Process Engineering Control & Manufacturing - Issue 51 2021 by MH Media Global

Process

MANUFACTURING

Control &

Engineering

C-MAC - 12

QMS INTERNATIONAL - 18

C-MAC SMT bounces back from Covid-19 to target £4m in sales

Why is quality management more important in manufacturing and engineering than ever before?

PECM

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Process

MANUFACTURING

Inside... Sections

Control &

Engineering Inside Issue 51

Editors Choice

Automotive & Engineering

Control & Automation

Electrical & Electronics

Facilities Management

Fasteners & Fixings

BMW

E-drive train production for the fullyelectric models BMW iX and BMW i4 begins

MITSUBISHI ELECTRIC

Want a robot but don’t know where to start?

FANUC

C-MAC SMT bounces back from Covid-19 to target £4m in sales

Automation works in tandem with workforce to deliver outstanding productivity

Fluid Handling

SPELSBERG

Gears, Drives & Motors

QMS INTERNATIONAL

Health & Safety

Hydraulics & Pneumatics

Machining & Machinery

Measurement & Monitoring

The considerations for establishing ROI in a UV bonding process

News & Events

Packaging

SULZER

Process Technologies

100

Software & Systems

102

Sulzer’s turbocompressors cut maintenance overheads, energy consumption and noise for Austrian wastewater plant

Storage, Handling & Distribution

106

Tools, Plant & Equipment

109

RDM GROUP

Valve & Flow control

112

CMAT

Why is quality management more important in manufacturing and engineering than ever before?

INTERTRONICS

Sales boost for RDM Group as carmakers switch to more local sourcing

Robust and flexible approach for LV switchgear enclosure

TFC

Fastener considerations in new and growing factories

AVT RELIABILITY

The important role that ‘smart sensors’ can play in improving reliability while delivering cost-efficiency

MICRO-EPSILON

Non-contact infrared temperature sensor offers ultra-high measuring speeds on metal and non-metal objects with a temperature of 0 to 500°C

Issue 51 PECM

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Process

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Issue 51 PECM

EDITOR’S CHOICE

CONTINUED EXPANSION BMW

E-drive train production for the fully-electric models BMW iX and BMW i4 begins Production of fifth-generation highvoltage batteries and bat-tery modules for use in the BMW iX* and BMW i4 is now underway at the Compe-tence Centre for E-Drive Production in Dingolfing. At the same time, the company is also increasing production capacity for its fifth-generation electric motor, which has been built in Dingolfing for the BMW iX3* since 2020 and will also power the BMW iX* and BMW i4. “We expect at least 50 percent of the vehicles we deliver to our customers worldwide to be electrified by 2030. To achieve this, we are relying on our extensive in-house drive train expertise: We are increasing capacity at exist-ing drive train production locations – like here in Dingolfing – and developing capa-bilities at others – like recently in Regensburg and Leipzig,” explained Dr Michael Nikolaides, Senior Vice President, Production Engines and E-Drives, BMW Group.

will invest a total of around 790 million euros in expanding capacity for electric powertrain components at its Dingolfing, Leipzig, Regensburg and Steyr lo-cations between 2020 and 2022.

The BMW Group is investing more than 500 million euros in expanding production capacity for e-drives at its Dingolfing location alone between 2020 and 2022. From 2022, it will produce e-drives for more than half a million electrified vehicles. The BMW Group

Standard production of the BMW iX* will soon get underway at BMW Group Plant Dingolfing, followed by production of the BMW i4 at Plant Munich in the autumn. The highly integrated e-drives and highvoltage batteries for these vehicles will all be manufactured at the Competence

PECM Issue 51

The BMW Group is investing more than 500 million euros in expanding production capacity for e-drives at its Dingolfing location alone between 2020 and 2022.

Centre for E-Drive Production in Dingolfing. The BMW Group already began producing battery components at Plants Regens-burg and Leipzig in April and May 2021. In line with growing demand for e-drives, BMW Group Plants Landshut and Steyr are also stepping up production of e-drive housings.

PRODUCTION OF FIFTHGENERATION BMW EDRIVE TECHNOLOGY The output and energy content of drive units and high-voltage batteries with fifthgeneration BMW eDrive technology can be flexibly scaled. This means they can be optimally adjusted to suit different model variants. Each vehicle uses up to two highly integrated e-drives, which combine the electric motor, power electronics and transmission in a single housing. Based on the de-sign principle of a current-excited rotor, the fifth-generation e-drive does not re-quire any materials classified as rareearth metals. BMW eDrive technology also comprises a high-voltage battery with state-of-the-art battery cell technology. The BMW Group agreed with its suppliers that they will only use renewable green power for producing fifth-generation battery cells. The entire high-voltage battery boasts outstanding qualities in the areas of perfor-mance, charging and discharging characteristics, durability and safety. The techni-cally standardised production process for battery modules has been further devel-oped in such a way that different module variants can be produced on the same production line – in line with the growing range of electrified vehicle models and performance levels. The production systems are highly flexible and scalable. Bat-tery modules are produced from supplied prismatic battery cells at the respective BMW Group production location. A modular system developed inhouse allows model-specific high-voltage batteries to be manufactured from these modules in a flexible arrangement.

The company has outstanding expertise and experience, both in the field of battery cell technology and in production of model-specific high-voltage batteries. The BMW Group conducts basic research in the fields of cell chemistry and cell design at its own Battery Cell Competence Centre. The BMW Group also produces bat-tery cell prototypes itself. These battery cell prototypes are used in tests to validate the development maturity of battery cells and to demonstrate the effectiveness of the production processes. In addition, the prototype production of the battery cells serves the identification of process potentials as well as the optimization of the pro-duction processes. In this way, the BMW Group gains a thorough understanding of the entire battery cell value chain and the decisive competitive advantages its chemical and technical properties offer. This enables battery cells to be manufac-tured to precise specifications that are geared towards each vehicle’s individual re-quirements.

COMPETENCE CENTRE FOR E-DRIVE PRODUCTION Following extensive expansion, the Competence Centre for E-Drive Production now provides a usable area of 125,000 sq. m. This is where the company manufactures electric motors and the components needed for them, as well as high-voltage batteries and battery modules. A paint

e-drive used for the first time in the BMW iX3*. Production of the even more powerful high-voltage batteries for the BMW iX* and BMW i4 is now getting underway. E-drives for future models can also be produced on the flexible production lines.

QUALIFICATION FOR LONG-TERM, SUSTAINABLE JOBS

coating is also applied to the battery cells at this location. The coating increases mechanical robustness and thermal conductiv-ity, thereby improving insulation and cooling of the even more powerful fifth-gener-ation battery cells. Plant Dingolfing has been manufacturing standard high-voltage batteries and bat-tery modules since 2013, when the BMW Group’s first all-electric vehicle, the BMW i3*, went into production. The first production lines for electric motors and high-voltage batteries for plug-in hybrids went on-stream there in 2014. The Competence Centre for E-Drive Production has been steadily growing ever since. The plant has also been producing highvoltage batteries for the fully electric MINI Cooper SE* since 2019 and, since 2020, also the highly integrated fifth-generation

With the BMW Group systematically pursuing progress in electromobility, the de-mands on employees and their areas of responsibility are also constantly evolving. “We are growing our staff for e-drive production almost exclusively through person-nel restructuring. We are actively shaping the transformation process and leverag-ing our employees’ skills so we can develop long-term sustainable jobs,” explains Nikolaides. The Competence Centre for E-Drive Production in Dingolfing currently has almost 1,400 employees. By the end of 2021, around 1,900 employees are expected to work in e-drive production in Dingolfing. Production employees receive further training at the in-house learning centre, which uses innovative vocational training and further education methods to provide employees with intensive preparation for their new tasks. Issue 51 PECM

Employees’ knowledge and skills are being expanded specifically to include new electromobility technolo-gies, with a training concept that is constantly updated. The training sessions are held in the classroom, at practice workstations and directly on the production lines. Digital methods and augmented reality play a bigger role here than ever before. Thanks to these methods, the training courses were also able to continue safely during the coronavirus pandemic, in compliance with health and safety measures.

supply chain and use phase. In Dingolfing, as at all BMW Group locations, production uses only green power. In addition, all BMW Group locations have been net carbon neutral since this year, through corre-sponding offsets and certificates. The company is also using many other levers: from building technology to energy-efficient installations to increased use of renewable energies. Electric trucks will be used for intra-company goods transport at the Competence Centre for E-Drive Production from the autumn.

“The learning centre takes a holistic approach that supports employees throughout their professional development and further education, from their first day in produc-tion,” reports Dr Sven Jochmann, head of Production E-Drives Dingolfing, Lands-hut, Regensburg, Leipzig. “As well as trainers and managers, new colleagues are also supported by trained mentors who help them quickly find their way around their new working environment,” adds Jochmann.

2030: AT LEAST 50 PERCENT OF GLOBAL BMW GROUP SALES WILL BE FULLY ELECTRIC

TRANSFORMATION OF THE DINGOLFING LOCATION The Dingolfing location is a prime example of the successful transformation of the BMW Group plants towards e-mobility and digitalisation. E-drive production, in-cluding electric motors and high-voltage batteries, is located in an existing, roughly 50-yearold building at the site, rather than using new space. The infrastructure was adapted to the new requirements and expanded

The BMW Group continues its massive electromobility ramp-up: The company will offer five fully-electric models by the end of this year: the BMW i3*, the MINI Cooper SE* and the BMW iX3*, as well as the two main innovation flagships, the BMW iX* and BMW i4. accordingly. A modern staff restaurant seats 300 and there is also a new parking deck with space for 800 vehi-cles. The structural measures are rounded out by a 25,000 sq. m. logistics hall, new office spaces and social rooms close to the production area, as well as an ad-ditional plant gate in the south for improved logistics flows. On the issue of sustainability, the BMW Group takes a holistic approach to reducing CO2 emissions and minimising resource consumption that covers the entire value chain, including in-house production, the

Between now and 2025, the BMW Group will increase its sales of fully-electric models by an average of well over 50 percent per year – more than ten times the number of units sold in 2020. Based on its current market forecast, the company also expects at least 50 percent of its global sales to come from fully-electric vehi-cles in 2030. In total, over the next ten years or so, the BMW Group will be releasing about ten million fully-electric vehicles onto the roads.

GLOBAL E-DRIVE PRODUCTION NETWORK WITH A FOCUS IN GERMANY The high-voltage batteries and battery components needed for all BMW and MINI electrified vehicles come from the company’s own battery factories in Dingolfing, Leipzig and Regensburg in Germany, as well as from Spartanburg (USA) and Shen-yang (China). The BMW Group has also localised production of high-voltage batter-ies in Thailand, at its Rayong plant, and is working with the Dräxlmaier Group for this. Munich is home to the e-drive pilot plant and the Battery Cell Competence Centre, where the BMW Group is conducting a full analysis of battery cell value creation processes and advancing technology for its production processes. The company produces electric motors at the Competence Centre for E-Drive Production in Dingolfing and at BMW Group Plant Landshut. BMW Group Plant Steyr builds the housing for the highly integrated fifth-generation e-drive. For further information, please visit www.bmwgroup.com

PECM Issue 51

EDITOR’S CHOICE

ABACUS digital water measuring system Adding a preset quantity of water to a mix has long been carried out using pails or hosepipes. Not very accurate and certainly not consistent. Now, Hertfordshire company Aquameter has developed the ABACUS digital water measuring system for dispensing accurate preset quantities of water straight into mixing vessels, tanks, etc. Easy to install and simple to use, the ABACUS delivers repeatable results day in, day out, reliably and consistently. Thousands of units have been sold worldwide to a whole variety of industries where water is added to powders or granules for mixing purposes. Just dial in the batch amount required and press the start button. The unit stops the flow of water when the required quantity has been delivered - easy. aquameter limited, 8 Woodlands Drive HODDESDON, EN11 8AZ Tel: 01 992 442 861

www.aquameter.co.uk

Issue 51 PECM

EDITOR’S CHOICE

3D PRINTING & DIGITAL INVENTORY 3DPRINTUK

Accelerating Satellite Manufacturing For manufacturing companies looking to revolutionise their responsiveness to customer spare parts demand, 3D printing opens up compelling opportunities. Today, 3DPRINTUK is promoting its ability to act as a satellite manufacturing facility for any overseas manufacturers to service UK spare part demand by curating their digital inventory. The advantages of 3D printing — promoting design freedom, attainment of hitherto impossible geometric complexity, no tooling (saving time and money), speedy and cost-effective production, and mass customisation — are now well-known and accepted throughout industry. However, the impact that 3D printing can have on inventory is less well rehearsed, as are the ways that manufacturers can use digital inventory to enhance their responsiveness to customer demands wherever in the world their customers are. The key is that 3D printing means that parts can be made on demand and delivered to customers in any geography from anywhere in the world. In general terms, spare parts management benefits from the agility, cost-effectiveness, and increasingly material agnostic nature of 3D printing, and also the fact that the technology is cost-effective for producing single items or low volume runs. The same cannot be said of traditional manufacturing processes, where production runs are only cost-effective in high volumes. Generally speaking companies do not like to hold large volumes of stock. 3D printing of spare parts can cut costs, increase the functionality of parts, add a high degree of flexibility and responsiveness in service, and reduce risks. It also means that spare parts can be printed on demand, slashing the costs associated with having to hold high stocks levels of all spare parts, and also reducing the reliance on supply chains (often international supply chains) meaning spare parts can be printed locally in the numbers required. Nick Allen, Managing Director at 3DPRINTUK says, “At 3DPRINTUK, we hold digital files — effectively digital

inventory — on behalf of customers, and our customers also hold digital inventories stored in-house on local computers or in the cloud. This means that these customers can drastically reduce stock levels, and can activate the production of any spare parts in any volume required at the click of a mouse. This is true just-in-time manufacturing and is possible using 3D printing, as production is direct from design files and does not require time-consuming and costly production of tools. As such, at 3DPRINTUK we are a critical part of a truly digital workflow, completely revolutionising the ways that manufacturers view the need for warehousing and associated logistical costs, and taking an enormous strain off the balance sheet.” Another advantage is that 3D printing from a digital inventory can localise production. Multi-national companies with production facilities in various geographies can print the spare parts needed as close to the customer as possible, therefore reducing the time and cost associated with international and often long-haul shipping. With this in mind, expert 3D printing service suppliers such as 3DPUK act as satellite production facilities for international

manufacturers with customers they want to service in the United Kingdom. Allen continues, “Consider a manufacturer based in the United States, with sales offices and customers across the world, but only one large manufacturing facility in New Jersey. Before the digital workflow possibilities that exist via 3D printing, this company would either have to hold large stocks of spare parts in costly and extensive warehouse facilities, and take on the expense of shipping them all over the world, or would just not provide a spare parts service which would have a significant impact on customer retention. Today, that company can hold an array of spare part design files in the cloud, make amends to them over time to enhance their look, feel, or effectiveness, have them printedon-demand by 3DPRINTUK for all UK customers (and by equivalent 3DP service suppliers in other countries), and they can be delivered in the hands of a customer in as little as 3 working days.” 3DPRINTUK welcomes the opportunity to discuss how it can help to streamline the approach of manufacturers to inventory, and at the same time enhance their agility and responsiveness to customer demand.

For further information, please visit 3dprintuk.co.uk

PECM Issue 51

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EDITOR’S CHOICE

LATEST NEWS FROM MAN GROUP MAN GROUP

C-MAC SMT bounces back from Covid-19 to target £4m in sales New automotive, electrification and medical opportunities are helping a specialist provider of complex printed circuit boards (PCB) and electronics assembly target a 50% growth in orders as industry emerges from the pandemic.

Under new ownership, the management team has shifted the focus from small oneoff orders to concentrating on strategic customers that offer repeat business, a focus that has already led to a string of new client wins.

C-MAC SMT, which employs 28 people at its state-of-the-art facility in Warwick, has bounced back from the challenges of Brexit and Covid-19 to post impressive sales of £3.2m for the last twelve months, with initial projections suggesting the £4m barrier is in reach for 2021.

“I don’t think anyone has ever seen 12-months like we’ve just had,” explained Richard Halton, Business Development Manager for C-MAC SMT.

It marks a record year for the business and comes just 24 months after it was bought by Belgian-based C-MAC in 2018.

From left, Barbara Hazi and Martin Hancock (both C-MAC SMT)

PECM Issue 51

“From the start of the pandemic to this day, we have managed to keep the factory open, with the shopfloor switching to socially distanced production and office staff working from home. Despite all of these challenges and many of our automotive customers halting work for a

period of time, we still grew turnover 29% in 2020.” He added: “This has continued in the first quarter of 2021, with the car industry bouncing back beyond all expectations, joining some new wins in the medical sector – an industry rich in potential for our expertise in PCBs and electronic assembly. “Electrification is a massive opportunity for us as well and this is why we are using our membership of the Manufacturing Assembly Network (MAN) to pool resources with the likes of Alucast, Brandauer and PP Control & Automation. Together, we have the complementary expertise to offer the OEMs and end users access to a single-source manufacturing solution.”

C-MAC SMT, which also offers X-ray inspection as part of its commitment to top level assembly and testing, has strengthened its offer for clients with re-accreditation to ISO9001:2015 and ISO:14001 standards and ongoing work towards securing ISO:13485, the medical device manufacturing standard. This ensures it provides world class quality and environmental performance across all of the different markets it serves, with all staff given IPC-A 610 Class 3 training, which is the highest level of electronics assembly.

Together, we have the complementary expertise to offer the OEMs and end users access to a singlesource manufacturing solution.”

Backed by its parent company, the business is also drawing up plans to construct additional semi-clean assembly areas on the existing mezzanine, so that it can offer additional final assembly capability – reflecting a growth in enquiries for this requirement. Richard concluded: “Brexit, at first, had little effect on our supply chain as the majority of our suppliers had all the necessary paperwork in place. However, during the last couple of months we’ve begun to see cracks appear and delays on components arriving to use from Europe. What would normally be two to three days has now gone out to three to six weeks delivery times. “Hopefully, this will just be a temporary issue as 2021 is shaping up to be a very good year for C-MAC SMT, as we aim to reach £4m for the first time in our history.” For further information, please visit www.cmacsmt.com or follow C-MAC SMT on LinkedIn. Issue 51 PECM

EDITOR’S CHOICE

THE ENERGY SAVING FAMILY EBE ENGINEERING

ECOFLOW venturi orifice steam trap DN40 and DN50 applications in every type of industry. Improving the overall energy efficiency of steam systems through the innovative venturi technology, and with no moving parts they are effectively maintenance-free. In contrast to traditional mechanical steam traps there are no mechanical sealing faces in the trap to fail and cause steam leakage. With no wear parts, ECOFLOW delivers a permanent solution for all your steam trapping requirements.

The highly successful ECOFLOW venturi orifice steam trap range has been further expanded to include fully cast DN40 and DN50 bodies. Using the modular concept developed in the smaller flange sizes from DN15 to DN25, the new DN40 and DN50 flanged design allows for maximum flexibility, as larger interchangeable nozzle sizes can be used and achieve higher flow rates (up to several tonnes of condensate per hour). The DN40 and DN50 are now cast in 1.4408 austenitic stainless steel. This antimagnetic material offers superior resistance to aggressive acidic environments and is ideal for chemically contaminated industrial as well as all other standard environments. Manufactured using precision investment casting which produces an excellent surface finish and dimensional tolerances. The completely homogeneous housing has no weld joints enabling EBE to deliver a product meeting the highest standards of the stringent European pressure equipment directive as well as the AD2000 Merkblatt W0 regulations.

EBE Engineering Managing Director, Nigel Egginton is happy to report: “This latest addition to our range gives us a complete product offering that cannot be matched by any other venturi orifice steam trap manufacturer. It has always been our intention to eliminate weld joints and supply fully cast venturi orifice steam traps. The expanded ECOFLOW range enables us to supply all industrial steam users with this exceptional product across the entire range of ISO EN 26554 flange requirements and meet all their process flow needs.”

The complete range is assembled and available from stock through EBE’s German subsidiary, where all European and global markets are serviced directly. For further information contact EBE Engineering on their website www.ebe-eng.com.

The unique ECOFLOW venturi orifice steam traps can be used on all steam

For further information, please visit www.ebe-eng.com.

PECM Issue 51

Delivering permanent solutions for all steam trapping requirements The ECOFLOW Venturi orifice steam trap, from EBE Engineering, is the most advanced Venturi orifice steam trap on the market today. The fully flanged cast housing was designed, developed and refined using 3D modelling and casting simulation software. Producing a Venturi orifice steam trap to meet the rigorous requirements of todays steam plant users. Developed Developed on on aa modular modular concept, concept, the the ECOFLOW ECOFLOW Venturi Venturi orifice orifice steam steam trap trap encompass encompass aa wide wide range range of of capacities, capacities, from from minimal minimal condensate condensate flow flow requirements requirements on on line line drainage drainage and and trace trace heating heating systems, systems, through through to to the the high high flow flow volumes volumes and and variable variable loads loads of of process process heating heating applications. applications.

● ● ● ● ● ●

Benefit Benefit from: from: Improved Improved production production efficiency efficiency without without downtime downtime due due to to failed failed steam steam traps traps Elimination Elimination of of expensive expensive steam steam leaks leaks Reduction Reduction in in maintenance maintenance with with aa full full ten ten year year performance performance guarantee guarantee on on all all Venturi Venturi orifice orifice steam steam traps traps

Increasingly the first choice for blue chip and forward thinking businesses.

Venturi Orifice Steam trap range EBE EBE Engineering Engineering Ltd, Ltd, Suite Suite 45 45 Venture Venture West, West, Greenham Greenham Business Business Park, Park, Thatcham, Thatcham, RG19 RG19 6HX 6HX •• Tel: Tel: +44 +44 (0)1635 (0)1635 600424 600424 pecmjuly2021@ebe-eng.com. pecmjuly2021@ebe-eng.com. • www.ebe-eng.com Issue 51 PECM

EDITOR’S CHOICE

Arc Energy Arc Energy Resources has successfully commissioned its new electroslag strip cladding equipment. The ESAB-manufactured machine was bought to support a project on the UK’s small modular nuclear reactor programme, providing weld overlay cladding on full size demonstrator parts. Arc Energy supplies weld overlay cladding and specialist fabrication to the nuclear, defence, petrochemical and oil & gas sectors. Cladding provides a corrosion-resistant overlay to valves, pipes, flanges and other components, significantly extending their service life. Arc Energy can offer a full range of services including material procurement, weld qualification, cladding, fabrication, machining, NDT, destructive testing, blasting, painting and CSWIP inspection. Certifications include ISO 9001, ISO 14001, OHSAS 18001, ISO 38342, EN-1090 Ex. Class 2, and ASME U & U2 Stamps. www.arcenergy.co.uk

Laser Cutting for Plastics As the UK distributor for Cutlite Penta and other market-leading international die-shop brands, we also run our own plastics engineering arm. We know that when it comes to performance you cannot cheat on having the appropriate technology. All Cutlite Penta lasers are equipped with linear motor technology that guarantees speed and accuracy. Well-regarded for innovation and performance, a single laser can operate on two separate beds, while metal and plastic cutting lasers can be combined on a single bed. Customers invest in our technology again and again because they are confident of the support from Italy together with Partwell’s UK service. If you are planning to invest in a laser, invest wisely. Contact us to discuss which Cutlite Penta laser machine best meets your needs. Email: Info@partwell.com Tel: 01254 671 875 www.partwell.com

PECM Issue 51

SWEP fulfils All-Stainless range for the most demanding applications SWEP, leading supplier of compact brazed plate heat exchangers (BPHEs), now enhances the existing All-Stainless product range with the introduction of new products developed for the most demanding applications and systems requiring 100% stainless steel components. All-Stainless is a range of durable, compact, and efficient BPHEs for the most demanding applications that often use aggressive media such as ammonia, deionized water system, or fluids with high sulphur content, all of which can be corrosive to copper. All-Stainless is therefore ideal for a wide range of industrial applications and utilities with high demands on corrosion resistance, low tolerance for contamination and/or high operating temperatures.

