to minimize lead time on components for Chevron

EXE

Speed, accuracy and reduced downtime

PORTESCAP

Why they’re used and how to make your selection

Issue 49 PECM

Smart ideas make work more efficient and faster. Han-Eco® B. Rear mounting option allows for the separate pre-assembly of cable harnesses.

The new connectors of the Han-Eco® B series provide valuable time advantages for equipment using the Han® B industry standard. Learn how! Han-Eco® B. Thought differently. Done better.

www.harting.com/UK/en-gb/rear-mounting

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

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Issue 49 PECM

EDITOR’S CHOICE

AN INNOVATIVE APPROACH SIEMENS

UK manufacturers must step-up energy resilience planning to meet the challenges of tomorrow All industries require access to reliable, uninterrupted power as well as robust dependable contingency measures to fall back on in the event of a failure. Yet despite the importance placed on maintaining the supply of energy, Siemens says UK manufacturers are failing to recognise the risks posed by critical ageing electrical energy assets. Manufacturers are being cautioned: more needs to be done to strengthen energy resilience plans if the challenges of tomorrow are to be met. “Critical electrical power equipment, which has accumulated over decades, forms a significant backbone of today’s manufacturing industry. Either housed in a single location or clustered across multiple sites, a complex patchwork of modern and legacy technologies makes up the electrical systems powering UK manufacturing. Interspersed throughout the country, these engineering assets have been added to, adapted, maintained and repaired or replaced over time; all are at various stages and states of health in a

PECM Issue 49

sprawling complicated picture of electrical systems,” says Toby Horne, senior lead for Siemens Energy Resilience - a multidiscipline practice in the UK with a remit to help businesses formulate a more strategic, comprehensive and innovative approach to energy resilience and modern power systems. Continues Horne: “These systems are supplying energy to, in almost all cases, mission critical operations but years

A lack of visibility makes it difficult to see and understand the level of risk within your power infrastructure.

of reactive maintenance, planned or emergency repairs and differing or inconsistent service practices have made it near impossible, for a significant proportion of businesses, to accurately gauge how these electrical assets are actually shaping up. Many are not aware of whether their systems can handle even greater demands, others are simultaneously grappling with an energy transition that is adding supply diversification, on-site energy production and decarbonisation targets to their sites – posing additional risks, more points of failure and ever more pressure.” Siemens is advocating a smarter, more sustainable way to manage energy resilience which will provide better insulation against the dangers of blackouts, the complete interruption of power that halts operations and brownouts, partial or temporary reduction in system capacity. Branded - Resilience-as-a-Service - the ‘vital signs’ of a business’ electrical estate are scrutinised from every conceivable angle.

The multi-pronged approach comprises three programmes: Risk Identification, Risk Management and Efficient Issue Resolution; designed to boost operational efficiency, business performance and minimise risk over the long term. On how businesses can build more energy resilience into their critical power infrastructure, Horne says: “A lack of visibility makes it difficult to see and understand the level of risk within your power infrastructure, but the outcome of downtime is severe – interruption to operations, damage to reputation, unforeseen costs accrued (in fines or revenues) or even a risk-to-life – requiring a more a proactive stance, instead of the conventional view through a maintenancelens. Risk can never be eliminated but the right resilience strategy, supported by a knowledgeable and trusted partner, can manage and mitigate the threats.” During the risk identification process, Siemens experts will perform a thorough audit to identify the risks associated with all the installed electrical equipment at the manufacturer. The process will help identify risks more intelligently, manage electrical equipment across sites and accommodate changing energy supplies including green energy, decarbonisation and on-site generation and storage. Risk Management involves the proactive management of

electrical assets and maintenance of its health to mitigate risk, streamlining the electrical infrastructure estate for simpler, more cost-effective management over time. While Efficient Issue Resolution grants access to global parts sourcing and worldleading capabilities to help resolve issues faster, repair assets on site and understand the optimum pathways for the power estate. Says Horne: “The prospect of imminent power infrastructure failure is ‘real’. There are approximately 65,000 panels of Siemens Reyrolle brand switchgear installed in UK industries, of which 70% predate the 1970’s. All continue to underpin critical power systems and remain fully supported by Siemens. There are also, as many, other similarly-aged assets from different manufacturers and, if not maintained correctly, all could potentially fail and create challenges.”

Horne: “It could mean a food producer’s line losing power which causes wastage and a drop in quality during a production run or an automotive manufacturer experiencing an unplanned blackout that incurs a 30-mins complete line restart; placing pressure on targets. We’ve had a business with £100k a year lost production through a handful of unplanned blackouts. After review, we recommended a £50k part change to remedy the issue – a solution, which in under six months had paid for itself.” An issue of strategic importance, Horne says energy resilience merits discussion in the boardroom: “Manufacturing is one of the most energy-intensive industries. Any power outages or pricing fluctuations can have significant ramifications on day-to-day operations and production output. The cost to businesses can be eye-watering when you consider ‘3% of all working days are lost in manufacturing through machine downtime, which costs UK business £180 billion each year. *’ There is an impression that many are sleepwalking into potential danger, not wholly aware of the risks. A resilience strategy helps to save time, stress and strain. UK manufacturers must embrace the concept and make it their own personal responsibility to prepare for the energy challenges of today and tomorrow.”

https://ciltuk.org.uk/News/Latest-News/ArtMID/6887/ArticleID/13644/Downtime-costs-UK-manufacturers-163180-billion-a-year Issue 49 PECM

EDITOR’S CHOICE

New for 2021 New for 2021 - OPM are delighted to announce the installation of a Controlled Environment Facility to enhance our Pharma, Food and GMP standard audited Leeds site. To meet increasing demand for product produced in Controlled, Critical Environments, OPM have installed a fully enclosed, segregated & controlled print room. Spanning 60 meters in length and 7 meters in height with vision panels throughout, this was a seamless installation taking only 6 days to implement. Providing an environment where air quality, temperature & humidity are highly regulated, to protect print & customer materials from possible sources of contamination & impurities. The integrity of the room is maintained through regular attention to cleaning, maintenance, and microbiological monitoring programmes. Having a protective room where materials are printed, finished & packed ensures OPM’s product meets stringent quality standards required & important within the, pharma, medical and specialist nutrition markets.

Flexible custom heating elements manufactured in an extension of your workshop… With an almost limitless scope for custom built designs, Holroyd Components offer 50 years of know how to create solutions for an extensive range of process heating applications across all sectors. Providing a full design, prototype and production service, Holroyd can manufacture virtually any shape or size of flexible heater pads in silicone or polyimide insulation, with numerous fixing methods and temperature control options. Holroyd Components are able to offer solutions for whatever projects you may have, all in accordance with an ISO9001:2015 Quality System with a fast, flexible and efficient delivery for both small quantity and large batch orders. We believe in innovation and bespoke design built around you, which is why our workshops are simply an extension of yours.

Cut costs with fuel cards from FLEETMAXX SOLUTIONS When it comes to managing fuel expenditure for your business, fuel cards offer distinct advantages. These include access to discounted fuel, HMRC compliant VAT invoicing, access to 24/7 reporting tools to help understand and manage your fuel usage and much more. We are FLEETMAXX SOLUTIONS and our fuel cards can save up to 10p per litre on diesel and petrol. Our fuel cards are valid to use at BP, Esso, Shell, Texaco sites and supermarkets (Fuelgenie), independent retailers and specialist diesel networks, such as Keyfuels and UKfuels. We are a wholly owned subsidiary of Oilfast Ltd, a substantial bulk fuel, lubricant and licensed Adblue® manufacturer and distributor.

www.opmgroup.co.uk

www.holroydcomponents.com

www.fleetmaxxsolutions.co.uk

KDP Electronic Systems

New White Paper: “10 Steps to Achieve Optimal Ball Screw Selection”

Lubricating Compound enables Long, Maintenance-free Service Life of Roller Bearings

Choosing the right ball screw can ensure machine accuracy, repeatability, long life and reduced total cost of ownership. Whether specifying linear motion components for small laboratory fluid pumps or large overhead gantry systems, there are many factors a design engineer must consider in order to ensure optimal application performance. This especially rings true for ball screw assemblies, which are found in countless automation applications.

Particular requirements and environments require special solutions. LUBCON Turmocomp HD 150 is a lubrication concept enabling effective lubrication of roller bearings even in complex operating conditions. The lubricating compound is a composition of ultrahigh molecular polymers and synthetic, temperature-stable base oils. For application in the food industry, H1-approved lubricants are used. In order to protect roller bearings against extreme operating influences such as dust and humidity, the hollow cavities are fully filled with LUBCON Turmocomp HD 150. This compound is suitable for almost any geometry of roller bearings. Bearings lubricated with LUBCON Turmocomp HD 150 can effectively be used at lubrication points where conventional greases or oils fail to provide long lasting and sufficient lubricity due to technical or environmental reasons.

KDP operate in the Industrial Automation, Safety systems, Environmental monitoring, Transportation and Aerospace markets providing intelligent drives, industrial sensors, signal conditioning instrumentation, cable assemblies, electronic/software/mechanical/ pcb design and manufacture through to full box build assembly/test. We are the UK distributor for Wilcoxon Sensing Technologies, Connection Technology Center (CTC) and Vigor Technologies. Our industrial sensors are perfect for a wide range of applications that include the measurement of vibration, displacement, angle and position. We manufacture a range of signal conditioning instrumentation that when coupled with the correct sensors, connectors and cables provides a full accurate measurement chain. As manufacturer of Norwin Drives and UK distributor of Serad Automation, we offer a comprehensive range of motion control solutions including AC Servo Drives, DC Servo Drives, Motors & Gearboxes. www.kdpes.co.uk | enquiries@kdpes.co.uk

PECM Issue 49

To help steer OEMs toward informed ball screw selections, a new, free white paper from Thomson Industries explores 10 vital factors that every motion system designer must consider. Thomson Industries, Inc. White Paper: https://info.thomsonlinear.com/ acton/media/3484/whitepaper-ball-screwselection

www.lubcon.com

EDITOR’S CHOICE

The new Tricor PRO Plus Series The new Tricor PRO Plus Series of Coriolis Mass Flow Meters is an accurate and highly repeatable meter with the smallest installation length on the market for installation into systems where space is limited. The TCD transmitter offers greater robustness, performance, diagnostics, and connectivity options. With a modern HMI interface and excellent logging functionality, the DSP transmitters provide users with an efficient configuration and analysis tool. PRO Plus Series Features: • High dosing accuracy due to short response time (max. 10 ms) • 100 Hz refresh rate makes this series suitable for pump monitoring and fast response control • Extremely short installation length makes for an easy fit in most configurations • Excellent zero stability for drift-free accuracy and longterm reading assurance

• Extensive diagnostics and self-monitoring, including empty pipe detection Sizes from ½” to 2”. Available for Litre Meter, call 01296 670200, now.

www.litremeter.com

Issue 49 PECM

EDITOR’S CHOICE

IFM’s new longer-tip conductivity sensors simplify CIP Particularly suited for use in CIP (cleaning-in-place) applications in the food and beverage industries, the new LDL201 conductivity sensors from ifm electronic have a 77mm long sensing tip which makes them versatile and easy to install in a variety of hygienic process connections. In addition, the tip features solid PEEK construction which virtually eliminates the risk of breakage even if the sensor is subjected to high levels of stress. Typical applications for the new LDL201 sensors include monitoring/control of cleaning agents, checking rinse water for residues and product validation. Since the sensors allow improved process control to be achieved, they typically enable users to cut costs by reducing energy usage during CIP cycles, along with the consumption of water and cleaning agents. LDL201 sensors have a conductivity measuring range of 100 µS/ cm to 1000 mS/cm and feature an integrated temperature sensor. They have a continuous operating temperature of -25 to +100 ºC and a maximum of 150 ºC < 1 hr. They are provided with an IO-Link interface which provides loss- and error-free transmission of measured conductivity and temperature values. IO-Link also allows easy parameterisation, which not only aids initial set up but also makes it quick and easy to adjust settings to accommodate recipe changes. With food-grade material used for all parts exposed to the media in which they are being used, ifm’s new conductivity sensors meet EHEDG, FDA and 3-A standards. They are available for fast delivery and are complemented by a wide range of accessories. These include welding adapters, clamps, hygienic pipe fittings and pre-terminated connecting cables.

https://www.ifm.com/gb/en/shared/product-news/2020/sps/conductivity-sensor-for-clamp-and-hygienic-pipe-fittings

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PECM Issue 49

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Discover the new easy way to control CIP processes.

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The new compact conductivity sensors LDL100 and LDL200 from ifm impress with their fast and precise media differentiation. This helps you to control CIP processes efﬁciently and to increase the availability of your system. The new LDLs are also simple to commission: They are ready for use out-of-the-box and transmit the conductivity and temperature of the medium via a single M12 connection - digitally and loss-free thanks to IO-Link. As there is no additional evaluation unit required, you also save system costs. So easy, so good. ifm – close to you!

Go ifmonline ifm.com / uk

EDITOR’S CHOICE

A RETURN TO PRODUCTION BENTLEY

Bentley extends covid safety and wellbeing colleague measures – increases community support programme

Bentley Motors today welcomes a return to production following an extended winter shutdown and a comprehensive review and extension of the luxury marque’s stringent COVID-19 health and safety measures. In parallel, Bentley’s critical role providing support to the local community continues with colleagues requested to help with the vaccine deployment within Cheshire and local care programmes plus the donation of laptops to schools. To enable a safe return for its 1,800 manufacturing workforce, Bentley has increased its rapid antigen testing programme four-fold to ensure all colleagues returning to site are tested and COVID-safe before full production resumes. This means administering 1,800 tests within a two day period, taking the total number of antigen tests provided by Bentley to nearly 15,000 since May last year. Just 272 mostly asymptomatic colleagues have returned positive COVID-19 tests in

PECM Issue 49

that time, approximately 5 per cent, with those affected then undertaking full selfisolation periods, regularly checked upon by Bentley’s Occupational Health team. As a mark of the success of Bentley’s testing programme, there have been no proven cases of on-site transmission yet recorded. But to be sure its Crewe site is a safe as it can be, Bentley sought external validation at the beginning of this year from Imperial College London and also independent occupational health specialists, Optima Health. They confirmed that Bentley’s 250 comprehensive and wide-ranging hygiene and social distancing measures introduced last year will remain in order to maximise the safety of production colleagues. This includes compulsory facemasks on site, enhanced cleaning routines and one-way movement and traffic flows throughout. Furthermore, a new site risk assessment app for all colleagues, designed, developed and deployed by Bentley’s own digital

The health, safety and wellbeing of our colleagues, their families and our communities will always be our number one priority. team, has been launched. This encourages extra vigilance especially in light of new COVID variants, details the thorough safety measures, including home self-assessment before the working day starts, and acts as a two-way dialogue between colleagues and health and safety representatives to heighten wellbeing around site.

Commenting on the extra precautions Bentley is taking, Dr. Astrid Fontaine, Member of the Board for People, Digitalisation and IT, Bentley Motors, said: “As we begin a new year under challenging circumstances, we remain committed to not only maintaining our strong lines of defence, but reinforcing them. The health, safety and wellbeing of our colleagues, their families and our communities will always be our number one priority and the measures that we have put in place will protect us in the short-term, while also building a secure basis for our future exciting strategic ambitions and growth, in 2021 and beyond.” Where on-site working is non-essential, colleagues will continue remote working which includes the majority of Bentley’s 4,000-strong workforce, approximately 60 per cent. This helps control the workforce density on site throughout the day and minimises the risk of exposure to colleagues.

strong emphasis on wellbeing and care for all colleagues impacted continues.

Bentley is also taking steps to help alleviate - where possible - childcare and homeschooling challenges that follow the recent closure of schools in the UK and the wider impact of lockdown on personal wellbeing. For parents, this includes additional flexibility around working patterns and the offer of additional laptops and Wi-Fi hotspots to support home-schooling where needed. A

Turning focus towards the wider community, Bentley’s crisis support efforts continue and widen. In addition to making at least 30 laptops available to local schools for those families in need of support with home education, the company is again encouraging colleagues to volunteer in the local community. Bentley products and support vehicles will be made available to

deliver essential items in the community including food and medication to those in need through the ‘Meals on 22 inch wheels’ service. With the high level of demand for volunteers around the country to support with the vaccination programme, and Bentley becoming partners to a number of support initiatives, the company is also encouraging colleagues to take part and volunteer to help at this critical time.

For further information, please visit www.bentleymotors.com/en Issue 49 PECM

EDITOR’S CHOICE

TIME-SENSITIVE NETWORKING CLPA

4 ways TSN can boost productivity in manufacturing Time-Sensitive Networking (TSN) is considered by industry leaders as the future of industrial communications. In effect, it is poised to bring data transfer to the next-level, enabling Industry 4.0 applications. While the adoption of TSN is still in its early stages, with future-oriented businesses picking up the pace, this technology holds enormous potential for numerous manufacturing sectors. Thomas Burke, Global Strategic Advisor at the CC-Link Partner Organization (CLPA), looks at how different industrial sectors can reap a multitude of benefits by leveraging TSN for industrial communications

1. SIMPLIFIED MACHINE DESIGN AND HIGHER PERFORMANCE FOR THE CONVERTING SECTOR

One of the key features of TSN that can bring great benefits to manufacturers is its ability to synchronize all network devices with high accuracy, especially when used with gigabit bandwidth. As a result, it is possible to ensure deterministic communications for time-critical high-speed applications, such as motion control. For example, when this feature is adopted in networks used in the converting industry, plants can achieve accurate synchronization between multiple axes on a machine. By being able to control the motion of many different axes simultaneously over one network, facilities can optimize product quality and production processes as well as increasing the flexibility of their architectures and machines, while simplifying the mechanical set up. The end result is reduced time for retooling and maximized product yield.

2. TRANSPARENCY AND TRACEABILITY FOR FOOD & BEVERAGE

Accurate and precise time synchronization, as offered by TSN technology, is also extremely important when transparency and traceability are crucial. The success of sensitive industries, such as food & beverage, relies heavily upon key process data, which need to be monitored to

ensure product quality and compliance with relevant regulations or good manufacturing practices. These data require accurate timestamps that support visibility within the network and throughout the production process, eliminating any “blind spot” where issues can grow unnoticed. By building a fully synchronized device network, TSN can support precise timestamping for timing analysis. In this way, food & beverage facilities can rely on a high degree of traceability throughout their networks and guarantee product quality and safety.

3. BETTER QUALITY IN AUTOMOTIVE

TSN technology, particularly when combined with gigabit bandwidth, can also push manufacturing facilities to speed up their production processes, whilst ensuring determinism. This can be particularly useful for automotive assembly plants. These facilities are responsible for the production of a wide variety of models, each characterized by different trim levels. Hence it is mandatory for these manufacturing systems to handle large amounts of data generated in real time during the assembly of various car parts. Only in this way, manufacturers can ensure that the different combinations of possible model variations do not slow down cycle times and the allocated parts are fitted correctly on the right models, at the right time, in a traceable manner. Automotive companies can use TSN to build production lines that ensure short cycle times, as the technology combines advanced synchronization with traffic prioritization capabilities. The latter allow the network to deliver time-critical traffic exactly when

needed, while allowing less critical traffic to co-exist on the network. Consequently, total cost of ownership can be reduced, since multiple types of network can now be combined onto a single hierarchy. The end result is higher performance, lowered costs and simplified maintenance. This finally translates into better quality vehicles.

4. HIGHER LEVELS OF INTEGRATION FOR SEMICONDUCTOR MANUFACTURING Synchronicity and traffic prioritization are also key to combining different types of process control on one network and effectively handling different recipes and activities across multiple machines and stations. For example, TSN can support the semiconductor industry, which is characterized by numerous processing stages, all requiring process, discrete and motion control, along with integration of robots and IT systems. TSN-based networks for the sector allow businesses to mix time-critical data for high-performance, high-speed motion control with slower, less time-dependent traffic, e.g. for machine vision process monitoring. Furthermore, manufacturers are given the opportunity to integrate auxiliary systems into their process and associated networks. Ultimately, semiconductor producers can enhance flexibility in their network architecture and in their processes.

MORE THAN TSN

While TSN offers a number of advantages to manufacturers per se, it provides a comprehensive solution when combined with an open network technology that offers high bandwidth. In this way, businesses are able to handle the large volume of data that modern Industry 4.0 applications will generate. As a result, they can further enhance network reliability, productivity and quality assurance strategies.

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

PECM Issue 49

EDITOR’S CHOICE

RESHORING OPPORTUNITIES SWMAS

Brexit challenges threaten to slow SME manufacturing comeback, reveals latest Barometer Brexit issues are causing England’s small to medium-sized (SME) manufacturers significant disruption as they look to recover from the economic effects of COVID-19. The latest Manufacturing Barometer, which is produced by SWMAS (the South West Manufacturing Advisory Service) and the Manufacturing Growth Programme (MGP), reveals almost two thirds (65%) of companies have seen negative price changes within their supply chain since leaving the EU, with the availability of raw materials an issue for 56% of firms. Of the 284 national respondents, more than half cited complications with exporting (54%) and importing goods (56%) since December 31st, causing potential short and long-term hits on volumes and new opportunities. This survey, the largest of its kind in the UK, also highlighted that less than a third of SME manufacturers feel they are getting the right support and guidance from Government on how to navigate changes caused by Brexit, underlining the need for better communication and additional tailored support.

On a more positive note, 21% of businesses believe Brexit could deliver new reshoring opportunities as firms look to bring their supply chains closer to home. “SME manufacturers have had to deal with unprecedented levels of change over the past 12 months and it is encouraging to see some green shoots of how the sector has adapted throughout this difficult time,” explained Nick Golding, Managing Director of SWMAS. “However, despite signs of an initial recovery, firms have a new set of issues to contend with now the Brexit deal is done. Price hikes in the supply chain have been immediate, and we are hearing tales of lead times being extended on raw materials. “Almost two thirds of respondents aren’t convinced that the Brexit guidance they have already received from the government is adequate and SMEs are asking for more clarity on key issues, such as logistics or freight forwarding (54%), sourcing components/services overseas (51%) and product markings (50%), including a CE replacement. These challenges need to be addressed and quickly.”

He continued: “Reshoring has been spoken about as a potential opportunity and there is some confidence from manufacturers that new purchasing trends might drive increased sales to the UK. We would love to see more made of this and perhaps even a co-ordinated campaign to promote the benefits of locating production back home.”

OPTIMISTIC PICTURE

Away from Brexit struggles, the latest Manufacturing Barometer paints a more optimistic picture of industry slowly starting to bounce back from COVID-19. Results show that 31% of companies have seen sales increase over the past six months, with 44% expecting further growth between now and August, both up 3% and 4% respectively on the previous report. “Nearly a third of firms are planning to take on staff going forward, whilst 39% are planning to spend more on new machinery and capacity as they look to replace sales volumes lost in previous months,” added Martin Coats, Managing Director of MGP. “Many were unable to continue production during the first lockdown and, therefore, put contingency plans in place to help them operate safely going forward. “Encouragingly, this report indicates that some companies feel these actions could be sufficient to help them survive and thrive over the coming months. It is reassuring to see that confidence appears to be slowly improving despite ongoing challenges, with the number of businesses expecting growth in future sales gradually returning to pre-pandemic levels, albeit on substantially lower expectations.” He concluded: “We hope that further support for the manufacturing sector will help avoid further disruption, safeguard jobs, and maintain future investment ambitions.” The Manufacturing Barometer covers trading activity in October, November and December, with responses taking place in January 2021.