Avoid Brexit border delays to keep your CHP running smoothly Importing quality European CHP spares has become more difficult this year. According to the Chartered Institute of Procurement & Supply (CIPS), 45% of firms have experienced delays getting goods into the UK from the EU since 1 Jan 2021, citing Brexit custom requirements and Covid-19 protocols as the main causes. Thanks to a significant investment in stock, Gen-C’s Sheffield warehouse contains multiple European CHP components, such as Motortech spark plugs, filters, HT leads and more. Purchasing quality European spares from a UK distributor such as Gen-C brings none of the hassle of importing from the EU – no red tape, no border delays and no additional fees. And with free technical support and same-day dispatch, your engine can continue to run smoothly no matter what’s happening at the border.

Learn more about the All-Stainless range: www.swep.net/campaigns/all-stainless/

To order your CHP spare parts minus the delays, fees and red tape, call 01709 718002 or go to www.gen-c.co.uk

Thermoplastics solutions for cryogenic environments

Analysis by Firth: transforming product design

Extreme low-temperature environments are challenging manufacturers and designers across the Energy, Aerospace, Food and Medical industries. The selection of suitable polymers for use at cryogenic temperatures is now an urgent issue. VICTREX™ PEEK polymer and its formulations provide a unique combination of high performance properties from high strength/ toughness at extreme temperatures, low permeability, low friction, and high wear resistance needed for seals, valves, and packings. With this combination VICTREX™ PEEK polymers have the potential to increase efficiency, reliability and service life and mitigate environment, health and safety (EH&S) risks.

As a manufacturer or product designer are you: • Looking to reduce design and development costs? • Or would like to solve current service problems readily?

With over 40 years of experience, Victrex expertise can support the development of the next generation of components needed for cryogenic applications. www.victrex.com

At Analysis by Firth, we help you to resolve existing challenges and identify design issues before they turn into problems. With a proven track record of resolving problems in industries such as road and rail vehicles, aerospace and industrial plant, we understand manufacturers’ needs. Our expertise has supported the successful development of everything from a foot file to a double decker bus. We pride ourselves on our client feedback which consistently highlights the quality of our personal and responsive services, even within the strictest of deadlines. Get in touch to find out how we could help you – or find out more about our services or training courses. www.abyf.co.uk

EDITOR’S CHOICE

Aughton Hire & Callibration Services

At Aughton Hire, our success can be measured by our wonderful customers who return regularly to enjoy our fast, friendly service and competitive test equipment rates. Our test and measurement equipment is top of the range, and our staff are experts in all aspects of calibration and repair. We offer a wide range of the latest test equipment for hire off the

shelf, complete with full certification. Calibration and Repair Service – Instruments calibrated to traceable standards. For all your test equipment requirements contact: 115 Evans Road, Venture Point Business Park, Liverpool, L24 9PB Kathy@aughtonuk.com | Roy@aughtonuk.com T: 01928 589600

www.aughtonhire.co.uk

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

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

www.mcs-corporate.com

01926 512475

gjw@mcs-corporate.com Issue 51 PECM

EDITOR’S CHOICE

QUALITY AND CONSISTENCY QMS INTERNATIONAL

Why is quality management more important in manufacturing and engineering than ever before?

Quality and consistency have always been benchmarks of good business in the manufacturing and engineering sectors, but after the turmoil brought by COVID-19 they have become even more crucial. COVID-19 brought widespread disruption – and the manufacturing and engineering sectors were not immune. Many businesses within these sectors had to temporarily down tools; at the height of lockdown, the Engineering Insights Dashboard from Engineering UK revealed that nearly a quarter (24%) of engineering businesses paused their work. This means that many businesses have faced, or are now facing, the reality of re-starting production on machinery that has been out of use with workforces that may still be limited due to ongoing social distancing.

PECM Issue 51

Supply chains have also been badly damaged. According to Engineering UK, one-fifth of engineering businesses who normally export and import products have ceased to do so. This means that many businesses are having to establish new supply chains, which are inevitably struggling with demand. This has resulted in higher prices and longer delivery times. Temporary closures and supply issues are also affecting contractors for both sectors. A backlog of work means contractors are stretched thin and projects are suffering with ongoing delays. These issues are being compounded by a recent uptick in activity. According to the latest HIS Markit/CIPS Purchasing Managers’ Index for April 2021,

the UK’s manufacturing activity grew at its fastest rate since 1994, when the index hit a record high. The results of the latest Manufacturing Barometer carried out by SWMAS and the MGP also shows that two-thirds of SME manufacturers expect to increase sales between now and October, while 48% of respondents believe that they will return to, or even exceed, their pre-COVID position within the next three months. With supply chains under pressure, the cost of materials rising, ongoing COVID restrictions in the workplace and a desperate need for more trained staff, ensuring that quality and consistency is maintained is even more important – and even more difficult.

The management system can also help to keep your staff safe in a COVIDsecure workplace.

Quality management systems create a robust framework of processes for leadership, planning, support, operation, and monitoring and improvement to maintain and develop quality and customer satisfaction. This helps businesses to: • Reduce errors • Improve customer retention • Increase efficiency for lower costs • Improve supplier relations • Create a more factual approach to decision-making

MAINTAINING QUALITY IN A POSTCOVID WORLD To combat these issues, manufacturers and engineering companies need the right processes in place to ensure they get it right first time, every time. With these processes in place, these businesses can ensure that their output remains at a consistent quality, that their suppliers are carefully chosen based on suitability and availability, and that the most talented candidates are attracted to their company to work. It can even put businesses in the right place to explore new markets and attract new business in the post-COVID world. One way of ensuring that quality is maintained throughout the business, in every operation, is by implementing a quality management system such as ISO 9001.

• Boost employee morale By implementing a renowned quality management system such as ISO 9001, business can also improve the reputation of the company, attracting both new business and the best talent. The management system can also help to keep your staff safe in a COVIDsecure workplace. One of ISO 9001’s requirements focuses on the environment for operations. This means you need to have the right processes in place to keep your staff safe and productive.

RISKS AND OPPORTUNITIES Quality management systems also develop risk-based thinking, which can help businesses to cope with uncertainty – something that has become

increasingly important in the wake of the pandemic. ISO 9001’s Plan, Do, Check, Act Cycle can help manufacturers and engineering businesses to identify risks, develop strategies to deal with them, monitor and evaluate the results, and create improvements for even stronger performance. Quality management systems can also highlight new opportunities and give manufacturers and engineering companies added clout when it comes to exploring new business in the post-pandemic world. During the pandemic, Efinity Labs recognised the importance of implementing best practice processes to produce quality products and enter the new market of alcohol sanitiser. They therefore went on to implement ISO 9001. By doing this, they have gained traction in other previously unexplored markets, such as the cosmetics sector. “The ISO is very much working in our favour at the moment,” reported Efinity Labs’ Operations Director. “All the new markets we are looking at will ensure that we will be busy.” Indeed, the company estimates that their new business will increase their turnover by three or four-fold. This article was authored by Claire Price from QMS International, one of the UK’s leading ISO certification bodies.

For further information, please visit www.qmsuk.com Issue 51 PECM

EDITOR’S CHOICE

A COST-EFFECTIVE UPGRADE IFM

ifm offers vibration monitoring without wires Powered from an internal battery with a life of at least four years, wireless vibration sensors in the new VW range from ifm electronic are fast and easy to install even in difficult-to-access locations. Since they require no wired connections of any kind, the new sensors offer a convenient and cost-effective way to upgrade critical machinery by adding condition monitoring for by adding condition monitoring for key mechanical components. VW vibration sensors are designed for use in conjunction with ZB0929 network gateways, with which they communicate wirelessly using an intelligent mesh topology that combines data security with reliability. Gateways can be connected to the plant network or fieldbus system using either an Ethernet cable or one of the supported wireless options, which include NB-IoT, LTE CAT 1, Wi-Fi and 2G GSM. Each gateway can support up to 30 sensors, making it easy to set up comprehensive monitoring systems even for complex machines.

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Data provided by the VW sensors includes v-RMS values over the range 0 to 25 mm/s and 10 to 1000 Hz, and temperature from -40 to +85 ºC. The data can be visualised and analysed with the ifm LR SmartObserver software package, which also has provision for setting alarm points, or it can be used directly in systems based on the ifm moneo IIoT platform. Two versions of the VW sensor are available: the VW001 has a single measurement axis, while the VW002 has three mutually perpendicular measurement axes. Both types have an IP68 ingress protection rating and an operating temperature range of -40 to +85 ºC, allowing them to be used in the most demanding of industrial applications. Available accessories include an M8 magnetic and stainless-steel adhesive mounting adaptors. www.ifm.com/gb/en/shared/product-news/2020/smart-vibration-monitoring-without-cabling

PECM Issue 51

Protect your critical assets from spinning out of control!

Vibration monitoring 24/7 Monitoring and Condition Based Maintenance of rotating machinery. This complete solution makes your machines fit for Industry 4.0

RANTY AR

years if m p r o d

• Continuous diagnostic: Full coverage of your critical assets at all times. • Early diagnostics: Monitoring of imbalance, wear and overall vibration. • Maximum efficiency: Permanent diagnostics helps keep your assets running efficiently. • Easy integration: ifm provides individual solutions suited to different types of machines. Reducing costs, avoiding unplanned downtime and optimising processes: The ifm application solutions. ifm – close to you!

Go ifmonline ifm.com / uk

EDITOR’S CHOICE

TERMINAL BLOCKS OEM

Choosing the correct terminal blocks for your requirements WHY ARE TERMINAL BLOCKS IMPORTANT? Terminal blocks, also called terminal strips, are the backbone of automation and electrical control systems. These devices secure two or more wires together and are enclosed in insulated housing. There is a clamping component and a conducting strip. Terminal blocks come in a variety of sizes, specifications and colours. Terminal blocks increase safety by grounding, isolating and protecting the other components in the electrical cabinet. They provide test points, adding functionality and safety to the circuit. They are finger-safe connections that prevent electric shock. Using the correct terminal blocks for your application from the start protects expensive electronics and measuring devices. It provides your business with essential insurance against dangerous electrical situations, shutting down of production lines, and losses in manufacturing, productivity and customer confidence.

STRUCTURED TYPES OF TERMINAL BLOCKS There are three structured types of terminal blocks: • single-feed terminal blocks providing a wire-to-wire connection, connecting two wires together safely • double-level terminal blocks stacking another level of connection terminal on the first one • triple-level terminal blocks with three levels of contacts stacked on top of one another. Multi-level blocks allow a number of connections to be made in the same block and can save space, simplify wiring and increase current capacity.

COLOUR CODING OF TERMINAL BLOCKS This can get rid of the need for additional labelling. It can indicate to the end user:

DETERMINE SPECIFICATION REQUIREMENTS – SPACE You should choose a terminal block and DIN rail that will fit well in the space you have, with enough clearance above and below for the terminals, accessories and the bend radius of the wires being connected. • high current or voltage • AC or DC input and output • signal distribution wires or power distribution wires • grounding and earthing.

CONSIDERATIONS IN CHOOSING THE RIGHT TERMINAL BLOCK FOR YOUR APPLICATION Key considerations are type of connection, specification requirements, compatible accessories and rail length.

DETERMINE WHICH TYPE OF CONNECTION SUITS YOUR REQUIREMENTS Different wire termination connections are used in different applications. They include push-in, screw-in, spring cage, insulation displacement and lugs. Will there be vibration (such as in shipping) or long usage in the field? If you choose a screw connection, you may have to write a torque specification and re-check the connection regularly. Push-in and spring cage connections do not need this. Will there be high currents? This could cause a spring cage connection to heat and cool regularly, weakening so that the wire is no longer safely anchored. In this case the spring should be steel reinforced. Will the connection have repeated use? How many times will it be required to operate and still make a reliable connection? Insulation displacement connections cannot be continually disconnected and reconnected without cutting and shortening the wire, which wears out the blades. Push-in and spring cage connections have a limited actuation life as well. panel@oem.co.uk | 0116 284 9900

PECM Issue 51

Always make sure you have met the proper agency approvals for safety and end user location.

DETERMINE SPECIFICATION REQUIREMENTS – ELECTRICALLY Consider the maximum voltage, current rating and the wire sizes used in your system. The wire size can be calculated through the current rating. Wire size (solid or stranded) also depends upon the type of conductor being used. The contact material of your terminal block and wires of dissimilar metals can corrode, and aluminium on copper will loosen if not properly treated. For a signal reading like a thermocouple, the metal of the terminal block has to match the metal of the wire in order to ensure an accurate measurement. Review the physical environment as well as temperature ratings. Consider maintenance requirements after installation. The actuation points to remove and re-attach wires should be easy to see and easily accessible.

WE’RE READY TO ASSIST YOU

Invest some time in choosing the correct terminal block to ensure they are robust, efficient and perform well. To choose compatible accessories to match your DIN rail requirements, click here to find out more. We will also show you how to calculate DIN rail length. As always, the Panel team at OEM Automatic is available to assist with your requirements and specifications.

HydroSym - saves you hours of design time. The only software you need for perfect hydraulic schematics every time.

Click and add components from the Paro Library of over 40,000 of hydraulic components and symbols.

Quick, Easy and Intuitive.

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Focus more on your schematics, and less on the administrative side of the design process. How? The many smart features that work for you such as custom headers, automatic generation of Bill of Materials (BOM), easy sharing with your clients and many more. Download your free one-month trial on our website and start drawing your schematic in the next 15 minutes.

HydroSym is an enrichment in our working life. lt is incredibly supportive when the result is not only perfect but also makes the work itself enjoyable and fun.” I thoroughly enjoy HydroSym. lt is the best schematic software I have ever used. lt is user friendly, easy to make new symbols and the support from you guys is just excellent.”

EDITOR’S CHOICE

Noise Controlling Metals

DESIGN

Manufacturing Quiet

Feasibility, Model, Create

DEVELOP

“sds – performs like metal, sounds like rubber…”

Processes, Tooling & Cost saving

OEM design retro-fit noise control kits materials components

MANUFACTURE Injection Moulding, Assembly & Quality Assured

Cybertools has been delivering the highest standard of plastic injection mould tools and moulded parts for nearly 25 years.

Conventional metals are efficient loudspeakers, radiating noise. sds manufactures highly damped quiet metals that don’t radiate noise. Simply swap your noisy metal for quiet metal and reap the rewards.

Our reputation for providing complete and innovative solutions for the plastic injection industry has established us as a key and trusted partner for large and small companies, around the world. Through our design, toolmaking and manufacturing capability we offer customers a comprehensive service from product conception to market.

galvanised, stainless, aluminium, combinations…

Talk to us when considering your next project. Cybertools Ltd Unit 2 + 3 + 4, Watermill Ind Est, Aspenden Road, Buntingford Hertfordshire, SG9 9JS. Main Office: +44(0)1763 271211 www.cybertoolsltd.co.uk

Effective, rugged, hygienic and low cost Noise + vibration control made simple sound damped steel

+44 191 2590700 sales@sounddampedsteel.com Les Thompson +44 7513 908060

www.sounddampedsteel.com/

ai16246126168_Metaltec 88mmw x 132mmh-HR.pdf

25/06/2021

Applications other bearings can’t handle? BowMet - Heavy Duty ToughMet Spinodal Bronze Bearings

t C

er than all t he ong r t S r

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max static load: 18.8 tonnes actual size bearing: 15 x 17 x 15mm T H E LU B R I C AT I O N S P E C I A L I STS

PECM Issue 51

www.bowman.co.uk

10:16

EDITOR’S CHOICE

Your technical experts for plastic injection moulding

DESIGN DEVELOPMENT MOULDING

A complete injection moulding service The Pentagon Plastics Group provide bespoke mould tooling solutions and plastic injection moulding production all from one site of UK manufacture. Unique in their offerings the group are one of the few UK based injection moulding companies with the ability to support customers throughout the life of a project. From the early design phase right the way through to repeat production of low to medium volume, your project will be

handled by their expert and experienced in-house team. Delivering consistency and accountability through each phase of a customer project, make Pentagon your supplier of choice for UK manufacture of plastic injection moulding. To make an enquiry, call us on 01403 264397 or email websales@pentagonplastics.co.uk

For more information on all of our services please visit www.pentagonplastics.co.uk

TOOLING BEYOND THE MOULD Make Pentagon your UK supplier of choice for Mould Tool manufacture and Plastic Injection Moulding. Whether you need a supplier for a new injection moulding project or sourcing a new manufacturing partner for existing production, Pentagon will support you at every stage.

www.pentagonplastics.co.uk | websales@pentagonplastics.co.uk Tel: +44 (0) 1403 264 397 |

Issue 51 PECM

EDITOR’S CHOICE

LUBCON CLEAN SERIES LUBCON

Food grade lubricants with unique formulation - the solution to avoid pathogen’s growth by Dr. Martin Wünsch, Head of Research & Development, LUBCON Lubricants UK Ltd The production of food and beverages requires a very high degree of cleanliness and industrial hygiene measures to prevent any hazards to consumer’s health. As a consequence, H1 approved lubricants are mandatory for all lubricating points where incidental product contamination is technically unavoidable or possible, but unlikely. Even if product contact is utterly impossible, H1 lubricants are recommended, due to the probability of a mix-up with standard lubricants if these are used in the same area.

THREATS CAUSED BY MICROBIAL CONTAMINATION

The European Machinery Directive 2006/42/ EC regulates (Annex I, Section 2.1.2.) that “instructions must indicate recommended products and methods for cleaning, disinfecting and rinsing”. However, in case of lubricated bearings or other sealed components it is nearly impossible to clean and disinfect the inside space properly once microbial organisms have penetrated and started growing within the grease. Microbial contamination in the environment of food and beverages production, however, is in particular of concern for gram-positive and gram-negative pathogens, e.g., Escherichia coli, Pseudomonas aeruginosa, Staphylococcus aureus, Legionella pneumophilia and Bacillus atrophaeus (see diagram). Incidental food contact with such germ-ridden grease can cause

Based on the example of the pathogen Bacillus atrophaeus, the diagram shows the germ formation within conventional grease in comparison to a product from the newly developed LUBCON Clean Series.

Obvious evidence in a petri dish: The growth of pathogens (here: Legionella pneumophilia) in a grease can evidently be reduced by the unique formulation of LUBCON Clean Series.

contamination of complete production batches, resulting in serious health risks for the consumers and the need for a product recall campaign causing severe damage to the company’s image.

The effectiveness of preventing pathogens from growth in these newly developed lubricants could be demonstrated in incubation tests by an independent microbiological laboratory.

EFFECTIVE SOLUTION: LUBCON CLEAN SERIES WITH UNIQUE FORMULATION

Potential applications for LUBCON Clean Series lubricants are in particular all processes where special measures for germ control like heat, radiation, sterilization, addition of preservatives etc. are excluded, e.g., for the aseptic cold filling of fruit juice.

In order to avoid these complicated situations, the application of H1 lubricants from LUBCON Clean Series based on an innovative formulation is highly recommended.

For further information, please visit www.lubcon.com

PECM Issue 51

Increasing Maintenance Efficiency with High-Performance Food Grade Lubricants LUBCON‘s H1-certified oils and greases allow incidental food contact and thus help to avoid product recalls due to contamination. By prolonging maintenance intervals and reducing machine downtimes, LUBCON lubricants increase machine availability and efficiency of food production facilities. We are the experts for streamlining your lubricant portfolio in order to improve production processes. Don‘t hesitate to use our long time experience in tribology for optimal machine performance.

www.lubcon.com

LUBCON LUBRICANTS UK LTD. Email: uk@lubcon.com | Phone: +44 1323 561030 Issue 51 PECM

EDITOR’S CHOICE

ROI ON A UV BONDING PROJECT INTERTRONICS

The considerations for establishing ROI in a UV bonding process Light curable adhesives have applications in the assembly of products in medical devices, automotive, aerospace, consumer electronics, appliances and more. The materials provide a way to reduce costs without sacrificing product quality. Once you have established criteria for performance and the application requirements to determine if a UV curing material might be suitable for your application, there are multiple considerations to get the best out of your investment. Here Simon Gibbs, Product Specialist at adhesives supplier Intertronics, shares insight on achieving return on investment (ROI) from a UV curing process. When designing a UV curing process, it is critical that you understand both the process and how it can deliver on your objectives, so that you can choose a material and equipment that meets your requirements. It is typical practice to narrow down the adhesive choice first, and then pair your material with a curing lamp with the correct spectral output, intensity and size. A robust process also requires comprehensive testing to prove process capability and ensure that the parts of the system work optimally together. There are several factors governing the ROI of a UV curing investment, including financial, environmental, materials, resources, quality and process considerations. UV curing equipment may be a larger upfront investment than other available technology, so it is important to understand the process and how you may be able to achieve financial savings over time.

ENHANCING QUALITY AND MINIMISING RISK UV curing materials offer good toughness, durability, shock and moisture resistance and structural integrity. As well as the properties of the adhesive, potential quality benefits can come from the UV curing process, which has characteristics that enable manufacturers to reduce chances of defects due to improper dispense or cure. Firstly, UV curable materials cure on demand in seconds. Manufacturers can therefore control the process so that cure is only initiated when the substrates are correctly positioned.

PECM Issue 51

UV curing materials can easily be combined with technology that makes in line inspection easy, such as See-Cure technology, which changes colour once the material has cured, building a visible safety factor into the assembly process. This can be further combined with Ultra Red™ fluorescence technology to streamline post-cure bondline inspection. This technology means the adhesive remains clear until exposed to low-intensity black light, at which point it fluoresces bright red, particularly useful when bonding plastics that naturally fluoresce blue.

UV curing materials offer good toughness, durability, shock and moisture resistance and structural integrity. The potential improvement in yield and ability to identify and remove defective products can help deliver a good ROI, although it is difficult to quantify the confidence and subsequent reputation gained by both you and your customers when you consistently deliver high-quality products.

REDUCING COSTS The ability to achieve a near-instant light cure means manufacturers can increase their production rates and reduce labour costs. Compared with that of a two-part material, the process can be simpler. For two-part products, the extended cure time will require more fixtures and space in the factory. A thermal cure may be required to speed up the process and reduce WIP, with the extra energy of an oven and load/unload overhead. The working life of the mixed two-part product needs to be managed to prevent excess waste or application equipment blockage.

UV curing adhesives may present inherent material savings when the process and waste is taken into consideration. For example, leading adhesive-manufacturer Dymax compared the cost of a UV curing adhesive with a two-part, urethane adhesive that had a lower cost per gram. Once the higher material usage, as a result of purging, improper mixing and general waste in the mixing system, was considered, the material cost benefit for the two-part material vanished. UV curing adhesives are 100% solids, include no solvent carrier and produce no volatile fumes; usually, there is no requirement for special venting in the facility. IMPROVING EFFICIENCY AND PRODUCTIVITY UV curing adhesives provide fast cure times that enable shorter cycle times and reduced work in progress. Their small process footprint means space can be freed up for other tasks — there is no racking or heating required, saving time and floor space. UV curing processes are well suited to automation, meaning the manufacturer can benefit from the typical automation benefits such as improved repeatability and precision, and the fact that robots do not get tired or need breaks.

TWO DIFFERENT UV TECHNOLOGIES Part of the ROI calculation will be the cost of a UV curing lamp. For optimal results and to get the full benefits of the technology, an industrial unit with the correct output is required. It is always a false economy to use UV sources which do not meet a minimum recommended intensity or output non-optimal wavelengths — incomplete cure being the most obvious result. A good supplier will work with you to choose and evaluate appropriate curing equipment. There are two types of UV curing lamp, based on fundamentally different technologies. The traditional light source used during UV curing is a mercury-based arc lamp, which emits broad spectrum light.