To download the full report, please visit www.swmas.co.uk

PECM Issue 49

EDITOR’S CHOICE

STAYING AHEAD OF THE CURVE TR FASTENINGS

TR announces two new appointments to its Plastics and Rubber team International fastener specialist TR Fastenings announces two new senior UK appointments; Kevin Rogers moves into the new position of Director of Plastics and Rubber - Sourcing and Category Management, and Andrew Fletcher is named as the Director of Plastics and Rubber – Commercial and Technical. Kevin and Andrew will both play key strategic roles in spearheading the continued expansion of this commodity within the TR Group. Kevin Rogers joined TR’s Global Strategic Team in 2012, and has been instrumental in growing this product range by developing the vendors that today support the huge increase in sales. With his new focus primarily on sourcing and category management, Kevin will be fully utilising three decades of experience to find opportunities to further expand upon an already comprehensive portfolio. Andrew Fletcher is a well-known expert in this Commodity. Previously the Managing Director and Technical Director of Optimas Solutions - previously known as Anixter Components, Andrew’s technical expertise lies in New Product Introduction (NPI), and managing the entire process from initial

Andrew Fletcher

Kevin Rogers

inception through to final product launch.

Andrew will be central to our on-going commitment in this area.”

Dan Jack, Global Sales and Commercial Director, Trifast plc commented; “We warmly welcome Andrew to the Team, he is a formidable asset to have on board with his deep knowledge and industry connections. Over recent years, we’ve developed our team and increased our knowledge to ensure we are not only keeping up to date with changing technologies but are staying ahead of the curve, and both Kevin and

“We’re proud that TR’s core brand remains competitive in the market; the strength of our partnerships with companies on an engineering level enables us to react quickly to customers changing requirements. With our talented design engineers and in-house support team working closely with customers, we are hugely optimistic about the future.”

For further information, please visit www.trfastenings.com Issue 49 PECM

EDITOR’S CHOICE

MANUFACTURING PARTNERSHIPS 3DPRINTUK

3DPRINTUK and 76 Projects 76 Projects is a fast-growing start-up company with huge potential for further growth thanks to the vision and the passion of its co-founders and owners Robert Johnson and Paul Robertson. 76 Projects was founded in 2016 by Rob and Paul – friends since they were on the same university course — based on a shared passion for cycling and industrial design. The ethos of 76 Projects is to create performance oriented cycling products that offer a genuine advantage over anything already in the market. The success of the company is reflected in the rapid growth of its own brand and an increasing number of collaborations in which 76 Projects provide development and manufacturing services in order to bring their clients’ products to the market. Paul Robertson, Co-owner and Designer at 76 Projects provided further insight: “We necessarily had to develop a trusted relationship with key suppliers for the manufacturing side of our business, and we wanted that to be within the UK. 3DPRINTUK is a key manufacturing partner for us and supported us on our growth trajectory to a point where we have now invested in our own MultiJet Fusion (MJF) additive manufacturing (AM) solution.”

maximum benefit and freedom from the PBF 3D printing process. To be frank, it has taken us a while to get away from designing for injection moulding, and the inherent limiting parameters such as draft, wall thickness, core access, and so on.”

Robertson provided some further historical perspective. “Our first introduction to 3D printing (or rapid prototyping as we called it back then) was 15 years ago whilst Rob and I were working with other companies. We were using this emerging technology as a fast and efficient way to speed up product development and to prove and sign off parts for injection moulding.”

“Our TT mount is a great example here, it is solely designed for 3D printing, it has sold over 3000 units, and it is used by professional triathletes and cycling teams worldwide. We did investigate going down the injection moulding route but it was cost prohibitive to produce 4+ tools with complicated movable cores. Going down the SLS route we could create geometry that could not be achieved by injection moulding and therefore allowed the mount’s unique 3D adjustability that is key to its success. 3D printing also allowed us to enter the market with low financial risk, and continually fine tune the design. We have now developed several other unique products following the same process and use the initial product runs to gauge market interest. For such a small startup this would not otherwise be economically viable using traditional techniques.”

Since the 2000’s PBF has evolved into a feasible production solution with reduced costs, consistent quality, and unprecedented levels of finishing. Paul explains the effects of this technology evolution and how it is reflected in the way the business operates. “We have had to alter the way we think and design in order to gain the

At 76 Projects, MJF and SLS are now the predominant processes used for both prototyping and production as this suits the business model and 3DPRINTUK is the preferred production partner. However, the company does still use other manufacturing processes including injection moulding, extrusion 3D printing, CNC, carbon fibre layup, and also textile

manufacturing where it’s deemed more suitable for strength, weight, cost, and quantity. The partnership with 3DPRINTUK is a vital one for 76 Products, according to Robertson. “We started working with 3DPRINTUK in 2017 after trialing many other 3D printing services in the UK. I’m not overstating it when I say that Nick, Connor and the team have been instrumental in the development of our company from the early days of testing and trialing product ideas. Their instant online quote tool, low costs, and transparency were just some of the key attributes for us. This enabled us to quickly consider what was the most cost effective way to produce something in SLS via quantity, size and finish. The 3DPRINTUK costing algorithm is the best we have found on the market as it is geared not only to prototypes but also production quantities. It incorporates suitable economies of scale where other services just multiply the price of a prototype.” Robertson goes on to expound further important features of the 3DPRINTUK service that have proved so valuable to the company. “The part quality we receive is second to none. More importantly, from a manufacturing perspective, large batches (250+) exhibit better than recommended tolerances and the finishes are consistent and reliable. We only order parts using the ‘shot peen and dyed black’ finish as it’s so good. Nothing else comes close.”

To download the full report, please visit www.3dprint-uk.co.uk

PECM Issue 49

3D PRINTING SERVICE SPECIALIZING IN LOW VOLUME MANUFACTURE AND PROTOTYPES T. 0208 692 5208 hello@3dprint-uk.co.uk www.3dprint-uk.co.uk Upload your .stl file on our website for an immediate quote. Price breaks for higher volume orders.

SLS AND MJF PA12

POLYMER 3D printing service NEW SERVICES AND MATERIALS AVAILABLE 3DPRINTUK are a leading service provider of polymer powder bed fusion (PBF) 3D printing processes for manufacturing and batch production applications. We have now fully executed an impressive £1 million strategic expansion plan.

FLEXIBLE PARTS

3DPRINTUK is now offering the production of flexible, rubberlike parts using our new material ‘SLS Flexible’ (PEBA 2301).

SHOT PEENED

A shot peening service for all SLS and MJF nylon PA12 printed parts that greatly improves the surface finish.

COLOUR SLS PARTS

Colour SLS parts available in Black, White, Green, Blue, Red and Yellow with more colours to follow soon.

HP 5210 MULTI JET FUSION

After the acquisition and installation of the most advanced polymer MJF system available — the 5210, we now offer the Multi Jet Fusion (MJF) 3D printing process.

SPECIAL OFFER FOR PECM READERS

10% OFF

Upload your .stl file on our website for an instant quote!

Order now and get 10% Off. Enter the following code at checkout: PECM10 Terms & Conditions apply. See our website for more information.

3DPRINTUK

ADDITIVE FOR MANUFACTURE

EDITOR’S CHOICE

SeaShield™ Systems Provide Long-Term Protection for Jetty Piles at Ullapool Harbour

60 years of innovation brings you the green line valve Muller Coax have developed a patented energy saving valve which can offer up to 80% power saving on similar sized valves. The new green line series has been specially developed as an energy efficient series of solenoid valves. For this reason directly controlled standard valves from Muller coax has been paired with completely new patented control electronics within the terminal box. The valve has an optical position indicator as standard on the terminal box for the open / closed position, the position indicator as also available as an electrical signal. Flanged or

threaded from 15mm through to 40mm orifice and 100 bar rated the design in the electronic circuitry within the box allows: • Different opening / closing speeds at the flick of a switch which helps to eliminate vibration and water hammer in the pipework. • Holding voltage as low as 7.5 watts for the smaller 15mm valve reduces the power consumption when energised for long periods and the solenoid remains cold.

www.co-ax.com john.osborn@coaxvalves.co.uk Tel 01908 067583.

In 2020, Shearwater Marine Services were awarded a contract to install protection for jetty piles at Ullapool Harbour in the Scottish Highlands, on behalf of The Ullapool Harbour Trust. As consulting engineers on the project, Wallace Stone specified the use of SeaShield™ Systems supplied by Winn & Coales (Denso) Ltd to protect the jetty piles. SeaShield Systems have an extensive history of providing long-term corrosion protection to marine structures. Shearwater Marine Services used a combination of the SeaShield 2000FD™ and SeaShield 70™ Systems on the piles and various supporting crossbeams on the structure. SeaShield 2000FD consists of Denso Paste S105™, Denso

The finished SeaShield Systems applied to the jetty

Marine Piling Tape™ and an outer HDPE jacket, which is hydraulically tensioned before being secured with stainless steel fixings. The SeaShield 70 System was used to protect the crossbeams and is an excellent option on areas where piles have obstructions. This system consists of Denso Paste S105™, Denso Profiling Mastic™, Denso Marine Piling Tape™ and Denso Glass Outerwrap 70™.

www.denso.net

MTM Products MTM Products have been established for over 40 years and are a leading manufacturer and supplier of industrial graphics products including self-adhesive labels, metal nameplates, graphic overlays, engraved labels and vinyl cut decals. We have the knowledge and experience to advise you on the optimum graphics solution for your application, taking account of operating environment. We supply to many sectors including industrial machinery, electrical, automotive, rail, construction, medical and audio equipment. We offer excellent quality and

PECM Issue 49

service at competitive prices. MTM are certificated to ISO9001 and ISO14001. Our products comply with the current RoHS and REACH requirements MTM – the industrial graphics specialists Let us share our expertise to make your life easier Contact us at sales@mtmproducts.co.uk or www.mtmproducts.co.uk

Are you ready to ship under ISPM15 regulations? For any UK business shipping goods within the EU, the latest changes to regulations will be a vital consideration. Wooden packaging, including pallets, must now meet ISPM15 standards when being shipped. This regulation ensures pallets have been treated to eradicate pests and are then stamped to reinforce this action has been carried out. While demand and prices for these types of compliant pallets will be on the rise, there are alternatives to consider.

The best alternative to Wooden Pallets, is Plastic Pallets. Plastic Pallets completely avoid the ISPM15 regulations, are more hygienic and reliable, and making the switch now will minimize any potential disruption to your supply chain now that these regulations have come into effect. Call: 0800 294 4394 Email: sales@exportaglobal.co.uk Visit: exportaglobal.co.uk

EDITOR’S CHOICE

QUALITY HINGES TALK TO THE EXPERTS.

The Future of Hydraulic Design is here

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

HydroSym is fast, intuitive, and will easily run on your home laptop. With HydroSym software easily click and add hydraulic parts and components from a built in library of over 40K hydraulic parts, resulting in faster and more accurate design. Move parts around, smart connection lines move with the part. With one click create Bill of Materials, and complete project file with all data sheets. This means faster customer proposals.

Easy collaboration with the maintenance team for excellent follow-up service. You don’t need any other program to use HydroSym. HydroSym will even run on your home laptop so you can work from home. The future is nice! And it’s here. Request a fee trial. Paro Software B.V. contact: info@paro-nl.com www.paro-nl.com

we make ideas come to life

RMIG is the world’s largest manufacturer and supplier of perforated metal and its related products. We know our customers’ requirements for price and quality and meet their demands with uncompromising service. Not only do we offer standard and bespoke perforated metal sheets, we are able to offer you a range of secondary operations as detailed below. Complete solutions With a continued investment in the latest equipment and a network of professional partners we are able to produce prime quality products and solutions – from a simple perforated sheet to the fully formed and coated custom made part.

Cutting We can cut and shape perforated sheet to meet the needs of your final application. Levelling For some applications a high degree of flatness is required, we have processes in place to ensure our perforated coils and sheets meet with your most demanding requirements. Rolling and forming We can roll, bend and form perforated sheets to match your design. Aesthetic finishes and protective coating We can offer powder coating and hot dip galvanizing solutions to meet your specifications.

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

Issue 49 PECM

EDITOR’S CHOICE

EXL CHAIN DONGHUA

A New High Precision Roller Chain Developed for the UK’s After-Market A new high precision Roller Chain, called EXL Chain, is now available in the UK and offers superior quality and durability over standard Roller Chain. Developed by the Hangzhou Donghua Chain Group, one of the world’s biggest chain manufacturers, and supplied through their UK headquarters in the Midlands, the EXL chain is a premium product positioned within their new Solution range. Aimed specifically for the UK’s after-market, EXL Chain is designed, manufactured and tested for unbeatable accuracy and performance in arduous conditions, offering enhanced wear and fatigue resistance and greater precision than their Standard Roller Chain range. By utilising different materials, material treatments and layer technologies, EXL Chain offers the best possible quality/ price ratio for all applications. New hardened, shot-peened wide waist plates deliver increased fatigue strength and a seamless cold forged solid bush and roller give full contact between the pin, bushing and roller for higher durability. Optimised cylindrical parts improve sliding contacts which help increase service life.

For chain lengths over five metres, the chain can be supplied matched & tagged for fitting in sequence. Bob Wellsbury, managing director of Donghua Limited, says: “EXL Chain has been specifically developed to incorporate Donghua’s unique Easy Break Technology. This unique feature enables EXL Chain to be cut in the field using Donghua’s Plate Extractor tools.”

Chains can be matched in pairs to close tolerances in Donghua’s UK workshop. For chain lengths over five metres, the chain can be supplied matched & tagged for fitting in sequence. Pre-lubricated, as standard, using high performance synthetic lubricant ensures high workload performance in arduous and abrasive conditions. Donghua’s EXL Roller Chain is available in standard pack sizes of five metres, reels available on request, and bespoke cut-to-length sizes in British standard 06B to 32B, American standard ANSI 35 to ANSI 160 in simplex and duplex ex-stock. All Donghua Chains are marked with production batch codes for full traceability. With increased precision, higher wear resistance and greater fatigue resistance, EXL Chain is the new Roller Chain solution of choice for UK stockists.

“I’m thrilled to introduce this new Chain to the UK and our Stockists are keen to see a new design of chain which offers significant benefits over standard Roller Chain.” EXL Roller Chain is supplied pre-loaded with 40-50% of the breaking load. Roller

E •

•

• • • • • • • •

For more information about Donghua’s EXL Chain and to download a catalogue, visit: https://www.donghua.co.uk/exl-chain

PECM Issue 49

SOLUTION CHAIN Solid Roller Wide waist plate design

Solid Bush

Easy Break Technology High performance lubrication

EXL®® Specification:

Chains according to ISO 606 (DIN 8187/8188) in size range from 06B to 32B and ANSI 35 to 160 inch pitch. Avaliable from stock in 5 mtr packaging incl. connecting link Solid Bush and Solid Roller design, seamless cold forged bushing and roller provide full contact between pin, bushing and roller. Optimal cylindrical for ideal sliding contacts will improve chain service life. Wide waist plate geometry for higher fatigue strength EXL®® chains are easy to dis-assemble through built-in Donghua Easy Break Technology.

High length accuracy Excellent press fit between pin, bush and plates. Controlling plate hole quality by ball drifting. Hardened and shot-peened plates are standardized for extra strength. Pre-loaded with 40-50% from breaking load Pre-lubricated with high performance synthetic lubricant to meet high workload requirements. Batch code number forcantrack and tracing *Up *Up to to 55 metre metre lengths. lengths. Longer Longer lengths lengths can be be supplied supplied matched matched and and tagged. tagged.

Donghua EXL®® chains are designed, manufactured and tested to meet the highest

pecifications for unbeatable accuracy and performance.

EDITOR’S CHOICE

LATEST NEWS FROM PTC WATSON-MARLOW

PTC technology accelerates Watson-Marlow’s digital transformation plans One of the world’s leading manufacturers of peristaltic pumps and associated fluid path technologies is accelerating its digital transformation by signing a major new deal with PTC®. Watson-Marlow Fluid Technology Group (WMFTG), which has multiple sites in the UK and more than 1700 employees globally, has invested in Augmented Reality (AR) technology to combat the restraints of the pandemic and bring its business forward. The company selected the Vuforia® Expert Capture, Vuforia Studio and Vuforia Chalk solutions to achieve several goals set to ensure operations continue seamlessly. This technology will primarily be used to support the transfer of production and assembly skills to help drive the opening of new manufacturing facilities within the group, as well as provide remote technical support and enable a virtual approach to sales and marketing. The firm finds itself juggling a softening of its industrial activity with increased demand from the healthcare industry, including exciting contracts to supply specialist pumps for use in feeding the fermentation tanks used to produce potential COVID-19 vaccines. At the same time, management must develop a whole new way of marketing and selling its products. Martin Johnston, Strategic Business Development Director at Watson-Marlow, explained: “We have been working with PTC for more than five years now, globally through its product lifecycle management tool Windchill and, in the UK, through Creo, a suite of computer aided design apps. “The pandemic has changed the way every manufacturing business operates and, in my opinion, has accelerated our need for digital transformation by two to three years. AR is something we had discussed, but it wasn’t until the pandemic struck that we decided

ensures repairs and service can continue without endangering the health of experts by bringing them onsite. David Grammer, General Manager for UKI at PTC, added his thoughts: “Industry has had to quickly find new ways to deliver services and AR can be a real game changer when applied in the correct way.

to press the button quicker and engage with PTC to explore how to do it.” He continued: “Skills transfer was our immediate priority and we needed to find a solution that would allow us to take the expertise of our engineers and replicate it at new manufacturing locations without having staff on site. “Vuforia Expert Capture will enable us to record the processes of an established production line, edit it in the cloud, and then, via wearable tech such as Microsoft HoloLens glasses, impart all of this knowledge through a step-by-step guide for new engineers. “The benefits will be huge if we can get this right. Speed of set-up will be dramatically improved, we will see significant cost reductions as staff aren’t travelling and we will gain the ability to train employees to perform out-of-core roles for a period of time - all whilst eliminating the risk of spreading the virus among our employees.” In addition to replicating production lines, Watson-Marlow is also keen to retain the skills of its older staff for the next generation of graduates and apprentices coming through the ranks. It is expected that PTC’s technology could also be used to produce permanent training manuals that come to life via wearable tech. Vuforia Chalk will be in place to aid in remote service and maintenance. Using this simple app with a handheld device

“Watson-Marlow approached us with a clear idea of what they wanted to accomplish, and our experts developed an integration plan that will see Vuforia Expert Capture, Vuforia Studio and Vuforia Chalk play an important role in its UK and overseas businesses. “I have every confidence the firm’s digital transformation plan will deliver a host of operational, cost and safety benefits.” Martin concluded: “Sales and marketing will be the final focus. In normal times, we would be attending over 100 exhibitions all over the world every year, but this has now been reduced to just a handful, which means we need to find a new way of talking to potential customers. “This could be through webinars, virtual shows, or even demonstrating our product capability by playing it out in real time through AR. Vuforia Studio will support us with endless opportunities.” PTC, which has bases in the UK and Ireland, provides a host of technology solutions to help industrial companies create value for themselves and the rest of the world. This is achieved through a combination of Augmented Reality, Industrial IoT, Product Lifecycle Management and CAD solutions. For further information, please visit www.ptc. com or follow @ptc on twitter. More details on Watson-Marlow Fluid Technology Group can be found at www.wmftg.com PTC, Vuforia, and the PTC logo are trademarks or registered trademarks of Parametric Technology Corporation and/or its subsidiaries in the United States and other countries

For further information, please visit www.wmftg.com

PECM Issue 49

BOILERS & MAINTENANCE

Commitment to apprenticeships and training underpins Lanemark success The success enjoyed by Lanemark Combustion Engineering Ltd. since its formation in the early-1980’s can be attributed both to its production and technical capabilities and its commitment to training and personnel development. Jeff Foster, Sales Director at the Nuneaton-based organisation, which manufactures process gas burner systems that are typically used in the heating of process liquids and air in industries ranging from metal pre-treatment and brewing to the petrochemical sector – draws attention to the benefits of this approach. “Some 30% of our current workforce either has been or still are apprentices,” he says, “reflecting our philosophy that remains strong to this day.” Lanemark’s defined structure enables apprentices and trainees to progress in the company to meet both their own and the organisation’s needs. “In all cases, apprentices start their careers with us in the workshop environment and are then given the opportunity to progress into different disciplines,” adds Jeff Foster. He highlights Aidan Lewis – Technical Manager, Chris Wilson – Service Manager, James Keene – Machine/Fabrication Shop Supervisor, and Matthew Jee – Service Engineer, all of whom have committed to the Lanemark approach and have benefited as a direct result. “Our customers all look for the same capabilities,” explains Paul Collier, Lanemark’s Managing Director. “They require installations to operate at the highest levels of efficiency and reliability while also meeting ever-more stringent environmental objectives, and our choice of system designs all look to deliver in both areas.” “We are firmly of the view that people are our most valuable resource and are the most direct influence on our equipment, performance and success,” concludes Paul Collier. “Our history shows that this approach has been fundamental to our track record to date and I am sure will continue in the same way long into the future.”

www.lanemark.com

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

• • • • FD-C high turndown oven/

FD-E low cost high turndown

dryer air heating burners.

oven/dryer air heating burners.

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

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

• • • •

Midco HMA Series Air Replacement or “Make-Up” Air Heating Burners Direct fired, high efficiency burner systems, for high volume air heating applications such as paint spray booths, ovens and dryers. Supplied either as Midco burner heads for OEM system integration or as Lanemark DB or FDB complete packaged systems including modulating gas valve trains and controls Wide range of firing rates to suit alternative temperature rise and air velocity system requirements DbCalc system design software

• • •

Midco HMA high efficiency,

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

TX high efficiency small diameter immersion tube tank heating systems.

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

X4620 Lanemark Ad SDAW.indd 1

•

COMBUSTION ENGINEERING

Issue 49 31/08/2016 PECM

09:04

CONTROL & AUTOMATION

THE HIGHEST STANDARDS BARA

RMGroup becomes the UK’s first certified robot integrator RMGroup UK (Rees Machinery Group) has become the first integrator in the UK to be accredited under the RIA/BARA Robot Integrators’ Certification Scheme. The leading automated packaging machinery and service company was awarded (26 January 2021) certified status following a successful audit at their headquarters in Newtown (‘Y Drenewydd’), Wales. It required the integrator to meet a rigorous set of national and international standards to ensure business compliance and capability. The certification scheme is the benchmark to assess robot integrators’ technical knowledge and safety practices The

PECM Issue 49

UK scheme was born out of the need to standardise integrators’ quality and workmanship, plus recognise effective safety controls to help give companies a competitive edge. Rosie Davies, director of RMGroup UK, said: “We are delighted to be the first integrator to achieve certification in the UK. It demonstrates RMGroup’s ability to deliver systems as per the required technical

expectations. It also assures end users that our expert programming team has the skillset to undertake a variety of integration projects. “The audit process was thorough, which gave us a great deal of confidence to know that we meet all the key performance and safety indicators from two reputable trade bodies.

“To have an independent register of certified robot integrators is vital for companies that are looking to automate, as it serves to verify customer reference sites and recommendations. We would certainly recommend the certification scheme to other UK integrators,” added Davies. Meanwhile, Jeremy Hadall, principal auditor for RIA (Robotic Industries Association) and BARA in the UK, said: “Integrators need to demonstrate that they are committed to providing the best service possible for their customers. The audit looks at the integrator’s technical approach, their project management processes, and how they ensure their system safety, service facilities and staff competencies all operate to the highest standards.