The alternative is an LED UV curing lamp, which differs by emitting narrow spectrum UV light.

of curing time (in practice many years), whereas the lifespan of a mercury arc lamp refers to running time.

For manufacturers establishing new processes, LED UV curing is usually the recommended option. The range of adhesives suitable for curing with narrow spectrum LED UV light is increasing all the time. Process control is much easier with LED UV lamps, as they offer more consistent output — up to or exceeding 20,000 hours. On the other hand, mercury arc lamps have a typical life of 2,000 hours, degrading throughout this period. LED curing lamps have no bulbs to change, which removes the need to pay for replacements. They run at lower temperatures, helping to avoid thermal rise and substrate damage.

LED UV curing lamps are attractive because of better process control and low running costs. However, if you are looking to switch from a mercury arc lamp to an LED UV lamp, it may not be as simple as a straight swap. It is important to ensure that your adhesive cures effectively with the narrow spectrum output; some, especially those designed for broad spectrum cure, will cure with unexpected characteristics.

LED lamps have no warm-up or cooldown time, so the manufacturer can turn them on, as and when needed, using them immediately. In contrast, the warm-up and cool down time associated with a broad spectrum lamp means that manufacturers leave them running all day, with the increased power consumption. The 20,000 hour life of an LED curing lamp therefore represents 20,000 hours

If you are already operating a mercury arc process, you may need to consider how often you are changing your bulb, the price of the bulbs, the downtime for bulb changes, and the cost of monitoring the output of the bulb, and calculate whether upgrading to an LED curing lamp will deliver an appropriate ROI. For manufacturers who can change their adhesive, consider whether you are trying to reduce costs, solve a technical problem, or both. Because switching adhesives may require revalidation, it is typically done by businesses with a

strong commercial or technical drive for the change. Some examples may be supply issues, a change in the regulatory environment, or a product update involving new substrates or bondline design.

CONCLUSION A UV curing adhesive can deliver good return on investment. It is important to take a holistic view, considering productivity, quality, yield, throughput, energy, H&S and similar factors in the calculation; material and equipment costs are often offset by these other benefits and the resultant savings. The materials offer fast, on demand curing, and can be easily combined with automation to further improve throughput and yield. Whether you are considering UV curing materials for a new or existing process, it is important to consult with someone who can talk you through the specifics. For more information on establishing a UV curing process, visit www.intertronics.co.uk/ product-category/uv-equipment/, where you can access our top tips for getting the best from your UV curing process.

For further information, please visit /www.intertronics.co.uk Issue 51 PECM

EDITOR’S CHOICE

ONE CHAIN FITS ALL DONGHUA

Multiple Brands, One Universal Attachment Chain No matter what brand of chain you use, Donghua’s Universal Attachment Chain will replace 99% of other manufacturer’s chain. Chain manufacturers typically design and build attachments that are unique to their own brand of chain which makes it difficult to replace with a different make. However, Donghua, one of the world’s largest chain manufacturers, has designed a range of Attachment Chain that does just that. Their Universal Attachment Chain has been designed specifically for the UK distribution market who supply end-users with chain from a range of manufacturers. Bob Wellsbury, managing director of Donghua Limited, explains “Because our Universal Attachment Chain has the same critical dimensions as other manufacturers’ chain, it means distributors and end-users are no longer tied into using the same brand for their replacement Chain. It provides the UK market with a unique ‘one chain fits all’ solution’.” Donghua’s Universal Attachment Chain is assembled in the UK in a purposebuilt, technical workshop at Donghua’s UK headquarters and distribution centre in the West Midlands. The facilities have been specifically developed to allow for quick turnaround of standard Attachment Chain and the design and build of bespoke Attachment Chain. The workshop boasts some impressive machinery including a Chain Length Measuring Machine which measures chain to within 10 microns per metre (that’s thinner

UK-built Universal Attachment Chain

Chain Length Measuring Machine than a human hair which is approximately 70 microns) and is capable of measuring up to five metres of chain at a time. Chain with little or no pre-load will have increased initial elongation before it levels off. To reduce the initial elongation which can often be found in ‘in-house’ built chain, Donghua’s Pre-loading machine prestretches their Attachment Chain to provide the best possible service and fatigue life. When two or more chains are used in parallel, such as in the food processing industry, precise positioning of chain is required. Donghua’s Matching Machine matches chain to within a close tolerance for correct tensioning which helps ensure the attachment links engage with the sprockets together to eliminate undue stress which can cause fatigue failure of the attachments. By ensuring Attachment Chain is measured, pre-loaded and matched, Donghua’s Attachment Chain is ready to fit from the box, saving engineer’s valuable time. Add a 72 hour turnaround to quote

Elongation of chain with & without Pre-load and deliver ready-to-fit, you can see why Donghua’s Attachment Chain has become a popular choice in the UK. With a 25,000 sq ft warehouse which stocks common builds of Attachment Chain and loose attachments, plus a network of UK Product Partners and Stockists who carry their own stock of chain, there’s plenty of Attachment Chain available ex-stock to supply the UK market. For more information about Donghua’s Attachment Chain visit their website at: https://www.donghua.co.uk/attachmentchain or call the team on 01902 866200.

For further information, please visit www.donghua.co.uk/attachment-chain

PECM Issue 51

No matter what brand of chain you use, Donghua’s Universal Attachment Chain has the same critical dimensions so it can replace 99% of other manufacturer’s chain.

Multiple Brands Need Only One

Our Universal Attachment Chain provides a unique ‘one chain fits all’ solution meaning distributors and end-users are no longer tied into using the same brand for replacement Attachment Chain. Built in the UK, our chain assembly workshop is equipped to produce high performance Attachment Chain, measured & matched and pre-loaded as standard.

Universal Attachment Chain

With a 25,000 sq ft warehouse, a network of Product Partners and Stockists, and high performance Attachment Chain ready to fit from the box, contact Donghua to order your Attachment Chain today.

Please call us on: 01902 866200 or visit: donghua.co.uk /attachment-chain Donghua Limited Units 9-10 Sidings Close Wednesfield Way Wolverhampton WV11 3DR

Tube

EDITOR’S CHOICE

A CASE IN POINT NORTHRIDGE PUMPS

24 Hour Remote Wastewater Sampling across 15 locations Wastewater monitoring has become increasingly important in not only ensuring a producers consent compliance through automated quality checks, data logging and discharge; but in an environment where there are increasing pressures socially, ethically and financially via increased economic penalties to adhere to set limits. It is a situation where a robust process has become essential. Producers not only need the confidence of compliance in an era of increasing fines, but also reduce and limit any impact made upon the surrounding environment. Reducing the amount produced and tracing its exact origin can be a challenging prospect. A customer contacted North Ridge Pumps with a requirement to remotely sample wastewater 24 hours a day, 7 days a week at set intervals across 15 locations. They needed to sample dirty water where water levels were very low at times meaning pumps were susceptible to dry running, there were fluctuating inlet pressures and a possible ingress of solids including grass, twigs and mud ruling out many pump technologies. They needed a low maintenance solution to pump at very low pressures, with a

flow requirement up to 500Lhour. Due to the remoteness of testing locations, and sampling required at various hours throughout the day they wanted to remotely control pump speed via a single-phase supply, have the ability to reverse units should they become clogged and have a way of detecting if the hose required replacement.

Our customer initially trialed a unit to check that the system performed as required, before ordering an additional 14 AMP16 3/4”Peristaltic Pumps complete with single phase inverter for speed control, hose leakage detector to enable the operator to know should the only wearing part fail via their installed PLC Controller, and with a remote input for reversing of the pump should any blockages occur. The units were supplied with forced air cooling allowing a wide operating flow with pump speed varying between 4 and 105 revolutions per minute. As the pump supplied is of roller design they are expected to experience as much as 30% reduction in unit power consumption compared to traditional designs of peristaltic pumps, extended hose life and see many years of troublefree service with inspection and lubrication intervals as much as 12 months apart. If you have a wastewater treatment application and are unsure of the most appropriate solution, consult with us. As North Ridge Pumps are not tied to a specific pump technology we can select the most appropriate pump for your application.

Visit us at www.northridgepumps.com or speak to a Technical Sales Engineer on +44 (0) 1773 302 660.

PECM Issue 51

EDITOR’S CHOICE

The LHS 210 / 410 Air Heater Series Leister’s new series of compact and powerful LHS 210 / 410 air heaters are suitable for installation in industrial plants where space is limited or tubular air systems such as furnaces for heat curing processes, due to their compact design and ease of integration. With a choice of eight air heaters with single (SF) or dual flanges (DF), the innovative design allows for easy electrical connection, with connection housing separated from the airstream, which allows unhindered air flows through the air heater with minimal loss in pressure. The connection housing is also protected against overheating, making it possible to work with an air inlet temperature up to 350 degrees Celsius. The SF-R and DF-R air heaters are equipped with an extension on the housing connection. The ceramic inside this extension ensures that the electrical connection on the tubular air heaters is sealed off and protected from high temperatures or backflowing hot air.

NEW AIR HEATER SERIES

LHS 210 / 410 COMPACT & POWERFUL The series SF-R and DF-R (“recirculation”) are designed for many industrial processes where hot air recycling is required. The recirculation abilities of these models’ lower energy consumption which reduces CO2 emissions and saves money. Welwyn supply the full range of Leister plastic welding and industrial process heat equipment and offers highly competent technical support by their team of dedicated engineers. For further information and technical advice for equipment in this field, please contact Welwyn Tool Group on 0800 856 0057, email them on info@welwyntoolgroup.com, or visit their website

EASY CONNECTION

COMPATIBLE NOZZLES

HOT AIR RECYCLING

HIGH AIR VOLUME OVERHEATING PROTECTION

$ ECONOMICAL

Tel: +44 (0)1707 331111 info@welwyntoolgroup.co.uk | www.welwyntoolgroup.com

www.welwyntoolgroup.com

SFL helps create the world’s first stainless steel coolant distribution unit for high performance cooling The challenge A major manufacturer of data centre cooling units needed help to design a coolant distribution unit (CDU) with stainless steel pipework instead of the traditional brass or copper. The solution They turned to Stainless Fittings Limited (SFL), given our extensive manufacturing knowledge of, and experience in, stainless steel pipework. The process We assisted our client in the design, manufacture and assembly of the world’s first stainless steel coolant distribution unit. The results • Stainless steel pipework in CDUs means improved performance, as the coolant fluid flows more efficiently through stainless steel pipes, compared to brass or copper.

U.K. SAMEDAY Delivery • Lower maintenance costs means the coolant fluid doesn’t need to be filtered or changed as frequently. • Stainless steel is resistant to both corrosion and leaks. To find out how SFL can help you with stainless steel fabrications contact Nicola on 0121 557 1188 or email n.whittingham@dpluk.co.uk

www.sfluk.co.uk

Small vans to full loads Collection within 30-60 mins

* Subject to availability

POD's on Delivery Online Quote & Book www.advanced-cargo.co.uk Issue 51 PECM

EDITOR’S CHOICE

SUMMER’S COMING RITTAL

Look before it’s too late! By Karl Lycett – Rittal UK’s Product Manager for Climate Control Even before summertime hits, we have already seen some good BBQ weather, with the mercury rising and letting us enjoy the great outdoors. Great for you, but it doesn’t bode as well for your electrical equipment. At this point in the year, there probably won’t be any alarms on your cooling equipment and therefore you’re mind wanders to other important issues on your site which need more ready attention. Climate Control can wait… Right? Wrong.. in fact, the opposite is true; this is the best time of year to turn your mind to your enclosures, carry out a climate review, and start to understand what changes or improvements need to be made before it’s too late. In a few months’ time, things will be very different.. Fans and filters won’t be cutting it if the ambient temperature is higher than you require inside your enclosures! While everything is settled down, it’s worth assessing any problem enclosures from last

year and making the necessary changes, to ensure that when summer comes you are free to spend your time on tasks other than firefighting. It’s important to remember that every degree above your set-point will be time removed from the life of your PLCs, variable

speed drives and transformers. Collectively, this can easily have a replacement value that tops £100k, even in a relatively small setup. If you replace only 2% of that equipment each year because of burnt-out or damaged componentry, then the costs can quickly mount up and it’s an entirely unnecessary spend.

Are you COOL about the internal temperature of your enclosures? ENCLOSURES ENCLOSURES

POWER POWER DISTRIBUTION DISTRIBUTION

CLIMATE CLIMATE CONTROL CONTROL

But it’s not just the cost of repair and replacement of the actual componentry. There are also the add-on operations costs caused by unexpected breakdown and stopping the processes it controls.

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

This lost output will continue for as long as it takes to repair the fault and is bound to have consequences for your wider business, impacting productivity and efficiency, and thereby reducing profits. Correct climate control is often overlooked during the installation of electronic equipment because the focus is all on the equipment, not on regulating the environment that it operates within.

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

So before summer arrives, reap the benefits of the optimising your climate control. Check out Rittal’s Webcast portal where you can view our latest webcast where we discuss this topic in more detail. Please visit https://info.rittal.co.uk/rittalukwebcast-0 For more information visit www.rittal.co.uk or to arrange a FREE Cooling Review, visit www.rittal.co.uk, call our customer service team on 01709 704000 or E-Mail cooling@rittal.co.uk

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

We’re offering users of Rittal enclosure cooling equipment the opportunity to receive a FREE inspection survey*

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

EDITOR’S HOICE

ALTERNATIVE FUELS ENERGYST

Making the switch A genset is a common sight on many construction and industrial projects, working hard to keep equipment, machinery and welfare running. But do you know what fuel is powering the system behind the scenes? While traditionally the answer would be easy — diesel — alternative fuels are becoming much more popular. Here Barry Hughes, Applications Manager at leading Cat® generator rental company Energyst UK & Ireland, shares insight into alternative fuels for temporary gensets.

savings and can be a steppingstone to reducing emissions further in the long run. Though you might assume that heavy fuel oil (HFO) is similar to HVO initially, the two are very different. HFO is a heavy, tar-like fuel used in vessels and ships, offering no environmental benefits — it is important not to get them confused!

TYPES OF FUEL AVAILABLE

FUTUREPROOFING OPERATIONS

Over the years, biodiesel has had bad press, mainly due to difficulties with quality control. While it is typically the first fuel that comes to mind when the topic of alternative fuels is brought up, it is not something we advocate the use of. There are several other fuel options in the UK and Ireland that offer better performance and reliability, such as hydrotreated vegetable oil (HVO) and gas to liquid (GTL).

The Red Diesel Tax reduces the cost of diesel in many applications and has been a challenge for alternative fuels, but it does not offer security for the long term. In line with the UK Government’s net zero by 2050 target, some companies are concerned they will be penalised in the future for diesel use, though there will of course be exemptions.

HVO is a direct ‘drop-in’ replacement for diesel and is not comparable to biodiesel. It does not require engine modifications to gain the maximum benefits from the start, you simply clean the fuel tank and system and add HVO and start the engine. Watch the exhaust emit no smoke, even on start-up!

The environment is a compelling reason to switch from diesel to an alternative fuel. For companies that have made a commitment to become carbon neutral, moving away from diesel is a natural step. But this is not the only reason, businesses may be looking to reduce the impact on the local area by reducing the amount of smoke or smell the genset emits.

In London, the Non-Road Mobile Machinery (NRMM) Low Emissions Zone is now stipulating and policing better environmental practices, such as adopting Stage V engines or improved solutions including early, including the approved use of alternative fuels. As other cities follow suit, it will contribute further to the uptake of alternative fuels. For companies already committed to carbon neutrality, alternative fuels can reduce the requirement to offset at the end of the year, such as by planting trees if they do not achieve their own commitments to the environment, impacting on the business’s operational costs. There are also opportunities to reduce maintenance costs compared with diesel. For this mixture of reasons, we are seeing a huge rise in the number of people looking for alternative fuels.

It also requires no change to servicing schedules, is odourless when burnt, is 100 per cent renewable and, because it is biodegradable, brings no concerns about spills or bunding. It results in a large decrease in emissions, up to a 90 per cent reduction of carbon footprint, a 10 to 30 per cent reduction in nitrogen dioxide (NOx), up to 100 per cent reduction in sulphur oxides (SOx), up to a 35 per cent reduction in particulate matter (PM) and a 20 per cent reduction in hydrocarbons. Its cold filter plugging point is -32⁰C, lower than both biodiesel (-5⁰C) and diesel (-12⁰C). Another option is gas-to-liquid (GTL), which is currently available in the UK and mainland Europe. Named after the process it is made by, GTL offers similar savings to HVO, other than carbon as it is a fossil fuel. GTL is often used with diesel as a blend, which offers some exhaust emissions and operational

CONSIDERATIONS BEFORE MAKING THE CHANGE While HVO is marginally more expensive per litre than diesel, there are more factors in the equation. Firstly, purchasing in bulk can make the prices much more comparable — on a long-term generator hire, the costs may be very close or even the same.. In addition, because HVO contains no carbon, it does not have many of the downsides associated with blends that include diesel, such as water contamination or fungal growth affecting fuel quality. For example, it helps overcomes the breakdown risk associated with sizing a generator incorrectly. If sized too large for the application, the generator will run inefficiently, produce smoke and build up carbon, meaning the operator will need to load bank test it and perform other maintenance activities to prevent a breakdown. While oversizing will still mean companies are paying more for a larger generator than they need, HVO does mean they don’t have to worry about carbon build up causing a breakdown. HVO can therefore reduce maintenance costs, as well as provide operators with peace of mind that unexpected downtime is not about to hit. Alternative fuels are growing in popularity as an environmentally friendly, reliable and financially justifiable option. In line with this, our entire generator fleet is suited to HVO and GTL, helping to keep your environmental conscience clear, and your equipment running. To speak to a trusted supplier about alternative fuels for your equipment, call 0845 769 7450 or 1890 369 469 for Ireland.

For more information, visit https://www.finning.com/en_GB/products/rentals/power-systems.html.

PECM Issue 51

EDITOR’S CHOICE

Celebrating 46 years Litre Meter celebrates 46 years being market leaders in flowmeter engineering. Established by Sandy Wemyss in the 70s, Litre Meter has continued to grow throughout the decades and now sits within the TASI Group. With over 125 years of knowledge and expertise in flow measurement, the four Applications Engineers are specialists in their fields; finding you the right flowmeter. Litre Meter operate around the global with local distributors and agents, ensuring our award winning

flowmeters are available to a wide range of industries. Throughout the pandemic Litre Meter has maintained its production of standard and bespoke flowmeters in the UK with no disruption to their customers around the globe.

If you would like a quote from the leading flowmeter experts, contact Litre Meter today at sales@litremeter. com, alternatively you can call on 01296 670 200 and the team will be happy to assist you.

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 51 PECM

EDITOR’S CHOICE

175,000 EUR SAVING PER YEAR SULZER

Sulzer’s turbocompressors cut maintenance overheads, energy consumption and noise for Austrian wastewater plant

The new HST compressors will save around EUR 175’000 per year Until the middle of last year, aging blowers were a constant headache for the operations team at the Linz-Asten sewage treatment works. The site’s integrally geared, single stage centrifugal blowers were temperamental and failure-prone, with absorbing around EUR 40’000 a year in maintenance costs. The twenty year old blowers were noisy too; so loud that you could not work in this area without strong hearing protection and it was a very heavy burden for the maintenance staff. Upgrading to Sulzer turbocompressor technology has addressed both issues at a stroke while also helping the plant to reduce its energy costs and carbon footprint. The largest wastewater treatment facility in Upper Austria, the Linz-Asten sewage

PECM Issue 51

treatment works serves a population equivalent of 950’000. The 900 square kilometer catchment area contains the regional capital Linz, 39 neighboring municipalities and a number of Austria’s major industrial companies. The search for a solution for new compressor had been ongoing for some time, but plans accelerated when the plant’s operations teams heard positive reports on the performance of Sulzer’s HST™ turbocompressors recently installed 130 km away at Salzburg’s main wastewater treatment facility. The HST technology is designed for exceptionally high reliability in demanding process applications. HST turbocompressors have few moving

parts and, thanks to magnetic bearings, are not subject to mechanical wear. That dramatically reduces routine maintenance requirements compared to older compressor technologies.

QUIET, SIMPLE AND EFFICIENT

After a competitive tender process, the contract to replace the blowers was awarded to Sulzer. To allow operation of the plant to continue uninterrupted during the upgrade process, the new Sulzer’s HST40 compressors were installed in a purposebuilt above-ground, single story compressor house. This approach was made possible by the very low operating noise of the Sulzer compressors, which produce only 70 dB(A), compared to the 100 dB(A) generated by the old units.

Since the new installation, energy consumption is on track to fall by 6’200 kWh per day two final turbo compressors have also been installed and commissioned.

The HST technology is designed for exceptionally high reliability in demanding process applications.

Since their installation, the new HST compressors have been quietly and effectively performing their role. For the LinzAsten maintenance team, that’s exactly what they wanted. With no temperamental blowers to look after, they can focus their efforts on performance, efficiency and reliability improvements elsewhere on the site.

The greater energy efficiency of the HST units has had a significant impact on energy costs. Energy consumption at the site is on track to fall by more than 6200 kWh per day. Combined with the maintenance cost reductions, that should save the facility around EUR 175’000 per year, while reducing annual carbon emissions by more than 580 tonnes.

The new blower house and pipework were designed to accommodate six HST40 units, with four installed during the initial phase of the project, to be operated in parallel with two of the existing blowers. That approach was chosen to enable a smooth transition to HST technology. To accommodate for the old blowers, which were slower to reach full speed, some smart adaptations to the control systems were made to ensure that they would operate in sync with the faststarting HST turbo compressors.

AN EASY SWITCH

The installation proceeded according to schedule and the four HST compressors were brought into operation with the changeover from the old blowers taking just 10 hours. Following on from this, the

Over recent years, annual maintenance costs for the legacy compressors has reached EUR 40’000 For further information, please visit www.sulzer.com Issue 51 PECM

EDITOR’S CHOICE

Intelligent steam boiler sequencing ensures cost effective operation

Precision Rotary Atomizer Technology

SCOPE is an all-new, PLC-based boiler sequencing control system from Fulton suitable for up to four steam boilers that optimises installations, ensures energy efficient operation and improves boiler longevity. It can be retrofitted to existing vertical and horizontal fuel-fired boiler installations, including Fulton’s own range of existing and planned products and those manufactured by other boiler OEMs.

For Effective Industrial Spraying and Misting Precise droplet size- adjustable electronically Very low energy use Long life, low maintenance Brushless motor technology Micron Sprayers Ltd, Bromyard, Herefordshire, England UK

Tel: +44 1885 482397 email: sales@micron.co.uk

By using SCOPE’s intelligent sequencing to provide redundancy and reliability, significant savings can be made by automating start-up and shutdown procedures, controlling and optimising main steam header pressure or temperature, ensuring steam supply is controlled precisely and loadbalanced across the boilers,

thus eliminating extensive losses from repeated start/stop cycling of burners. At launch, SCOPE features a high-definition touch screen for system programming and displaying boiler status, with values presented including firing rate, fault history, TDS value logging. Remote access allows service engineers to review boiler status and/or alarm conditions and control system functionality according to process demand. Tel: 0117 972 3322 E-mail: sales@fulton.co.uk

www.micron.co.uk

Web: www.fulton.co.uk

Global PCB Solutions 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,

PECM Issue 51

automotive, rail, construction, medical and audio equipment. We offer excellent quality and 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

Understanding the requirements and applying the ‘right fit’ technology and ‘supply chain solution’ is essential in your selection of a PCB vendor. Exception PCB Ltd is a European leader in time critical and technology driven printed circuit board manufacture. Specialists in quick-turn, high density interconnection (HDI) solutions for a wide range of market sectors. Our technical and production skills and experience combined with fast turnaround capability, has made Exception PCB the ideal partner of choice for customers requiring prototype, new product introduction (NPI) and low to medium volumes.