The audit process was thorough, which gave us a great deal of confidence to know that we meet all the key performance and safety indicators from two reputable trade bodies.

All companies certified under the RIA/BARA Robot Integrators’ Certification Scheme are required to be re-audited every two years using the same 25-point list of measurable criteria. Therefore, choosing an independently audited integrator means that the risk to the end-user making the investment is reduced. More information on the certification scheme and a list of certified robot integrators can be found on the BARA website (www.bara.org.uk). UK-based robot integrators who are interested to become certified can complete a free self-assessment here to ensure they meet the necessary criteria.

“RMGroup’s expert technologists were audited on an ABB IRB460 robot to prove their proficiency using the robot safely, its functionality and creating a programme based on a palletising operation. “I was really impressed how seriously the team at RMGroup took the audit, which included having the evidence and staff available to back up the self-assessment scorecard they completed prior to formal audit. It ensured the audit went smoothly,” added Hadall. For further information, please visit www.bara.org.uk Issue 49 PECM

CONTROL & AUTOMATION

VERSAFLEX MK PROFILE SYSTEMS

Conveying, buffering and positioning in three-dimensional spaces The new versatile and flexible flat top chain conveyor system Versaflex is a conveyor system that grows with your requirements. It features the modular design we have come to expect with the complete mk range. The standardised modules and components make it simple and cost effective to integrate the system into any production process, as well as to adapt and expand it. Moreover, it is compatible with systems that are currently available on the market. The single-track design and curve radii starting at 150 mm allow complex track designs within a three dimensional space. The chain runs on wear strips to ensure low wear and can be operated at speeds of up to 50 m/min and system lengths up to 40 m with just one drive. The system is extremely flexible and efficient with chain widths of 44 mm to 295 mm and a large selection of drives, bends, cleats, side rails and other accessories. Gentle transport and exact positioning using workpiece carriers is also available as standard. Versaflex has been used very successfully by an mk subsidiary for many years in various industries; it transports a wide variety of products reliably to their destination. The many benefits of Versaflex include economical realisation of complex track designs with simple and fast configuration and commissioning. It is suitable for all industries and is both user friendly and low maintenance. Versaflex can be quickly adapted to new production and environmental conditions saving energy and space. Accessories, side rails and such like can be attached in the slots on the conveyor frame profile. The conveyor chains are made from the material POM and are available in a wide variety of designs for virtually all applications – with an adhesive surface for inclines, with steel covering for sharpedged parts or flocked for transporting very delicate items. In addition, a large number of different cleats are available – rollers in a wide range of dimensions for accumulating products, or flexible cleats for implementing clamping conveyors. Furthermore, chain

It is suitable for all industries and is both user friendly and low maintenance. links with embedded magnets can be used to transport magnetisable parts. Areas of application for Versaflex include primary and secondary-packaged products from, among others, the food, pharmaceutical, chemical or consumer goods industry. Also for the transport of workpiece carriers in assembly lines e.g. of the automotive industry and for the linking of machines in the manufacturing industry. To ensure the precise positioning of products, workpiece carriers can also

be transported on the A08 system. The system is 85 mm wide (chain width 83 mm) and is designed for products weighing up to 10 kg per carrier. The carriers have a standard width of 150 mm and are guided by side rails and positioned exactly in three levels in the locating stations. So the products are fixed, buffered and transported gently, safely and accurately. The workpiece carrier can be customised and equipped with individual fixtures. The locate station can be freely positioned without changing the side rails. A positional accuracy of ± 0.1 mm can be achieved by lifting the workpiece carrier off the conveyor chain. The Versaflex workpiece carrier system enables simple and accurate positioning for automated processes with stability even for products with unfavourable geometry. Gentle product transport can also be achieved for sensitive product surfaces. Versaflex workpiece carrier systems offer safe transport even with changes in position, higher machine autonomy and buffer function for cycle decoupling in the manufacturing process.

To find more contact mk Profile Systems on (01949) 823751, email info@mkprofiles.co.uk or visit www.mkprofiles.co.uk

PECM Issue 49

Flat Top Chain Conveyor System

Economical realisation of complex track designs Simple and fast configuration and commissioning Modular system of standardised components

www.mkprofiles.co.uk

CONTROL & AUTOMATION

EFFICIENCY & PRODUCTIVITY WARNER ELECTRIC

Warner Electric XS & WR Series brakes reduce footprint of six-axis robot Six-axis robots have become the standard solution for automated assembly tasks due to their ability to carry out complex manoeuvres. As they have grown in popularity, robot OEMs have strived to reduce the size and mass of their six-axis designs to promote space efficiency and productivity. When a German manufacturer of stepper motors was approached by a robot OEM to downsize its assemblies for a six-axis robot, they turned to Warner Electric to deliver highly compact X-Small (XS) and WR Series brakes. Able to approach a work piece from any angle, six-axis robots are now a common sight on manufacturing lines. However, floorspace is still at a premium, so there is a continuing design trend towards decreasing the size and mass of robots. Reducing size improves space efficiency, allowing for the addition of more robots or other equipment on the line. Minimising mass allows for six-axis robots to enhance speed and acceleration without compromising payload – which results in increased productivity. The end goal is a production line with a high density of robots, working within reduced space, delivering high output. Therefore, any advantage that can be gained from reducing the size and mass of components and assemblies must be seized by robot OEMs.

SPECIFYING AN OPTIMAL ROBOT BRAKE This has been exemplified by a robot OEM, which asked its German supplier of stepper motors to assess downsizing opportunities for an updated six-axis robot design optimised for small component assembly. The German manufacturer quickly identified the brakes mounted on the back of each stepper motor as an area for optimisation. The brakes provide static holding in precise positions, ensuring the accuracy of the assembly process. Particularly, the stepper motor controlling the sixth axis of movement, which holds and turns the

Six-axis robots have become the standard solution for automated assembly tasks due to their ability to carry out complex manoeuvres.

Image Source: AdobeStock

tooling at the end of the robot arm, required a specialised braking solution.

DELIVERING TANGIBLE IMPROVEMENT

The manufacturer contacted Warner Electric, a leading brand of Altra Industrial Motion Corp., due to its exceptional expertise regarding advanced braking technologies. After collaboration with the customer’s engineering team, Warner Electric experts recommended a XS electrically-released, spring-set brake to fit the stepper motor on the sixth axis.

For the higher braking torques required on the other five axes of the robot, Warner Electric supplied highly compact Model WR220 and WR225 spring-applied, electrically-released brakes. These are specifically designed as statically engaged/ disengaged holding brakes, ensuring reliable positioning of the robot arm in operation.

Warner Electric’s range of XS brakes is specifically designed for applications where weight saving and space efficiency are paramount. Each model offers reliable braking to an optimised torque level. Consequently, XS brakes are often specified for applications in aeronautics and robotics. It is a highly versatile range featuring six standard sizes, with Warner Electric able to customise designs to exactly match application requirements.

With the new brakes now installed, the German motor manufacturer could approach the robot OEM with a highly optimised design that reduced footprint without compromising productivity. This delivered increased space efficiency for end users, improving available floorspace and enhancing production capacity.

The XSB33S supplied to the German motor manufacturer offered a torque rating of 35 Ncm and a weight of only 90 g. Its design ensured a significant size and mass advantage compared to the previously utilised brake. A customised adaptor flange was also included to allow for customerspecific mounting.

Warner Electric provides a global design, development, manufacturing and supply service to its customers – offering standard and bespoke braking solutions tailored to specific application requirements. Experts worldwide work closely with customers’ engineering teams to provide products that deliver tangible operational improvements. This ensures that the special requirements of advanced industries such as robotics can be met with exact solutions.

For further information, please visit www.warnerelectric-eu.com

PECM Issue 49

Safety systems: food and beverage industry The Schmersal Group develops and produces safety switching appliances and systems for the entire machinery and plant construction industry. In some industries special requirements are applicable. As a customer focussed company who intensively deals with the wishes of the manufacturer and users of machines, Schmersal has taken up these challenges from the start. As a result, specific products and solutions were developed for many industries. For the sensitive fields of the food and beverage industry we have developed tailor made product series, which do not only guarantee the safety of the machine but also contribute to an enhanced productivity and availability. This applies for instance to plants which were developed according to the Hygienic Design standards and to machines, for which the directives regarding the dust explosion protection must be observed during the filling, bottling and storing of powdered food products.

Industries

Product Ranges

Services

• Packaging

• Safe switching & monitoring

• Application advice

• Food & Beverage

• Guard door monitoring safety switches

• CE conformity assessment

• Medicine / Pharmaceutical

• Command devices with safety function

• Risk assessment in accordance

• Machine Tools

• Tactile safety devices

• Construction machinery

• Optoelectronic safety devices

• Stop time measurements

• Renewable energy sources

• Automation technology

• Training courses

• Automotive

• Safety monitoring and control modules

• Chemical Industry

• Machine guarding systems

Schmersal: T: 01684 571980 E: uksupport@schmersal.com W: www.schmersal.co.uk

with the machinery directive

Scan the QR code for your food and beverage industry brochure

CONTROL & AUTOMATION

A MATCH MADE IN HEAVEN OPTIMAL INDUSTRIAL TECHNOLOGIES LTD

Integrating PAT and robotics to bring pharmaceutical manufacturing to the next level Martin Gadsby, Director at Optimal Industrial Technologies, looks at why robotics and PAT are a match made in heaven on the manufacturing line. Ensuring high-quality, effective drugs that meet regulatory requirements and customers’ expectations are challenges that the pharmaceutical and life science sectors constantly need to address by means of robust and comprehensive quality assurance and process control strategies. The digitization and automation of laboratories and drug manufacturing processes can be a powerful ally to these industries, specifically, the cooperation of PAT and robotics. This establishes a real-time link between process control and process automation, which can be used to promptly implement quality assurance and manufacturing decisions. In this environment, the physical information from sensors and analytical instruments are passed on to a higher-level system for adaptive decision-making, i.e. PAT knowledge management, that communicates with industrial or collaborative robots to act promptly on the basis of the decision taken.

INTEGRATED PAT-RPA SOLUTIONS ARE ALREADY A REALITY

environments, as well as ensure the materials are used and processed correctly. When looking at innovations in the pharmaceutical field, it is evident that implementing integrated PAT-RPA systems can offer a pathway to success in offering more commercially viable precision medicine. Within this framework, the pharmaceutical product composition determines the processes that are required, and the associated factory robots and machines carry out the necessary operations. and autoimmune diseases treatment and prevention of xenograft rejection.

PAT AND ROBOTIC ARMS ADDRESS CHALLENGING APPLICATIONS In addition, the use of integrated PAT-RPA systems can be extremely useful in sensitive applications such as those conducted within cleanroom environments. In these situations, rigorous aseptic conditions are a must to produce regulatory compliant sterile products. The use of fully automated manufacturing and quality assurance tools can significantly reduce contamination risk as well as particulate generation, resulting in higher drug quality and lower production of waste and off-spec material.

Pharmaceutical filling and preparation of growth media for life science, for instance, is turning into an increasingly robotic process in order to reduce cycle times and increase consistency. When coupled with PAT monitoring quality via spectral analysis, this system can further increase its speed whilst reducing waste.

In particular, recent advances in robotics have allowed articulated robots to meet even the most demanding ISO 3 (Class 10), 2 and 1 cleanroom standards. In addition, these robots can be easily cleaned, are waterproof and can withstand sterilization procedures, such as hydrogen peroxide vapor disinfection.

Researchers in this field have been able to create a high-performance, high-throughput automated robotic workflow for monoclonal antibody (mAb) and glycan purification that enabled the implementation of PAT and Quality by Design (QbD) approaches. Plate-handling robots are used to collect, prepare, incubate and test liquid samples. The solution reduced cycle times from over 18 hours to only 5.1 This specific innovative system offers a fast and efficient method to produce biotherapeutics for cancer

Conversely, the use of robots and PAT in particularly hazardous conditions can minimize human operator exposure to certain compounds and ingredients. In this way, the combination of real-time testing, process control and process automation can increase operational safety and reduce health risks. More precisely, PAT knowledge managers can guide industrial robots in handling pathogens, highly reactive, corrosive and hazardous substances, conducting chemical reactions in extremely cold or hot

INTERCONNECTED PHARMA 4.0

The connection of PAT and RPA also offers a starting point to integrate data from systemwide physical, operational, and robotic assets to drive not only manufacturing and quality assurance activities, but also maintenance, inventory tracking and many other variables and KPIs across an entire plant. This is, in essence, the level of interconnectedness that Industry 4.0 and Smart Manufacturing aim at. Nonetheless, the synchronicity of PAT and RPA not only helps to build a Pharma 4.0 factory, but also it improves the practical everyday operation of pharmaceutical manufacturing systems by streamlining operations, lowering production costs and cycle times whilst increasing throughput and performance. Hence, the large-scale adoption of these technologies is not a matter of ‘if’ but ‘when’. When committed to implement a successful integrated PAT-RPA, it is important for manufacturers to rely on skilled and knowledgeable specialists that have extensive experience in process automation, robotics and PAT. They can design and build bespoke solutions that address specific plant requirements in the most efficient manner, smooth the process before and after installation as well as ensure that the automated line is running at its optimal performance level. In this way, industries in the pharmaceutical and life science sectors can be sure to benefit from the most suitable solution for their specific applications.

For further information, please visit www.optimal-tech.co.uk

PECM Issue 49

CONTROL & AUTOMATION

TF Automation automate manual process for Textile client TF Automation has recently delivered a new machine to long-standing customer, Genesis Patterns, which has automated a timeconsuming and problematic manual process. Over the last thirty years Genesis Patterns has grown into one of the leading suppliers of sampling products to the flooring industry. Originally supplying swatches and pattern books, the company has invested in machinery and staff to expand into the shade card sector. TF Automation has worked with Genesis Patterns for several years designing and building a number of specialist machines to support their expansion and development plans. Genesis had a recent requirement to automate a manual process of taking precut carpet swatch samples from a strip and adhering them to “dec” boards, to create carpet sample books. TF Automation project engineers worked with the team at Genesis to build a machine that would de-laminate and remove the pre-cut samples from the strip and place in the exact position required on the larger board. This activity is currently carried out by hand and is open to large fluctuations in output and accuracy.

The new machine removes the individual samples from the strip and places accurately in position on the boards, ensuring precision placement and standardisation every time. The new machine has enabled Genesis to improve productivity of this activity and enable more cards to be completed in a shorter time frame, whilst also ensuring consistency and uniformity.

Tony Hubbert, MD at TF Automation, comments, “We have worked with Genesis for a number of years and were delighted to support them in automating this manual process to improve their efficiencies and ensure standardisation and accuracy.”

www.tfautomation.co.uk

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Issue 49 PECM

CONTROL & AUTOMATION

CROSSEN ENGINEERING FANUC

Injecting innovation into Northern Irish manufacturing Belfast-based Crossen Engineering is a leading full-service manufacturer of custommade metal and plastic parts. Able to provide customers with a seamless single-source solution from concept through to production, across a range of sectors, Crossen Engineering has witnessed an extraordinary increase in demand for its services. In a bid to increase productivity, it turned to FANUC’s ROBOSHOT α-S100iA – in what was the automation specialist’s first electric injection moulding installation in Northern Ireland. Crossen Engineering was established over 40 years ago, primarily serving automotive clients with prototype pressed metal parts. As the business developed, it began to move into production, and invested in a press shop to facilitate this. By the late 1990s, Crossen Engineering had developed an injection moulding arm, and as with metal pressing, an initial prototyping service swiftly grew into larger-scale production. A commitment to helping its customers develop ideas into prototypes, and then scale up production tooling to supply finished products, has established Crossen Engineering as one of the most innovative manufacturers in Northern Ireland. This dedication to being an integral part of the design process, alongside advancements in its injection moulding capabilities, has provided a pathway into the cutting-edge medical products sector.

INJECTING INNOVATION

As part of this, Crossen Engineering has recently assisted in the development and production of colostomy solutions. Crossen Engineering moulds the seal rings which interface between the user’s body and the stoma bag, before supplying them to the customer who secure them to their bag solution. Peter Crossen, Business Development Manager at Crossen Engineering, comments: “We’d known this customer for over 15 years, stemming back to our metal pressing days. When they required a solution for sealing a colostomy bag, they knew that we had the design and prototype capabilities, as well as the production capacity, to provide an effective solution. “We’re now in the process of developing a

PECM Issue 49

second product with that same customer, and it is this increase in demand, especially from the medical sector, that prompted us to explore automation options.”

AUTOMATED INJECTION MOULDING

To help meet growing demand, Crossen Engineering undertook research on how to increase productivity, while simultaneously reducing running costs. Electric moulding machines were highlighted as the ideal way to achieve this, offering the opportunity to introduce automation into the production process.

The ROBOSHOT has been perfect, enabling us to keep up with the increasing orders we are receiving.

Owing to its prominent position in the polymer processing machinery sector in Ireland, supplier JL Goor was identified to assist with finding and installing a turnkey manufacturing solution. The recommendation was made to opt for two FANUC ROBOSHOT α-S100iA high precision electric injection moulding machines, which would in turn be the first ROBOSHOT machines to be installed in Northern Ireland1. Peter explains: “This was the first time we were introducing automation into the process, so we were eager to get a reliable name to assist us with this. FANUC’s standing within the moulding industry, and particularly with our customers, meant it emerged as the obvious choice.

“It also has a compact footprint, especially when you consider the output capacities, which drastically reduces the factory floorspace required. Combined with the reduction in energy usage, this significantly minimises the total cost of ownership.”

“The FANUC ROBOSHOT has been brilliant, and we’ve actually just accepted delivery of a further two onto site. They’re currently being used to manufacture face shields, which began in reaction to the increased demand for PPE following COVD-19.

INTO THE FUTURE

“We’re unique in Northern Ireland in that we build tools from scratch, and work closely with the customer to ensure we deliver the right product. As we grow alongside our clients and become increasingly involved in the medical product supply market, we will undoubtedly be introducing more FANUC machines, with its prestigious name proving popular amongst our customer base. For now, we intend to keep improving our injection moulding productivity with the four ROBOSHOTS we have at our disposal.”

The ROBOSHOT electric injection moulding machine can also be used with robotics, to automate machine tending, loading, and unloading. Crossen Engineering is already using robots to help with part removal, further increasing the productivity gains associated with the machine. With business booming, Crossen Engineering has confirmed further investment in automation. Peter continues:

“The ROBOSHOT has been perfect, enabling us to keep up with the increasing orders we are receiving. As our customers grow, we grow with them, and we’re now ramping up our production to assist in targeting global sales.” Alongside boosting productivity, the ROBOSHOT can contribute to substantial energy savings. Michael Reynolds, Sales Manager at JL Goor, comments: “The combination of CNC with the electric injection moulding technology ensures that the ROBOSHOT uses between 50-70% less energy than hydraulic machines, and 10-15% less than other electric machines. For more information, please visit https://www.fanuc.eu/uk/en, http://www.jlgoor.ie and http://crossenengineering.co.uk/ Issue 49 PECM

CONTROL & AUTOMATION

A PERFECT MATCH OEM AUTOMATIC

OEM Automatic stock entire range of Basler’s intelligent lighting solutions As any Instagram user will tell you, lighting makes all the difference to images. For machine vision applications, Basler have certainly got that covered and OEM Automatic are delighted to be stocking the whole new lighting range. Basler’s new camera light range brings together its high-quality lighting equipment with its popular ace U and L camera models. It’s a perfect match which significantly reduces any of the complexity associated with a vision system. Users will have a simpler image processing system and the best possible repeatable image quality. Any user can integrate the lighting early and easily.

THE BASLER SLP SYSTEM This close integration of camera and light rests on the Basler SLP feature which enables direct communication between the two. It makes the entire process simpler and shorter: • allowing easy synchronisation between camera and lighting

The plug and play setup and its low operating costs make it very userfriendly and cost-efficient. • giving non-expert users easy access to the popular strobe mode (which provides more light and a longer LED lifetime) • simplifying the setup for vision applications. A plug and play set-up means that it’s straightforward for users to choose an easy approach for quick results. Or they can choose a more flexible approach, suitable for those customers with lighting experience who have applications with specific lighting requirements. Lighting can be easily operated in different modes such as continuous, strobe or overdrive.

BASLER AND OEM AUTOMATIC “Basler’s new range is fantastic,’ says Gareth Ford, Business Area Manager for OEM Automatic’s Machine Vision & Code Reading team. “The plug and play set-up and its low operating costs make it very user-friendly and cost-efficient. OEM Automatic is a strategic partner of Basler and we’re very pleased to be supplying its whole range in the UK.” Please contact the Machine Vision & Code Reading team for any enquiries. Vision@oem.co.uk | 0116 284 9900

Both camera and lighting share the same software interface, the Basler pylon Camera Software Suite, which makes installation and operation easy.

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

PECM Issue 49

CONTROL & AUTOMATION

MACHINE VISION & CODE READING

OEM Automatic have a large portfolio of machine vision products including cameras, camera software, lighting, lenses and accompanying accessories. The machine vision experts at OEM Automatic are on hand to advise on all machine vision applications.

vision@oem.co.uk +44 (0) 0116 284 9900 www.oem.co.uk

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, at e, BEPC’s BEP EPC’ PC’s C’s selection C’ sele se lect le 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 Issue 49 PECM

CONTROL & AUTOMATION

TAKING THE NEXT STEP RAPIDDS

Overcoming the Challenges to Automate Manufacturing Working with an expert fabricator and integrator that is flexible enough to customize can help meet requirements while expediting completion For manufacturers, the continual need to increase production speed and efficiency while reducing labor has spurred a shift toward implementing automated systems. However, off-the-shelf equipment will not accommodate every application, particularly those that are complex with robots and conveyors, as well as a host of equipment for manufacture, assembly, packaging, labeling, palletizing, etc. that must be flawlessly coordinated. For this reason, even some large automation companies will not take on applications considered too difficult. In such cases, companies looking to increase the speed and efficiency of their manufacturing lines need an automation partner that can quickly and cost-effectively deliver tailored, even custom solutions. This includes the ability to design, build, and integrate high-speed, high-volume automated equipment and systems for some of the largest companies in the world, as well as growing corporations seeking to become world-class. For projects of any size, however, it can be crucial to partner with an expert supplier to overcome a range of obstacles such as meeting specifications and regulatory requirements, system integration, and necessary customization, as well as completing the work on time and within budget. “While implementing off-the-shelf solutions can be a starting point for some projects, automating and incorporating robotics frequently requires a custom solution that meets very specific process requirements. For this reason, even large suppliers in this space will often pass on opportunities if they are not easily resolved,” says Leon Gurevich, founder and Chief Technology Officer of Rapid Development Services (RDS). RDS is an industrial automation equipment builder, providing design, engineering, integration and fabrication of production

PECM Issue 49

Automation suppliers and integrators need a ‘tool box’ full of solutions including the ability to design and build from scratch in order to fit together all the pieces of the puzzle. machinery. The company has implemented over 300 complex, robotic, assembly and manufacturing projects worldwide, and has been awarded more than 40 patents. So, at the risk of delay or failure on larger, more complex projects it is particularly important to work with a supplier that not only has expertise, but is also nimble and flexible. “When it comes to automating production, equipment can range from very small to complete lines several hundred feet long that can consist of robots, conveyors, vision systems, server drives, etc.,” says Gurevich, who has worked with companies such as

Anheuser Busch, Johnson and Johnson, Cargill, General Mills, Abbott Labs, Pfizer, Medtronic, and Cooper Industries. “So, automation suppliers and integrators need a ‘tool box’ full of solutions including the ability to design and build from scratch in order to fit together all the pieces of the puzzle.” In the case of RDS, the company typically uses standardized off-the-shelf solutions and integrates it with other systems, but can design and manufacture equipment and sub-systems from scratch, as needed. This includes equipment such as automated assembly solutions, inspection systems, packaging equipment, labeling/marking systems and palletizing automation, as well as filling systems and machine tending automation. As an example, after trouble with an initial vendor, this approach helped Monsanto Dairy Group stay on schedule with the construction and start-up of a veterinary pharmaceutical facility in Augusta, Georgia, according to Chris R. Redford, P.E., Principal Pharmaceutical Engineer, Monsanto AG Engineering, St. Louis, MO. “The custom handling system [originally] purchased by the construction was found unacceptable after a full year of design and fabrication effort. This put us in a very difficult position.