Services and Capabilities Offered: • QTA / NPI • Low to Medium Volume • Technical support • Urgent Operational Requirements (UOR’s) • Flexibility of supply. Consignment Technologies Supported • Std multilayers • ½ stack multilayers • HDI Sequential • Flexi - Rigids • Pure flexibles • PTH

T: +44 (0) 1684 292448 E: info@exceptionpcb.com W. exceptionpcb.com

Graphalloy_Extremes_88mmx132mm.qxp_Layout 1 10/21/20 1:06 PM Page EDITOR’S CHOICE

GRAPHALLOY® Bearings... We Go to Extremes

IdentifEYE - The Smart Labelling Solution 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. 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. 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/

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

Yonkers, NY USA

+1.914.968.8400

•

www.GRAPHALLOY.com

QUALITY HINGES TALK TO THE EXPERTS. 60 years of innovation brings you the green line valve

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

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.

Issue 51 PECM

AUTOMOTIVE ENGINEERING

LATEST NEWS FROM RDM GROUP RDM GROUP

Sales boost for RDM Group as carmakers switch to more local sourcing A specialist automotive supplier has secured a string of new contracts to help it bounce back from the Covid-19 pandemic. RDM Group, which provides electronic and software engineering, automotive wiring harnesses, CNC machining, carbon fibre and trim and upholstery, has seen sales rise past pre-lockdown levels after carmakers switched to sourcing more locally to reduce dependencies on long, global supply chains This has seen orders jump 30% on this time last year, creating up to 18 new jobs across manufacturing, software development, logistics and in the firm’s autonomous technology division Aurrigo, which has recently launched Auto-Dolly®, the world’s first driverless cargo and luggage dolly for airports. Bosses at the Coventry-based company are now looking to capitalise on this demand by investing more than £500,000 into increasing engineering capacity, capital equipment, further recruitment and the opening of an additional international office in Singapore. David Keene, CEO of RDM Group, commented: “We have definitely noted a shift in purchasing decisions by the big OEMs, who are experiencing significant supply chain issues from Brexit, Covid-19 and natural disasters. “The requirement for local sourcing has never been greater and we have certainly

benefitted since lockdown was eased, both in immediate sales and future pipeline of opportunities.”

RDM Group was founded twenty-eight years ago when David decided to take voluntary redundancy from MG Rover.

He went on to add: “At our Advanced Engineering Centre, we have the capability to support design, development, prototyping and medium volume supply across a range of engineering disciplines.

Over next three decades it has overcome a number of major economic and global shocks to remain a critical supplier of engineering services to some of the world’s best-known automotive manufacturers, including Aston Martin, JLR and Morgan Motor Company.

“This means customers can use us to single-source manufacturing solutions in anything from electronics and trim to injection moulding and carbon fire parts as lightweighting becomes increasingly important.”

All components are manufactured to IATF16949 global quality standards and can be delivered in batches starting at one-offs right up to 50,000 units per week. “Our Autonomous Vehicle division Aurrigo continues to go from strength-to-strength, with the Auto-Pod® and Auto-Shuttle® resuming trials in Milton Keynes and on the roads in Cambridge respectively, whilst Auto-Dolly® is enjoying massive interest from global ground handling specialists, airlines and airports,” continued David. “The latter is a massive opportunity and this, combined with our Auto-Sim® modelling technology, could deliver more than £10m sales over the next twelve months, which will generate 50 new technology jobs in the area.”

For further information, please visit www.rdmgroup.co.uk or www.aurrigo.com

PECM Issue 51

HENKEL INNOVATIONS FOR THE AUTOMOTIVE INDUSTRY

ZERO-EMISSIONS MOBILITY OF THE FUTURE Henkel has been a partner of the automotive industry for many years. Our high-tech solutions are now supporting the transition to electric mobility: Battery cooling with thermal gap fillers in battery packs Functional coatings, for instance to electrically insulate the cooling plate High-performance adhesives, optionally combined with heat-conducting properties to bond cells Flame-retardant materials to prevent thermal chain reactions within the battery

www.henkel-adhesives.com/emobility

CONTROL & AUTOMATION

IDENTIFICATION & INTEGRATION MITSUBISHI ELECTRIC

Want a robot but don’t know where to start? Industrial or collaborative? This is the question everyone is asking. We all want to get the most out of our production, however the demarcation line between the two options is not as clear as you might think. It all depends on the setting in which the machine operates, how operators need to interact with the robot and its main functions. Barry Weller, Solutions Marketing Manager – OEM at Mitsubishi Electric, looks at how to identify what type of robot best suits your application and how to integrate it. The first question that companies interested in automating their processes should ask is: what do we want to achieve? The answer to this will determine the role and type of robot needed. Consequently, conducting a comprehensive risk assessment will shed light on the safety requirements.

For example, if speeding up operations is the main objective behind deploying a robotic solution, conventional industrial robots, such as Mitsubishi Electric’s MELFA RV articulated arm and RH series SCARA robots, are quite likely to be the most suitable option. As the application will dictate, these robots move at high speed which means they are suitable for applications where workspace is to be shared with human operators only by adopting additional safety provisions. The options to integrate them are to construct physical safety perimeter guards or implement systems that allow automated speed control when humans approach the robot working area. Conversely, if the main goal is assisting employees in their activities, for example by passing or holding parts, the application would be considered collaborative. As a result, any conventional physical

separation between humans and robots would obstruct the application. In this case, the ISO/TS 15066:2016 standard supports the development of suitable safety measures, as highlighted by the risk assessment. An example of a robot designed for collaborative applications is Mitsubishi Electric’s MELFA RV series Assista articulated arm robot. The guidelines indicate different types of collaborative applications which include safety-rated monitored stop, speed and separation monitoring, hand guiding as well as power and force limiting. This is where the grey area between the two types of robot starts to appear. With the increase in safety options now available, industrial robots can also achieve many of the requirements needed in a collaborative application.

Designed to work alongside humans, collaborative robots or ‘cobots’, can provide a safe solution. Source: Mitsubishi Electric Corporation, Japan

PECM Issue 51

As technology evolves, the demarcation line between industrial and collaborative robotic applications also changes. human operators. Because of this, the use of a conventional robot is likely to be the right choice for these applications. In other situations humans may need to infrequently enter a robot’s workspace to briefly interact with the application or there could be a limited area of interaction. These systems will run as fast as possible under normal operation and only slow down when there is a risk of collision. Again this would suggest that a conventional industrial robot would be right for this application due to its ability to operate at high speeds in normal safe operating conditions. As suggested, the most effective way to make such applications fast, safe and reliable would be to utilise standard industrial robots operating in a cooperative way, coupled with additional safety features such as physical guards or safety light curtains and scanners. More precisely, businesses can implement high-speed, high-payload industrial robots, such as the MELFA RV articulated arm robot, equipped with a MELFA SafePlus safety system from Mitsubishi Electric. This means humans and robots can work safely and in harmony. Utilising the speed of an industrial robot within a cooperative environment requires additional safety provisions, such as systems that allow automated speed control when operators approach the robot working area.

INDUSTRIAL OR COLLABORATIVE ROBOT?

Designed to work alongside humans collaborative robots or ‘cobots’, can provide a safe solution. However, there are some obvious caveats. The term collaborative, as specified by ISO/TS 15066:2016, actually refers to systems or applications where automatically operated robots share the same workspace with humans. This means that robots for collaborative applications, just like any other type of robot, still require a risk assessment. There are different industrial operations whose risk assessment would support the

use of cobots, for example, if the robot is required to work alongside the human as part of the assembly process to pass objects to operators. Here the risk of a collision between the two is high and so this application would fall into the category of power and force limiting. Features such as safe torque range to detect the impact and prevent injury are needed. There are situations where the use of robots would require additional safety measures. For example, if potentially harmful chemicals, sharp edges or extremely hot items need to be handled, the robot would need to be enclosed by physical safety perimeter guards to protect

MAKING THE RIGHT CHOICE

As technology evolves, the demarcation line between industrial and collaborative robotic applications also changes. The most important consideration when implementing a robotic system is to ensure the system meets the needs of the specific application and delivers against the user requirement specification. The system must achieve both the throughput required and also operate in a safe environment for operators in line with the risk assessment for the application. The inclusion of collaborative robots has widened the choice and the type of applications that robotics can now be used for. It is not a question of which is best, industrial or collaborative robotics but which is best for the application. With its wealth of experience and proven track record, the robotics team at Mitsubishi Electric helps businesses find the right solution.

For further information, please visit gb3a.mitsubishielectric.com Issue 51 PECM

CONTROL & AUTOMATION

ROLLER SCREW TECHNOLOGY MOORE INTERNATIONAL

Is it still under appreciated? Mark Moore of Moore International Ltd explains their advantages Even though the very first patent for a roller screw was granted in 1949, why is roller screw technology a less recognised option, when compared to other mechanisms for conversion of rotary torque into linear motion? When designers consider the options for controlled linear motion, do they fully examine the benefits that the roller screw offers in performance in relation to hydraulic or pneumatic cylinders, as well as ball or lead screws ? Roller screws have distinct advantages over these four other rivals in all of major selection considerations. Of course, each designer may have differing selection criteria, which will be determined by the application. So, in examining the major selection concerns, here is how the roller screw performs ... If we take efficiency as primary criterion for selection, the roller screw is over 90% efficient, and only the ball screw out of the five recognised choices can compare. Life expectancy is very long for a roller screw, typically 15 times longer than a ball screw, and only the hydraulic or pneumatic cylinder options give similar service life, however, they both need maintenance to retain long life. When it comes to maintenance itself, the roller screw requires very little maintenance as the friction created by the rolling screw design is minimal compared to that generated by sliding friction. However, the roller screw should still be lubricated to minimise wear and to dissipate heat. Providing sufficient protection against contaminants is also critical to long functional life, so wipers can be added to the front or back of the nut to scrape particulates from the threads throughout the screw stroke. Maintenance intervals will depend on two main factors, the operating conditions and the screw diameter. By comparison, both hydraulic and pneumatic cylinders need much higher levels of

attention, and ball screws can suffer from pitting in the ball groove and the ball bearings can be lost or need replacing. The load ratings of a roller screw can only be matched by a hydraulic cylinder. In performance, roller screws have, in some specific applications, been able to move up to 20,000 times its own weight, so are capable of carrying greater loads in relation to their size. They are also very suitable to carry heavy loads for continuous duty and in the most arduous of conditions. The combination of speed and acceleration can only be equalled by that of a pneumatic cylinder. Both the stiffness and the effects of shock loading also make the roller screw an attractive option. Automated industrial production lines are being designed to be more compact systems that take up less space. One of the biggest advantages of the roller screw is that it requires only minimal space requirement as it is very much more compact and is much easier to install than hydraulic or pneumatic cylinder alternatives, both of which can be very complex and expensive to fit. At the same time the roller screw achieves considerably better positional accuracy compared with a ball screw.

supply the ROLLVIS Swiss range of roller screws which are used to transform rotary movements into linear movements and vice versa. The rolling elements are threaded rollers between the screw and the nut. The high number of points of contact enables satellite roller screws to support very heavy loads. The ROLLVIS range comprises satellite roller screws with no recirculation (RV and HRV types), inverted roller screws (RVI type), Differential roller screws (RVD type) and screws with recirculating rollers (RVR type). Bearing units are also proposed to equip the different roller screw designs. The RV screw is a high precision, robust assembly where the rollers do not recirculate, thus enabling a very stable driving torque. Special gears are designed on the rollers and nut to maintain a good kinematics even in the most severe conditions. The internal thread of the nut is identical to that of the screw. To ensure no axial movement occurs between the nut and the rollers, there is a singlestart thread with precise angle accuracy between the nut and the rollers.

Environmentally the roller screw is less noisy in operation, which compares well to pneumatic systems, but also has the obvious advantages of leak free functionality (air and hydraulic fluid) and less power consumption. The return on investment by purchasing roller screw technology is offset through total cost of ownership and life cycle costs. It is realised through the reduction in the cost of maintenance, early replacement and resulting downtime.

HOW DO ROLLER SCREWS FUNCTION AND WHAT ARE THE OPTIONS? Roller screws use rollers to transmit force from the nut to the shaft. The main elements are the screw, the nut and the satellite rollers. Moore International

The RVR roller screw is a design which incorporates recirculating rollers. The rollers are guided within a cage and their motion is controlled by a set of cams. This design combines extremely high positioning accuracy, resolution and stiffness while capacity ratings are at the highest thanks to a robust thread geometry. This concept is perfect for all applications that need a very high accuracy under small or moderate speeds.

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

PECM Issue 51

Specialists in Mechanical Motion Transfer Systems and Automation Products

Moore International has extensive CNC machining capabilities which enables sub-contract manufacturing of precision components to customers’ drawings, or by reverse engineering using CAD files and SolidWorks software.

T: T: 01202 01202 623 623 393 393 E: E: sales@moore-international.com sales@moore-international.com W: W: www.mooreinternational.co.uk www.mooreinternational.co.uk

Authorised Distributor:

CONTROL & AUTOMATION

PULLING IN THE SAME DIRECTION FANUC

Automation works in tandem with workforce to deliver outstanding productivity

Sheet metal volume manufacture and fabrication specialists, Contracts Engineering, entered 2020 with an increasing demand for its services. In order to boost productivity and meet this rise in orders, it turned to systems integrators Cyber-Weld Ltd to help identify, install, and support its first foray into the world of welding automation. Now, with FANUC’s ARC Mate 100iD/8L a key part of its production process, and a conscious effort to generate engagement with current employees, Contracts Engineering is reaping the rewards. 2020 was a challenging year for manufacturing, as the industry grappled with the unprecedented effects of the COVID-19 pandemic. However, one of the standout success stories was undoubtedly Kentbased sheet metal volume manufacturer and fabricator, Contracts Engineering Limited (CEL), whose savvy investment in automation enabled it to weather the storm and continue to grow. Underpinning this growth was an increase in orders from one of its core clients, for whom Contracts Engineering fabricate their

PECM Issue 51

main product line sold to cities around the UK and Europe. Furthermore, two of CEL’s other clients had high volume welding requirements that couldn’t be met by manual welding. CEL needed an automated process to manage the high volumes and repetitive, tight-tolerance nature of the MIG welding. Troy Barratt, Managing Director at Contracts Engineering, comments: “We have a strong working relationship with this client, built over years of supporting their development and production ramp-ups across several of their products. We started having conversations back in 2018 to try and predict what volume of product we’d be required to deliver in the years ahead. The projections highlighted that sooner or later manual welding wouldn’t be able to keep up with demand, and it became clear that we needed to invest in automation.”

THE CRUCIAL ROLE OF SYSTEMS INTEGRATORS

Given this would be CEL’s first experience of robotic automation, finding the right systems integrator was key. It meant identifying someone who would not only deliver the most appropriate solution, but also work as a partner to ensure seamless implementation.

Troy continues: “We were quite upfront in how we went about finding the right partner. We were honest and said that this was our first robot, and while it probably won’t be our last, we’ll need some help on this. We are experts in welding, we know that side of the business, but we need expertise, advice, and training when it comes to robots.” Troy, alongside Ross Campbell, CEL’s Operations Director, arranged meetings with a number of integrators, and following visits to the leading candidates identified midlands-based Cyber-Weld Ltd as the clear leader, and ultiamtely their chosen systems integrating partner. Alongside specifying the most appropriate automation solution, Cyber-Weld Ltd also ensured it was installed and set-up correctly, conducting on-site training to alleviate concerns and navigating travel restrictions during 2020’s first lockdown. Fraser Reid, Managing Director at CyberWeld Ltd, comments: “First and foremost, we wanted to make sure we specified the right robot, that could meet the demands of highvolume, precise welding, and would fit neatly into Contracts Engineering’s production processes.

We opted for a FANUC ARC Mate 100iD/8L with 3 auxiliary axes, because not only does this model deliver fantastic performance, but it also integrated nicely with the FANUC CNC that was already being used at the facility. “It also became clear that having an internationally recognisable name like FANUC would be of benefit to the wider business. FANUC’s reputation proceeds itself and from CEL’s point of view it’s great to be able to say to their clients that they have a FANUC machine. There’s an element of assured familiarity there. It also helped that CEL’s CNC Turret Punching machine is programmed with a FANUC controller, so they had some familiarity with FANUC’s industry leading control units.”

EMPLOYEE ENGAGEMENT

One of the most commonly cited concerns with introducing automation is the effect it will have on existing employees. There is an unfounded fear that robots will replace jobs, and as Troy explains, this is something that needs to be addressed from the very beginning: “Nothing determines a business’s success more than its team. It’s a cliché but it’s true, and we were determined to ensure our staff, our fabricators, our people in offices and the factory were on-board with the improvements that would be brought about by automation. Very early on in the procurement process we talked openly about the benefits during our ‘All-Hands’ meetings, and offered training opportunities for our staff to learn about robotics. “We got amazing engagement with this, with more time for training as the robot undertook the laborious, time-consuming

Nothing determines a business’s success more than its team. and repetitive tasks. We have developed and trained one of our best welders to lead the robotic programming, and he is doing a brilliant job. Furthermore, many of our other fabricators are learning more advanced welding techniques to go beyond what the robot can do, including more TIG welding of aluminium and stainless steel.” CEL’s focus on investing in its staff has had a significant impact on Contracts Engineering’s workforce. Employment has grown +50% since 2012, and average pay is up 20% on top of a bi-annual company profit share. Job satisfaction is also high, with a low staff turnover of 5-10% per year, compared with a UK manufacturing average of over 25%.

GETTING RESULTS

Crucially, this culture of openness has ensured the ARC Mate 100iD/8L has slotted seamlessly into the facility, and by September, just three months after delivery, it was operating at full production capacity. Productivity has doubled, with weld time cut by as much as 60-70%. This has ensured Contracts Engineering has been able to keep pace with its key bicycle rack client’s orders. Troy continues: “Without automation, we may have been in the position where we would have had to turn away work, just because we couldn’t keep up with demand through manual welding alone. Now, we’re able to

deliver to existing clients, while also actively seeking out work which requires more advanced welding applications, thanks to our increasingly skilled employees. “Aside from the tangible producitivty gains, we’ve found that automation has also facilitated greater integration of some of our departments. Engineers who are doing the CAD work are now working closely with the machine operators, which helps to bring the whole process closer together. By the end of 2021 we plan to have our 3D CAD designed integrated with robotic programming so we can do it offline”

LOOKING AHEAD

In spite of the difficult circumstances of the past year, Contracts Engineering has managed to increase its client base. Working with the knowledge that the ARC Mate 100iD/8L would see a return on investment from the cycle parking project alone, it has allowed Troy to pursue further business with full confidence, including engaging with the other clients that had robotic requirements. He concludes: “Investing in robotic automation during a pandemic could be seen as risky, but open and frank conversations with Cyber-Weld Ltd helped to minimise the fear factor that was associated with it. From a business point of view, it’s meant an increase in operational capacity that has enabled us to generate more business, and offer our existing clients even greater support. “Most importantly, we’re delighted with the engagement we’ve seen from our staff. It’s a perfect example of how automation can enhance job roles, equipping employees with new skills that diversify their working day and ensure we’re all pulling in the same direction.”

For more information, please visit: www.fanuc.eu/uk/en, www.contractsengineering.com and www.cyberweld.co.uk Issue 51 PECM

CONTROL & AUTOMATION

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PECM Issue 51

ELECTRICAL & ELECTRONICS

THE AUTOMAX RANGE SWITCHTEC

Sirena’s Automax Signalling Towers: Essential for Industrial Automation Distributed by Switchtec, Sirena’s Automax range of signalling towers are an essential component in the production process, control, and industrial automation. They are commonly used to report the status of a machine or process to operators, technicians, and production manager. Therefore, they represent an indispensable device for informing the operator about errors or transmitting information on process needs, allowing an increase in productivity and better management of machine failures. Reliability, efficiency, and ease of installation are the key factors that operators demand from a signal tower and Sirena has met those needs with the Automax range. The Automax signalling columns are available in three sizes 35mm, 50mm and

70mm diameter and come in either round or elliptical shape. The different sizes and the IP66 high degree of protection make them a solution applicable in many different production environments: large plants with the need for visible signalling from a distance and industrial areas where personnel work near machines or heavy industries. The Automax offers further versatility thanks to the numerous mounting solutions, including wall brackets and extensions of different lengths and materials (TWS accessories). The latest multifunction LED technology allows you to manage different lighting effects – continuous or flashing. There is also the option to add an acoustic signal by simply inserting the acoustic module in the combination. The basic principle of any light tower is to

provide a quick visual indication, warning or notification. Most light towers are preassembled and have to be ordered in the required colour sequence, voltage and illumination type and are manufactured as a complete item. The Automax is available in both modular and preassembled versions. Sirena’s Automax range provides flexibility to customers, stockists and distributors by the use of a modular system. The customer simply orders the colours they need, output type (flashing or continuous), then by use of Sirena’s simple assembly mechanism, stack the colour modules in the order required. Available from Switchtec ex-stock and Switchtec field sales engineers are available to provide product selection and general design assistance.

For further information, please visit www.switchtec.com

PECM Issue 51

Electrical Control Products

Surge Protection Devices

Alarms & Beacons Timers

Pilot Lamps Distribution Blocks Power Supplies

Relays

Panel Temperature Control

DIN Rail Terminals

Pushbuttons

Switch Disconnectors

Over 35 years experience in the supply and distribution of high quality Control Products. Switchtec Ltd, Brooms Road, Stone Business Park, Stone, Staffordshire. ST15 0SH Tel: 01785 818600 Fax: 01785 811900 E-mail: sales@switchtec.com Web: www.switchtec.com

ELECTRICAL & ELECTRONICS

A TRUE WARRANTY WILKINSON STAR

JASIC 5 Year Warranty Charter on all models There is no compromise on the quality of JASIC equipment..such is our confidence in this technology we can offer an unparalleled 5 year ‘true’ warranty on all models. Jasic’s manufacturing site is over 80,000m2 and is arguably the largest and most modern inverter manufacturing base in China.

team of technicians in our JASIC Technology Centre. • We have the facility to test products extensively on load banks and can validate machines to certification requirements.

How do Wilkinson Star provide such an industry leading product guarantee?

EQUIPMENT QUALITY WE ARE SERIOUS ABOUT PRODUCT QUALITY. SOUND PERFORMANCE AND RELIABILITY IS WHAT YOU CAN EXPECT FROM JASIC PRODUCTS • The manufacturer has invested millions of dollars into cutting edge integrated test laboratories on site – JASIC undergoes 42 individual tests to meet high quality standard.

• If required, Wilkinson Star will arrange at its expense to collect and return your JASIC product to carry out service or repair in our workshops

• Jasic’s 4 centre strong R & D facilities has been ranked as the most progressive facility along with being the first welding laboratory awarded UA certification by China from TUV Rhineland.

BE VIGILANT WHEN PURCHASING EQUIPMENT WITH EXTENDED WARRANTY

UNPARALLELED AFTER SALES SUPPORT

JASIC’s warranty is a true 5 years; this means a problem at 6 months, 3 years or 4 years 11 months is treated with the same level of care.