We either had to accept a poor-quality piece of equipment – and modify it to meet our requirements, or accept a lengthy schedule delay,” stated Redford. In response, Redford turned to RDS, and credits its effort in getting the facility rollout back on track. According to Redford, in working with RDS, “We were able to design a new handling system from scratch in just a few weeks. [Rapid Development Services] designed the new system in modular sections that could be brought into the facility through standard door openings. This allowed us to continue facility construction with no delay.” Despite the complexities of manufacturing automation, due to market requirements even very technical systems often have to be developed and put into production under compressed time schedules. Such was the case when wireless communications manufacturer Triton Network Systems created a high-volume manufacturing line for the assembly of high frequency, RF modules used in the broadband wireless industry, according to Joseph Kreuzpaintner, Principal Engineer at Orlando, Florida-based Triton Network Systems. Kreuzpaintner stated that the manufacturing requirements involved precision alignment

and mounting of odd shaped components, dispensing of epoxy, electrical testing of product on laser equipment, in-line processing of modules at a heated test station, installation of cables, and mechanical assembly of a circuit card to a housing. He notes that after conducting a survey of integration companies meeting Triton’s manufacturing work cell requirements, RDS was selected as the primary equipment integrator for the Module Factory at Triton, which helped to expedite project completion. “Rapid Development Services’ technical expertise in handling products, test socket and integration methods, precision in machining, robotic, PLC and actuator integration, and customer support allowed Triton Network Systems to complete the integration of five work cells within 9 months. Their participation in the project has provided… solutions that were identified by other integrators as “not possible” or “need 12 months to develop,” stated Kreuzpaintner. When automated manufacturing systems are developed, the equipment must also be robust enough and the integration reliable enough to operate with near flawless capability and minimal supervision for the long haul.

In this regard, a distinct advantage can be gained when working with an integrator that can couple the knowledge of custom machine building with standardized robotics, as well as develop specific control and communication support between production machinery and operator or inventory management systems. Pohlman, Inc, a Chesterfield, MO-based manufacturer of screw machine products benefitted from such an approach, according to Hank Studt, Pohlman President. “RDS has provided 3 different automatic robotic pick and place machines that have been in use at Pohlman, Inc for over 10 years. The machinery has operated without any service needed by them. This technology helped us to get our products into mass production with a competitive advantage,” stated Studt. He concludes, “The flexibility of 6-axis robotic technology…allows us to produce an array of products on the same equipment while maintaining a high-quality product. We have relied on this equipment … to continue serving our customers.” For more information, call (866) 9001033; visit https://rapidds.com; email info@ rapidds.com; or write to Rapid Development Services at 4329 Green Ash Drive, Earth City, MO 63045.

For further information, please visit https://rapidds.com Issue 49 PECM

CONTROL & AUTOMATION

NEW OPPORTUNITIES TLM LASER

BODOR flat bed and tube processing technology cuts through traditional barriers to ownership Large format flat-bed and tube laser cutting systems play an important role within many industry sectors, producing the individual parts required for the fabrication of a multitude of component assemblies. The benefits of laser technology for these applications mean that it continues to replace other cutting methods such as Plasma, Oxy-Acetylene and even Water-Jet. However, for some, the initial investment cost of these systems from mainstream suppliers has been such that the technology has remained out of reach. A new partnership agreement between Bromsgrove based TLM Laser and Chinese metal laser cutting equipment manufacturer BODOR is set to break down the cost inhibiting barrier to ownership of these types of systems within the UK and Ireland. Recognised as one of the UK’s leading suppliers of laser technology and systems, TLM Laser continually evaluate opportunities to enhance their comprehensive product portfolio, to be able to offer the most technologically advanced and cost effective solutions to a wide range of laser processing applications. As an advanced domestic supplier within their home market of China, BODOR Laser specialises in laser systems applications and integration. The company manufactures a wide range of flat-bed laser cutting and tube processing systems, designated CE compliant from TUV and therefore meeting European standards and International quality control levels.

With options on fiber laser sources from IPG or Maxphotonics, and laser power up to 40kW these systems are ideally suited for applications on a wide range of metals including Carbon Steels, Stainless Steels, Alloys, Aluminium, Copper and Brass. TLM Laser’s Andy Toms explains the economic benefits of the BODOR Systems: “With the largest laser cutting equipment production workshop in the world, BODOR can leverage the benefits of scale when it comes to manufacturing cost. These systems are not only extremely attractively priced but also offer a wide range of innovations to ensure the highest levels of performance and reliability.” The full range of BODOR systems now available from TLM Laser have working envelopes ranging from 600mm x 600mm up to 6m x 2m for the flat-bed systems, and up to 6.5m in length for tube processing. Capable of cutting carbon steel up to 100mm thick, depending upon model and laser power, and with the ability to cut

bevel edges to 45 degrees, the systems also feature a 360 degree fully enclosed design surrounding the working area, which provides a safe working environment by isolating both fumes and laser radiation. A series of features such as Auto-Focusing which is suitable for multiple focal lengths, with the focal position automatically adjusted based on sheet thickness, and Automatic Obstacle Avoidance, which offers full 360 degree monitoring of the environment to avoid collisions further enhance the capability of these attractively priced systems. Andy Toms concludes: “There is no doubt that the price / performance characteristics of these systems will open up new opportunities for investment from a wide range of companies, including SME’s, who have until now been unable to take advantage of this type of technology. This is great news, especially at a time when many UK companies are seeking to re-shore manufacture and shorten the supply chain.”

For further information, please visit www.tlm-laser.com

PECM Issue 49

High Performance Laser Processing Technology That Won’t Break The Bank

Affordable Flat Bed Laser Cutting & Tube Processing Systems From TLM Laser

• • • •

Laser power from 1,000W to 40kW Up to 6.0m x 2.0m work envelope - up to 6.5m in tube processing systems High accuracy and repeatability Linear speeds up to 140m/min

Carbon Steels | Stainless Steel | Alloys | Aluminium | Copper

Contact TLM Laser for more details... Tel: +44(0)1527 959 099 www.tlm-laser.com | sales@tlm-laser.com

ELECTRICAL & ELECTRONICS

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

Customised components, sensors and connectors • Specialist distributor for more than 25 leading manufacturers • In stock, manufactured-to-order and customised solutions 01342 330 470 sales@rhopointcomponents.com www.rhopointcomponents.com

your reliable solution partner...

+44 (0)1925 811 290 / sales@tempapano.co.uk / www.tempapano.com

PECM Issue 49

FACILITIES MANAGEMENT

Avoid Costly Downtime from Overheated Electronics Easy to install Vortec Enclosure Coolers prevent electrical enclosures from overheating. The NEMA 12, 4, 4X, and HazLoc Coolers, require no refrigerant or wiring and will protect and cool electronics minutes. Vortec’s line of Vortex A/C Enclosure Coolers provide our customers with many advantages, one of which is quick and easy installation. A Vortex A/C can be installed on a standard enclosure in about 5 minutes. Thanks to the mechanical thermostat, there is no need to provide electricity to a thermostat or hook up a solenoid valve. This allows you to get the unit up and running in a fraction of the time. Vortex cooling is a low-cost alternative to expensive, high-maintenance air conditioners; and avoids contamination commonly found with dirty, humid air caused by fans.

The compact size, mixed with the ability to be installed on the top, front or sides of any enclosure allows for simple installation even in tight spaces. Vortec offers multiple types of enclosure cooling systems to meet your enclosure cooling needs, all available in a variety of cooling capacities along with hazardous locations, ATEX, and UL certified models. Nearly all Vortec Enclosure Coolers are covered by a 10-year warranty and are a part of Vortec’s trusted 59 years of innovative compressed air solutions.

www.vortec.com | sales@vortec.com | 1-800-441-7475

SIMPLE GREEN® THE SAFER ALTERNATIVE FOR HIGH PERFORMANCE CLEANING Finding a cleaning product that is safer for the environment and employees whilst still being powerful and effective can be a challenge. For many organisations in different industries around the world, SIMPLE GREEN ® is the answer - trusted globally for high quality, environmentally safer cleaning and degreasing products. Solvent-free SIMPLE GREEN ® is non hazardous, breaks down dirt, grease and grime and is: • Kinder to the environment • Safer for employees • Gentler on equipment, metals, plastics and coatings From general all purpose cleaning to degreasing engines, manufacturing equipment, removing machining oils, or maintenance and repair operations on aircraft and wind turbines, SIMPLE GREEN ® concentrated cleaners and degreasers do it all. Call 01825 740575 to find out more or visit www.simplegreen.co.uk Simple Green UK: info@simplegreen.co.uk biodegradable ~ non-toxic ~ non-hazardous ~ non-flammable ~ non-corrosive ~ non-abrasive - VOC compliant

Issue 49 PECM

FACILITIES MANAGEMENT

THE CW3

SEELEY INTERNATIONAL

Seeley International proudly presents the very latest in its Climate Wizard range Using only water and electricity, Climate Wizard will not have you in a quandary about refrigerant legislation. We cool wisely with water and no synthetic refrigerants or chemicals to harm the environment.

Using the latest innovation, a new MicroCore® technology for smaller or uniquely challenging applications. The concept of how it works remains unchanged, combined with equally effective cooling performance found in Climate Wizard’s other commercial models, such as the CW-P15, CW-H15 and CW-80. CW3 provides hyper-efficient cooling of outside air and up to 80% lower cooling energy costs, compared to equivalent reverse cycle systems, with the added benefit of supplying 100% fresh, cool air into the building, increasing Indoor Air Quality (IAQ).

Designed to meet the cooling and fresh air requirements of buildings across many sectors, particularly where there is constant access by customers or occupants, spaces constantly open to outdoors or where doors are frequently opening and closing.

CW3 delivers incredible part load performance due to its inverter technology fans. The CW3 contains an on-board sophisticated control system that ensures peak efficiency during all operating conditions.

Seeley coolers are designed for applications with zero or minimal recirculation requirement, so effectively purging the space of pollutants, dust and germs. This is especially helpful as an aid against Covid-19.

With the added benefit of being able to use rain water to run the cooling cycle and the facility to utilise any waste water for grey water (irrigation, fire tanks, toilet flushing), this makes for a very carbon friendly, low water usage solution. That’s not only great for reducing energy bills, it’s also great for the environment. So when you consider your company’s return to work, think about enthusing your employees with confidence, be a Climate Wizard! T +44 (0)115 963 5630 uksales@seeleyinternational.com

For further information, please visit www.seeleyinternational.com

PECM Issue 49

The world’s leading hyper-efficient air conditioner with an exceptional compact footprint

Indirect D U Evaporative A L SCooling Y S technology T E M uksales@seeleyinternational.com tel. 0115 963 5630 www.seeleyinternational.com

FASTENERS & FIXINGS

SPOTLIGHT STAR FASTENERS

Huck® Fasteners designed for use in composite panel Sandwich panels, also known as composite panels are generally characterised by their performance characteristics. They are made by bonding two thin facings to a lightweight core material using adhesive bonding. The core separates the two skins providing strength and durability and offers very little increase in weight, producing a highly efficient panel structure. Manufactured from a wide variety of materials including foam, polypropylene or aluminium honeycomb core and glass fibre reinforced plastic (GRP) or aluminium facings, these panels are now used in a wide range of applications. The technology is not a new one, for years these panels have been used in the manufacture of civilian and military aircraft, and its success and benefits in this field has made it desirable across a wide range of industries seeking to apply its advantages to their applications. Sandwich panels are now the preferred material in efforts to lightweight vehicles and are used in a multitude of industries and applications including, emergency vehicles, light truck construction, commercial vehicle trailers, event vehicles, containers, housings, wind power housings, potable structures, welfare units, in fact application possibilities are endless. Technological and design innovation has advanced rapidly and unique and flexible manufacturing processes have made it possible for the material to be extremely tough and lightweight, they are now being used as a high-strength alternative to traditional materials such as aluminium and steel. The strength of the composite panel often depends on its overall size, the surface material used and the density of the cells inside it. New product design and fabrication methods involving composite materials alter typical fastener material requirements. This is where Star Fasteners knowledge and expertise is often called upon by design teams and engineers. Initial consultation encompasses a complete assessment of the application and materials to be used. Once this has been established the joint geometry and the range of stresses imposed can be determined, selecting an appropriate fastener ensures that stress levels on both the fastener and material are kept sufficiently low so as not to cause fatigue problems.

PECM Issue 49

Huck® Encapsulated Hucktainer

Thanks to its high pullout strength, Penta-Lok is suited for use within thin materials or delicate composites. ADVANTAGES OF USING HUCK FASTENERS IN COMPOSITE PANELS Simple joint configuration – speedy, low skilled assembly process compared to a purely bonded system which requires a controlled application environment. Easy to disassemble if required – if a repair is necessary often the fastener can be removed, the panel replaced without damage to the adjoining panels / surrounding structure.

installed mechanical fasteners do not distort or penetrate the appearance of the panels and are weather and water resistant. Environmentally sustainable – approximately 90% of the automotive scrap can be recycled into other products. Huck fasteners offer a secure fastening solution that can also be recycled when they reach the end of their useful life. Fastener longevity – as well as quality plated steel fasteners, plastic encapsulated heads, aluminium and stainless-steel varieties ensure a long life of the finished structure. Mechanical fixing - offer structural integrity to a build; their mechanical properties offer reliable performance. Time efficient – time associated with the assembly process can be a major factor. Both the 2-piece Huckbolts and structural blind fasteners combine unmatched speed of assembly.

Inspection is straightforward – quick and easy visual inspection once installed.

No special training required – Huck engineered fasteners do not require any special installation training for someone to become proficient in installing them.

Few thickness limitations – the Huck fasteners product range caters for a large variety of joint thicknesses. Correctly

High Pin retention in structural blind fasteners – prevents possibility of noise or vibration in dynamic assemblies.

Huck Penta-Lok installed in load restraint

Hucktainer® is a two-piece specialty fastener that has been designed specifically for composite board, fiberglass reinforced plywood (FRP) and metal clad composite panel applications. It is a popular choice for commercial trailer manufacturers, as its direct-tension installation process provides consistent clamp which reduces the potential for crushing or crazing of the panel. This accurate tension ensures a secure, durable connection, time after time. Star Fasteners have brought to the market a coloured encapsulated Hucktainer.

SIX UNIQUE ADVANTAGES OF HUCKTAINERS’ COLOUR ENCAPSULATED HEAD. • Colour matched to any colour of your choice • Low minimum order quantity and fast turnaround. • Plastic encapsulated, UV resistant head reduces corrosion. • Helps to prevent weather ingress. • Increased head diameter spreads the load; helps eliminate panel crushing. • Neat appearance gives a professional finish and blends seamlessly with the livery / panel colour. Penta-Lok™ structural fastener has come to the market driven by the need for a fastener specifically designed for the lightweight panel market. Thanks to its

high pull-out strength, Penta-Lok is suited for use within thin materials or delicate composites. Customers specific focus is often to fasten Load-Lok® / load restraint systems and other components to the lightweight panels. The Huck Penta-Lok is an easy-to-install, 6.4mm diameter, all steel (body and mandrel) plated, peel structural fastener with superior blind side strength. It has a neat domed head and its positive mechanical pin retention ensures structural integrity. Its uniquely engineered peel system installs with ease into shallow panels. If the tip of the body is inserted into material (minimum 8mm composite / honeycomb /foam core panel) the PentaLok will do the rest. The installation process seats the flange to the surface of the material as it claws itself in on the blind side; resulting in a supportive load spread of approximately 16mm. It is a perfect fastener to use in conjunction with adhesives and sealants. Using the Huck Penta-Lok in key areas of a build enables quick panel stability; no need for as many clamps or tape and the project can immediately be moved onto the next production process allowing the adhesive to effectively cure. The longevity of a finished product is undoubtedly connected to the quality of materials used. Huck fasteners are a proven, versatile, quality fastening solution.

A-Lock™ blind rivets also provide robust fastening of metal to wood, FRP, plastics and fiberglass without through holes. They expand on the blindside when installed and lock themselves into the application. Once locked in place they offer superior pull-out strength and vibration resistance. As well as being the largest UK stockist of the Huck® fastener brand and an authorised tool service and repair workshop, Star Fasteners stock a comprehensive range of rivets. These include standard, sealed, multi-grip and many specials for bespoke applications and are available in a wide range of materials and finishes. An in-house powder coating service ensures that any stock item can be coloured to meet customers’ requirements and despatched at short notice.

For more information on our complete range of services go to www.starfasteners.co.uk Issue 49 PECM

FLUID HANDLING

MAK CHEM & MAK LUBES join A&S International Ltd

Successful Cooling Solution For A UK Beverage Closure Company

THEALE, Reading, Berkshire, UK - A&S International is excited to start the new year with not one but two excellent new additions to its growing range of quality brands. MAK CHEM’s range of maintenance chemicals have been acquired along with the MAK LUBES range of maintenance lubricants. A&S International will offer both product lines to their global distributor network & developing UK direct client base with immediate effect. Sales of these new quality maintenance chemicals & lubricants steadily grew during the second half of 2020 despite the limiting business conditions created by the COVID-19 pandemic. Particular success has already been enjoyed by the MAK CHEM brand in Greece, Philippines & Portugal. The majority of the products can be easily & effectively demonstrated to clients; however, a range of demonstration videos have been produced for the corporate websites & social media. New UK Distributors & Resellers are welcome.

UPM Conveyors, manufacturer of high quality conveyor systems, recently designed a stainless steel system to improve efficiency at a UK beverage closure company. The bespoke system solved manufacturing issues that were resulting in ovality due to a high closure temperature above 45-degrees Celsius, a high level of static and a high reject rate. UPM’s specialists created the bespoke conveyor design, presented it to the company, manufactured and then installed and tested it on the premises, including a static eliminator and a bespoke control system. The closure temperature was reduced to ~30-degree Celsius and the company now benefits from stainless steel conveyor sides, a mobile support frame and PET-G dust covers. Staff can use the bespoke control system via a touch screen HMI to operate variable speed adjustments, to continuously monitor the temperature of the cooling system, and much more.

www.aands.international

www.upmconveyors.co.uk/news/coolingsolution-for-uk-beverage-closure-company/

Palamatic Vacuum Tube Lifters solve manual handling of door cores, for Leading Fire Door Manufacturer 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’’. T: 01246 452054 | E: sales@palamatic.com www.palamatic.com

Fluid Carrying

Flexibility Articulated Torsion Pipework In Hoses Rotating Cylinders

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

Tel:

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

PECM Issue 49

+44(0)1663 735003

E-mail:

Rotaflow and the Silver Screen Most of the work Rotaflow design engineers do involves thinking up solutions to pressure, heat and fluid related problems, so when the special effects department of a major Hollywood film production house gets in touch, it sparks a bit of excitement in the office! Rotaflow swivels have helped production of some major blockbuster films… one that is set in a galaxy far, far away! Another film Rotaflow swivels have been used in investigated the framing of a famous cartoon rabbit… These two aren’t the only examples of Rotaflow swivels being used in film production.

In July this year two Rotaflow multiports were delivered to a film set. They’re designed to not only allow the rotation of hydraulic control lines but also incorporated electrical wires to pass through the centre of the unit, which facilitates the full rotation of a green screen rig. It means the action can spin from a central axis point smoothly, capturing footage more easily. The Rotaflow design and manufacture standards are what has led to repeated work between the studios and the Derbyshire-based swivel joint specialists.

www.rotaflow.com

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

Labtex.co.uk 01484 600200”

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

Issue 49 PECM

GEARS DRIVES & MOTORS

Cost effective fail safe power off brake for e-parking SG Transmission has developed a 40 mm diameter static holding brake (12Volt DC, 0.6Nm Torque) for a German automotive customer as a parking brake with fail safe power-off braking. The approach is a fully automated production process with single part feed, including an air gap preset during the manufacture process with reduced part count for simpler assembly. The electrical connection is with integrated terminals.

- reduce cost - cover high quantity needs of over 100,000 pieces per year

The spring applied brake has been optimised to: - reduce complexity of parts - reduce manual handling

Call us on 01388 770360 or visit www.sgtransmission.com with your requirements.

SG Transmission design and manufacture electromagnetic clutches brakes and electromagnets with: • Dedicated design service • Superior product quality • Safety and Product • Accreditation (ISO 9001,ISO 14001,ISO 18001, RoHS, REACH ,CFSI approved) • Singular to mass volumes • Sales, Design and • Manufacture in house Competitive pricing

Ultra Slim Permanent Magnet Brake SG Transmission has supplied a robotics manufacturer with a new Ø56 diameter x 24.5mm Permanent Magnet Brake. The client, who has applications such as servo motors and cobots, based in Asia with locations across the world, has worked with SG Transmission for a number of years. Adam Russell, the lead design engineer on the project said, “This is our sixth brake we have designed and manufactured for this successful blue chip electronics Company since we began working with them four years ago.” SG Transmission customises electromagnetic clutches, brakes and magnets to meet the customer requirements. Get in touch regarding your application with sales@sgtransmission.com.

www.sgtransmission.com

PECM Issue 49

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

DSEAR 3 DAY - Risk Assessment Training Course March 16-18th | June 15-17th | Oct 12-14th

Our “Three Day” DSEAR course is aimed at those who responsible for conducting DSEAR assessments, but are not necessarily fully confident with the process. They may work in a flammable environment, in-addition to being responsible for managing the area, day to day. The course content: • Legal foundations • How sources of danger arise. • What is the difference between flashpoint, fire point, boiling point and Auto Ignition? • The fundamentals on the origin of Explosions, Deflagrations and Fires • Risks resulting from improper storage or handling of these substances • The meaning of the danger triangle and pentagon. 01952 947682 - 07989 597569 https://www.dsc-ltd.co.uk

Short Cuts May Cut A Life Short!

New Sharklet Germ Control film

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

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

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

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. Issue 49 PECM

HEALTH & SAEETY

ONLINE TRAINING BY EXPERTS REMBE

REMBE Safety Days Digital Home Edition In recent years, the ‘REMBE Safety Days’ series of events has repeatedly made Brilon a meeting place for global explosion safety and process safety. The content of the events was to present and discuss current topics in these areas as well as to create a platform for networking. In November 2019, 150 participants from five continents were welcomed to the Sauerland region. Unfortunately, no live events can take place due to the current situation. In order to nevertheless enable such an important exchange of knowledge, REMBE is offering a digital version of the REMBE Safety Days. Safety is essential – especially in difficult times like this. REMBE has launched the ‘REMBE Safety Days - Digital Home Edition’ to enable experts to continue to exchange their experience in the field of safety technology. “We are proud to be able to provide a platform like this,” says Claire Lloyd (Team Leader Process Safety Europe and one of the speakers at the REMBE Safety Days – Digital Home Edition). This format is an ideal solution to exchange up-to-date expert knowledge, the latest experience and safety approaches. The presentations are aimed at operators, planners, technicians, engineers, maintenance personnel, safety officers, experts and inspectors in monitoring organisations. The event has aroused great interest in recent months. The REMBE Safety Days Digital Home Edition was launched in April 2020 and had 1,000 participants by end of the year. Every two weeks on Wednesday from 1:15pm, a 45-minute presentation from the REMBE Safety Days - Digital Home Edition will take place on a wide range of topics relating to explosion safety and process safety. As the participants have always been an international audience, there will be both German and English presentations. The overview of all presentations can be found at: www.rembesafetydays.com If you are interested in participating in one or more of the presentations from the REMBE Safety Days - Digital Home Edition, please register at safetydays@rembe.de or via the form on the website stated above.

TRAINING BY EXPERTS – EXPERIENCE SAFETY (13:15 – 14:00 CEST) 03.03.2021

It is only a silo!? Challenges towards explosion safety of a seemingly simple vessel Andreas Hansen – Sales Engineer Explosion Safety REMBE S.r.l. Till Westerbarkey – Dep. Chief Business Development Officer, Explosion Safety

17.03.2021 Two phase flow sizing of rupture discs – Dead end route vs. highway Dr.-Ing. Mondie Kimandi Mutegi – Process Safety Engineer & Development Specialist Advanced Engineering Solutions Mathias Meyer – Project Engineer Advanced Engineering Solutions 31.03.2021

Engineering of explosion venting Marius Bloching – Corporate Senior Engineer Explosion Safety

14.04.2021

Clean pressure relief Claire Lloyd – Team Leader Process Safety Europe

21.04.2021 Sustainable Safety – REMBE green, more than just a brand colour Milena Westerbarkey – Global Sales Explosion Safety 28.04.2021 Anything but a dry topic – Explosion safety of dryers Till Möhle – Project and Sales Engineer Global Sales Explosion Safety

For further information, please visit www.rembe-rtc.de/en

PECM Issue 40 49

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

NEWS & EVENTS

HEALTH & SAFETY AT WORK INSTITUTION OF OCCUPATIONAL SAFETY & HEALTH

Improving productivity, efficiency and reputation

Could your business benefit from greater productivity, increased efficiency, reduced costs, enhanced reputation and a safer workplace?

how safety and health can positively impact the whole business.

If so, now is the time to invest in IOSH’s Managing Safely, the market-leading safety and health course for businesses of all sizes. It has been delivered worldwide for over 25 years by a huge network of training providers. It is tried, tested and trusted.

• It’s contextualised. The content of the course and the scenarios that are explored will directly reflect your sector, workplace and even factors relating to your geography or business demographic. So, it’s easy to put everything they’ve learned into practice. • It’s world-class. IOSH is the Chartered body for safety and health professionals and the quality of the training and the content of the course reflects that.

And there’s more: • It’s thorough but flexible. With the consequences of safety and health failure potentially fatal, you cannot rush training. Our three-day course takes the right amount of time to get learners up to speed. It’s available face-to-face or via e-learning to suit your business needs.

Who should attend? This course is for anyone who manages or supervises people, in any industry sector or environment. They’ll learn to:

• It’s business focused. IOSH works with business leaders in the development of flexible courses to ensure they deliver the insights and efficiencies you need to gain a competitive edge.

• assess risks • control risks • understand responsibilities • understand hazards • investigate incidents • measure performance

• It’s unique. Managing Safely combines practical step-by-step guidance with an engaging and inspirational approach that will make your managers think afresh about

They’ll learn about the ‘why’ as well as the ‘how’. Why should we look out for our colleagues? Why should we continue to innovate? How can I make a difference?

Successful delegates are awarded an internationally-recognised IOSH Managing Safely certificate. It’s a vital achievement and demonstrates that they have the knowledge to be more efficient, productive and safe in the workplace – to the benefit of all.

Why IOSH? Here’s why: • Track record. Managing Safely from IOSH is the market leader in safety and health and we’ve trained 172,000 delegates on 23,000 training courses in 76 countries. • Vision. We can help you prepare for tomorrow. The world of work is transforming at a rapid pace and we want to ensure that you are ready to embrace those changes and profit from them rather than being left behind. • Status. We are a global organisation with 47,000 members in 130 countries, many of whom are business owners themselves, and we represent their views to governments and regulatory bodies to make sure business can continue to drive the positive change we all need and deserve.

For further information, please visit www.iosh.com

PECM Issue 49

There’s a reason Managing Safely doesn’t cut corners The consequences of rushing health and safety training can be fatal. So Managing Safely takes exactly the right amount of time to get participants up to speed. That’s why our three day health and safety course is the most popular for line managers, in any sector, worldwide.

Managing Safely Tried. Tested. Trusted. www.iosh.com/managingsafely

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. 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 producers the world

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

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

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

MACHINING & MACHINERY

CUTTING-EDGE TECHNOLOGY SULZER

Sulzer creates a hybrid additive manufacturing process to minimize lead time on components for Chevron Companies involved in oil and gas production hold parts inventories to minimize downtime, especially when process-critical assets are involved. With so much capital invested in parts, any strategy that would allow this to be reduced without compromising reliability and productivity warrants in-depth examination. The ability to create complex components, such as pump impellers, within just a few days, has the potential to cut inventory costs significantly. Pumping systems are central to moving raw materials as well as the finished product, and many processes in between. So standby pumps are retained as well as spare parts, such as impellers. Now, there is an opportunity to reduce this stockholding. Manufacturing technology has taken a significant step forward following the completion of validation and trial part manufacture. The technology incorporates laser metal deposition and precision machining. Additive Manufacturing (AM) using this technology can create finished parts in one machine, significantly reducing lead times.

DEVELOPING TECHNOLOGY

Chevron is a leader in the energy industry and a strategic partner of Sulzer. Sulzer is

a leader in manufacturing processes for rotating equipment, including pumps, and is developing new additive technology. As such, Chevron and Sulzer were interested in developing their partnership so as to reduce parts inventory and improve flexibility. Back in the 1990s, Sulzer played an important role in creating laser metal deposition technology. Building on this background the company has constantly been working to develop and implement new additive manufacturing techniques for key applications. Today, the company has developed and implemented additive manufacturing technology to produce new pump impellers of the highest quality, without the need for tooling. The project offers Chevron the potential to reduce lead times for new parts without compromising on quality.

GATHERING EXPERTISE

For the past two years, Sulzer and Chevron have established a joint project. The collaboration also involves other partners such as suppliers of equipment for the manufacturing cell, powder suppliers, audit and certification bodies.

Charles Soothill, Head of Technology for Rotating Equipment Services for Sulzer explains: “Together, the teams have worked to combine the capabilities of 5-axis CNC milling and laser metal deposition equipment to create this hybrid additive manufacturing process. This combination of additive and subtractive elements enables the new process to be quicker because setups are avoided.”

SIMPLIFYING COMPLEX GEOMETRIES

Starting with a piece of stock material of the required grade and quality loaded into the hybrid machine tool, it is possible to machine the most complex geometries of the eye of the impeller. Material is then added and finish-machined while remaining in the same cell. This process enables Sulzer to create finished machined quality on far more complex components than would normally be possible with a conventional machine tool. In addition to all the standard cutting tools that are stored in the tool changer, there is also the laser metal deposition head, which can be used to build up material on the workpiece, or core. The machine can quickly change between the milling tools and the laser head, a process that would normally require the component to be repositioned in a separate machine. The additive technology has also required the development of new processes, using a fine powder, 50 to 100µm, and a laser. The powder is melted by the laser and deposited on the surface of the stock material held in the hybrid machine tool.

HYBRID IMPELLER MANUFACTURING

Sulzer has been a pioneer in developing technology for pumps and other rotating machinery for more than 100 years. Now, the company is using this latest development to manufacture precision parts, such as impellers.

The cutting-edge laser metal deposition head

PECM Issue 49

Pump impellers are complex components to manufacture, the internal geometry is too complicated to be created by a conventional milling machine.

Trials of the combined 5-axis CNC milling and laser metal deposition head installation on site in 2019. Both Sulzer and Chevron are confident in the performance and durability of the new component.

Starting with a forging, the core of the impeller can be machined using a 5-axis milling machine. Then further material is added to the outside of the impeller using laser metal deposition.

Robert Rettew, Program Manager, Materials Technology Development at Chevron, comments: “We have worked closely with Sulzer to develop the technology and systems required to achieve hybrid manufacturing and now Chevron is the first customer to benefit from this cutting-edge solution. There is considerable opportunity to increase the applications and widen the scope of materials used in the process.”

The use of milling tools means that the internal hydraulic surfaces have a very high-quality finish, much better than those achieved with a casting process. The process of adding material and machining is repeated until the complete impeller emerges. The whole process, which can be completed in a matter of days, is much quicker than casting a new component, which can typically take 15 – 20 weeks. The greatly reduced build time for a new impeller means that, in the event of a pump needing a new component, the standby pump can be brought online while the new part is manufactured and delivered. Although this time could be reduced further if necessary, the consensus is that a few days is sufficient for the majority of applications.

PROVING THE THEORY

The development work has now been put into practice and applied to a real-world application. Chevron has a CPT pump from Sulzer operating with a corrosive fluid, an application that requires specific material properties to ensure the durability of the pump. The impeller was identified for replacement and an

An example of the complex geometry that can be achieved ideal subject for the new manufacturing process. Using the original design drawings, a 3-dimensional model was fine-tuned and a final set of coded instructions for the hybrid manufacturing machine was generated. Within a few hours the new impeller had been created and was ready to be installed. The new impeller was installed in the pump and tested at Sulzer first. It has now been operating successfully since its

Chevron has a strategic plan to take advantage of new and innovative technologies that can offer improvements for its operations and improve efficiency. One of these is additive manufacturing. This process is also very important for components that are now obsolete, enabling parts for heritage assets to be sourced with a short lead time. Charles Soothill concludes: “For Sulzer, the goal is to offer customers the best possible service and, when time is of the essence, deliver the solution with the shortest lead time, while maintaining the highest quality standards. In addition to receiving a new part quickly, customers also benefit from the latest design standards that have benefitted from decades of experience in designing and manufacturing pumps.”

For further information, please visit www.sulzer.com Issue 49 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 49

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

RELIABLE FINISHING FINTEK

Post processing of 3D printed petal parts in UK to benefit from Fintek deal bringing Hirtisation® to the UK Metal component surface finishing specialist, Fintek, have become exclusive UK agents for RENA Technologies Austria GmbH H-series range of machines that use their patented Hirtisation® process for reliable finishing of 3D printed metal parts. Fintek managing director, Jonathan Dean, commented, “The RENA H-series complements our existing disc, drag and stream finishing ranges from OTEC. They expand considerably our subcontract capability and machine offering for the surface finishing of additively manufactured metal parts. RENA is a global company, and we are pleased to be able to draw on their extensive experience.” The Hirtisation® process effectively removes support structures and powder cake but goes further by reducing the surface roughness of metal parts manufactured additively by 3D printing. The process is suitable for all common metals and alloys and all types of metal 3D printing technology such as Selective Laser Melting (SLM), Direct Metal Laser Sintering (DMLS) and Electron Beam Melting (EBM). Importantly, the fully automated chemicalelectrochemical process is able to reach deep into cavities, undercuts and other design intricacies inherent in many AM parts and often impossible to reach by manual or mechanical methods. Along with support structures, partially melted grains are also eliminated. As there are no harsh mechanical processing steps, the smoothing effect does not compromise the precision of edge profiles. Printed metal parts leave the machine clean and vacuum dried in perfect readiness for subsequent finishing processes such as protective coatings. Cycle times are short, from just 30 minutes depending on part size and target quality. H-series machines are easy to operate, requiring the minimum of training for personnel, even if they have little or no surface finishing experience. Designed to scale-up to any metal 3D

printing operation, all process chemicals are fully integrated and can be safely refilled.

different materials at once. It also has a parallel post processing capability of up to 500 parts per hour.

Available in three versions, the H3000 entry level is ideal for part sizes up to 300 x 300 x 150mm and can handle the part feed from up to three AM-printers. The H6000 takes parts up to 500 x 500 x 350mm and can handle the part feed from up to four AM-printers at a rate of up to 100 parts per hour. The H12000 is designed to integrate seamlessly into larger industrial additive manufacturing processes and can handle the part feed from up to 25 AM-printers using four

Fintek operations manager, Jamie Phillips, concluded, “Achieving a commercially viable surface finish on additively manufactured metal parts has prevented the adoption of the technology for many applications. The Hirtisation® process removes this barrier and at Fintek we also have the capability with the OTEC range of high energy stream finishing systems to take external surface roughness down to Ra values of 0.01μm.”

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

PECM Issue 49

MACHINING & MACHINERY

Multi-purpose laser cutting & engraving machines If you’re looking for powerful, compact and easy to use laser cutting, CNC machining, part marking or engraving machines, look no further than Boxford’s range of multi-material processing equipment. Their cost-effective and space-saving BFL1390 & BFL2010 Fibre Metal Cutting Lasers, ranging from 500W to 2KW, are capable of producing industry standard precision profiles. The BFM110 bench-top Fibre Marking Systems provide high detail part identification and branding solutions and Boxford’s popular C02 lasers offer all-in-one non-metal cutting and engraving capabilities. Boxford also continue to offer a range of CNC lathes, routers, milling and combination machines on which the UK manufacturer has built its long-standing name and reputation.

Do you still weld, rivet, or re-shape … or are you crimping already? UNIFLEX hydraulic crimpers offer a broad range of applications. Besides, for the general hose assembly, you can use crimpers to re-shape or calibrate pipe ends, and to assemble pushrods or cables. Using double or multiple crimpers, you can assemble several parts simultaneously, which increases your productivity considerably. In addition to saving time, you also ensure the perfect assembly of every part. Individually optimised special crimping dies are suitable for the re-shaping of round and square pipes for pipe connections or complete plug-in systems, for instance, in scaffold construction.

If you have a new machine enquiry, the Boxford team are always on hand to discuss your requirements.

Video: https://kurzelinks.de/special Catalogue: https://kurzelinks.de/applications

info@boxford.co.uk www.boxford.co.uk

info@uniflex.de https://www.uniflex.de/

First UK installation of Konecranes’ S-series crane Konecranes has supplied a material handling system, incorporating an S-series crane, at ABB Limited’s Drives Service Workshop (DSW) in Coalville, Leicestershire. The contract represents the first installation of the new generation S-series model in the UK. The system supplied comprises a 16.1 m span overhead single girder gantry and a 3.29 t SWL S-series electric rope hoist. The crane has cross and long travel speeds of up to 20 m/min and a hoisting speed of up to 3.1 m/min, with a 4.29 m height of lift. The crane is operated via a radio remote controller. ABB is a worldwide leader in the fields of electrification, robotics, automation and motion technology, with an emphasis on energy saving and sustainability. Its UK operation employs 1,800 people, operating from 15 locations and supplies £0.5 billion of innovative solutions, products and services to a broad range of market sectors. www.konecranes.co.uk

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

These panels can be used for various applications such as conveyor belts, fans, centrifugal pumps, hoists, mixers, grinding machines and many more…………. Manes Controls Ltd Unit 504, Phoenix Park Ind Estate, Phoenix Close, Heywood, Lancashire, OL10 2JG

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

Issue 49 PECM

MACHINING & MACHINERY

SIFWELD EVOLUTION WELDABILITY SIF

The next generation of technologically advanced welding and cutting solutions from Weldability Sif Weldability Sif launch their range of Sifweld Evolution welding machines packed with new features and technology normally only available on high end welding machines but surprisingly these come without the price tag. The SifWeld Evolution range of MIG, TIG and Plasma Cutting equipment meets the most demanding needs of professional applications in a variety of welding environments. Because welding applications vary, we have developed the range to include power sources that can meet various needs and requirements including higher energy efficiency and large colour LCD displays which allows for user friendly control of all the welding parameters to keep running costs lower compared to traditional equipment.

input, increase travel speeds, eliminate burn through and control the bead profile while welding aluminium. The new Dual Pulsed Sifweld Evolution MIG technology enables operators to tailor the arc length to match their personal preferences.

TIG

MIG

machine is the ideal work horse for high production manufacturing in both air cooled or water cooled versions. Using the built in Synergic facility the machine will automatically give the optimum welding parameters for the specific material, wire size and shielding gas.

The SifWeld Evolution MTS200SYN with PFC technology for 230Volt or 110Volt in single-phase operation combines intelligent Synergic and Manual MIG welding, providing smooth and powerful genuine Lift TIG and MMA performance. It also features a large colour LCD display with a simple, easy-to-use interface allowing configuration of current, voltage, gas, arc-force, burn-back and inductance in MIG, you are also able to have full control of the Lift TIG and MMA functions.

SifWeld Evolution MTS500DP (Dual Pulse) and MTS400 Robot are suitable for MIG, MMA and TIG welding applications. Both machines are 500 amp with a 400 amp output at 100% Duty Cycle providing smooth and powerful genuine Lift TIG and MMA performance. Incorporating the built in Synergic and Dual Pulse facility the machines will automatically give the optimum welding parameters for the specific material, wire size and shielding gas, including optimum MIG welding of aluminium. The MTS500 Robot has all the high quality and high production features of the MTS500DP, with the added advantage of Full Digital or Analogue Control from most types of industrial and collaborative Robots.

The Sifweld range of MIG welding machines, delivers a high build quality, reliability, energy efficient technology and functional user benefits for welding professionals with high production environments, in and around the workshop and on the move site work.

The SifWeld Evolution MTS300SYN high current 230Volt single phase and the MTS400SYN, 400Volt Three Phase professional machines are microprocessor-controlled inverter welding package for MIG, MMA & Lift-TIG applications. 100% Duty Cycle at 400A and 60% at 500A for the MTS400SYN this

Dual Pulsed MIG technologies, like that of the MTS500DP, and MTS500 Robot have advanced to provide excellent welding performance on thin gauge aluminium, stainless and other alloys. Upgrading to a modern MIG inverter can improve productivity, reduce weld costs, and improve operator efficiency. Dual Pulsed MIG can replace AC TIG by giving welders the ability to control heat

The advanced Sifweld Evolution Aerotech range of AC/DC TIG machines have features normally only available on high end Aerospace specific TIG welding machines, including: Four power levels of HF ignition strength, fully adjustable cleaning and welding current levels on both the positive and negative parts of the AC Square Wave Cycle. The SifWeld Evolution TS200AC/DC and TS320AC/DC Aerotech Inverter TIG welder is fully digital and programmable professional, microprocessor-controlled inverter welding power source for AC TIG, DC TIG & MMA applications. The use of IGBT technology providing a compact and lightweight machine that is feature rich including the advanced Aerotech features and High-Speed Pulse. There is also a fully digital control with large colour LCD for showing and changing all welding parameters. The SifWeld Evolution TS200DC Dual Voltage Inverter TIG welder is a fully digital welding machine used for TIG and MMA welding. It has PFC Technology so the machine can be used on 230volt or 110volt Singe Phase supply. High Frequency ignition and High-Speed Pulse with the complete range of fully adjustable parameters normally expected on a professional TIG welding machine. Designed for welders with an eye for detail, SifWeld Evolution TIG/MMA equipment as well as SifWeld Evolution MIG DC inverters keep technology on the inside and simple, easy to use control and performance on the outside, offering reliable solutions to keep you welding at its best. For more details contact sales@weldability-sif.com

For further information, please visit weldability-sif.com

PECM Issue 49

Industrial Power From The all NEW range of Inverter Welders and Plasma Cutters New Synergic MIG programs featuring Dual Pulse and MIG brazing solutions

Aerospace technology without the price tag! Sifweld Evolution delivers energy efficient powerful performance to professionals on the move

Sales @weldability-sif.com | 0345 130 7757

MACHINING & MACHINERY

PRODUCTIVE WORK CELLS UNISIG

Across every industry, manufacturers are working to meet growing customer demand in a globally competitive market Originally published in Cutting Tool Engineering Across every industry, manufacturers are working to meet growing customer demand in a globally competitive market.

toolchangers, doors and inspection stations keep parts moving swiftly into, out of and around the cell.

Because deep-hole drilling tends to apply to long, cylindrically shaped parts, workpiece configuration eases or Increase your mold manufacturing complicates some aspectsversatility of automating Despite a widening skills gap, by organizing and load-outwith cycles tied to drilling the powerload-in of gundrilling the advanced technology into using highly optimized operations. Workholding axes, for example, work cells, manufacturers are maximizing leaders in deep hole drilling, UNISIG. Oﬀering can provide automatic part gripping with productivity through automation. complete solutions for everything from operated pneumatic or hydraulic chucks through advanced controls forUNISIG deep-hole Specialized equipment, like a deep-to complex mold components, simple drilling systems. In this configuration, hole drilling system, often is challenging machines help moldmakers improve machines can pick up a part, drill it and to integrate, which quickly can create set it back down on a conveyor eﬃciency, throughput and precision withor part production schedule bottlenecks. To collection area. In deep-hole drilling eliminate the risk, shops that perform deepoutstanding part-processing versatility at an systems themselves, specialized designs hole drilling should seek out OEMs that exceptional value. also offer automatic chucking, while robotunderstand the needs of high-production tending systems can add further flexibility manufacturers and have the capabilities to bring technology into the factories and work with end-of-arm tooling, workholding and measuring systems. TAKE YOUR MOLDMAKING OPERATIONS cells of the future.

FURTHER WITH UNISIG TODAY.

Deep-hole drilling systems, which can produce holes that exceed a 20-1 depthto-diameter ratio, are a unique class of manufacturing equipment because of the Find out more focused tasks they conduct. An increasing number of machining centers boast deep-hole drilling capabilities, but these machines simply cannot operate at needed speeds, particularly for parts that require exceptionally high accuracy. Manufacturers that must perform deep-hole drilling capable of rapid production and high throughput should instead select machines designed for the task.

AUTOMATING HOLEMAKING These shops increasingly opt for deephole drilling systems that also work with automation. In a typical deep-hole drilling work cell configuration, such as one for producing rifle receivers or automotive shafts, the equipment can use automation to time its cycle completion to mesh with other production processes. For straightforward automation, conveyors and pick-and-place robots move and position parts for deep-hole drilling with exacting repeatability and accuracy while automatic

As the automation configuration grows more complicated, however, manufacturers require an OEM that can act as a collaborative partner to find available at www.UNISIG.com solutions or engineer individualized products for unique applications or production lines. Shops that depend on deep-hole drilling as part of a highproduction environment should seek a partner that has a demonstrated record of working directly with manufacturers to modernize processes and create robust automated work cells.