NO OTHER DISTRIBUTOR CAN MATCH US ON THE LEVEL OF SERVICE FACILITY INVESTMENT MADE IN THE UK • Wilkinson have 50 years’ experience in servicing welding equipment. Our state of the art service workshop facility and our 16 strong after sales service team offer the most recognised technical support in the welding industry. All equipment is fully supported by Wilkinson Star trained technicians. • No other UK wholesaler can repair inverter boards to component level. At Wilkinson Star we have a dedicated

WITH JASIC 5 MEANS 5

CUSTOMER CONFIDENCE CARE IS OUR BYWORD AND YOUR PRODUCTIVITY IS OUR PRIORITY • We provide a dedicated technical support line which you can call for any technical support queries

No extensions. No additional costs…… just 60 rolling months of product peace of mind ALL YOU NEED TO DO IS REGISTER YOUR PURCHASE AT JASIC.CO.UK FOR 5 YEARS PEACE OF MIND – IT’S REALLY THAT SIMPLE

• If on site support is needed we provide this through our highly trained technicians who cover the country • We can also interchange power sources to keep you up and running

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

PECM Issue 51

ELECTRICAL & ELECTRONICS

your reliable solution partner...

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

New, OLED display with USB, SPI, I²C and PCAP touch MMS Electronics Ltd introduced two new intelligent graphic OLED display with PCAP touch, USB, SPI and I²C interface. Two screen sizes are available: EA PLUGL128-6 2.9” diagonal 128x64 pixel and the smaller EA PLUGS102-6 1.7” diagonal 102x64 pixel. The displays are easily programmed with powerful graphic commands and integrated fonts. New fonts are added with the free development software. Text, images, animations and macro code can be saved on-board the display. Text and pictures can be rotated for the display to be used

in landscape or portrait mode. OLED display technology is extremely fast, offers high contrast on a pure black background with nearly 180° wide viewing angle. MMS Electronics Ltd is a specialist supplier of LCD, OLED and TFT displays and UK distributor for Electronic Assembly Gmbh. MMS Electronics Ltd Tel 01943.877668

www.mmselectronics.co.uk

Issue 51 PECM

ELECTRICAL & ELECTRONICS

SWITCHGEAR PROTECTION SPELSBERG

Robust and flexible approach for LV switchgear enclosure

Enclosures play a vital role in protecting switchgear from damage, as well as ensuring the safety of people nearby. Combining these aspects with a flexible, modular system that can be customised appropriately creates an enclosure layout that’s a best fit for switchgear protection needs. Chris Lloyd, Managing Director of Spelsberg UK, discusses the key considerations for specifying an enclosure for low voltage switchgear. When housing low voltage switchgear the fundamental requirement is protection of the electrical system to keep it running, whatever the environmental conditions it faces. Whether for outdoor use or harsh indoor industrial settings, an IP rating sufficiently high to prevent ingress, combined with IK protection against impacts, are prerequisite enclosure

PECM Issue 51

requirements. So too, protecting operatives or the public from harm, which will typically be achieved with IEC Protection Class II. Once these imperatives are met, creating an enclosure that fits switchgear protection requirements amongst situational design constraints is the next challenge. While some facilities prefer steel enclosures, the difficulty in creating a flexible, modular system in steel often results in an enclosure that is larger than required. Polycarbonate is a preferable alternative, providing high durability and design flexibility, allowing a modular approach where smaller enclosures fit together to protect a more precise area. Lighter than steel, polycarbonate also enables easier installation, especially for installing at height or in more complex settings. While the external structure of the housing has to protect against ingress and impact,

a common requirement of LV switchgear design is to segregate the architecture within the enclosure and provide isolated protection. To fit this need, the enclosure has to be modular with interconnected housings that can be easily designed and quickly assembled together, often without making additional modifications on-site. The modular approach taken by Spelsberg’s GTi enclosure features removable flange panels that can be rapidly locked into place to isolate areas of the switchgear network. Alternatively, they can be easily removed to allow connectivity of wiring and components. The enclosures and panels are flush-fit, leaving no penetrative gaps and affording maximum protection. Modularity and simple connectivity of enclosure walls also enable fast, easy expansion of the switchgear circuit if required at a later date. Spelsberg’s service helps engineers create

The enclosures and panels are flush-fit, leaving no penetrative gaps and affording maximum protection. the most effective structure according to the specification, reducing design time and ensuring that the required protection is achieved. With various size enclosures in widths up to 320 mm and length up to 640 mm, GTi housings can be fully interlinked and connected together with one connector for all sizes of enclosure. This gives a high level of flexibility to protect a switchgear layout with the most effective design. The enclosures are also available with pre-assembled fixtures such as bus bars and clamping points for distribution boards, improving the ease of installation. Fuse and switch housings are also provided by the Spelsberg AKi, giving the same high level of protection and complete with fittings such as fuse load circuit breakers that save time in installation. For outdoor applications, built-in protection against lightning, with special screws for pressure balance, makes the installer’s task easier. While the enclosures have been developed for ease and flexibility in switchgear design and installation, further customisation can be provided by Spelsberg UK. Common requirements include CNC machining of cable entries and disconnects, or cut-outs to enable specific component installation. Fully customised enclosures designed to house and protect specific switchgear configurations can also be provided and the UK service means that a project can be completed and delivered direct to site within days.

For further information, please visit www.spelsberg.co.uk Issue 51 PECM

ELECTRICAL & ELECTRONICS

Mobile tablet boom enables business practices There has been an increase of 63% of UK companies looking to mobile-enable business practices according to ComputerWeekly.com. IT Pro reported that the second quarter of 2020 saw global tablet shipments increase by more than a quarter, from 29,7 million to 37.5 million. This is largely due to the rise in remote working and the heightened demand for virtual office components, and tablets that “tick so many boxes for remote work and education use”, according to Canalys analyst Ishan Dutt. Andrew Cahill, managing director of MobileWorxs, specialists in rugged tablets for enterprises in the UK and EMEA, said that tablets are experiencing a revival due to their affordability combined with added functionality compared to cell phone and laptops. “The new generation tablets are designed for rugged and robust usage for example, in the field,

in-premise in factories and warehouses, in healthcare facilities, or by government utilities. “There are a wide range of tablets, from Microsoft Surface to the more rugged tablets from global companies like MobileDemand, that offer a wide range of accessories, such as rugged cases, cameras, forklift mounts, barcode scanners, full communication options etc, which means that these devices can now be used effectively in rugged environment by the workforce, and also link to a company’s backend software system.

For more information about the use of tablets in the workplace, contact MobileWorxs on +44 (0)1905 799555 or visit: www.mobileworxs. com/flex/rugged-tabletthat-does-not-bust-yourbudget/

Reduce risk of lightning hazards at work with a lightning warning system Lightning strikes the ground in the UK around 300,000 times a year, putting at risk those who are often outdoors in exposed, unsheltered locations. Although there’s no full-proof protection from lightning, measures can be taken to reduce the risk of getting struck. Meteorological equipment specialist Biral is offering its BTD200 self-contained, standalone lightning warning system so employers can take precautions to prevent exposure to lightning and ensure workers’ safety. The BTD-200 is a modular system, designed to operate out-of-the-box and is expandable as requirements grow or change. The system comprises of a lightning detector which is placed outside, whilst a PC located indoors runs the supplied Lightning Works software. Users view the lightning in real-time on a map whilst displaying the urgent lightning alarm levels.

PECM Issue 51

For more information call Biral on +44 (0)1275 847 787, email info@ lightningearlywarning. com, or visit www. lightningearlywarning.com

ELECTRICAL & ELECTRONICS

A low-cost cooling option for your facility that will keep workers, processes and products cool even on the hottest day of the year EcoCooling provides an effective large space cooling alternative to refrigeration, at just 10% of the operating costs and 60% of the capital spend. The eco-friendly direct evaporative cooling and ventilation solutions enable you to maintain internal temperatures below 25°C all year round. Whether you’re looking for blanket cooling or spot cooling for workstations and production lines, EcoCooling’s systems are versatile and can be tailored to meet your specific requirements. Effective and low cost The evaporative cooler is coupled with ventilation so on days where additional cooling isn’t required you can take advantage of the system’s free cooling, which helps to make it so cost-effective. Even on the days when evaporative cooling

SAVE UP TO 90%

COMPARED TO AIR CONDITIONING

✓ VENTILATION BASED

EVAPORATIVE COOLING

is enabled our standard unit can cool a 250 sqm space for less than 14p per hour. More information and case studies are available on our website. Get in touch to discuss your requirements:

sales@ecocooling.co.uk 01284 810586 www.ecocooling.co.uk

✓ SPOT COOLING FOR

PEOPLE & PROCESSES

✓ ENERGY EFFICIENT ✓ NO REFRIGERANTS OR RECIRCULATION

BOOK A FREE SITE VISIT www.ecocooling.co.uk sales@ecocooling.co.uk

LABELS & NAMEPLATES

High quality labels, nameplates, waymarkers and more Richard Ching & Son is a leading supplier of high-quality labels, overlays, nameplates & more. We have unrivalled expertise in the design and manufacture of a wide range of products, from simple on roll labels to large fully bespoke stainless steel nameplates. By combining modern digital printing with more traditional silk screen methods our flexible manufacturing processes enable us to tailor our products & services to suit almost any application including Anodic Printing & Chemical Etching. • Under Surface labels can be produced in Polyester, Polycarbonate & PVC. • Metal Nameplates can be produced in Brass, Stainless Steel & Aluminium. • On Roll labels are available in Paper, Vinyl, Polyester & Polypropylene. 34 Lady Lane Industrial Estate Hadleigh, Suffolk, IP7 6BQ www.ching.co.uk

Axium Process’ Universal SS Filter Housing enables Pick & Mix Filter Solutions Axium’s pick and mix filter solution can result in significant costs savings for manufacturers with variable filtration requirements as only one filter body needs to be purchased and installed. They can then choose any filter screen option from Axium’s comprehensive range. This Universal Filter Housing remains fixed-inplace but permits rapid switching of the screen or change in level of filtration. Benefits include: • Consistent product quality • Dependable, high specification • Minimal downtime • Filtration levels from 5µm – 6,000 µm • Simple and easy to clean – no specialist cleaning • Can be custom manufactured to meet end users requirements • Certification and traceability dossier on request www.axiumprocess.com

The leading edge of energy management Suresense Technologies specialisesin providing the food and industrial sectors with a complete LED solution, we manufacture our intelligent Eluma LEDs in the UK which are built to last, we provide a 10-year warrantee which allows maintenance free operation for over a decade. All our Eluma LED fittings come with our own Atmos sensor, that is also designed and manufactured by us. Our Atmos sensors form the intelligence behind making sure every LUX per Watt delivered is optimized. Suresense is also a world leader in fixed speed variable load energy saving, the Integra unit works on Granulators, Conveyors, Injection molding, Crushers, Mixers and Hydraulics to name a few. We also provide a full financial support document with every Survey, please contact us for a free Survey. sales@suresense.co.uk www.suresense.co.uk Issue 51 PECM

14-16 SEPTEMBER 2021 NEC, BIRMINGHAM

CO-LOCATED WITH NEW FOR 2021

WHAT CAN YOU EXPECT?

This year the Manufacturing Management Show conference joins Subcon and The Engineer Expo! The conference will be focused on providing best-practice advice to today’s senior manufacturing leaders.

Over 200 exhibitors will be at this year’s show. This a must-attend event for UK manufacturers looking to meet and source new solutions from the very best of British manufacturing and world-class suppliers.

The Launchpad is back and will showcase engineering start-ups and entrepreneurs, giving them a stand to showcase their innovations and be in with the chance of winning a free stand at our 2022 show! Find out more on the show’s website (including how to enter).

WWW.SUBCONSHOW.CO.UK JOIN THE CONVERSATION SPONSORS

@SubconShow #SubconShow MEDIA PARTNERS

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

NEW ProxATEX™ Digital Temperature Controller for Hazardous Areas This brand-new temperature and power controller brings a host of ‘world-firsts’ to the table, for design-in use as a digital controller fully adjustable within potentially explosive atmospheres. Built for worldwide “Ex” use with ATEX/IECEx and UL/ CSA standard certifications, its high current 25A design is the perfect match for our legendary THERMOSAFE® induction drum heater, but is also ideal for control of “Ex” rated industrial ovens and process plant trace

heating projects. Secure NFC programming cards add a new dimension to application security, with up to 15 parameter settings. Zones 1, 2, 21 & 22. T3 155°C / T4 135°C Rugged and reliable with IP66 all-weather protection for use in demanding environments UK, European, USA worldwide patents.

lmkthermosafe.co.uk

CE and UCKA Marking Now that the UK has left the EU single market, the UKCA mark is being phased in from 1st January 2021 to replace the CE mark within the UK. Conformance has led the field in CE marking for over 20 years and is perfectly positioned to guide you through the CE marking and UKCA process.

your products on the EU market if you do not have a physical presence within the EU. With our Dublin office, we can support manufacturers to place their products legally on the market by becoming the responsible economic operator.

Our sister company Authorised Representative Service is also available to help you place

https://www.conformance. co.uk/our-services/authorisedrepresentative-services

Learn more here:

Issue 51 PECM

FLUID MANAGEMENT

FLUID MANAGEMENT MILLERS OILS

How to successfully manage your hydraulic oil SELECT THE RIGHT FLUID FOR THE APPLICATION

There are many types of hydraulic fluid, the key variables being viscosity, viscosity index, base oil type and anti-wear additive type. Viscosity is the most crucial property – if the viscosity is too high (i.e. the fluid is too “thick”), your equipment will run less efficiently due to reduced mechanical efficiency, which will result in excessive energy consumption and heat generation. If the viscosity is too low then the film strength of the oil will not be strong enough, resulting in increased friction from metal-to-metal contact, and premature component wear. For outdoor hydraulic equipment, or systems operating at high pressure or over a wide range of temperatures, then a high viscosity (HV) index fluid may be required. The viscosity of oil decreases as temperature increases, however an HV fluid uses additives to minimise this variation. For the majority of industrial hydraulic applications, fluids using mineral oil offer reliable protection against corrosion and wear. However for more arduous operations where greater oxidation resistance and thermal stability is required, and unplanned down-time comes at a premium, synthetic oils provide inherently better protection and longer oil life. Today there is also a growing requirement for biodegradable product for use in environmentally sensitive applications, as well as fire resistant fluids for improved safety. The majority of anti-wear additive technology is zinc-based which performs well and is also very cost-effective. However zinc can cause chemical reactions with certain component materials, e.g. yellow metals and silver. Zinc additives should also be avoided in environmentally sensitive applications as they are non-biodegradable. Millers Oils always recommends checking the original equipment manufacturer’s specification to ensure the oil meets the requirements, then considering any additional benefits for your specific application with the technical help desk team.

ENSURE THE SYSTEM IS CLEAN

When used oil is drained from a system during an oil change, there will still be sludge and other contaminants remaining in the tank and pipes. Millers Oils recommends a full drain and oil flush before refilling with new oil. In cases with heavy varnish and lacquer, a non-manual cleaner such as Milliclean 1000T can be added at 20% sump capacity 48 hours before the planned oil drain, whilst the equipment is still in operation. This will lift lacquer, varnish and sludge from the tank and pipework, which will then be removed on flushing to ensure that you get the full life from your clean oil, and reducing risk of blockages and failures.

CONDITION MONITORING

In many industrial applications, the sump is often filled with oil then left to run throughout the year. Actuators, valves and other components can start to stick or wear, without the maintenance department knowing there’s a problem. If the oil isn’t sampled regularly, it’s impossible to know whether everything is running smoothly, or if the machine is on the verge of a costly break down.

Milliclean 1000T: the bottom portion of this inspection panel was in contact with circulating oil containing Milliclean 1000T and all lacquer and varnish has been removed. The top portion was above the oil level and shows the original level of contamination.

ENSURE THE OIL IS CLEAN

Depending on your application, sometimes even new oil isn’t clean enough. Check the original equipment manufacturer’s ISO oil cleanliness specification – the oil may require filtration down to a certain particle count to avoid wear, damage and blockages on precision equipment. Millers Oils offers initial fill filtration services, as well as remedial filtration work to keep oil within specification to extend drain intervals.

Frequent oil sampling keeps the maintenance department informed of not only the condition of the oil but also the machine components, allowing maintenance to be planned around production – saving both time and money. Millers Oils offers oil sample analysis kits for industrial applications. Analysis reports are sent directly to your inbox and include comments on viscosity, contamination, additive levels and wear metals, as well as recommendations from our technical team. Millers Oils is a leading manufacturer and independent blender of oils and lubricants, operating since 1887 in Brighouse, West Yorkshire. The company prides itself on its award-winning innovation and its independence which allows maximum flexibility to meet customers’ needs. For more information about Millers Oils products and fluid management services visit www.millersoils.co.uk or call 01484 713201.

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

PECM Issue 51

Planning your summer maintenance shut down? Milliclean 1000T is a nonmanual, solvent-free cleaner for hydraulic systems • Add at 10-20% sump capacity 48 hours before a scheduled oil change • Removes lacquer, varnish and sludge while operations continue as usual • Contaminants are drained out with the old oil – no additional cleaning down-time is required

Millers Oils is a leading independent UK oil blender, offering specialist product and fluid management services to the plastics industry. T: +44 (0) 1484 713201 E:sales@millersoils.co.uk www.millersoils.co.uk

FLUID HANDLING

Optimise your pipework with swivels

Fluid Carrying

Rotaflow have 35+ years experience in designing and manufacturing Swivel Joints. We solve and resolve engineering problems where fluids need to be transferred across rotating interfaces, without leakage. Our units are in most engineering sectors: From Brewery, Dairy, Food & Drink, Process & Plant, Drilling & Mining, Oil, Gas and Subsea, Nuclear and Chemical. Through design and in-house manufacture our swivel joints can allow one or more different flows through a single unit, enabling the pipework to rotate 360 degrees whilst carrying fluids (including hydraulic and pneumatic) of different pressures without crosscontamination or leakage. There are many different forms of Swivel Joint… from very straight forward designs of our F and FS series, Compact swivels or Heavy Duty to Articulated Pipework configurations, Floating Suction Arms, Jacketed, Highpressure. A Swivel Joint reduces costs by reducing the risk of leakage with its

Flexibility associated downtime. And by fitting a quality designed swivel you are improving your production capacity.

Tel: +44(0)1663 735003 sales@rotaflow.com

www.rotaflow.com

epco Pipe Systems are specialists in supplying comprehensive pressure pipe systems for both Industrial and Commercial applications, available from our UK stockholding in Leeds. We are proud to announce the arrival of our new C-PVC range including Pipe, Fittings, Valves and Accessories. Thanks to its high temperature resistance, reaching up to 80°C, C-PVC has excellent chemical resistance and is suitable in applications such as metal surface treatment, chemical processing, pulp and paper production and the food and drinks sector. Manufactured in Europe to DIN 8079/80 & DIN 8063 under the ISO 9001:2015 Quality Management system, C-PVC enhances our current range of ABS & U-PVC, offering an ideal and more cost-effective alternative for legacy materials such as steel. sales@epco-plastics.com | Tel: 0113 249 1155 www.epco-plastics.com PECM Issue 51

Swivel joints allow pipework to

Rotating Cylinders

We are specialisists in taking your bespoke requirements and being able to design a solution that can fit your budget, dimensions, materials, FAT/ witness testing; hygeinic and pressurised environments. We regularly test to Hyperbaric, Seal Life and conduct Temperature/ Pressure/ Load Cycle Testing. We are ISO 9001:2015 certified.

New C-PVC pressure pipe range

Swivel Joints

Articulated Torsion Pipework In Hoses

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

Tel:

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

+44(0)1663 735003

E-mail:

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/

GEARS, DRIVES & MOTORS

Implementing customers’ ideas for the future forteq UK located in Huddersfield produce high volume injection moulded plastic components. They are a well-established supplier into the Automotive and Industrial product sectors. Plastic gear applications is a focus area for forteq Group, they have world class development facilities in Switzerland that support the manufacturing plants globally. Technical expertise and knowhow allow forteq to develop and produce very precise gears of all types using engineering and advanced polymers. At forteq UK, applications such as door latch plastic gears and worm mechanisms,

gears for valve actuators, power steering worm-wheels, over-moulded gear shafts with magnet for wiper motors are some automotive components produced. forteq are also specialists at plastics used in Industrial applications such as gas and water meter components, valve mechanisms and internal functional components, including 2K moulding.

forteq UK have capacity for new projects, please get in touch with Steve Roberts on 01484 483516 – steve.roberts@forteqgroup.com to discuss upcoming projects.

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

Issue 51 PECM

GEARS, DRIVES & MOTORS

DIGITAL SERVICE SCHAEFFLER GROUP

Schaeffler and Siemens to cooperate on intelligent diagnostics for drive systems Electric motors drive our core industrial processes, and the rolling bearing is their central mechanical component. The bearings experience all of the loads and stresses that occur in the electric motor. Therefore, bearing diagnostics provide a crucial indicator of the overall condition and reliability of a motor. In addition to developing a portfolio of condition monitoring solutions for operators, the automotive and industrial supplier Schaeffler is also working with OEM customers such as Siemens on joint offerings to increase the availability of machinery and equipment. “This partnership between Schaeffler and Siemens is based on a solid foundation of product knowledge and specific expertise. Both companies are playing an instrumental role in driving digitalisation forward in the industry while keeping their entire focus on customer value,” adds Dr. Stefan Spindler, CEO Industrial of Schaeffler AG.

SERVICES SEAMLESSLY INTEGRATED IN ONE PLATFORM The collaboration between Siemens and Schaeffler combines Sidrive IQ – the digital platform for drive systems and solutions from Siemens – with Schaeffler’s decades of experience and expertise in designing, manufacturing, and servicing bearings. Sidrive IQ integrates a number of

The collaboration between Siemens and Schaeffler combines Siemens’ IIoT platform Sidrive IQ with Schaeffler’s decades of experience and expertise in designing, manufacturing, and servicing bearings. Picture: Siemens

functionalities into one seamless solution and augments drive systems with AIbased analytics and digital content. For the customer, this means the ability to make better decisions when it comes to operation, maintenance, and maintenance measures for drive systems.

NEW DIMENSIONS OF COLLABORATION IN THE INDUSTRIAL IOT The integration of Schaeffler’s analysis service for automated bearing diagnostics in Sidrive IQ makes it possible to determine the bearing condition with greater certainty and precision. “This cooperation and automated exchange of algorithm-based

diagnostic data is one of the first of its kind in the industrial IoT. It’s a great example of a new dimension of cooperation among established technology companies,” says Hermann Kleinod, CEO of Siemens Large Drives Applications. With the help of well-founded insights and specific information, operators can quickly determine whether the drive system can continue to operate or whether, in the event of impending damage, the bearing needs to be replaced immediately or can wait for the next maintenance interval. This reduces maintenance effort and cost, and most importantly, unplanned and costly downtimes can be prevented.

For further information, please visit www.schaeffler.com/fork

PECM Issue 51

GEARS, DRIVES & MOTORS

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 ◊ Blacking Drilling & Tapping ◊ Marking 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 www.CrossMorse.com

NSK bearings help bakery save €9400 per annum A large bakery has replaced the type of bearings used in its cake-cutting machines after experiencing repeat failures on the integral blade saw pulleys. The switch to NSK Molded-Oil bearings immediately reduced maintenance costs and increased productivity, leading to total savings of approximately €9400 a year. NSK´s Molded-Oil bearings (stainless steel variant) are ideal for applications in food and beverage plants. Not only do they prevent the ingress of contaminants such as water and particulates, but no lubricant can escape the bearing and enter other parts of the machine, where it could conceivably contact food. Molded-Oil bearings are equipped with a proprietary oil-impregnated material that consists of lubricating oil and a polyolefin resin with an affinity for oil. This carrier material releases the lubricant continuously over a long period.