GUNDRILLING APPLICATION UNISIG, for instance, worked with a manufacturer of rifle barrel receivers to help it accommodate growing demand and relieve production bottlenecks. The manufacturer’s older gundrilling machines were replaced by a multiple-spindle machine, the UNI25HD. It had the power and controls necessary to apply indexable gundrilling tools, significantly improving feed rates. To enable fast one-piece-flow manufacturing, UNISIG integrated the

system via automation for in-feed, pickand-place, conveyor loading and automatic clamping, which fed two lathes that turned the parts. The result was an effective work cell that produced more than 100 parts an hour, a dramatic financial and process improvement. The viability of automated deep-hole drilling production can depend on tool life and part length. At extreme depths, for example, some parts require more than one set of inserts to produce a completed hole, and the high level of hardness of some workpiece materials causes rapid tool wear. To overcome this challenge, UNISIG programs its machines to detect wear and predict when a tool will reach its breaking point, allowing operators to prevent a failure that could stop the line. For further process efficiency, deep-hole drilling machines should have either a CNC or programmable logic controller. Both can integrate with other control systems and interface with a controller in the work cell. Systems such as a fully automated barrel cell are capable of unmanned, lights-out production with efficient programming. Deep-hole drilling equipment’s applicationspecific configurations suit the production of parts that necessitate techniques and processes that go beyond the easy capabilities of general-purpose equipment. In years past, many manufacturers thought of this kind of specialized equipment as old-fashioned and a drag on production. But with the right equipment—and a partner with the right engineering and applications expertise—deep-hole drilling in work cells can keep up with the productive factory environment that manufacturers need to succeed. Further information on all machines of the B series and the complete UNISIG machine program is available at: www.unisig.de or follow the company on LinkedIn and Twitter (@UNISIG).

For further information, please visit www.unisig.de

PECM Issue 40 49

UNISIG.COM

UNISIG TAKES YOUR DEEP HOLE DRILLING PRODUCTION FURTHER

Gundrilling and BTA deep hole drilling for highly productive shops. Whether your shop needs on-center or oﬀ-center holes, specialized job shop work or fully automated production, UNISIG has a deep hole drilling solution with the accuracy and performance you need.

Take your shop’s production further - learn more at UNISIG.COM.

Machines • Tools • Automation UNISIG machines, engineered and manufactured in the USA

MACHINING & MACHINERY

CLEVER COMPOSITES EXEL

Speed, accuracy and reduced downtime Cheetahs are famed for their ability to reach high speeds, but it is in fact their agility that is truly impressive. Cheetahs can accelerate from zero to 60 miles per hour in just three seconds, and then quickly decelerate, turn, and sprint in another direction. But this exceptional combination of speed and precision doesn’t purely belong to the wild, and innovative composite materials are helping bring these qualities to the factory floor. Here, Robert Glass, head of marketing at global composite technology company, Exel Composites, explores how composite components can enhance the performance of automated machinery. Improving manufacturing efficiency while maintaining high product quality is a common challenge in production facilities. Automation has undoubtably boosted productivity, but rising consumer demands drive a need to further optimize production equipment. By incorporating composite components into automated machinery, production speed and accuracy can be increased while reducing downtime.

AS FAST AS YOU CAN

Composites, also known as fiber reinforced plastics, are fabricated by combining a resin matrix with reinforcement fibers. The blend of materials gives composites combined benefits, such as low weight with high strength and stiffness. In fact, composites have a specific gravity a quarter that of steel and two thirds of aluminum, and have a much higher strength-to-weight ratio. This low weight gives composites the ability to move quickly, making them ideal for fast-moving machine parts. By using composite machine parts, which are lighter and stronger than their metal counterparts, the operation speed of a production machine can be increased, therefore increasing manufacturing efficiency. This is especially true for textile machines. The textile industry must transform millions of miles of yarn into lengths of fabric to supply industries such as clothing and home furnishing. However, producing one

will not change their dimensions even if the temperature rises or falls in the environment. By maintaining the dimensions, the composite components can keep machine operation to tight tolerances.

Robert Glass length of fabric requires hundreds of weft yarns, making enhanced speed essential to keep up with demand. In rapier weaving looms, finger-like carriers called rapiers repeatedly move the yarn back and forth across the width of the fabric. By using lightweight composite rapiers, as opposed to metal alternatives, the yarn placement process can be carried out faster and in greater volumes, therefore increasing fabric production efficiency. The high strength and durability of composites means the rapiers will be able to withstand working at the increased speed without breaking under greater force.

PROCESS PRECISION

Composites not only allow production machines to move with increased speed, but also higher accuracy. Composite materials have low inertia, which means composite machine parts can start movements and change speeds more quickly, therefore performing with increased agility. The low weight and high stiffness properties of composites means they can provide vibration dampening up to 20 times better than steel. This increases the stability of the machine, allowing the composite component to perform with superior accuracy. Composites also have a low coefficient of thermal expansion, so machine components

An application where agility is essential is robotics. Robotics on the production line must accurately maneuver products without causing damage. This is especially important when handling small, delicate products like electrical components or even chocolates in boxes. Here, by using carbon fiber for robotic arms instead of aluminum or steel, the arms can perform movements with quick changes in direction and high placement accuracy.

REDUCED DOWNTIME

Composite machine components don’t just perform well — they perform for a long time. Composite materials exhibit high durability, meaning they require less maintenance and less frequent replacement, therefore reducing factory downtime. Vibration dampening properties mean composite components display reduced wear from processing, as they are unlikely to experience cracking in applications with high levels of oscillation, and their resistance to fatigue means they can withstand repeated load cycles. Composites are also resistant to many external factors, such as chemicals, temperature and moisture. Exel provides strong and lightweight composite solutions to the machine industry, from carbon fiber robot delta arms to textile machine parts. With over 60 years’ experience in engineering, we can work closely with customers to find a solution that is tailored to their unique project. This includes optimizing the properties of composites for a specific application by altering the fibers, matting and resin system. The speed and agility of cheetahs demonstrates the incredible design of the natural world, a source of inspiration for manufacturing. Composite components help advance automated machinery, making them perform with increased speed and precision, while also exhibiting extended durability.

For further information, please visit www.exelcomposites.com

PECM Issue 49

MEASUREMENT & MONITORING

Which Simple Instrument Can Easily Prevent Expensive Compressed Air Problems? Water contamination originates through the air compression process and is normally removed through filtration and drying systems. Without this, the water vapour in the air stream can become a carrier for oils, chemicals, particles and promote the growth of potentially harmful microbiological organisms, any of which could be a major hazard for the production process.

S305

If the dew point sensor installed on the compressed air dryer or the dryer itself fails, often the user will only find out during a periodic audit unless the contamination levels become an issue with the product or plant systems. At that point, eradicating the contamination from the whole distribution system is a massive and very costly problem, involving shutdowns, extensive maintenance and possibly a new distribution system. The S305 is a self-contained dew point monitor ideal as a safety net in the event of dryer failure and will allow action to be taken without delay as signs of water contamination increase. Designed for wall or panel mounting and available with two choices of measuring ranges, the built in LCD screen and two relay outputs allow the user to easily set a pre-alarm warning threshold and a full out of range alarm signal.

An alternative would be to regularly use a hand held dew point sensor like the S505 to test critical points of use. Note that the air quality out of the dryer can read within parameters and out of range at a point of use because of past contamination of the system. This is why periodic checks for dew point are so important and the cost of resolving issues is always far lower when detected early.

PECM mar 21 hori.pdf 09/02/2021 16:27:11

S505

www.measuremonitorcontrol.com

Why Measure Compressed Air Purity? Dew Point - Particle Concentration - Residual Oil Vapour

When many of your systems are reliant on compressed air, can you afford to neglect the quality of their motive power? Ensure consistent product quality

Guard against the consequences of treatment plant failure

CMY

Improve effectiveness of planned maintenance Comply with plant quality standards

Portable S600 Compressed Air Purity Analyser

Wall Mounted S601 Continuous Compressed Air Purity Analyser

For free expert advice call, email or chat online to us through our website

T: +44(0)1443 772500

E: sales@measuremonitorcontrol.com

Issue 49 PECM

MEASUREMENT & MONITORING

ENCODERS

PORTESCAP

Why they’re used and how to make your selection Encoders provide feedback for accurate motor control relating to speed and positioning. Chris Schaefer, Applications Engineer at Portescap, looks at the technologies involved and explains how to choose the encoder for your application. To ensure that an exacting volume of insulin is delivered with each pump of a medical infusion device, or that a robotic arm used in manufacturing assembly moves to a precise point at the right time, an electric motor has to be combined with an encoder. A rotary or shaft encoder is an electro-mechanical device which provides information on the position, count, speed and direction of a motor, and is connected to an application with a controlling device, such as a programable logic controller (PLC). The PLC uses the encoder’s information, commonly known as ‘feedback’, to ensure precise accuracy of motor control.

ENCODER TECHNOLOGIES

The two main types of encoder are known as incremental and absolute. Incremental encoders identify real-time feedback and track precise motion relating to changes in position and direction, rather than referencing a specific point. They achieve this by providing feedback on the relative movement between positions with continuous high and low feedback pulses. Absolute encoders show exact position however their increased complexity makes them more expensive and means that incremental encoders are more cost effective for most applications. Adding an incremental encoder interface, such as an Application-specific Integration Circuit (ASIC), can also add exact position reference capability. An encoder’s sensor usually operates on an optical or magnetic principle. Optical encoders pass infrared light emitted from an LED through a metal code wheel, comprising clear and opaque segments, which create distinct light signals received by optoelectronic sensors. This technology means that optical encoders are able to create highly accurate, precise positioning. In addition to its high accuracy, the measurement of an optical encoder, such

as Portescap’s E9, is unaffected by potential magnetic interference. Meanwhile, a magnetic encoder comprises a magnetised disc with a number of poles surrounding the circumference. When the disc rotates, sensors detect the change in magnetic field, such as those measured by Hall effect devices, which monitor the change in voltage. Magnetic encoders, like the Portescap MR2, are ideal for use in demanding applications which could include the potential for impact or ingress. The MR2 magnetic encoder, for example, is insensitive to temperature and has low sensitivity to unwanted external fields.

HOW AN ENCODER WORKS

As the encoder rotates, it generates two square wave outputs, A and B, which are normally 90 degrees out of phase with one another. By measuring the phase shift of the A and B outputs, the encoder’s direction can be determined. To measure its distance of travel or speed, the encoder’s resolution must also be taken into account. Resolution is the number of points of measurement within one 360 degree revolution of the shaft, also known as the duty cycle or period. Generally, the greater the number of points, which are termed Lines per Revolution (LPR) or Pulses per Revolution (PPR), the greater the measuring accuracy. For example, Portescap’s M-Sense magnetic encoder has up to 1,024 lines per revolution in a compact design. Each output, A and B, switches between high and low. The two bits of information thereby create four times the counts for each line or pulse and this is known as quadrature decoding. Thereby, quadrature

decoding can increase resolution by up to four times, for example turning the Portescap MR2 encoder’s 512 lines into 2048 counts or angular steps. In addition to the two A and B output channels, a third channel, Z, is sometimes included which can be used to determine the reference position.

WHERE ENCODERS ARE USED

Understanding how encoders provide feedback for motor control, we can see how their use is crucial across various applications. Taking our original example of insulin administration, a drug delivery system requires a precise amount of medication dispensed at a specified rate and the encoder is used to confirm that the exacting dose is delivered. This example also shows how the greater number of lines for increased encoder resolution can help ensure precision to the most exacting rate of flow. A robotic gripper can be used for example in manufacturing to handle relatively delicate components. It’s key to ensure that the right amount pressure and speed is used to correctly handle the component to avoid damaging it. Thanks to an encoder, the robotic gripper’s function is optimised by the motion control of its motor’s speed and position, specific to each component it handles. Similarly, pick and place applications used in the assembly of electronic equipment require high speed motion control to quickly and repeatedly detect the size and weight of PCB components, placing them with precision. Encoders enable this high speed, high accuracy control to ensure productivity and quality of manufacture.

For further information, please visit www.portescap.com

PECM Issue 49

MEASUREMENT & MONITORING

Thermocouple Cables / Wire Labfacility offer a wide range of thermocouple, PRT and extension cables / wire in stock for immediate despatch. Thermocouple cables are available in IEC or ANSI colour codes. Insulation types include PFA, PTFE, PVC & Fibreglass. We also offer retractable curly leads and extension leads. Labfacility are proud to announce that in 2021 we will be celebrating our 50th birthday. We want to say a big thank you to everyone who has made this 50th year anniversary possible. Quality and Service are key elements in the continued growth of Labfacility; technical support for both sensing and instrumentation is always freely available from our experienced technical sales teams.

Email: sales@labfacility.com Phone: +44 (0)1243 871280 Website: www.labfacility.com

Vaisala to expand its premium Indigo product range Vaisala, a global leader in weather, environmental, and industrial measurements, introduces a new HUMICAP® Humidity and Temperature Probe HMP1. With its top-of-theline accuracy and sensor purge functionality that ensures excellent stability over time, the HMP1 is an ideal choice for demanding humidity measurements in environments such as pharmaceutical facilities, data centers, cleanrooms, or any other environments that require strict humidity monitoring and control. The HMP1 complements the Indigo product family, which is a premium solution for multi-parameter measurements with flexible connectivity. The modular product family consists of interchangeable smart probes, transmitters, and Vaisala Insight PC Software, which together create a strong chain of data to ensure energy efficiency, safety, and endproduct quality. Contact: Vaisala Ltd, +44 121 6835620, uksales@vaisala.com www.vaisala.com

Variable Temperature NMR Spectrometer for Materials Studies of Liquids & Solids Designed by a British company active in the NMR field for decades, this highly compact time-domain NMR relaxation spectrometer provides physical information on liquid and solid materials in the lab and in the field, at a very competitive cost close to typical non-NMR instrumentation. Thermo-electric elements precisely control temperature from -35C to +80C, with additional gas-assist available down to -80C. Variable temperature NMR Relaxation is a vital quantitative technique for material science, particularly for studying polymers and porous materials. This enables the measurement of crystalline/amorphous component masses and qualities which are variously described as mobility, dynamics, stiffness, viscosity or rigidity. In addition, pore-size distributions can be measured from sub-nanometer to over 1 micron. +44 (0) 7805 437 241 https://nmrspectrometer.lab-tools.com/

LAUDA Technology Ltd LAUDA continues to provide an expanding range of feature-rich, future proof solutions with energy efficiency and connectivity front of mind, serving a diverse range of industries including automotive, aerospace, chemical, pharmaceutical, biopharmaceutical, food & beverage, brewing, digital printing, laser and beyond. With the capability to provide temperature control solutions in the range -100 °C up to 550 °C and supply solutions for viscometry, tensiometry, surface and interfacial tension measurement, LAUDA has the proven capability and expertise to assist across a diverse range of workplace types from Research & Design laboratories, to pilot plants and full-scale production lines.

Email: info@lauda-technology.co.uk Tel: +44 (0)1780 243118 www.lauda-technology.co.uk

What Makes Decade Unique to Midlands Manufacturing? Being the designers, manufactures and installers of our own equipment, we offer unrivaled service to our customers. Decade begin each project with a dynamic and tailored approach, aiming to meet clients’ requirements using in-house manufacturing. Experts in load monitoring systems for power presses, process monitoring and control in assembly machines, through to production recording systems. Services include calibration, test work, breakdown support, consultation and training. Decade recognize that a quick response is paramount for all customers, and therefore aim to provide a reliable service. As members of The Metal-forming Machinery Makers’ Association, Made In The Midlands and The Safe Contractor scheme, we work to achieve a “World Class” status in power press automation and system monitoring. Telephone: +44(0)121 359 3978 E-mail: sales@decade.co.uk www.decade.co.uk

NEW MM7010 Bluetooth Logging Thermometer/Print Combo Do you regularly process goods-in for fresh/ frozen food, pharmaceuticals or other temperature-sensitive products? Are you responsible for temperature data integrity of products delivered to or from your kitchen, factory, warehouse or supermarket? Would you like to digitally log product temperatures with a handheld device AND produce an instant paper receipt at the same time? If the answer is YES, YES and YES, you can also make yourself a great saving of nearly £50 when you buy the NEW MM7010 Bluetooth Logging Thermometer Print Combo : 2 pieces of kit – 1 price. TME’s MM7010PRINT combines a handheld Bluetooth Logging Thermometer MM7010 with a Bluetooth Printer (MMPRINT) delivering digital logging and instant paper receipts at the same time. sales@tmethermometers.com www.tmethermometers.com Issue 49 PECM

Compact Surface Mount Loop Powered Intelligent Display Model ALP

Quality and Simplicity, out of the box. • • • • • • • • • • •

Sealed loop powered instrument module No additional power supply required CNC machined stainless steel housing Surface mount fixing (3-holes) Intelligent 6-Digit LCD display Single pole change over relay – NO/NC User set display messaging 5000 Point Logger with USB Interface M12x1 lead connections – pre-wired Easy fit and connect Ideal for local indication and monitoring of process values from obscure sensor locations • Ideal for upgrading blind analogue process instruments

Versatility

Pressure

Temperature

Flow

Level

Analytical

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

01623 427701

‘The most comprehensive range of instruments from one manufacturer’ www.kobold.com

Quality Robust Process Instrumentation

MEASUREMENT & MONITORING

WHOLE SYSTEM MONITORING DCO SYSTEMS

3 compelling reasons to integrate whole system monitoring

Have you ever spent time and money on a problem only to discover it was not the root cause? With machines and equipment working together, there is often an unforeseen knock-on effect within a process. DCO Systems offer a whole system monitoring approach that works to eliminate guesswork and pinpoint the true issue. Taking on the bold approach of monitoring the entire system provides a clearer picture for engineers that can uncover the costliest and most concealed problems. There are 3 compelling reasons of why this approach works and how it can drastically improve your current monitoring efforts.

GAIN A HIGH-DEFINITION PICTURE If you already have a monitoring system in place but need upgraded capabilities, DCO can help. Affordable equipment sensors and dashboard analytics can complement what you already have and fill in the gaps. Simple plug and play options allow for an extension of the number of machines and

performance characteristics monitored. For a true, complete picture of your whole system and performance details, their solutions are scalable. With continuous monitoring, DCO’s sensors move you into a high-definition world, making your world view bigger and sharper.

MONITOR FOR MULTIPLE AND INACCESSIBLE LOCATIONS Remote monitoring is a key component of whole system monitoring. If a problem arises, you need to know about it. DCO’s monitoring tools make it possible to know how your machines and processes are functioning at any given moment without being on-site. Equipment sensors securely transmit data to a cloud-based dashboard and is available to your engineers on smart phones, tablets or PCs. Information on your machines and processes are kept in one centralised dashboard, making it easy for engineers to communicate and diagnose problems.

GET ALERTS FOR MAINTENANCE Finally, machines and equipment need maintenance to keep them going strong. DCO Systems’ whole system monitoring gives you the advantage of viewing your equipment as needing predictive and/or preventative maintenance. Engineers can identify which machines perform well with a routine, scheduled service and which machines carry on well until something goes wrong. And before that ‘something’ goes wrong, dashboard analytics will identify any inconsistencies that could lead to mechanical production failures. DCO System’s whole system monitoring gives you the complete picture, filled with detailed, accurate information. Take the guesswork out of diagnosing problems. See your system in a bold, new way. To get started with DCO’s affordable monitoring tools, go to dcosystems.co.uk.

For whole system monitoring solutions, go to dcosystems.co.uk

PECM Issue 49

Leave behind tedious manual inspection.

Move into high-definition monitoring of your equipment and processes. DCO Systems design and build sensors to monitor equipment and the software to understand the data collected. With continuous, real-time monitoring, DCO’s sensing solutions provide engineers with a more detailed, bigger picture of their process. Data collected can be viewed by engineers on any smart device, anytime, anywhere.

Affordable monitoring. Retrofitted. Energy harvesting. dcosystems.co.uk info@dcosystems.co.uk +44 (0)1285 359059

MEASUREMENT & MONITORING

MEASURING & POWER SOLUTIONS TVR INSTRUMENTS

A full suite of products to allow complete accuracy The accurate and correct measurement, control and protection of the AC and DC power systems within an installation is critical. The AC is the workhorse of the power distribution network whilst the DC is the backup that secures the communication and recording. TVR Instruments, an experienced and knowledgeable distributor of electronic components for the measurement, protection and controls of AC and DC power networks, focuses on both the networks to assist in supporting their resilience. The team concentrates on the delivery of components for measuring, power and protection applications, predominantly in the LVD distribution and panel building sectors. Its full suite of products includes multifunction meters, current transformers, voltage transformers, shunts, transducers, energy meters (MID), ELR, protection relays, battery chargers, power supplies, DC UPS, remote monitoring and ventilation control systems. The protection devices available for purchase specifically cover loss of mains G99/G98, temperature, frequency and phase sequence (to name a few core examples).

CUSTOMER FOCUSED

TVR Instruments will work hard to propose the most appropriate equipment for the job in hand and ensure continued reassurance with their first-rate level of service. Their European suppliers are also backed up by industry recognised accreditation, as all products are made under ISO9001 quality certified factories in accordance with the relevant CE marking directives (EMC and LVD). ‘We are a service provider with a customer focused ethos,’ Tony Robinson, owner of TVR Instruments, commented. ‘Our strategy revolves around delivering the best customer service as possible, offering suitable units for control and display from our extensive product range. We remain focused on clients’ specific requirements whilst taking the time to understand their situation, providing a solution for the individual application.

‘All our suppliers work rigorously to remain compliant with all of the necessary industry standards and up to date regulations. With our high-quality products, we can provide short lead times and close application support. The closeness of the production facilities allows for direct real time support and application development.’

for remote access or for cloud storage. This offers an additional level of security and reduced cost for the owner. Updates are free and provided to the owner direct from Frer. Frer manufacture a range of energy meters with a simple compatibility to Frerlogger via Ethernet, MODbus or USB interfaces

PRODUCT LINES

From Adel System TVR market their range of European manufactured Power Supplies, Battery Chargers and All-in-One DC UPS for use on 12, 24 or 48V DC systems up to 35A output.

The product portfolio is made up of reputable European based manufacturers and Emko Elektronik in Turkey from whom we source and supply a range of genset controller and process control instruments. TVR Instruments is the UK and Ireland agent for Frer s.r.l of Italy for all switchboard measuring components and a stockist of Adel Systems battery chargers and power supplies. It is also a stockist of Ziehl Industrie-elektronik GmbH for mains, temperature and transformer protection relays Amongst the new product lines TVR is offering is the Frer QUBO96 range of Panel or DIN Rail mounting Multifunction meters with options for inbuilt communications for remote monitoring, Ethernet with onboard memory and Digital Earth Leakage Relays to meet the requirements of Types A, A-F and Type B earth leakage protection applications with earth leakage relay compliant to IEC60947-2 or EN62423:2013 and the XTDB022006 6mA dc Residual Direct Current Monitoring Module according to IEC62955 for Electric Vehicle charging. For remote monitoring and logging off energy consumption at up to 2000 monitored points is the Frerlogger software package. The Frerlogger package is a package installed and controlled inside the firewall of the facility. There is no need For more information, please visit tvri.co.uk

PECM Issue 49

The CBI DC UPS combine the functions of a Power Supply, a Back Up Module and of a Battery Charger in one unit. They use switching technology with microcontrollers and optimise the supply to the DC load either when the AC mains is present or when the battery backup is in operation. The CBI units do not allow for deep discharge of the batteries. The CBI units switch from the mains to the battery in the event of a mains failure without any interruption, maintaining power security when it is most needed. The Flex series of power supplies are greater than 90% efficient and are rated at 40, 50 and 60 deg C so you plan your DC load requirements with accuracy against temperature. There is a decoupling module available for redundancy application for up to 25A load. With experience providing instrumentation across both Europe and the Middle East, TVR Instruments is well-versed in the source and supply of competitively priced products for use within the switchboard and control panel market. For more information please contact us on 01206 5575755 sales@tvri. co.uk or visit our website www.tvri.co.uk

Measuring, Power & Protection Solutions for the LVD Distribution & Panel Building Industry

TVR Instruments supplies a range of instrumentation devices for use in LV systems as well as Battery Chargers, Power Supplies and DC UPS to support DC Networks. The range of protection devices we supply cover Loss of Mains G99/G98, Temperature, Frequency, Phase Sequence and many more.