For more information, visit www.nskeurope.com Issue 51 PECM

HEALTH & SAFETY

EXKOP EXPRESS REMBE

Controller for multiple isolation systems In the event of an explosion, the EXKOP Express controller receives a trigger signal, for example from the signalling unit of a flameless venting device, an explosion vent, a pressure detector or an IR-Flame sensor. The EXKOP Express controller then activates the connected explosion isolation systems, causing adjacent plant components to be isolated within milliseconds and protected against explosion propagation. The EXKOP Express is suitable for the following isolation systems: REMBE quench valves QV II and QV III, the Q-Bic extinguishing barrier and the RSV Slide Valve and REDEX Slide. Together with the REMBE iQ Safety Cockpit, a software program to centrally display the explosion safety of your plant, the EXKOP Express offers the complete monitoring of plant components, process sections and statuses of various protective components. As soon as the EXKOP Express receives a trigger signal in the event of an explosion, it passes this information on to the REMBE iQ Safety Cockpit. Due to the direct notification to the desired communication medium, e.g. the mobile phone of the person in charge, REMBE has enabled causes to be identified in an optimised and targeted manner, thus allowing downtimes to be reduced.

Fig. 1: EXKOP Express controller

By detecting operationally relevant components for explosion protection or temperature/fire gas detectors and grounding systems for explosion prevention, they can be registered via the REMBE iQ Safety Cockpit and connected to material management. So if a disruptive event such as an explosion occurs, the system detects which areas are affected and provides information about which spare parts are needed to restore the plant to a safe condition as quickly as possible. These functions can be presented in the operator’s system as a “suggestion” or can be sent directly to the manufacturer as a nonbinding request. Continuous optimisation of processes is made possible through detailed documentation and evaluation of all results.

For further information, please visit www.rembe.de

PECM Issue 51

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

Made in Germany

Your Specialist for

PRESSURE RELIEF and

EXPLOSION SAFETY

Consulting. Engineering. Products. Service.

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

HEALTH & SAFETY

Creating transformation. For flexible production processes in the packaging industry. Packaging industry processes are becoming more complex due to issues such as sustainable packaging materials and the increasing customization of packaging: As a sensor manufacturer, our goal is to make your automated packaging processes even more flexible, efficient, and safer through the use of our innovative products and solutions. This is how we ensure your success in an industry that is ever evolving.

www.leuze.com/packaging

AZ_Packaging_210x148_EN.indd 1

08.04.21 14:53

50 Year old product makes dramatic comeback to help beat the virus!

Alpha Solway

The current necessity for virus protection is why the Melaphone® Speech Unit is enjoying renewed success. Its unique design eliminates the muffled sound of speech through a screen. Completely air-sealed, certified to ISO 14644-1 Class 5 Class 5, it is specified by architects and designers for hospitals, laboratories and cleanrooms. This simple but ingenious invention requires no servicing, no electricity and is very easy to keep clean. The Melaphone® is built into our Defender Virus Screens which the company has supplied to hundreds of UK doctors’ surgeries, medical centres, and pharmacies. Screens are made to the highest quality, providing hygienic, sleek and permanent protection in any environment.

With Alpha Solway, chemical suits are not only available in standard green! Our revolutionary Chemcre8 system now allows you to design bespoke colour variations by area, identifying and keeping your staff or contractors safe and ensuring they are comfortably protected at all times. This is your bespoke chemical clothing solution. Whatever feature specifications or fabrics you require, or whether you need colour coded suits for different hi-viz areas, the list is (almost!) endless with Chemcre8. Fully compatible with other PPE, the range also helps support environmental programs, helping to reduce waste and disposal costs.

All ‘MADE IN THE UK’ - by us in London and now being used for safe communication in the AstraZeneca factory. www.melaphone.co.uk

PECM Issue 51

Create colour coded protection for the right area with Chemcre8

Available in XS – 6XL sizes, please visit our website, call 01461 202452 or email sales@alphasolway.com www2.globusgroup.com/alphasolway/ chemcre8

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

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

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

HEALTH & SAFETY

DSEAR 3 DAY COURSE Risk Assessment Training (Book On-line) Our “Three Day” DSEAR training course is aimed at those who may be responsible for conducting risk assessments, but are not necessarily fully confident to do so with such a technical subject. The Course Content : • Legal foundations of DSEAR and COSHH • How Fires and explosions occur, • The fundamentals of understanding the explosive potential - Deflagrations • Understanding the Chemical Properties of a substance • Risks resulting from improper storage or handling of substances • The danger triangle and dust pentagon. • Dust explosion potentials An overview of the regulations is included along with, explanations and understanding of solvents and their physical properties, explosive dusts, ATEX classifications and coding, gas groups, temperature ratings and BS 60079-10 Ex Zone determination, all giving a greater understanding of how ATEX fits into the DSEAR equation when establishing hazardous zones. Reference is also drawn to the theoretical understanding of flammable vapours with

examples of how the Lower Explosive Limit can be converted into a meaningful quantity or volume of chemical per cubic metre of space. The course includes: A detailed 140-page, training manual for all delegates

Working group activities A “multiple choice” exam Buffet Lunch Tea Coffee and refreshments. Venue and Dates 2021: Cannock Staffordshire 15-17th June 12-15th October

www.dsc-ltd.co.uk | sales@dsc-ltd.co.uk | 01952 947682 | 07989 597569

Full range o plastic & me f tal

PRODUCT LABELS

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A full range o plastic & me f tal

PRODUCT LABELS

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PECM Issue 51

TIO XIA

CO RR O

Y PH AS

O SI

INTO XIC ATI ON

LIAN

EXP O

RIS

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Detection of safety hazards. Gas and flame detection enables you to identify, Our experts provide an end-to-end solution that monitor, and eliminate the sources of danger for is backed by more than 100 years of gas detection experience. your site and your workforce. We consult with you to identify your specific A gas leak can be colorless, tasteless and com- needs, design an appropriate fixed gas detecpletely undetectable by human senses, which tion system to meet those needs and ensure its proper installation and ongoing operation. makes it extremely dangerous.

Explosion, intoxication, corrosion of your equipment, site compliance: don’t wait any longer, let us guide you:

w w w. Te l e d y n e G F D . c o m

gasandflamedetection@teledyne.com

HYDRAULICS & PNEUMATICS

INTRODUCING FILTERFINDER FILTERFINDER

Your Solution to Hydraulic Filters Trying to identify the hydraulic filter you need, frantically searching the part number online hoping to find someone who can deliver quickly. Does this situation sound familiar to you? Introducing FilterFinder, your solution to hydraulic filters, using our website you can quickly and easily cross reference more than 600,000 part numbers and order exactly what you need with 95% of orders delivered in 2-3 working days. As well as an easy to navigate site you will find a transparent pricing structure, free carriage over £30 and each of our parts with a downloadable technical datasheet, a real image of the part and live stock updated in real time to make your experience quick, simple and hassle free. Need a hand with anything, our staff on our hand with a live chat and manned phone lines, just have a look at our great reviews to back us up.

28 April 2021

Mercury Power Transmission Ltd Replacement Labels 28 April 2021

Kenneth Great help with sourcing replacement filters. 1st class service.

Now introducing our replacement labels, write your install date, replacement date and FilterFinder number. Scan the QR code when replacement is required to take you straight to our website where you can re-order and get your parts ready to be easily swapped out.

For further information, please visit www.filterfinder.co.uk or email support@filterfinder.co.uk

PECM Issue 51

MACHINING & MACHINERY

AN ALL-IN-ONE SOLUTION OMNIFLEX

Why buying whole solutions from OEMs protects your investment When you buy an industrial monitoring and control system, you want it to last. However, it is often the case that when systems are purchased using third-party sellers, the relationship ends at the point of sale and ongoing support is minimal at best. Here Gary Bradshaw, director at remote monitoring specialist Omniflex, explores how buying whole solutions directly from original equipment manufacturers (OEMs) protects investments by providing fully integrated solutions and reliable ongoing support. Whether it be something like fire alarms and automatic door locks in a prison, or radiation monitors and local alarm annunciators in a nuclear power plant, integrating systems seems like a common sense approach to improving operational efficiency across a facility.

end monitoring system, in the form of the Datalog umbrella platform, which can be used to consolidate all building systems into one easy-to-use interface. This can be used to monitor all incoming data across the facility, as well as produce reports including data trends and statistical analysis.

However, facilities managers often face a dilemma when it comes to purchasing monitoring and control systems — should they purchase all-in-one solutions directly from OEMs or should they buy different parts of the system individually from different suppliers?

Ultimately, there are several key benefits for businesses that implement all-inone solutions like this to handle all their networking, data capture and top end analysis needs. Crucially, it drastically lowers project costs and reduces any operational disruptions associated with implementing the solution compared to a traditional approach, where you would have different companies providing different parts of a solution. Furthermore, it is often the case that the ongoing support provided by OEMs is better than that provided by third-party sellers.

BENEFITS OF AN ALL-IN-ONE SOLUTION

Buying whole systems directly from the people that made them ensures that each part of the system works seamlessly with the rest. This means you do not need to worry about things like how your local alarm annunciators will interact with your top end supervisory control and data acquisition (SCADA) system or if the annunciator in question is even compatible with your network infrastructure. Even questions like are you better off connecting your equipment over a cable network or a wireless one can be easily answered by opting for a fully integrated all-in-one solution. For our customers, this could be a case of installing all local area alarm annunciators and connecting them to the top end SCADA system using an industrial network. Then, through our partnership with Cortech Developments, we can provide the top

PROTECTING YOUR INVESTMENT

I regularly hear stories from people who have bought systems from third parties and found that they are unable, or unwilling, to provide the support needed to fix any issues that occur. This is rarely the case when buying from OEMs, who tend to take pride in ensuring that their systems do not let you down, often going the extra mile to get you back up and running if problems arise. Furthermore, when dealing with OEMs, you can pick up the phone and speak directly to engineers with an intimate knowledge of your systems — in many cases this might even be the same engineers who put your

systems together in the first place. The level of service this allows cannot be matched when dealing with third-party sellers who, despite any technical expertise they might have, simply won’t know your systems as well as the people who made them. This is equally true when it comes to software support. In the event of a software bug, the people most likely to identify and fix the problem are the ones that wrote the software. This means that any problems that arise with your systems have the best possible chance of being fixed quickly and thoroughly to get you back up and running as soon as possible. “Through our partnership with Omniflex, we can provide a comprehensive support package that connects system managers directly with the people that made them,” explained Jason Blundell, head of sales and marketing at Cortech Developments. “Whether it be frontline technical and hardware support from Omniflex, or troubleshooting by our in-house software development team, the people who made the systems are always on hand to offer support to keep you up and running.” Ultimately, buying directly from OEMs helps to protect your investment by helping to keep you operational for longer and minimising any costly downtime. For more information about remote monitoring and data acquisition, visit Omniflex’s website or call +44 (161) 491 4144. And to find out more about its software, visit Cortech Developments’ website.

For further information, please visit www: www.omniflex.com

PECM Issue 51

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LET US TAKE THE LOAD...CONTACT US AT: Y YA AP PL LE EX XL LIIM MIIT TE ED D D DE ER RB BY YR RO OA AD DB BU US SIIN NE ES SS SP PA AR RK K C CL LA AY YC CR RO OS SS S C CH HE ES ST TE ER RF FIIE EL LD D D DE ER RB BY YS SH HIIR RE E S S4 45 59 9A AG G

TEL: 01246 860114 EMAIL: SALES@YAPLEX.CO.UK

MACHINING & MACHINERY

Ready for the US market— new AZM40 solenoid interlock with UL certification The new compact AZM40 solenoid interlock now has UL certification, which means that it can be used in machinery and systems intended for the North American market. In addition, Schmersal has optimised the interlock as well as developed additional versions that incorporate specific customer requirements. The new development has generated considerable market interest thanks to its compact ‘on-trend’ dimensions. With dimensions of 119.5 x 40 x 20 mm, the AZM40 is the smallest electronic solenoid interlock in the world. The AZM40 is the ideal safety solution for all machine builders looking for optimisation through miniaturisation, simplification and minimisation of materials. The compact AZM40 can also be installed easily in confined and hard-to-access areas thanks to 180° angular flexibility of the actuator. www.schmersal.co.uk

Making lifting equipment more affordable Lifting equipment specialist, Konecranes, has welcomed the introduction of the tax superdeduction initiative as a boost for UK industry. Under the scheme, announced in the March budget, companies can claim 130% capital allowances on qualifying plant and machinery investments made between 1 April 2021 and 31 March 2023. Konecranes has introduced its own initiatives to promote industrial investment and make the acquisition of new lifting equipment more affordable, including its RENTALL programmes. RENTALL represents a packaged approach to operators’ material handling requirements, combining the lease of the lifting equipment with service regimes, maintenance plans, spare parts and remote performance monitoring. The equipment and support are provided for a fixed term and for a regular monthly payment, providing predictable fixed costs for the material handling system and its maintenance. It also eliminates large upfront investment for improved cash flow. www.konecranes.co.uk

PECM Issue 51

Used Equipment & Refurbishment Services

Demag extends the scope of its KBK light crane system

Perry Process Equipment Ltd buys and sells used & refurbished process machinery for the chemical & pharmaceutical industries. Established in the UK in 1990, they are the European Headquarters of the PERRY Group, a trusted name in the used process equipment market for almost 90 years. Perry’s UK site includes a 20,000 sq.ft warehouse and workshop where they store a wide range of equipment such as reactors, mixers, blenders, centrifuges and heat exchangers. All service work, from testing to full mechanical refurbishment, is done in-house by time served process engineers.

Material handling specialist, Demag, has added new components to its universal KBK crane construction kit, allowing users to create even more versatile lifting systems with higher load capacities, improved use of the available space and reduced installation work.

Perry will be exhibiting at the CHEMUK exhibition and will have sales managers available for an informal chat about the benefits of used process equipment. You’ll find them on stand G30. Email: ppel@perryprocess.co.uk Website: www.perryprocess.co.uk

Seiki AIR – Next generation manufacturing software product launch at MACH

The Demag KBK modular light crane system is a proven construction kit, designed to create bespoke solutions for lifting, moving and handling operations. KBK may be configured to meet the needs of specific working processes, the loads to be transported and the operational environment. The ergonomic system is suitable for standalone workstations, as well as integrated production and assembly lines with loads weighing from 80 kg to 3.2 t. New components include stronger suspensions and improved trolleys, which can be used for KBK single-girder cranes with load capacities of up to 2,000 kg. www.demagcranes.co.uk

Investing for your Future Requirements

Seiki Systems will be showcasing the next generation browser-based version of its established manufacturing operations management software, Seiki AIR, for the first time at MACH 2020. In addition to the currently available Seiki AIR WIP Booking and Monitoring modules, Seiki AIR Jobpack DNC will be officially launched at MACH, completing the full suite of manufacturing execution software modules. Seiki AIR delivers a host of new features, live data capture and display options that provide users with the best tools for an integrated, collaborative and controlled approach to the production process. Exciting new features include a digital batch card, weekly order promise screen, first off inspection traceability, user notification controls, administration of parts and operations and performance dashboards on the shop floor.

Accurate Laser Cutting (SJS) Ltd of Rotherham, has made a significant investment in new equipment, to enable then to offer the very best service and quality to their clients. A total investment of £1.2 million will be made on two new pieces of equipment and supporting software. The equipment will comprise of a brand-new laser cutting machine and a press-brake, the very latest technology and spec in the region. The laser cutter will be a powerful 12kW model, on a 4m x 2m bed. with a 320 ton, 4.1m press-brake to match. Both machines will be operated in conjunction with cutting edge, top level 3D and bending software and will be installed and fully operational by January 2020. This is another great example of the company’s commitment to continued investment in the very latest technology to provide their customers with the very best products and service.

www.seikisystems.co.uk/product/air

www.accurate-laser.co.uk

MACHINING & MACHINERY

DRILL SERVICE (HORLEY) LTD WWW.DRILL-SERVICE.CO.UK

Hand Tools

CNC deburring and polishing

P09 XEBEC BrushTM Surface End Type

P07 XEBEC BrushTM Surface

P10 XEBEC BrushTM Wheel Type

Cutter mark removal and flat surface polishing.

Deburring after face-milling, end-milling and drilling. Cutter mark removal and surface polishing.

Deburring after end-milling, threading, and drilling. Polishing side surface and inner diameter.

P18 XEBEC StoneTM Flexible Shaft

P11 XEBEC BrushTM Crosshole

P15 XEBEC Back Burr Cutter and PathTM

Hole deburring.

Deburring after drilling. Cutter mark removal and inner diameter polishing.

Deburring after drilling.

For more information please visit our website www.travin.co.uk or call us

FOR YOUR DEBURRING AND SURFACE FINISHING SOLUTION Xebec deburring tools give an unrivalled performance versus traditional abrasive products, resulting in increased productivity, improved quality and reduced costs. The UK’s most comprehensive stockist of these innovative tools.

TEL: 01293 774911 EMAIL: SALES@DRILL-SERVICE.CO.UK Same day dispatch for all stock orders received before 3.45pm

Introducing The New

TP MONSTER 94 Gram shot weight (Max) 98cm Capacity

Contact Travin Plastic Mouldings

01444 241 429

Our ZB50000 dynamic balancing machine

The most comprehensive balancing service in the UK Whatever your balancing requirement we’ve got you covered. From market leading balancing machines, support services delivered by our very own highly trained engineers and swift parts availability, through to contract balancing to cover any capacity or capability constraints. And all delivered via our UK-based teams. Machines for all applications Our ZB50000 machine is for large rotors up to 60,000 kgs. Typical applications include large turbines and fans or rotors with high inertia. Contact us today on We also offer a range of portable T: 0161 872 3123 or instruments for vibration analysis E: services@cembhofmann.co.uk and two plane balancing. www.cembhofmann.co.uk

Issue 51 PECM

MACHINING & MACHINERY

YTRON-Y

YTRON-QUADRO (UK)

Ensuring a homogeneous mix throughout the whole batch

Ytron-Quadro (UK) Ltd have recently supplied 3 very large YTRON-Y directed jet mixers to Yeo Valley Farms Production. These 55 kW mixers are installed in 45,000 litre and 100,000 litre vessels in the Crewkerne facility containing a highly viscous yogurt base.

The YTRON-Y mixers ensure a homogeneous mix throughout the whole batch. Computational Fluid Dynamics (CFD) simulations were created to ensure the size, design and installation position of the YTRON-Y mixers were optimised for efficient and effective mixing.

The YTRON-Y units were part of the new facility completed by the Somerset based engineering company, Sycamore Process Engineering.

Due to the size of the mixers, a special design has been used to allow maintenance of seals without the need to remove the large/heavy motor.

Yeo Valley Farms Production have been using YTRON equipment in their factories in Blagdon, Cannington and Newton Abbott for mixing, dispersing and for “smoothing” of certain of their yogurts since the 1990’s. This has included YTRON-Y units and the YTRON-Z in line rotor/stator homogeniser for various uniform mixing applications including mixing of fruit into yogurt as recently shown on the BBC program “Inside the Factory”

For more detail contact sales@ytron-quadro.co.uk or visit www.ytron-quadro.co.uk

PECM Issue 51

Presses (servo feeder)

be used anywhere where there is an adequate floor surface and a suitable compressed air supply. AeroGo Load Modules distribute the load over a larger surface than rollers or wheels, spreading any stress evenly on the floor. Applications are numerous and include factory relocations, movement of large or bulky items, rearranging production lines and precise alignment of equipment. AeroGo Load Module Systems float loads from 100kg to over 350,000kg. Standard AeroGo Systems include Load Module Systems, Aero-Plank Systems and Aero-Pallet Systems.

MACHINING & MACHINERY

Presses available in a large range and can, in most cases, be customised if required No pit required — One years’ warranty — Made in Turkey and CE marked Let us have your enquiries — We will also take part exchanges Tel: 0845 230 7040 Mobile: +44 (0)7860 765 184 E: sales@zebramachinery.com

Load Moduleqtei133-(108)-79 System

£ TOP PRICES Paid For all sheet metal machinery inc CNC lasers, pressbrake, shear rolls, process equipment, hydraulic presses, ducting equipment, folders, roll form machinery and kindred equipment. Immediate payment and removal single machine including complete factories.

We will take all your part exchanges.

Mob - 07834205699 / 07860765184 Email - sales@zebramachinery.com

Aero-Plank System

Aero-Pallet System AeroGo Systems are lightweight and can be easily positioned under the load taking in account weight distribution and support points. As there are no moving parts maintenance costs are minimal.

The advantages of using AeroGo Air Skates AeroGo UK’s Pro-Jacks

AeroGo’s Load Moving Systems • AeroGo Load Module Systems Jacking from an insertion height of only 25mm they complement AeroGo’s Air Skate Equipment can be used to on their own. They are robust, lightweight portable. floatandloads from 100kg to over allowor any load be literally Pro-Jacks are available in a variety of sizes with a single Jack capacity of up to 65 tonnes. 350,000kg. floated to its destination on a thin film of air. Moving the load is • Standard AeroGo Systems P1/2 easy, exceptionally smooth and include Load Module Systems, omnidirectional. Air Skates can Aero-Plank Systems and AeroPallet Systems. be used anywhere where there is • AeroGo Systems are an adequate floor surface and a suitable compressed air lightweight and can be easily supply. positioned under the load taking in account weight distribution and support points. AeroGo Load Modules distribute • As there are no moving the load over a larger surface than rollers or wheels, spreading parts maintenance costs are minimal. any stress evenly on the floor. Applications are numerous and include factory relocations, For a limited time only – You movement of large or bulky get a 20% discount on all items, rearranging production AeroGo Systems. lines and precise alignment of equipment. www.aerogo.uk AeroGo UK Ltd

Registered Office: 10-12 Mulberry Green, Old Harlow, Essex CM17 0ET Directors: B. Dean F. Janssens

Registered in England number 5137477

Issue 51 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 51

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!

PRECISION ENGINEERING 3D ADDITIVE MANUFACTURING REVERSE ENGINEERING TOOLMAKING

Precision Engineering at Agemaspark Agemaspark Ltd is a precision engineering company, founded in Doncaster in 2002, that serves industries including the aerospace sector for civil and military aircraft engines and power generation turbine engines, the Oil & Gas industry providing bespoke tooling aids, plastic mould tools for medical components, building products and caps and closure tooling for food industries along with many more sectors that require mould tools. We assist many businesses to solve their engineering problems to produce many individual components for a wide range of sectors.

OUR FACILITIES:

OUR SECTORS:

‣ CNC spark and wire erosion ‣ Small fast-hole drillers

‣ Aerospace ‣ Food manufacturing

‣ CNC milling - 4th and 5th axis ‣ CNC turning ‣ Cylindrical and flat grinding machines ‣ Assembly and finishing ‣ CAD design ‣ CAM programming software ‣ 3D additive manufacturing

‣ Defence ‣ Oil & Gas ‣ Automotive ‣ Plastic mould tooling ‣ Pharmaceutical ‣ Space

With the introduction of a brand-new EOS 290 additive manufacturing 3D metal printing machine. The EOS 290 now allows Agemaspark to create a variety of new parts and products ideal for injection mould tool inserts, functional engineering prototypes and low volume part manufacture. This new machine complements their existing downstream capabilities to create and supply complete tools. The possibilities and scope for 3D printing are limitless and the installation of this machine opens up countless opportunities for Agemaspark to support businesses across a variety of industries, from aerospace to pharmaceuticals and all aspects of plastic injection mould tooling, by providing cost-effective, accurately manufactured solutions. This new EOS 290 machine gives Agemaspark the ability to manufacture parts up to 250 x 250 x 290mm in size in Maraging (MS1) steel, and with the in-house heat treatment inserts can be hardened to 54Hrc. within 12 hours of being sintered. Examples of the possibilities for conformal cooling are shown above, this is a core 6.5 mm X 22mm x 90mm high with a conformal cooling channel giving an even cooling area in place of conventional drilled hole, pictures left show a full stack with cooling channels.

PECM Issue 51

The ability to offer endless ways to help reduce not only the cycle times of moulding but reduce the impact on the environmental concerns of plastic products by reducing the size of tooling and the energy required to produce parts.

Conformal cooling in mould tools is reducing both quality errors and cooling time Conventional mould tool making has limitations, meaning the moulds are being designed larger and larger so they can take more impressions to increase numbers of components and keep up with demand. As a result, the moulding machines are being supplied as large operational units taking up significant factory space and requiring high energy for operation. Laser sintering has been demonstrated to be a more effective manufacturing process for mould tool making. However, there remain barriers to its application for mould tooling in the plastic caps and closures industry due to concerns around the mould cooling technology and the need to provide enduring wear resistance. The current cooling channels are straight drilled and cause lengthy and uneven cooling, which often results in the formation of hot spots and high scrap rates. Conformal cooling works by creating a suitable cooling channel at a well-defined distance from the cavity—which is impossible using a conventional drilled cooling mechanism—thereby reaching areas where it is difficult to do so using conventional methods. The temperature sensors embedded on each cavity will enable effective control of the cooling. Agemaspark seeks to overcome these barriers by developing a highly efficient advanced manufacturing process for the production of laser sintered mould tools with a novel ceramic coating. The mould tools will make use of the breakthrough

Agemaspark Ltd Units 1 & 2, Croft Court, Sandall Carr Road Kirk Sandall Industrial Estate, Doncaster South Yorkshire, DN3 1QL United Kingdom Tel: +44 (0)1302 882666 Email: admin@agemaspark.com

AGEMASPARK.COM

process utilising conformal cooling channels embedded with temperature control sensors enabling localised temperature control. This will overcome inherent deficiencies in the current plastic caps and closures mould tooling technology (pictured below left). In December 2020, we purchased an EOS 290 which is already demonstrating examples of how we can produce conformal cool in Maraging Steel with a hardness of 54 Rc, and if required, apply a ceramic coat to give increased tool life and a friction free release (pictured below right). Results show that it is possible to reduce cycle times by up to 20% and at the same time increase the continued quality of the moulding. The environmental advantage from using this method is to increase the impression on the same envelope or reduce the size of the tools and therefore the size of the mould press, reducing energy consumption. The cooling water requirements reduced from tens of thousands of litres used in any 24 hours to just 10-20 litres because the heat transfer is just local to the moulding and is contained in a closed loop system (pictured below centre). Agemaspark has also used this approach on existing tooling by removing the tops and re-sintering with conformal cooling channels replacing the moulding area.

Issue 51 PECM

MEASUREMENT & MONITORING

CLEARING THE PATH TO NET ZERO ETI

Electronic Temperature Instruments introduces measures to achieve net zero status by 2025 Electronic Temperature Instruments (ETI), the UK’s largest digital thermometer manufacturer and exporter of electronic thermometers and temperature probes, has introduced a company-wide strategy to help it achieve net zero status by 2025. The company, which exports globally, is committed to reducing its carbon footprint and improving its environmental performance. As recently as April, the UK government set the world’s most ambitious climate change target into law to reduce emissions by 78% by 2035 compared to 1990 levels. Many of the UK’s largest organisations have now outlined their own targets with the BBC and Sky both aiming for net zero carbon status by 2030, Sainsbury’s by 2040, and British Airways by 2050. To achieve net zero status by 2025, ETI has already introduced many positive changes to its processes to improve energy performance and efficiency. This includes: • Installing renewable energy on all four ETI sites or switching to renewable energy suppliers • Reducing transport use through improved logistics and/or switching to electric vehicles • Continued use of online conferencing facilities instead of travelling to meetings • Designing products for reuse, repair and recycling • Reusing production waste materials where appropriate • Develop strategies for more sustainable product packaging • Recycling redundant materials that can’t be reused • Sourcing products and materials from companies with recognised net zero policies and commitments • Separating and minimising waste for easier recycling and reuse • Reducing paper records and expand cloud storage

Moving forwards, ETI will now wish to see its own suppliers reference their approach to meeting this target within their own environmental policies. Jason Webb adds: “This is something that we should all be working towards together. Our net zero target of 2025 underlines our commitment to improving environmental performance. To curb emissions and limit global warming all organisations will have to reimagine their existing business models and aim for sustainable growth. We are continuing to take a leadership position in this effort – and are encouraging our clients and peers to do the same.”

For more information please visit https://thermometer.co.uk

PECM Issue 51

MEASUREMENT & MONITORING

Bartington Helmholtz Coil Systems Bartington’s range of Helmholtz Coils provides solutions for a variety of industrial and research applications, where creation of an accurate and controllable known magnetic environment is important. For example, many of today’s devices include compasses for navigation, such as mobile phones, satnav systems, and rangefinders. Our Helmholtz Coils are ideal for calibrating these devices accurately, enabling maximised performance and improved accuracy of the data obtained from these compasses. Our range of coils is available with diameters of 350mm(HC16), 500mm (HC1®) or 1m (HC2®). They can be supplied on their own, or with our Power Amplifier (PA1) and Control Unit (CU1). The CU2 Module allows for closed-loop compensation to take place for improved field stability, especially over slowly varying ambient field changes. We also offer a compatible National Instruments acquisition card and LabView™-based package, which enables

a turnkey solution for software control of your Helmholtz Coil system. Each pair of coils generates a homogeneous magnetic field in one specific axis: X, Y or Z. The coils can be calibrated to add or subtract from distortions in the Earth’s magnetic field. For the HC1®, you may specify the number of axes, and hence pairs of coils, required. The two-axis version is available in any combination (X+Y, X+Z or Y+Z), which may be specified when placing your order. The HC2® coils are provided in flat-pack form for easy shipping and assembly at your convenience. In addition, Ferronato Helmholtz Coils with 1.3 and 2m diameters from Serviciencia are also available, and are compatible with our control system. When developing new magnetic sensing technology, our Helmholtz Coils and reference sensors are invaluable in ensuring the new sensors are calibrated and tested

appropriately. Our Mag-13MS three-axis magnetic field sensor is an ideal high precision reference sensor for field measurements.

www.bartington.com/bartington-helmholtz-coils

Time-Domain NMR Spectrometer for Materials Studies & Process Measurement & Control Time-domain NMR Relaxation is an extremely useful quantitative technique for material science and process measurement & control. This time-domain NMR spectrometer can be used to study solids such as polymers and porous materials. This gives information on qualities which are variously described as mobility, dynamics, stiffness, viscosity or rigidity. This highly compact Mk3 low-field time-domain NMR relaxation spectrometer provides physical information on liquid and solid samples in the lab and in the field, at a size, cost and complexity

typically 1/10th to 1/100th of that of typical high field chemical analysis NMR systems. The Graphical User Interface has extensive software for on- and off-line analysis of material and sample data, and built-in modules for process on-line monitoring and control. This spectrometer is robust, and compact enough for use in the field. It has a 3D printed solid metal case, gold flashed, and weighs just under 1kg.

+44 (0)7805 437241 nmrspectrometer.lab-tools.com www.Lab-Tools.com

Electric Vehicle Charger: Power We are truly at the beginning of the electric car age. With countries around the world introducing mandates to cut the number of diesel and petrol cars. Public car chargers are going to be scheduled as part of the strategy. The first hurdle system designers will have to overcome when developing and deploying public EV chargers is the huge power requirement. There are three main types of EV charging stations: AC Level 1, AC Level 2 and DC fast charging. AC Level 1 chargers

provide 120V charging to deliver up to 1.9kW of output power. AC Level 2 chargers provide 240V charging to deliver anywhere from 3kW to 19kW. Colloquially known as a sort of “level 3” of charging stations, Direct Current Fast Chargers (DCFCs) are designed to fill an EV battery to 90% in as low as 20 minutes.

www.componentsbureau. com/market-sectors/ transportation/electricvehicle-ev-chargingstations

Issue 51 PECM

MEASUREMENT & MONITORING

SMART SENSORS AVT RELIABILITY

David Stevens, Technical Authority and Skills Competence Manager for AVT Reliability®, explains the important role that ‘smart sensors’ can play in improving reliability while delivering cost-efficiency Digital condition monitoring (CM) can bring considerable benefits in terms of improved asset performance and lifespan, reduced downtime, increased safety on the plant floor and more productive use of personnel – all of which can have a significant impact on maintaining a strong bottom line. However, a company looking to digitalise its CM programme should carefully consider the capabilities of the technological tools available, to ensure they get the best return on investment. The selection of sensors - the device fixed to a rotating machine to take measurements such as vibration and temperature - is a good place to start. Fixed sensors with low price tags are available, but they require physical monitoring, cannot be configured to the specific requirements of the process, and produce no analytical data.

the cloud, provides real-time analysis, issues alerts about impending problems and suggests pre-emptive action to avoid unscheduled downtime. This information can be accessed via any web browser, from any location.

By contrast, advanced ‘smart sensors’ demand a higher price but deliver: • Configurability • Detailed analysis • High data storage

A smart meter enables access to previously to hard-to-reach assets, or those in chemical environments, while remote data collection from, for example, an offloading pump, removes operator risk.

• Accessibility and hazard limitation Configurability enables a smart sensor to collect readings after a pre-determined time period and only when the machine is running. After a specified period of anything from one hour to four weeks, the sensor ‘wakes up’, ready to collect a full set of triaxial vibration readings. This is particularly valuable for batch process applications. With advanced systems, the portal uses component templates with predefined vibration measurements. This can facilitate different frequency ranges and lines of resolution for vibration measurements, depending on the rotational speeds of the components. While many sensors only work

between 10Hz and 1kHz, a smart sensor can be configured to take readings up to 5.5kHz, delivering more information at a far greater range and enabling a more tailored CM solution. It can also measure the components’ surface temperature particularly useful for continuously running machines. Digital data collection enables up to 5,000 readings to be stored securely in

There can be a significant return on investment by investing in a CM programme. For example, one large chemical company saved £252,320 over 12 months after investing in an advanced cloud-based system and digital sensors, which enabled it to plan its maintenance instead of letting critical assets run to failure. When it comes to digitalisation, they proved the old adage: ‘you get what you pay for’.

For further information, please visit www.avtreliability.com

PECM Issue 51

MEASUREMENT & MONITORING

Wire-Wound and Thin Film Platinum Temperature Sensing Resistors from Labfacility

On-line, Real-time Process Elemental Analysis for Liquid Stream Applications

Labfacility offers a wide range of precision platinum temperature sensing resistors in both wire-wound and flat film construction. All standard items are available in quantity from stock; non-standard detectors can be supplied to order. • Precision platinum temperature sensors • Pt100, Pt500, Pt1000 & other values available • Wire-wound and flat film types • Wide range of sizes • Available from stock • Tolerance values include class A or B, to 1/10th of class B • Single or duplex detectors

Featuring advanced flow cell designs in combination with energy dispersive X-ray fluorescence (EDXRF) technology, the NEX OL from Applied Rigaku Technologies represents the next evolution of process elemental analysis for liquid stream applications. Nondestructively analyze aluminum (Al) to uranium (U), from parts per million (ppm) levels to weight percent (wt%) concentrations.

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. E: sales@labfacility.com T: +44 (0) 1243 871280 www.labfacility.com

The NEX OL multi-element process analyzer serves a broad range of process control applications spanning from heavy industrial to food-grade process gauging solutions. NEX OL is configurable for use in classified and non-classified areas, features an intuitive industrial touchscreen user interface, easy calibration and routine operation, standard communications protocols, and a 2-year manufacturer’s warranty.

One tool – everything under control The PLC-ANALYZER pro 6 is the widely appreciated solution for logic analysis, failure diagnosis and data recording on PLC controllers (SIMATIC S7, Allen-Bradley, Mitsubishi, Schneider, OMRON, CoDeSys, OPC UA and others). Up to 16 million variables from 250 signal sources can be recorded simultaneously. Every PC connected for PLC programming can be used for recoding process data without modification. Video data can be recorded synchronously with the PLC process data. Symbol files or PLC programming projects (e.g. TIA) can be loaded directly by PLCANALYZER pro 6 making all settings and variables immediately available for easy drag’n’drop selection. With this unique tool you have always everything around your PLC installations under control. >>> Wanted: Reseller for UK <<<

PC-SEP16-TM ELECTRONICS.qxp_Layout 1 12/09/2016 09:23 Page 1

www.rigakuedxrf.com/nex-ol.php

www.autem.de

For a free quote: +44 (0)1903 700651 sales@tmethermometers.com

www.tmethermometers.com

Issue 51 PECM

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.

www.measuremonitorcontrol.com

Miniature Broadcast Cameras Ltd Rubi4G Live Video Streaming What does this equipment do?

• Sends pictures and sound from anywhere to anywhere via the Internet • Sends pictures and sound remotely anywhere via the Cellular Network and internet

Rubi4G Live Video Streaming applications

Rubi-Power Unit

• Portable 12 Volts DC 24Ah Lead Acid Battery in Lockable Flight Case

- a few examples shown below...

Measures 180mm X 160mm X 260mm at Approx. 11Kg

• A gas or oil rig in the North Sea has developed a very serious problem and it is imperative that senior engineers see live pictures of the situation from their office computers that may be many miles away

• Safe & Secure built-in Charger unit with Temperature Shut down control feature

• A product in the design stage needs to be seen in the factory 500 miles away

• Suitable for all work functions that require a Heavy 12 Volt DC supply

• Using the Live Remote facility any of the emergency services can send live pictures to their respective control rooms

• Examples: Industrial applications, Camping equipment, Portable Lighting, DC Motors and Associated equipment

• Live pictures can be sent remotely from a moving vehicle

Miniature Broadcast Cameras Ltd Farm Office, Patch Park Farm, Ongar Road, Abridge, Romford, Essex, RM4-1AA Mobile: +44(0)7966 753226 | Web: www.mbc-ltd.tv | Email: sales@mbc-ltd.tv

PECM Issue 51

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MEASUREMENT & MONITORING

THERMOMETER CTM-4SF10-C3 MICRO-EPSILON

Non-contact infrared temperature sensor offers ultra-high measuring speeds on metal and non-metal objects with a temperature of 0 to 500°C Precision sensor manufacturer MicroEpsilon has extended its thermoMETER CT series of non-contact infrared temperature sensors (pyrometers) with a new ultrahigh speed version that offers a 300 µs response time (90 µs exposure time) on metal and non-metal objects with a temperature of 0 to 500°C.

HIGH SPEED PROCESSES AND LOW TEMPERATURES In high speed processes with very short cycle times, requirements for pyrometers used for temperature measurements are extremely challenging. Previously, the combination of high speed, low temperature and short wavelength was never realised and there was always a compromise on at least one of the three. The new thermoMETER CTM-4SF10-C3 infrared temperature sensor (CTM-4) from Micro-Epsilon uses a new detector that measures within the spectral range of 2.2 to 6.0 µm and is therefore ideal for low temperature (0-500°C) measurements on metals, metal oxides, ceramics and plastics, as well as materials with an unknown or changing emissivity. The CTM-4 is Micro-Epsilon’s fastest infrared pyrometer to date. While the previous models in the CT series operate in the millisecond range, the CTM-4 outputs a measured value every 300 µs and takes just 90 µs to acquire a stable measurement value. A spectral wavelength range of 2.2 to 6.0 µm supports the measurement of various objects including metals and non-metals (e.g. ceramics and plastics). For fast parameter set up, the CTM-4 provides an integrated USB interface. With a sensor head diameter of just 14mm and a length of 28mm, the CTM-4 can be easily installed in restricted spaces on a machine or production line. The pyrometer can be used in ambient temperatures

up to 70°C without cooling. The remote electronics unit (controller) is connected to the sensor head via a cable, which can be up to 15m in length. Important parameters can be entered directly via three keys and an illuminated display on the controller. An integrated USB interface enables the CTM-4 to be connected directly to a PC, where all settings can be fine-tuned using the CompactPlus Connect software. Data capture and recording are also possible using the software. Other serial interfaces or an Ethernet interface are also available as options. Two scalable analogue outputs and three programmable I/Os are available as standard for connecting the CTM-4 to the user’s own process environment. Glenn Wedgbrow, Business Development Manager at Micro-Epsilon UK comments: “If speed matters in the customer’s

production process, the thermoMETER CTM-4 is our fastest infrared temperature sensor yet. We see numerous temperature measurement applications for the pyrometer, including high speed, high volume production such as PET preform temperature monitoring, assembly and packaging processes that involve hot glue dispensing, high speed traffic and rail safety applications where hot box detection is required, as well as the more obvious processing of metals and metal oxides, ceramics, plastics and other materials with unknown or changing emissivity.” For more information on the thermoMETER CTM-4SF10-C3, please visit www.micro-epsilon.co.uk or call the MicroEpsilon sales department on +44 (0)151 355 6070 or email info@micro-epsilon.co.uk

For further information, please visit www.micro-epsilon.co.uk Issue 51 PECM

MEASUREMENT & MONITORING

A CLASS LEADING TRANSMITTER KOBOLD

New pressure instrument release from Kobold Kobold have released the latest version of their electronic digital pressure gauge; model MAN-SC for battery powered, and model MAN-LC for 24Vdc power with IO-link. Outwardly, the two versions are similar in appearance and share most of the screen functionality features which are now accessed via capacitive Touchpads, however, depending on the application and use, each instrument version may be defined differently. For example, the battery powered instrument defined as a Digital Pressure Gauge, while the 24Vdc version can be defined as a Digital Pressure Transmitter, which considering the innovative features of each version is rather simplistic, but it goes some way to define the natural application areas of the two versions. Kobold’s previous Digital Pressure Gauge, the MAN-SD, remained in production for 23 years, proving a very robust and popular instrument. With that record of robustness and reliability in mind, Kobold carefully developed the new MAN-SC/LC instruments, prioritising these core values, but also incorporating the wishes of customers worldwide to produce a high-quality digital pressure gauge which satisfies traditional user applications, but also reaches out to new industry sectors. A key target requirement in Kobold’s design brief was not to exceed the retail price of the previous model, which for a new innovative electronic instrument product manufactured in Germany was not an easy task for Kobold’s production engineers, however, the retail price remains the same, and we think this offers considerable value for money in the current global marketplace.

SO WHAT’S NEW?

• The new alpha-numeric 14-segment reflective LC‑display screen is impressive, with a full 5-digit display, and digit height of 16mm. • The electronic screen module can now be rotated in 90° increments; ideal for side mounted or inverted installations. • The gauge head position can now be radially adjusted after installation for perfect positioning.

• Access to the screen options is now by capacitive Touchpads. • An impressive range of measuring units are now accessible for selection from the programming menu, for example; kPa, MPa, bar, mbar, psi, kN, N, torr, inWC, mmWC, inHg, USR (user-defined measuring unit), providing more options than any comparative instrument so far. • Peak memory is featured, as is password protection, and reset to factory setting. • Battery life with 9V Lithium is now increased to 22,500 hours (2.5 years). • A zero (tare) function is now more easily accessible from within the menu, ideal for calibration. By popular request, a rubber protective case cover is now available as an option, ideal for test engineers and vulnerable areas of installation. Measuring ranges are now available from -1…0...+1600 Bar, which is impressive. The range of process connection threads has also been substantially increased and now include metric threads. Additionally, from the options list Kobold are able to assemble diaphragm and hygienic process connections. Another unique application feature, only available from Kobold, is calculation of Force Value which is included in the programming menu. This is calculated from the measured pressure value and a programmable reference area. There are many industrial applications that will benifit from this feature but the most common request came from the construction test and safety sector for a digital pressure gauge to be included as part of the test equipment for compliance to DIN EN 1090, for example, testing of anchors and fastenings in masonry and concrete to provide conformity assessments and certification in accordance with DIN EN 1090.

SO WHY PRODUCE A DIGITAL PRESSURE GAUGE WITH AN INTEGRAL TRANSMITTER?

The MAN-LC provides so much more than the traditional barrel style digital pressure transmitter such as Kobold’s popular PSD instrument, which followed the industry design trend for compact digital instruments. The most beneficial features of the MAN-LC are the clarity of the large digital display, and the multiple programmable features of the instrument.

SO WHAT’S NEW?

• The new MAN-LC model comes with IO-Link, the only Digital Pressure Gauge worldwide with IO-Link. • Many of the standard features included in the battery powered MAN-SC model are typical, however, the MAN-LC is 24Vdc powered and therefore further features are included, most noticeable when viewing the LC-display, is a backlit screen which combined with the new large display characters provides a clarity which traditional digital barrel transmitters cannot provide. • Analogue and frequency, plus alarm outputs are standard, and an optional pluggable relay module with 2x potentialfree SPDT contacts is available either factory assembled, or as a retrofit kit. This enables a customer to specify a very powerful pressure instrument specification. • Added to these features, the addition of a variety of flanged and diaphragm seal process connections extends the application reach to many industrial applications. Kobold believe they have answered the most requested technical wishes from their customers worldwide, and in doing so, have produced a class leading digital pressure gauge/transmitter, in line with future Industry 4.0 requirements. Kobold has International sales offices and distributors who will be happy to offer support.

For the product datasheet and national contact details visit www.kobold.com

PECM Issue 51

NEW PRODUCT RELEASE

Introducing the MAN-SC/LC New Innovative Digital Pressure Gauge from KOBOLD Class Leading Features & Performance • 5-digit, 14 segment alpha numeric LCD display with16mm digit height for clear indication • Capacitive touchpads • Peak memory • Analogue output, frequency output, switched output (MAN-LC) • IO-Link function (MAN-LC) battery operated, or 24Vdc

• Up to 2 relays possible (MAN-LC) • Selectable measuring units • Force value calculation • Tara function • Stainless steel process connection • Rubber protection sleeve for tough operating conditions • Assembly with various diaphragm seals possible • MAN-SC: power supply via 9 V block battery Battery life: up to 2 ½ years • MAN-LC: external power supply via 24 VDC (M12x1 plug)

variety of diaphragm seal options

01623 427701 www.kobold.com info.uk@kobold.com Measure – Control – Analyse – Calibration – Systems – Commissioning

NEWS & EVENTS

RAPID EXPANSION DERITEND GROUP

Framework extension delivers £1m opportunity for Middlesbrough fabrication specialist A leading fabrication and mechanical engineering specialist is setting its sights on rapid expansion after securing a string of new contracts, including a £1m framework extension for Northumbrian Water.

This will involve investment in training and workshop equipment to allow the business to compete in highly compliant sectors and the recruitment of a new lead administrator and two new apprentices.

Deritend Group, which employs 14 people at its purpose-built workshop on the Riverside Park Industrial Estate in Middlesbrough, has achieved the deal that involves design, fabrication, coating and site installation of load bearing platforms and other structural fabrications.

Richard Brown, General Manager at Deritend Group’s Middlesbrough site, commented:

The company is now looking to bounce back from the challenges of Covid-19 lockdowns by maximising recent investment by GE Renewables and the announcement of a Teesside Freeport, not to mention transferring its technical manufacturing expertise into new opportunities in nuclear, oil and gas, chemicals and renewables.

PECM Issue 51

“Last year was very challenging and we had to adapt to a downturn in orders with businesses reluctant to spend and only carrying out essential work. “In typical ‘Deritend’ fashion, we have met the difficulties head-on and worked closely with our clients to ensure this has been carried out safely, efficiently, on time and in budget. We are now seeing the benefit of this with enquiries up 20% and major orders being secured.”

He continued: “The Northumbrian Water contract, which could be extended to 2024, highlights the level of service we provide to the customer and how our multi-skilled team can offer response times that few in industry can match.” Deritend Group, which recently passed its ISO:9001 and ISO:1090 audits with commendations, delivers a full turnkey service, working closely with clients from concept and design right through to assembly, testing and installation. It boasts a design-led structural engineering department capable of offering a full range of bespoke highly compliant fabrication and machining services, with the 15,000 sq ft workshop equipped with a 10-tonne crane and a high-definition plasma cutting machine.