Tel: +44 (0) 1206 575755 Email: sales@tvri.co.uk www.tvri.co.uk

instruments ltd

TVR Instruments Limited 143 Butt Road, Colchester CO3 3DP Essex United Kingdom

MEASUREMENT & MONITORING

CONTINUOUS MONITORING SULZER

Pioneer in plastic-free packaging one of the first to install Sulzer’s wireless condition monitoring Kotkamills is a forest products company based in Kotka, Finland. The company specializes in consumer boards, laminating paper, and sawn products – and is an innovative pioneer in introducing new technologies. Kotkamills actively accelerates the adoption of plastic-free options in convenience packaging. The Sense condition monitoring system has been employed at Kotkamills from July 2019, ever since the first stages of the solution.

THE CHALLENGE

Kotkamills was one of the first customers to use Sulzer Sense in their process after it was launched in 2019. The system monitors the condition of five process pumps and one medium-consistency (MC) pump in the pulp production line. The system consists of one gateway designed for industrial conditions, located in the process area, and six sensors installed in the bearings of the monitored equipment. The devices are battery-powered and operate in a wireless mesh network. Sulzer Sense measures vibration and temperature every 30 minutes. The gateway is connected to the Internet / Sulzer’s cloud service via a cellular connection. The monitored devices are within a radius of about 10 meters from each other. This allows for an excellent network and the use of a single gateway.

THE SOLUTION

The commissioning of the condition monitoring system was quick, easy and effortless and did not require special skills from the installer. The mobile app provided by Sulzer for the deployment of the system is unambiguous and easy to use. The Sulzer Sense monitoring device measures machine vibrations and temperature to detect possible imbalance, misalignment, looseness, and bearing wear. It helps to identify changes in equipment condition parameters and indicates potential faults at an early stage, thus supporting predictive maintenance.

The sensors are installed in the bearings of the monitored pumps. The cloud service provides the customer with easy access to device information. Through the cloud service, the customer can monitor the condition of the devices and view hardware trend information anywhere and anytime.

CUSTOMER BENEFIT

In addition to the advantages of continuous monitoring, one of the most significant benefits to the customer is access to detailed equipment information such as spare parts lists and product documentation

through the service. For maintenance and repair work, there is no need to look in the archive for instructions and drawings. Sulzer Sense is suitable for all pumps, agitators, mixers and motors regardless of the type or brand in all industries. “The system has worked reliably, and the measurement results are in line with our own reference measurements.” Harri Carling, Supervisor, Condition Monitoring and Reliability at Kotkamills.

For further information, please visit www.sulzer.com

PECM Issue 49

NEWS & EVENTS

New name in Scottish Electrical Services The continued growth of new VSD Contract Partnerships and Electrical Projects has led to the acquisition of Lothian and Borders Electrical by Quantum Controls, forming Q Electrical Industrial Services. Lothian and Borders electrical is one of Scotland’s leading electrical contractors and through this acquisition Quantum now have a nationwide network of 6 Service Centres and a growing team of engineers providing a range of Electrical Services and solutions across the UK; • Electrical Contracting Services • Electrical Installation in many industrial processes. • Turnkey projects from design to control panels, PLC programming, SCADA and Installation • 10 Variable Speed Drive Service Engineers based in Scotland. • Electronic Repairs for industrial equipment and Instrumentation • Inspection & Testing • Power Factor Correction “Continued growth in our business activities in Scotland has led to this exciting new investment in the Scottish economy. The Service Centre will create a local support which will allow us to offer more services for all customers based throughout Scotland.” says Kevin Brown, Managing Director of Quantum Controls. “Establishing the new Company with Robert and Lyall Colvin who have 40 years’ experience in delivering electrical contracting services is an exciting opportunity that allows us to invest in the Scottish Economy and creating a base in Scotland to best service all our clients at a local level”.

“I’m looking forward to the benefits our existing client base will receive from the acquisitional partnership and our growth throughout Scottish industry”. Lyall Colvin, Managing Director. If you would like to know more about our new services in Scotland, please contact Lyall Colvin. Lyall Colvin lyall@qelectrical.co.uk or 07775 666 306 Q Electrical Industrial Services The Cross, Pencaitland, East Lothian, EH34 5DA

www.qelectrical.co.uk

Abacus Flooring Solutions Ltd, complete work for UK leading Manufacturer Sub-CNC Precision. - Bedfordshire, UK

New Appointments to the Board at Winn & Coales (Denso) Ltd On the 1st January 2021, the board of Directors of Winn & Coales (Denso) Ltd were delighted to announce three new appointments to the Board. Mr Andrew Sweeney has joined Mr Chris Winn as Joint Managing Director of Winn & Coales (Denso) Ltd. Andrew qualified as a Chartered Accountant in South Africa and has held senior financial positions in multinational companies in various countries around the world. He joined Winn & Coales (Denso) Ltd in 2018 as Finance Director. Mr Andrew Stuart has assumed the role of Sales &

Marketing Director of Winn & Coales (Denso) Ltd. Andrew joined the company in 2015 as Export Sales Director and brings a wealth of knowledge to the role, having had 25 years’ experience with Denso South Africa working to develop their sales in not only South Africa, but also in the African export markets. Mr Ryan Darlow has been appointed as Production Director for Winn & Coales (Denso) Ltd. Ryan originates from Durban, South Africa and attended Rhodes University.

www.denso.net

Despite a challenging year one of the major success stories of 2020 is that of Abacus Flooring Solutions Ltd. An industrial & commercial flooring specialist founded by Nick Megson in August last year. Nick has over 30 years’ experience in commercial and industrial flooring and UK leading Bedfordshire manufacturer Sub-CNC Precision required the reliability, skill and knowledge possessed by Nick and his team when installing a new resin floor for their new unit purchased in 2020. With the move, they wanted to ensure that the space was of the highest quality and this included a durable and safe floor space in which Abacus Flooring Solutions provided.

Yian Stavro who is the cofounder of Sub-CNC Precision Ltd wanted his new unit to shine. In keeping with the companies’ high standards, Yian was keen on enlisting Nick’s expertise to ensure a workspace that coincided with the prestige of his business. Yian added: “The overall commented was very good. Nick and the guys he had working for him were very professional throughout the lifespan of the project. Nothing was too much trouble for them and I wouldn’t hesitate in recommending Abacus to other companies in our industry.”

07904 396962 Nick@abacusflooringsolutions.co.uk https://abacusflooringsolutions.co.uk/

Issue 49 PECM

NEWS & EVENTS

ECOSHIELD® VPCI®-380 CORTEC

Water-based, Micro-Corrosion Inhibiting Coatings™ Alternative to Solvent-based Coatings Cortec® Corporation is pleased present powerful EcoShield® VpCI®-380 topcoat for industrial painters. EcoShield® VpCI®-380 is a fast drying, water-based fluoropolymer modified acrylic one-coat system that can be applied direct to metal and provides corrosion protection and weatherability on metals in harsh outdoor environments. Whether for coating railcars, structural steel, or assembly line parts, EcoShield® VpCI®-380 is an outstanding water-based outdoor protective coatings option from Cortec’s portfolio of MicroCorrosion Inhibiting Coatings™. As a water-based fluoropolymer modified acrylic one-coat system, EcoShield® VpCI®-380 has many special advantages for protection in challenging environments.

PECM Issue 49

With excellent UV resistance (color and gloss retention), it gives optimal outdoor performance without cracking or chipping upon prolonged exposure to sunlight. Its hardness (H-2H Pencil Hardness), moisture resistance, and fast-dry properties make it an excellent choice for air-dry/force-dry industrial finishes. EcoShield® VpCI®-380 also exhibits good corrosion protection, having passed more than 1,000 hours in ASTM B117 salt spray conditions and ASTM D1748 humidity conditions at 4.0-4.5 mils (100-112.5 µm) DFT. EcoShield® VpCI®-380 can be applied direct to metal (DTM) on carbon steel and top-coated over a wash primer (e.g., VpCI®-373 Green) on stainless steel, galvanized steel, and aluminum. It shows

excellent 5B adhesion and even adheres well to some engineered plastics for greater versatility. It is thixotropic and exhibits alkyd-like gloss, flow, and leveling properties with good resistance to sag. It can be tinted to most custom colors and has a VOC of 1.6 lbs/gal (192 g/L). The possible applications for EcoShield® VpCI®-380 are endless. Originally designed for the railcar industry, the most obvious use of EcoShield® VpCI®-380 is to coat railcars or shipping containers for protection against corrosion and the elements. However, it also makes an excellent choice for mass-produced parts needing to be force-dried with a high durability, high gloss coating for outdoor use.

As a water-based fluoropolymer modified acrylic one-coat system, EcoShield® VpCI®-380 has many special advantages for protection in challenging environments

Structural steel, tanks, and any other metal equipment that will sit exposed to harsh conditions outdoors are good candidates, as well—particularly for anyone desiring a water-based, Micro-Corrosion Inhibiting Coatings™ alternative to solvent-based, zinc rich coatings. Those in the following industrial painting markets should especially take note: • Railways • Refineries • Power plants • OEMs • Heavy equipment users • Outdoor storage yards

Whether industries need a protective coating that adheres well to a metal roof, that does not sag on the side of a railcar, or that resists cracking on equipment stored outdoors, EcoShield® VpCI®-380 is an outstanding water-based Micro-Corrosion Inhibiting Coatings™ option for good weatherability and corrosion protection in harsh outdoor environments. Be sure to take advantage of this coating for your next outdoor metals painting project and learn more here: https://www.corteccoatings.com/product/ ecoshield-386-water-based-fluoropolymertopcoat/!

Contact Cortec® directly for further assistance: https://www.corteccoatings.com/contact-us-2/ Issue 49 PECM

NEW FOR 2021

Biojet® packaging has been created to deliver biodegradable transparent tubes, boxes and clampacks.

bi-products as decaying organic matter – humus (soil), CO2 and CH4 both of which can be captured to produce clean energy.

As people seek better environmental packaging solutions, Bell Packaging is delighted to announce the introduction of this exciting new product which means we can now offer a complete environmental range for new packaging projects in 2021.

Biojet® packaging is 100% recyclable through the normal PET recycling centres. This additive has been independently tested and complies with the Intertek Greenleaf Biodegradability Standard. Biojet® is 100% organic and approved for direct food contact and therefore ideally suited for confectionery and gift packaging. Other applications include hardware, cosmetics and medical products.

Traditionally biodegradable / compostable products are very expensive and are not widely used. There has also been concerns expressed about the viability of biodegradable products questioning what remains after Testing to date shows that Biojet® performs in the same the degradable process has been completed. Biojet® answers both of these challenges. It is a much lower cost way as standard recycled plastic. The shelf life, solution and has many exciting environmental credentials. appearance, clarity and strength remain constant and will only degrade when it is put in the correct environment. Most plastic products are made from crude oil which is converted into polymer. This is used to make plastic sheet ® which we use to make PET Boxes, tubes and clampacks. Biojet Our challenge has been to make these designs biodegradable but not affect the performance of the packaging while it is in use. To make Biojet® we introduce an additive which attracts microbes that uses plastic as their source of food and energy. These microbes can be found in landfill, the ocean floor, rivers and swamps where bacteria and microbes thrive. When the microbes meet the plastic, the biodegradation process is accelerated as the plastic is consumed. This process will only happen in the correct environment where microbes exist. What used to take thousands of years to break down plastic now takes much less time as the microbes consume the entire product. After the process has been completed, the microbes leave behind the same

www.bellpackaging.com

Biojet® has a patent pending and is only available to Bell Packaging clients. For samples and more information, please contact our sales ofﬁce.

Biojet®

Designed to keep our oceans cleaner

www.faceguards.co.uk

+44 (0) 1582 459292

NEW FOR 2021

Biojet® packaging has been created to deliver biodegradable plastic tubes, boxes and clampacks.

At last biodegradable packaging for food, cosmetics and hardware. Made in Great Britain all at a sensible cost. Call us today for FREE samples and design services.

Biojet®

Designed to keep our oceans cleaner

DESIGNED & MANUFACTURED

IN GREAT BRITAIN

www.bellpackaging.com

www.faceguards.co.uk

+44 (0) 1582 459292

PACKAGING

LEADING THE SECTOR BRILLOPAK

UniPAKer robotic packer at the ‘core’ of apple producer’s automation Kent apple producer Adrian Scripps is leading the sector in terms of automation – and Brillopak’s award-winning UniPAKer robotic crate packing cell is the cornerstone of its intrepid approach.

Reduction of labour is a consideration, but it is productivity per person that we are really interested in.

and blackcurrants, are grown on five farms totalling 750 hectares. The family owned farming business is one of Tesco’s key apple suppliers – a relationship that stretches back more than 30 years and has seen much change in the way that fruit is handled at the company’s centralised packing facility on Moat Farm.

Adrian Scripps’ unwaning commitment to automation has been key to building and maintaining its market-leading position as Tesco’s largest apple supplier. Few apple packing facilities have adopted robotics, as they haven’t found solutions that enable high speed packing without damage to fruit, so instead they elect to stick with manual methods. However, by putting its trust in Brillopak’s pioneering UniPAKer technology, Adrian Scripps has seen a threefold improvement in productivity per person.

mechanical system. Brillopak rose to the challenge,” says James Simpson, Managing Director of Adrian Scripps.

In 2018, Adrian Scripps took the decision to invest in two completely new fully automated packing and palletising lines and upgrade the end-of-line kit on two existing lines, following an investment in new flow wrapping equipment. Its existing mechanical layer crate packing systems were limiting output, as they could not keep pace with the flow wrappers.

“Apples are not an easy fruit to handle because they bruise very easily. This, combined with the need to execute a range of crate patterns, made this project a challenge that couldn’t be met by a

Adrian Scripps is one of the UK’s premier growers and packers of English fruit. Several varieties of apple – Braeburn, Kanzi, Jazz, Opal, Gala, Red Prince and Bramley – along with Conference pears

“Our existing packing system was working flat out at 15 cycles per minute; we soon worked out that we could put apples into the flow wrapper much quicker than this,” recalls James.

PECM Issue 49

a different approach to vacuum handling than others in the industry, deploying cups with independent vacuum generators for greater control over the picking and placing operation. A further benefit of the UniPAKer is that it is a standard machine. This means it is proven technology and customers are not paying for the development costs associated with bespoke robotic systems.

Brillopak has developed a robot control system that has allowed it to optimise the acceleration/deceleration curve by enabling greater adjustability of parameters. The company considered other packing systems, but it was the inherent flexibility of the award-winning UniPAKer robotic crate packing solution that convinced Adrian Scripps to partner Brillopak on this project. “We looked at mechanical systems where the pack is turned to orientate it, but the flexibility of the UniPAKer won us over – it is infinitely programmable and allows you to make very small adjustments to get the pack to the exact target location,” explains James. Each of the four UniPAKer crate loading cells at Adrian Scripps houses two delta type robots, each performing a single pick. The benefit of a single pick is that it eliminates the need for accumulation. To maximise packing speed, the crate is dynamically loaded as it is moving; working alongside each other, the robots take it in turn to partially fill the crate, picking individual packs off the infeed conveyor and positioning them deftly and precisely in the crate at the programmed orientation. The robots perform this task with a degree of dexterity and rotation that would not be feasible with a layer-based automated handling system.

can successfully pack apples at speeds of 75 ppm, without damaging the product. We have achieved this via innovative end-effector design, combined with our knowledge of motion control and robotics,” explains David Jahn, director at Brillopak.

The project saw Brillopak install four UniPAKer robotic crate packing systems, four Crate DESTAKers, four vertical accumulation units and three robotic palletisers. Thanks to this investment in automation, Adrian Scripps now has a fully automated crate packing operation that is capable of running at up to 75 ppm, giving the company the capacity uplift it needed. But the true measure of the success of the project is the threefold increase in per person productivity that Adrian Scripps has experienced.

One of the hotspots for damage is the point at which the pack is released from the endeffector, with some rival robots dropping fruit from heights of 250mm. Brillopak has developed a robot control system that has allowed it to optimise the acceleration/ deceleration curve by enabling greater adjustability of parameters.

“Reduction of labour is a consideration, but it is productivity per person that we are really interested in,” says James. “Thanks to our investment in automation, this is considerably higher than it was. In 2013, we were working at 2.5-5 packs per person per minute. Now we are working at 15 packs per person per minute. That is a threefold increase.”

“When lifting a pack of apples, the robot arm accelerates strongly upwards into a curve, then decelerates down into the crate, so the pack is tightly controlled as it reaches the bottom of the crate.” explains David.

James concluded “You can honestly trust Brillopak. A British company, on our doorstep at the forefront of their field. They’re innovative, proactive and delivered everything we asked. We couldn’t have worked with a better partner on this project

The UniPAKer can run with a variety of end-effectors depending on the product being packed. For apples, a vacuum head ensures gentle handling. Brillopak takes

The robots perform this task with a degree of dexterity and rotation that would not be feasible with a layer-based automated handling system.

Many robotics suppliers shy away from applications involving delicate fruit such as apples, as they bruise very easily. The speeds required to achieve target paybacks cannot be met without unacceptable levels of product damage, rendering some automation projects unfeasible. Brillopak overcomes these challenges through innovative end-effector design and unrivalled experience of motion control. “Apples are very delicate products, making them very difficult to pack at high speed. We are the only automation supplier who

Each of the four UniPAKer crate loading cells at Adrian Scripps houses two delta type robots, each performing a single pick.

For further information, please visit www.brillopak.co.uk Issue 49 PECM

PACKAGING

FOAMplus® perfect protective packaging solution from Storopack As a leading global protective packaging supplier Storopack recognizes the importance of ensuring goods are protected during transit and arrive in perfect condition. Damaged goods not only incur costs for replacement orders but also affect businesses’ reputations. So while costs need to be kept to a minimum it is vital to choose the correct protective packaging type. Usually a void fill packaging medium will suffice. However when the product is more sensitive to shock and vibration, such as engineering, electronics, aeronautical, and many other expensive products then more consideration has to be given to using the right type of in-the-box protective packaging. Storopack’s FOAMplus® range is a perfect solution for companies that manufacture or ship products that require this highest degree of protection eliminating transit and handling damage. The success of FOAMplus® polyurethane foam is based upon its huge versatility as a packaging medium. The foam can either be dispensed directly into the carton where the expanding foam will mould itself to the contours of the product shape or can be made into pre-moulded cushions to enhance presentation. The product will satisfy the most rigorous cushioning demands for high value, fragile and awkward shaped products. The light weight foam packaging also ensures that shipping costs are kept to a minimum whilst providing customers with total product protection. As a space saving solution FOAMplus®, polyurethane foam packaging is ‘on demand’ and mixes two components together which then expands up to 200 times its liquid volume negating the necessity for large storage areas required for pre-fabricated packaging. The benefits for customers are numerous. As well as an ideal solution for protecting awkward and valuable products, customers with product

design changes and new product line additions are able to quickly adapt the packaging without the need to carry a large range of bespoke cartons or fabricated packaging. There are two dispensing methods available for the insitu protective packaging solution. Either FOAMplus® Hand Packer, a manually operated system, with a fully electronic microprocessor control to maintain consistent quality that delivers the foam direct into polythene lined carton via a foam dispensing gun. Alternatively the Bag Packer² Foam-in-Bag dispensing system is fast, easy to use, efficient and economical. The machine can produce up to 23 foam-filled bags per minute at the touch of a button. Polyol B 5504R, foam B component is made from 30 percent recycled polyurethane.

www.storopack.co.uk

FOAMplus® Your products deserve the best protection. Expanding polyurethane foam pads mould around any product shape within seconds. Exceptional protection for fragile or awkwardly shaped products.

T: +44(0)114 249 2004 E: packaging.uk@storopack.com *subject to qualification

PECM Issue 49

www.storopack.co.uk

SUPERIOR INDUSTRIAL PACKAGING PROTECTION PAPERplus® - Paper pads provide maximum performance, high density, and strength. Ideal in-the-box protection for heavy products.

100% recycled content and 100% recyclable

Issue 49 PECM

PROCESS TECHNOLOGIES

The Right Mix Developing a liquid mixing process requires specialist expertise, whether manual or automatic in operation. Factors such as solids suspension, distribution and shear sensitivity determine the type of agitation, blending, or mixing required. Positioning of the mixer, access, temperature control and CIP requirements must be considered, along with risk assessments at the design stage to ensure compliance with directives such as PED or ATEX, and appropriate CE markings or Notified Body approvals. Axium Process specialises in all aspects of liquid processing, including the development and design of hygienic mixing vessels and processing skids, from a simple blending skid up to a full-scale automatic PLC controlled mixing system. In-house operations include welding, fabrication, mechanical and electro-polishing, with quality control at all stages in compliance with EHEDG and ASME BPE guidelines. Operating in industries where qualification, traceability and full documentation is paramount, Axium provides full traceability dossiers which can include materials certification, borescope direct view and video record, welder qualifications, weld maps, logs, dye penetrant, pressure testing, ferroxyl testing, TSE certification and Approvals. As a leading UK based Hygienic Engineering company, Axium Process specialises in hygienic process systems and precision fabrications, offering a complete engineering service that encompasses Stainless Steel, Hastelloy, and Aluminium alloys. The company’s reputation for delivering innovative solutions has been built on, responsiveness, reliability, and engineering excellence.

www.axiumprocess.com

New lightweight filling material with high damping properties

IdentifEYE - The Smart Labelling Solution

Production, Quality control and Batch tracking with barcodes

Numerous machines are impaired in their performance by vibrations. To counteract this, the German durcrete GmbH has developed the lightweight and highly damping filler material durcrete®cell.

Loop Technology, specialists in industrial automation and robotics, have developed a flexible solution for affixing labels on virtually anything with a 3D profile – from irregular parcels to avocadoes and melons.

durcrete®cell is a mineral filler to reduce vibrations in metallic structures. Damping is increased by over 300% and vibration amplitudes are reliably reduced. The damping material eliminates harmonics caused by sheet metal vibrations and reduces noise radiation. With its balanced weight-to-rigidity ratio, the lightweight material is ideal for moving components and for filling hollow steel and aluminum sections. While natural frequencies are changed only minimally, guiding rails and motors can be designed economically and the machine retains its dynamics. The material is optimally used as a filling material in machine tools, in automatic placement machines and in measuring technology.

By combining real time 3D image processing with conveyor movement tracking and robot motion controllers, products can be analysed, placement location calculated, and labels applied without slowing down your process.

Recording production batches and quality control tests are an essential part of the production process. This enables fast identification of problems in the process or materials and enables inspection of the complete test records of each batch from production to warehouse.

www.durcrete.de

PECM Issue 49

Key features: • Print and apply labels to up to 1,200 parts per hour per robot. • Product size can vary from 50 x 50 x 5mm to 450 x 400 x 400mm. • Maximise machine time with simple batch changeover at the touch of a button.

Read more: https://www.looptechnology. com/products/identifeye/

High end software to achieve this is expensive so we have come up with some low cost affordable solutions for smaller companies. Our systems are barcode based and real time and can be implemented for as little as £3k. We help you to set up the quality control testing and production run recording, and we do this on line without needing a factory visit. Free 2 month trials available

Tel: 08:00 to 13:00 01992 554 552 Email: support@britsoft.com Website: www.britsoft.com

PROCESS TECHNOLOGIES

Peak

Performance for your filtration system

metafilter servicing, spares and on-site training for optimum reliability and long operational life

023 8027 9969

| www.stella-meta.com

restoring the clarity to your filtration system

Process Cooling Solutions for Food & Beverage Systems A range of non-toxic high performance heat transfer fluids, with antifreeze function, for use in food and beverage cooling systems.

tel: 01792 586800 www.hydratech.co.uk

Issue 49 PECM

Kecol Pumping Systems Kecol Pumping Systems offers solutions to many product transfer problems – read on to find out more.

ecol Pumping Systems Ltd are manufacturers of Air driven, Positive Displacement Piston Pumps and Priming Devices in polished stainless steel or carbon steel, for transferring high viscosity nonflowable products from drums and containers as used in the cosmetic, food, pharmaceutical, chemical and general industries. Products in drums or similar sized vessels that normally need to be heated in order to reduce the viscosity - can be transferred cold. Products with a viscosity up to 10,000 Poise can be transferred (cold) using the Kecol Maxiprime Pump and follower plate system and is also used to transfer pastes and products that stick to the inside of an open top drum, wiping the inside of the drum or vessel, eliminating product waste. Kecol Air Powered Drum Pumps and transfer systems are suitable for all standard size closed top or open top drums and can be adapted to suit open top containers with an internal diameter up to 1200mm. Non contact parts as well as contact parts are available in polished stainless steel, clamp - type construction is also available for hygienic applications. Typical applications in the food industry include transferring tomato

The inside of a standard 200 litre Open Top Drum is wiped clean – as the drum is emptied – with minimal product waste

puree, concentrated fruit juice, honey, fruit pastes, biscuit creams, jams, butter, margarine, sweet mince meat, sausage meat and meat pie fillings with cooked vegetables. Applications in the pharmaceutical and cosmetic industries include transferring mascara, petroleum jelly, face creams, base creams, magnesium hydroxide, aluminium hydroxide, toothpaste, lip-gloss waxes and suntan lotions.

Kecol’s articulated pump systems

The Kecol Follower plate system will also work on 200 litre Open Top Drums fitted with an aseptic bag – wiping the bag clean

Applications in the chemical and general industries include the transfer of paints, resins, adhesives, polymers, latex, high viscosity grease, mastic’s and inks – all pumped cold without pre-heating the products. As manufacturers, Kecol Pumping Systems can offer solutions to your particular product transfer problem, by offering a bespoke system designed to exceed your particular production requirements for single drum/vessel use or multi drum use.

Kecol Pumping Systems Ltd Faraday Drive Bridgnorth Shropshire WV15 5BJ T: 01746 764311 E: sales@kecol.co.uk www.kecol.co.uk

THE HOME OF VISCOUS PUMPING SOLUTIONS

Kecol have over 25 years of experience in handling all types of viscous products in the food, pharmaceutical and cosmetics markets, as well as general industrial applications.

A sample of products we already pump… ✓Honey ✓Petroleum Jelly ✓Mascara ✓Sauces ✓Lanolin ✓Lip Gloss ✓Essences ✓Eye Ointment ✓Meat Paste ✓Paraffin Wax

T: +44 (0)1746 764311 E: sales@kecol.co.uk W: www.kecol.co.uk

✓Face Scrub ✓Teething Gel ✓Tomato Puree ✓Medical Adhesives ✓Veterinary Creams ✓Fruit Paste ✓Toothpaste ✓Malt ✓Jam ✓Wax

SOFTWARE & SYSTEMS

IFPAC 2021 OPTIMAL INDUSTRIAL TECHNOLOGIES

Free trial of leading PAT data management software available

Optimal Industrial Technologies will showcase the advantages of Process Analytical Technology (PAT) at the virtual IFPAC-2021. Optimal Industrial Technologies will showcase the advantages of implementing Process Analytical Technology (PAT) with its industry-leading PAT knowledge management platform synTQ at the virtual IFPAC-2021. During the event, the company will demonstrate how a dynamic, qualitycentric data management infrastructure for Smart Manufacturing can enable effective Industry 4.0 applications. A limited number of fully functioning synTQ licenses will be available to qualifying visitors to Optimal’s virtual booth.

PAT solutions for all types of manufacturing activities, Optimal will contribute to the discussion with a number of presentations. These presentations will focus on dynamic flow modelling in continuous manufacturing, advanced predictive control, and how to leverage the power of data to optimize operations. The online sessions will also showcase how Optimal’s synTQ, a leading PAT knowledge management platform adopted by over 60% of leading global pharmaceutical manufacturers, helps users benefit from these functions.

IFPAC is an essential networking event that provides the opportunity to discuss and learn about the latest developments in PAT, Quality by Design (QbD), automationdriven process monitoring as well as control strategies for manufacturing and processing. This year, the interactive virtual event will be held from 28th February to 5th March.

A limited number of free, time-limited licenses will be available for qualifying visitors to the booth, allowing them to gain hands-on experience on how to use the platform for their processes and instruments. By doing so, they can experience how the software can support Smart Manufacturing strategies. To apply for this offer, attendees should visit Optimal’s virtual booth, and contact the company’s dedicated experts.

As a provider of advanced automation and

Martin Gadsby, CEO at Optimal, comments: “A PAT knowledge management platform, such as synTQ, enables data-driven manufacturing and data transparency. It offers an in-depth understanding of complex production processes, can perform advanced computations for dynamic control and support continuous improvement strategies. This is why the framework has become increasingly popular. We look forward to presenting the real-world benefits of PAT at IFPAC-2021. We invite anyone interested in improving their current manufacturing and research practices to attend the online event and get in touch with one of our experts during the conference.” Attend Optimal’s presentations and visit its digital stand at the virtual IFPAC 2021 from 28th February - 5th March by registering at: https://www.ifpacglobal.org/AttendeeRegistration

For further information, please visit https://www.ifpacglobal.org/Attendee-Registration

PECM Issue 49

SOFTWARE & SYSTEMS

Procentec

DIN11864 and DIN 11853 Aseptic Unions for Orbital Welding

High Flexible Industrial Ethernet Cables

DIN11864 and 11853 unions were developed to meet the exacting needs of the food, chemical and pharmaceutical industries. This range of unions has been developed from the three most common systems used in the hygienic and sanitary industries; namely the “Aseptic” screwed union to DIN11864-1; the “Aseptic” flange union to DIN11864-2 and the “Aseptic” clamp union to DIN11864-3.

Size range: 10mm to 150mm and 1” to 4” Specials are available up to 304mm Materials: 316L SS 1.4404 and 1.4435 Specials available in Duplex and Alloy 22

70 years after its foundation, SAB Bröckskes presents itself highly innovative as answer to the mega trends of digitisation and industry 4.0. The company presents a range of new industrial Ethernet cables 6, 6A, 7 and 7A that are not only extremely robust but also ensure a quick and efficient data transmission. SAB is not only a cable manufacturer but also offers support in automation technique for example in the range of new communication systems for drive technology. Herewith, the individual requirements of the customer and the long-term experience of SAB as manufacturer of highly flexible cables are combined in new products. The quick and flexible production of sample lengths is no problem at all. The strength of SAB Bröckskes is not only the manufacturing of standard cables but also the construction of special items. Every year SAB manufactures more than 1500 special cables on customer´s request.

Tel: 01269 841 324 Web: www.alchemprocess.co.uk

www.sab-cable.com

It’s even easier to bin the pen and paper for calibrations

Bridge Amplifier with Linearity Correction for Load-Cell Systems

DDM has changed perceptions of PDM / PLM software

Beamex LOGiCAL – a subscription-based calibration software solution that streamlines and digitalizes the calibration process – has already helped hundreds of users complete thousands of calibrations since its launch in 2020. A new update introduces a host of enhancements that will make it easier than ever to say goodbye to time-consuming, error-prone manual calibration processes. The cost scales based on how much you calibrate, making LOGiCAL easy to understand and budget for, and because it’s hosted by Beamex there’s no IT investment needed – just sign up and start using it with a free trial. LOGiCAL allows seamless movement between on-line and offline environments to enable digital calibration even without internet access. With LOGiCAL, it’s easy and inexpensive for companies of all sizes to take their first steps towards a streamlined and digitalized calibration process.

The AS200706 is a small compact board for 3-wire systems providing a 4mA - 20mA current output with adjustable linearity correction. The unit has individual multi-turn potentiometers for the precise setting of Zero, Span and Linearity without the need of a computer. This unit is also available with mid. zero output (12mA for example) for compression / tension transducers. The inputs provide EMI-/RF-suppression. Transducer wires can be easily connected to board via soldering or SIL sockets (standard).

DDM is a low cost yet versatile solution that is easy to implement and intuitive to use. Speed, Simplicity, Scalability & Stability are its core foundations.

Procentec are an innovative company specialising in diagnostic solutions and support for PROFIBUS, PROFINET, EtherNet/IP and other Industrial Ethernets. In todays’ world, uptime must be maximised. To achieve this, permanent monitoring and preventative maintenance is vital. Our permanent solution for PROFIBUS users is ComBricks, a modular system that monitors networks 24/7, feeding back electrical and message level diagnostics whilst simultaneously improving your physical layer by segmenting your network. In conjunction with our latest release, SNAP, an automated self-learning processor, engineers are informed of faults on their system to 91% accuracy. By using Delphi, our virtual network engineer, end-users are then notified of the best practice of how to solve the fault. This results in saving hours in the troubleshooting process. For more information on our solutions, please contact Jay Somerfield directly at jsomerfield@ procentec.com or by phone +44 07496288894. www.procentec.com

www.beamex.com/software/logicalcalibration-software/

Available with optional lengths to suit both orbital and manual welding, these unions have been designed to match tube and pipe specifications to DIN11866 Table A (DIN11850); DIN11866 Table B (ISO 1127) & DIN11866 Table C (ASME BPE).

Features • Wide range power supply 16-30V • Bridge sensitivity 0.6mV/V – 3mV/V • Size 29mm x 29mm, 7.5mm height • Fast calibration procedure • Reverse-polarity protection Tel. + 44 (0)7763 740906 Email: info@aieng.co.uk Website: www.aieng.co.uk

At a basic level it can be used as a file vault system but at an advanced level it can satisfy the needs of a global multi-site organisation with document, project and process management. The DDM CAD license contains all the below features at no additional cost or modules: - Multi-CAD Management - Office Document Management - Project Management & Tasks Functionality - Intelligent Business Process Workflow Engine - BOM Management - Auto downstream to ERP/MRP Visit our website for more information, view videos and testimonials, ask for an online demonstration or request pricing. www.designdatamanager.com Issue 49 PECM

TOOLS, PLANT & EQUIPMENT

Snickers Workwear HighPerformance Jackets

Enhanced Visibility and Safety With Snickers Workwear Hi-Vis

With street-smart designs for men and women, all Snickers Workwear jackets include musthave features that focus on fit and freedom of movement as well as using innovative fabrics that deliver long lasting protection and stretch comfort. Whatever you need – if it’s for work, play or protection against hazards – Snickers Workwear has Jackets that will work on site, are ideal for leisure, always ensuring optimal performance, comfort, good looks and visibility. ALLROUNDWork Jackets are just what the name suggests, delivering a great all-round performance. There’s also FLEXIWork Jackets that provide superb comfort and weatherproofing if you’re always on the move and LITEWork Jackets that keep you feeling cool and looking good whatever you’re doing in warm weather. So check out the performance, comfort and protection features of Snickers Workwear Jackets, there will be one to suit you - wherever you are, whatever you need, whatever you’re doing.

Snickers Workwear takes personal wellbeing at work very seriously. That’s why this range of HiVis protective wear is streets ahead of anything else. With updated styles and designs added to the extensive range of Jackets, Trousers, Shorts, Toolvests, Shirts and Fleeces for men and women, there’s a host of garments in the range to satisfy the specific requirements of Classes 1, 2 and 3 protection levels.

www.snickersworkwear.co.uk/products/93

PECM Issue 49

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

These ‘outstanding’ products combine Snickers’ unrivalled hallmarks of functionality and comfort with the requirements of the EN20471 standard for high visibility warning clothes.

Intelligent washroom controls and water efficiency specialist Cistermiser has launched a new CPD learning module entitled: “Using the Internet of Things for Water Temperature Monitoring to Help Reduce Risk of Legionella”. This CPD discusses how remote monitoring systems using IoT platforms can deliver significant advantages for management of commercial buildings in the 21st century. 1 hour in duration with a closing Q&A, this CPD learning module from Cistermiser is presented in “short seminar” format and is approved by 3 third party organisations: The CPD Certification Service, RIBA and CIBSE.

Getting more information on the Snickers Workwear range of ProtecWork and Snickers Workwear Hi-Vis protective wear is easy. You call the Helpline on 01484 854788; check out www.snickersworkwear.co.uk and download a digital catalogue; or you can email info@ snickersworkwear.co.uk

www.cistermiser.co.uk

TRAINING & RECRUITMENT

A UNIQUE OPPORTUNITY ROTAFLOW

Domestic and Global Engineering Still Welcomes New Graduates For students, the engineering world could appear to be in a state of flux. Whilst engineering is a key global industry, the usual routes into internships and employment appear to be closed, because most of the usual job fairs have be cancelled. The cancellations of job fairs has left a lot of students in a state of confusion and anxiety as they take their first steps into industry, but in an attempt to reassure graduates about their employment prospects, UK engineering has never been so important and domestic engineering talent has never been in so much demand. As the geopolitical landscape changes, more of our services have been brought onshore. The global pandemic has put pressure on supply chains, highlighting the importance of domestic production of food, goods, medicines and the like. As UK manufacturing starts a resurgence, we’ll need more and more engineers.

As the geopolitical landscape changes, more of our services have been brought onshore.

There’s also the green revolution – renewable energy production is still relatively small scale and we’ve barely gotten started with electric vehicles. Over the next decade there’ll be an enormous roll out of infrastructure designed to power the country as we move into the next revolution in energy production.

We’ve built up excellent relationships with past students and we’ve been lucky enough to be able to offer them work after their placement has been completed.

THE FUTURE IS BRIGHT FOR ENGINEERING

A PATHWAY TO EMPLOYMENT

Despite the global shutdown, engineering remains as important as ever and students need not worry - the world is crying out for your knowledge and skills, so companies like Rotaflow will always be interested in hearing from you.

At Rotaflow we have built up a strong relationship with Loughborough University and have offered many of their engineering students both internships and paid work with us. Where we’d usually attend their Placement Fair, this year we had to attend an amalgamated event with other STEM subjects over a Teams virtual event. Where it was a little unusual, it gave us a chance to showcase what we can offer students.

A GLOBAL REACH FROM UK ENGINEERING BUSINESSES

We were happy to see there was a lot of interest in what we could offer at Rotaflow, because as a small engineering company the hands on nature of what we provide is a unique opportunity for students to experience both the design and manufacture of our products.

We’re a classic example of the esteem in which UK engineering is held. With a wide customer base across a number of industries, new graduates will learn how to problem solve, apply their expertise and understand how their work will impact both domestic and global business.

The world is slowly emerging from the worst pandemic in history, but the importance of engineering has not diminished – if anything it has increased. Various industry reports show that there’s a huge shortage of skilled engineers in this country, so your career prospects are fantastic. You can confidently plan your future, knowing you’re entering a sector that will benefit us all in some way.

For further information, please visit rotaflow.com Issue 49 PECM

TRAINING & RECRUITMENT

DEGREE APPRENTICESHIPS UNIVERSITY OF STRATHCLYDE ENGINEERING

Developing the next generation of professional engineers Degree Apprenticeships are available to employees based in England and can be fully funded by apprenticeship levy funds (effectively tax previously paid by employers). Smaller, non-levy paying employers, can also access up to 95% of the required funding from government. The programme may be suitable for school leavers who are hired directly into a Degree Apprenticeship role, or for existing employees whom the company wish to develop into an engineering position. Successful graduates will be awarded an IChemE accredited, BEng honours Chemical Engineering from the University of Strathclyde, and a Degree Apprenticeship award from the Institute of Apprenticeships. The Degree Apprenticeship in Chemical Engineering is built on the distance learning BEng honours Chemical Engineering, established at the request of local industry in 1992, to enable the progression of experienced technicians, into engineering roles. Unrivalled experience working with employers and industry-based students, combined with the industry developed Science Industry Plant and Process Engineer Standard (SIPPE), has resulted in a Degree Apprenticeship in Chemical Engineering that is perfectly suited to employer’s needs. The online approach to the academic components minimises time off site and maximises flexibility. Alongside their work-based learning, apprentices study the core chemical engineering subjects, including fluid mechanics, thermodynamics, mass transfer, process design, learn how to use engineering programming tools, as well as gaining broader knowledge in subjects like

project management, ethics and teamwork. The programme concludes with an Engineering Design project, showcasing the skills gained in the Degree Apprenticeship, and enabling the End Point Assessment and degree award. The course is taught by a world class team of academics and industrialists, and industry experience is integrated within the curriculum. The Programme Director, Dr Kenneth Moffat, has over 10 years’ experience managing distance learning industry focussed degree programmes, and 20 years of industry experience prior to this. As a former apprentice and distance learning student, he is in tune with the needs of industry and can relate directly to the experience of industry-based students.

The course is taught by a world class team of academics and industrialists. Employers or Employees who would like to know more about the opportunities available through Degree Apprenticeships in chemical engineering, or any of our programmes and services to industry, should contact Kenny Moffat at Kenneth. moffat@strath.ac.uk.

For more information, please visit www.strath.ac.uk/engineering/chemicalprocessengineering/studywithus/distancelearning/

PECM Issue 49

IChemE accredited

INDUSTRY BASED, DISTANCE AND ONLINE LEARNING DEGREES AND DEGREE APPRENTICESHIPS BEng Honours Chemical Engineering

MSc Process Technology MSc Advanced Chemical and Management and Process Engineering

n 3 years part time

n Entry through HNC or equivalent and industry experience

n Conversion modules for engineers of other disciplines

n Advanced Chemical and Process Engineering options

n Work based final project

Degree Apprenticeships (SIPPE standard) based on above BEng honours, fundable with apprenticeship levy credits www.strath.ac.uk/engineering/chemicalprocessengineering/ studywithus/distancelearning/ or contact

chemeng-online@strath.ac.uk +44 (0) 141 574 5306 for more information.

VALVES AND FLOW CONTROL

Robust & Resistant Workhorse – Designed to Meet Your Most Challenging Applications

Bonut Engineering Ltd Bonut Engineering Ltd was established in 1966 and is a leading UK manufacturer and supplier to the fastener and general engineering industry. We specialise in the UK manufacture of engineer’s studs, shaft collars, precision turned parts and valves in stainless steel, high grade alloy and non-ferrous metals.

Looking for robust and resistant lined diaphragm valves for Industrial applications? GEMÜ offers highly versatile lined diaphragm valves that withstand both corrosive media and a wide temperature range. They meet even the strictest requirements in conjunction with the appropriate diaphragm material, thereby ensuring a high degree of operational reliability. There is no other sector in which demands on valve bodies are as varied as in industrial applications. In many cases, a valve with a full metal body cannot be used, since the corrosive medium attacks and can even destroy the material.

Bonut has also acquired the Dereve Safety and Water Valve business as well as the fusible plug business which is now consolidated under the Dereve brand. Our experience of both the fastener and valve manufacturing businesses enables us to support our customers over a wide sector of Industry.

www.bonut.co.uk

A fully plastic body is often also unsuitable, since the temperatures can be higher than the material allows. Produced using high-quality materials under strict quality controls (e.g. spark testing), GEMÜ lined valve bodies are available in polypropylene (PP), fluoroplastics such as PFA, as well as soft and hard rubber lining – making the valve an ideal workhorse when exposed to heavy chemical and mechanical loads.

Tel: 01925 824044 Email: enquiries@gemu.co.uk Web: www.gemu.co.uk

Control

Isolation

Safety

Steam trapping

Actuator

Systems

ARI-Armaturen UK Ltd ARI-Armaturen UK Ltd. is a subsidiary of a large German engineering company, reputed to have the largest valve stock in Europe. We specialise in pipeline equipment for the steam and condensate loop, hot water, thermal oil and products, including an extensive range of valves, controls and steam trapping equipment in cast iron, SG iron, cast and forged steel and stainless steel. These include: • Control Valves • Isolation Valves • Safety Valves • Steam trapping • Heat Exchange Systems These products are produced to exacting German, European, ANSI other internationally recognised standards, and covered by Lloyd’s Register Quality Assurance DIN EN ISO 9001. We have completed many successful projects including for the NHS, Food and Beverage and EfW sectors, as well as smaller process and building services projects. Vicki Chatfield, Marketing & Sales Development Victoria.Chatfield@ari-armaturen.co.uk Tel: 01684 275752

PECM Issue 49

Cloud-based Intelligent Asset Management system from Rotork Rotork’s Intelligent Asset Management is a cloud-based system for intelligent actuators and the flow control equipment they operate. The system of advanced analytics improves the reliability and availability of key assets (such as valves) for industries that use flow control processes. Failure of key equipment on any plant can result in unplanned downtime, poor performance, reduced output yields and reputational damage. Intelligent Asset Management uses the information downloaded from the data logs recorded within intelligent actuators. The robust, safe and secure online platform has a simple user interface that can run on all operating systems. Summary views and colour coded maps simplify complex analytics into easy to understand visuals. The key areas of information that are taken from data loggers and uploaded to the system are torque, temperature, vibration and event log information. www.rotork.com/en

Flotronic pumps Ltd Founded in 1981 in West Sussex, Flotronic Pumps is a world-leading manufacturer of air operated double diaphragm pumps (AODP). With the invention of our ground-breaking ‘One Nut’ pump design, Flotronic have revolutionised the application of diaphragm pumps throughout the industry. Over the last 30 years our ‘One Nut’ double diaphragm pump has proven its success in an incredibly diverse range of international industries including but not limited to pharmaceuticals, food & beverage, cosmetics, personal and household care and chemical manufacturing. Our global customer base can rely on our expertise in delivering the highest quality products as well as our abilities to provide engineering excellence, thus enabling them to achieve their competitive edge. For more information please contact: +44 (0)1444 881871 or email salesteam@flotronicpumps.com

Portable Confined Space Ventilators & Air Blowers Fume & Dust Extractors Where fumes, smells or dust occur, the Miniveyor Air VAF fans can move contaminated air out of a confined space or building. They effectively exhaust fumes, ventilate confined spaces, and increase the flow of fresh air. The Miniveyor Air range are tough! The rugged VAF ventilators easily withstand blows without denting, giving less downtime and greater productivity and come with an industry leading 10 year warranty on the body. The vane axial fans work on positive and negative airflow and are at home either extracting dust and fumes or blowing clean air into a confined workspace. In fact whatever the industry you work in, from marine, construction, mining, telecoms, fabrication or maintenance services, our VAF series fans will take whatever is thrown at them.

VAF-200 (8”)

VAF-400 (16”)

VAF Air Ltd Tetbury Ind. Estate Tetbury, United Kingdom sales@vaf-air.com +44 (0)330 016 0002 or visit -

VAF-300 (12”) Pneumatic

www.vaf-air.com

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Anti-Vibration & Noise Isolation Solutions

TICO are the industry leaders in manufacturing off-the-shelf and custom-made solutions to vibration, noise, movement and impact isolation. With over 60 years’ experience, TICO has provided elastomer attenuation and technical excellence to our customers, making us the brand of choice for isolating solutions.

Machine Mounting

Structural Bearings

Slide Bearings

Pipe Supports

High Duty Resilient Seatings

A division of

Tiflex House, Liskeard, Cornwall. UK PL14 4NB

Email: tico@tiflex.co.uk Tel: +44 (0) 1579 320808 Web: www.anti-vibration.solutions