Last year was very challenging and we had to adapt to a downturn in orders with businesses reluctant to spend and only carrying out essential work.

Continuous investment in the firm’s weld procedure matrix gives it the capability to handle different specifications, material thicknesses and positions, with semiautomation of the welding process providing greater efficiency and quality. Richard continued: “There has also been a lot of interest in our mechanical department, which provides manufacture and overhaul services for industrial rotating equipment, such as gearboxes, pumps and motors. “We provide a 24/7 service from collection and inspection through to reverse engineering of components and the supply of fully overhauled ‘production critical’ items delivered back to site as efficiently as possible in the required timescale.” He concluded: “Large companies like British Steel, PD Ports, Spartan and JN Bentley all count on us for essential maintenance and engineering services and these type of high-profile customers are ones we’ll be targeting going forward.” Deritend Group employs over 100 people across its three centres of regional excellence in Luton, Middlesbrough and West Bromwich.

For further information, please visit www.deritend.co.uk or follow @deritend on twitter Issue 51 PECM

SCAN TO REGISTER

28 - 30 SEPT 2021 NEC, BIRMINGHAM

WHERE PRODUCTIVITY MATTERS

See the latest processing equipment, packaging machinery, robotics and machine vision in action Gain a competitive advantage through the latest innovations and seminars

ppmashow.co.uk O OW WN NEED D A AN ND D O OR RG GA AN NIISSEED D B BYY

PPMA PPMA Group Group of of Associations Associations is is aa trading trading brand brand of of PPMA PPMA Limited. Limited.

When managing real pressure is your job… MIPC® helps engineers stay on-site and on top of the latest industry developments and good practice in primary containment of hazardous substances. Using a blend of live, online classes, MIPC® one-to-one sessions with expert shortlisted for tutors, and e-learning, enhanced the Best E-learning/ by a mentor’s support and Online Education guidance, EEMUA’s Mechanical Initiative Integrity Practitioner Certificate memcom membership excellence awards course delivers in-depth training to 2020 engineers where they work – to give professionals the flexibility to learn on-site or on-call. Options for induction to suit your schedule from July 2021 Learning starts in September 2021

Registration open now.

For more information please contact EEMUA online-learning@eemua.org +44 (0)20 7488 0801 www.eemua.org

PACKAGING

EFFICIENT PACKAGING ADAPTSYS

Component manufacturers and distributors can seal small parts in pocketed tape produced in-house, as a cost-effective and space-efficient solution for storage and shipping By James Cawkell, Technical Director, Adaptsys Tiny components such as small springs, miniature machined or stamped parts, and moulded parts present many handling challenges from the point of manufacture to the point they are fitted in the end product.

PACKING CHOICES FOR STORAGE AND SHIPPING Items are usually packed in bags, small boxes, or component trays for transit and storage. Neither is ideal. Bags and boxes do not protect individual components and can allow bulk-packaged parts such as springs to become interlinked. Also, bags and boxes are not well suited for presenting components to a customer’s automated assembly processes and mis-counting can occur. Trays provide protection for individual components and can be used with tray-feeding mechanisms for automated assembly. However, sufficient numbers of the right types of trays must be available to package the parts ready for shipping. Also, trays are not well suited to shipping very large numbers of components. Pocketed tape offers an alternative that provides individual protection for parts while also allowing large numbers of components to be stored efficiently on a reel. Carrier tape is created by embossing small pockets at pre-defined intervals into a semi-rigid backing. A transparent cover strip is added to seal the components in their pockets. The packaging cost per pocket is low. Component tapes supplied on reels are widely used in high-speed automated manufacturing scenarios such as surface-mount electronic assembly. There are already reliable and economical mechanisms for feeding the carrier tape, removing the cover strip, extracting the components, and discarding the used materials. On the other hand, some of the challenges that apply to trays apply equally to

PECM Issue 51

pocketed tape. Enough tape, of the right width and with pockets the right size, must be available to package the components. Without enough tape, parts cannot be despatched to fulfil customers’ orders. Also, holding large quantities of tapes, with different widths and pocket sizes, occupies a significant storage space.

BRING TAPE FORMING IN-HOUSE Producing pocketed tape on demand can help overcome these inventory and supply problems. Cost reduction and the flexibility of producing just the amount of tape required for each application reduces cost, stock levels, space, and wastage. With such capability, part manufacturers and distributors can take advantage of pocketed tape for protection, space-

saving storage, convenient and efficient shipping, and compatibility with automated manufacturing. Flat tape is easier to store than pre-formed tape. In fact, the space needed to store stock carrier tape can be reduced by as much as 95%. There is also potential for a recurring financial saving by purchasing unformed tape instead of preformed pocketed tape. Even companies that do not intend to produce all their own packaging in house can benefit from having an independent pocket-forming capability. In the event of an emergency, having the option to produce a small quantity of tape on demand to fulfil an order can mean the difference between delivering on time and delivering late.

PAYBACK TIME The up-front investment needed to start making tape in house can be surprisingly low. Adaptsys’ Re-flex II system comes at a price that enables companies to recoup their investment in as little as 12 months, depending on usage. The latest model incorporates upgrades to the motor-control system that allow tape speed up to four metres per minute thereby ensuring high throughput. Its compact footprint, measuring just 75cm x 35cm occupies minimal realestate in a factory or packing area and the system requires only a standard AC supply and compressed air. The system can handle tapes up to 88mm wide and gives users the flexibility to create pockets in standardised or custom dimensions simply by changing the tooling. The pockets may be simple shapes, such as a square, rectangular, or rounded recess, or may be specifically shaped to fit a particular component or provide certain functions such as protecting vulnerable pins or protrusions. Adaptsys can help customers create custom tooling where required and has successfully developed solutions for various special components such as small electronic modules and electrical connectors. The system is designed to allow tooling to be designed and produced quickly and cost effectively. Changing the tooling to a different tape design in a production setting requires no special skills and takes just a few minutes, enabling users to produce pocket designs in almost any quantity

from low and medium to high volume. In addition, Re-flex II provides quality inspection and traceability of each formed pocket. Re-flex II can be used with any standardsize input and output reels up to 22” (560mm) in diameter, taking flat tape from the input reel and delivering formed pocketed tape to the output reel. It is also possible to create pocketed tape in realtime to be fed directly into a component taping process for packaging large numbers of components. Here is a simple example. The Re-flex II supply reel can contain up to 1000 metres of flat tape. In contrast, the same size reel can carry only about 40 metres of pre-formed carrier tape assuming a pocket depth of 6mm. If the taping process operates at 2 metres of parts every minute, the operator needs to change both the supply and output reels every 20 minutes. When feeding the taping process directly from the Re-flex II system, the supply reel only needs to be changed once every eight hours – equivalent to once per shift, or less - thereby greatly reducing stoppage times and raising the overall productivity of component taping.

EFFICIENCY-BOOSTING OPTION While Re-flex II is intended primarily for feeding pocketed tape directly into a component taper, the new Crosswinder option now enhances owners’ flexibility to produce tape onto reels to be stored for later use.

With the Crosswinder, Re-Flex II gives extra flexibility to store more components on a reel by increasing the reel width. Crosswinder neatly winds tape of a standard width, say 12mm, across a 100mm-wide reel to increase the storage capacity by a factor of 8 compared to an ordinary 12mm reel. In the end-customer’s factory, a crosswound reel can supply significantly more parts to a high-speed component taper before needing to be replaced thereby reducing changeovers. The Crosswinder ensures the tape is neatly ordered to unwind smoothly, which helps avoid problems that may otherwise require the taper to stop. Crosswound reels are available in various widths to provide high maximum capacity.

CONCLUSION Tape and reel packaging is a proven solution widely used to protect parts such as electronic components during shipping and present the parts for automated assembly. In fact, the packaging is suited to a wide variety of component types across many industries. The Re-flex II offers a compact and affordable tape-forming solution, capable of operating at high speeds to synchronise with downstream component-taping equipment. Delivering the flexibility to produce pocketed tape on demand, to custom or standard designs, and in almost any quantity, the equipment is easily able to repay the initial investment within a year.

For further information, please visit www.adaptsys.com | https://reflex-odt.com/thank-you-metal/ Issue 51 PECM

PROCESS TECHNOLOGIES

Croft Filters ltd

Strata Technology Ltd

Croft Filters ltd are the sole UK suppliers of high-quality self-cleaning filters manufactured by HiFlux Filtration A/S Denmark. The Company can provide a variety of models for different applications within various industrial sectors. Made from stainless EN 1.4404 steel, the HiFlux Auto-line filters can be used for cleaning a diverse range of liquids, including paint, lacquer, lubricating oil, bitumen, HFO, grease, paint, toothpaste, water, fermentation liquids, petrol, syrup, condensate, CIP liquids, antibiotic suspensions, many types of waste water. The self-cleaning filters can help reduce downtime, save on operating costs and improve productivity and quality within the operating systems. Croft Filters are also the leading UK manufacturers and suppliers of custom filtration solutions for over 30 years to the Oil & Gas, Food & Beverage, Pharmaceutical and other sectors.

Strata Technology Ltd specialises in supporting the development of green technologies and works with both academic institutions, including the University of Nottingham and University of Sheffield, and with industrial partners, including C-Capture and EDF. A consortium led by EDF, of which Strata is a key member, was recently award government funding from the BEIS to develop a Direct Air Capture process for carbon dioxide. The proposed process utilises waste heat from Nuclear Power generation to drive the process and achieve a cost-effective method for removing greenhouse gas from the air. Do you have a project for which you need engineering support? We can offer in-house process development, mechanical and electrical engineering, construction and commissioning services to enable you to develop and commercialise your process.

Phone: 01925 766265 Email: sales@filters.co.uk Website: www.filters.co.uk

Tel: 01932 732340 Email: enquiries@stratatec.co.uk www.stratatec.co.uk

“All-in-one” process for feed and fertiliser production Lödige Process Technology developed a process engineering solution for the production of monocalcium phosphate (MCP). The powder, which is an essential component of feed and phosphate fertilizers, can thus be produced economically in an “all-in-one” process. Monocalcium phosphate (MCP) is formed by the reaction of pure phosphoric acid and calcium carbonate. Powerful process technology is just as important to the production of high-quality MCP as the quality of the raw materials used. Lödige offers a solution that is specially designed for this application, based on a type KM Ploughshare® Mixer for continuous operation. A variety of different machine sizes is available for throughput rates in a range from 1t/h to 50t/h. www.loedige.de

Accept no imposters – the one and only true V-Cone meter Whilst it’s very common for cone meters to be called a V-Cone, McCrometer, Inc. invented and patented the first successful cone meter, the one and only V-Cone® Flow Meter, in 1985. Due to the dynamics of liquids and gases flowing through elbows, valves, pumps, and other pipeline structures, every flow meter methodology has its own design limitations. Unlike Venturi meters, pitot tubes, orifice plates, and other devices, V-Cone meters provide highly accurate and reliable readings with minimal straight-

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PECM Issue 51

pipe length restrictions and virtually no maintenance, in pipe sizes up to 120”. The advanced V-Cone Flow Meter requires only 1-3 straight pipe diameters upstream and 0-1 downstream to operate effectively. In comparison to traditional DP instruments, the V-Cone Flow Meter’s design is inherently more accurate because the flow conditioning function is built into the basic instrument. Contact info@able.co.uk today where are specialists are waiting to assist you.

SOFTWARE & SYSTEMS

SUITE X

WSCAD

E-CAD integration reduces time to market by 80% for automation control specialist The time to market for automation system design and development has decreased by up to 80% for a control technology specialist following the introduction of a comprehensive electrical system design package. WSCAD’s E-CAD software platform Suite X has delivered the result for automation system builder Bruckmann Steuerungstechnik GmbH (BSG), based in Uedem north of Düsseldorf, Germany. BSG needed a solution that would interface with its own in-house developed configuration software and an established ERP system to deliver an intuitive, easy to use design and specification tool. BSG is a control technology integrator, automating systems for process and manufacturing industries from single machines to full production lines. Author of its own software suite, the capability of BSG’s ONEsystems platform includes machine automation and control, data acquisition and vision across the automated operation, as well as software integration between ERP-level IT and real

machine data. BSG demanded a CAD package which could manage the design of its automation integration projects, and crucially, it also had to integrate with ONEsystems and be fully interoperable. Aware of the track record in deploying time-saving CAD packages for industrial automation solutions, BSG engaged with WSCAD with the aim of developing a partnership to create optimum automation design and streamline the design and development process. The key challenge for BSG is time to market. Whether a new project or retrofit, BSG’s customers demand quick project delivery in order to optimise productivity. Integration with ONEsystems’ ERP system would be vital in order to reduce time on data transfer, management and accuracy. ERP integration would also increase efficiency of the project planning and procurement processes. A further aspect to achieve reduced time to market is consistent product

standardisation and the re-use of predeveloped, effective solutions. Crucial to reducing project time at BSG is electrical engineering design, from the development of individual machines and circuit diagrams with wiring and distribution components, through to complete production plants and switchgear. As a result, the re-use and automation of electrical design would be a key factor in achieving rapid time to market. WSCAD was able to fulfil BSG’s requirements through deployment of its electrical CAD system Suite X. “It was important for us that the interface from the E-CAD supplier would be able to directly integrate with our ERP system, as well as enabling project replication to speed-up future projects,” says Leendert van Straalen, Operations Manager at BSG. “WSCAD was able to provide the features we needed to design individual machines through to complete greenfield site project

Cabinet layouts, including all the production data for labelling, wires and cabinet enclosures, are generated without any additional licence costs using the Cabinet Engineering Expert module and sent to the NC machines of renowned manufacturers.

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Images: WSCAD GmbH

Above left, The items in the tender already contain all the information required for using the “ONEtool” configuration tool created by BSG itself and the “Project Wizard” add-on from the WSCAD SUITE to generate circuit diagrams and cabinet layouts including a complete set of documentation in accordance with standards. Above right, At BSG, the whole electrical engineering design process using WSCAD, including switch cabinet configuration and production control, is controlled directly from the tender.

development - and be able to re-use these effective designs again. With the Project Wizard within WSCAD Suite X we received exactly the interface with which we could dock our self-developed solution to our ERP system.” WSCAD Suite X’s integration with BSG’s ERP system means that projects which can be transferred directly are 80 to 90% faster to plan, according to BSG. Even projects which deviate from the standard design can be up to a third quicker in the planning stage. Based on the customer’s specification, the bill of materials is placed with the ERP system and all relevant component data is then transferred from BSG’s ONEsystem software to WSCAD’s Suite X, ready for design. Integration includes the transfer of part numbers and technical data between the ERP system and WSCAD Suite X, speeding the design process.

also ensures consistency of engineering data, especially important for large-scale projects such as the design of a process plant. This capability has also resolved BSG’s requirement to re-use plans, meaning that once a design has been created, regardless of project size, it can form the basis of a new project with only specific adaptions required. BSG has also reduced project time by relying on WSCAD’s library, comprising over 1.4 million parts and including over 300 manufacturers, with 3D STEP drawings available. WSCAD Suite X’s integration with BSG’s ERP system means that projects transferred directly are 80 to 90% faster to plan.

arranging the macros and their variants,” says Leendert van Straalen, Operations Manager at BSG.

Thanks to WSCAD’s basis of open integration, it can also communicate directly with other third-party ERP-related software, such as material suppliers. BSG uses WSCAD Suite X to communicate data to a supplier for the procurement of larger wire sets and bundles, making the process faster, more efficient, and more accurate.

Using ERP-generated data combined with WSCAD’s Cabinet Engineering Expert module, which is inclusive within the suite, BSG’s designers can also quickly create cabinet wiring diagrams. Component selection is generated within BSG’s software, then once transferred to WSCAD Suite X, detailed design adjustments can be made accordingly.

WSCAD Suite X’s Project Wizard stores macros for various function requirements, such as circuit diagrams and cabinet wiring, and automates their use, able to follow pre-set specifications on deployment. It also generates electrical engineering documentation in a structured format, making service and maintenance faster and easier for BSG’s customers.

BSG’s control programming is based on a Siemens platform, with control data also integrated with the WSCAD Suite. Programming configurations are recorded within the CAD software and any changes are automatically updated. WSCAD Suite X can also reciprocally communicate any changes made within its designs back to the Siemens portal.

“The Project Wizard puts everything together automatically. Once planned and saved in sets, the Project Wizard follows all company specifications when

Similarly, WSCAD Suite X’s integrated approach means that replacement of a component in one plan is automatically updated across associated plans. This

Speed of development also means a CAD platform which is intuitive to use. The interface has been developed in conjunction with the experiences of designers within industry, including only occasional E-CAD users, making it usable with a limited number of settings. It’s also joined by the WSCAD Augmented Reality App, aimed at maintenance engineers, which visually identifies cabinet components and displays the relevant schematics and data, giving the engineers the data they need to quickly resolve any challenges. “What we particularly like about WSCAD is the openness of the system and its logical structure. Handling the application is simple and easy to learn. Once understood, you can explore and use the many functions without further guidance. This is much more difficult with other systems,” says Leendert. WSCAD Suite X increases the speed of time to market with its integration capabilities and intuitive design functionality. It also further reduces total cost with additional modules included as standard and retails at a price point significantly lower than comparable solutions.

For further information, please visit www.wscad.com/en Issue 51 PECM

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At its core Sapman v12 is a sophisticated Manufacturing, Warehousing and Stock Control solution. This modular product provides extensive facilities for Stock Control, Sales and Purchase Order Processing, Warehouse Management, Bill of Materials, Works Order Processing, Engineering Control, MRP and CRP. With the Microsoft SQL database engine at its core this product provides a leading edge business management solution. Our highly skilled team has 20 years of experience resolving our customers’ Assembly, Manufacturing Control and ERP requirements, their Stock Control and Warehouse Management needs using our advanced, effective and efficient software solution. Sapman v12 fully integrates with Sage’s Accounting solutions: Sage 50 and Sage 200. It also provides an upgrade path from Sage 100.

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

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

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

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

BOM V12 produces the BoM : tree-view with collapsible/expandable nodes

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

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

SoP : The Sales Order Processing gets underway

WiP With Shop Floor Data Capture SFDC v12 knows :

MAKE IT

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

Stock : Stock Enquiry : Check material Needs : Make to Order or Ex Stock? If not it may generate a Purchase Order for more Stock

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

If the Sale item is Make To Order (MTO) then the Works Order Processing routine kicks in

Stock Finished item is booked into Stock

v12 is suitable for Batch Manufacturing, Make to Stock, make to Order, Kanban & service works

v12 knows where it is; it covers multiple sock locations and stock with Sub Contractors

Stock values from v12 update Sage50 Nominal Ledger

Stock values per client defined categories can be up dated to Sage50 Nominal at client defined times

PoP Purchase Order Raised Purchase Invoice received & Sage 50 updated for Nominal Codes, Purchase Ledger and VAT WoP The confirmed order has to be manufactured & v12 produces the works order

SEND IT Stock Stock records updated, Despatch note raised; Certificates of conformity produced

Sales Invoice raised & Sage 50 updated for

WHAT THEY SAY “We really like the Shop Floor Data Capture system which enables us to see the current status of any Works Order live and onscreen.” Alan Saitch, Managing Director, Lada Engineering Services Ltd

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

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

Nominal Codes, Sales Ledger & VAT

For more information on Sapman v12 please visit our website at Sapmanv12.co.uk. Email us on info@sapmanv12.co.uk or please telephone us on: 0333 456 12 12.

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SOFTWARE & SYSTEMS

COMPREHENSIVE ERP SYSTEM SAPMAN V12

If you make stuff we’ll help you make it If you have a warehouse we’ll help you manage it If you hold stock we’ll help you control it Buying an ERP system used to be a major capital expense, potentially running to tens of thousands of pounds for an up and running system. The cost of the software purchase and associated consultancy made it a hugely considered financial outlay. For manufacturers looking for a rapid Return On Investment – this was a major obstacle for many businesses : together with the desire to spend their CapEx budgets on modern machinery and increased manufacturing capacity rather than software!

For companies that want the software “out of the tin” - and do not require any bespoke programming – a system install and set-up, including training and data conversion would be around £2,950. Our licencing is £95-£20 per month (depending on user numbers) with no minimum contract obligation. Additional users can be added as required and, indeed, reduced.

and Sage200, and we still have some clients on Sage Line 100 yet to upgrade.

A key market for us is Sage users. Sapphire Manufacturing Systems Ltd. The developer of Sapman v12 has been an Authorised Sage Developer for over 20 years. So most of our users run on Sage50

We can demo the software remotely via Team Viewer or organise a visit to your premises or you can visit our Bristol Demo Suite: call us on 0333 456 12 12 to have a chat.

One of the great advantages of Sapman v12 for Sage users is that users can benefit from multi depot stock and full Serial Number and Batch Traceability without the need to upgrade their accounting engine from Sage50 to Sage200. This is an additional cost saving benefit

STOP PRESS Problem Sage announce Sage50 Manufacturing is End Of Life Solution Sapmanv12 More Features – Less Cost – Sage Developer Fully Supported – Continuous Development Sapmanv12.co.uk COME AND VISIT IS AT SUBCON : 14 - 16 SEPTEMBER 2021 NEC BIRMINGHAM - STAND A69 Issue 51 PECM

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STORAGE, HANDLING & DISTRIBUTION

Engineered For

Endurance Industrial and clean area lifting and handling solutions Palamatic boasts over 35 years of experience in materials and powder handling, placing it at the cutting edge of lifting and handling solutions for all manufacturing industries. As a leading expert in handling solutions, Palamatic offers an extensive range of equipment, which includes vacuum tube lifting systems, support gantries, automatic sack opening machinery and bespoke handling solutions for the pharmaceutical and healthcare industries. In addition to this, Palamatic also keeps spare parts in stock for standard systems,

This excellent product range is supported by an exceptional end to end service, from sales enquiry through to after sales services. Highly experienced staff are available to offer help and advice at all stages of the process, and Palamatic can assist with parts, servicing and annual certification requirements to ensure customers’ equipment provides many years of active service.

T +44 (0) 1246 452054 sales@palamatic.com | www.palamatic.com

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.

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Internal and external rolling doors and shutters to improve and protect your productivity both safely and securely.

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

■High-speed doors - improve workflow efficiency ■ Fire doors - ensure staff safety ■ Shutters - security and asset protection ■ Custom doors - designed your

way

Design | Install | Maintain Get a free consultation, contact us on +44 (0) 191 214 0404 | info@hartdoors.com

www.hartdoors.com

STORAGE, HANDLING & DISTRIBUTION

A COMMITMENT TO QUALITY YOUNG BROTHERS

Flexible haulage services, tailored to you for an affordable cost

We are a family business, based in Kent. Founded in 1968, we operate from our purpose-built site set in a prime location immediately adjacent to the A299 which links the M2 and Ramsgate/Thanet. 2.8 miles to the east of M2/A2 junction, which serves Canterbury and Dover to the south and M25 to London and the west. We are proud members of the pallet track network - The Pallet Track national network consists of over 90 strategically placed depots enabling us to offer a comprehensive pallet delivery service across Europe Our experienced and motivated transport management team provide a comprehensive and professional service to existing and potential customers. Accessible and accountable, our commitment to quality, efficiency, cost effectiveness and continuous improvement is guaranteed. Here at Young Brothers we are committed to providing reliable, consistent and flexible

Our experienced and motivated transport management team provide a comprehensive and professional service to existing and potential customers. haulage services to suit all of our customer’s needs – with a wide, varied fleet of vehicles we can transport almost anything for you. Due to having over 52 years of experience, we have built strong relationships within the transport industry worldwide – this means we are able to deliver your goods not just nationally but all across the world.

For further information, please visit youngbrothers.co.uk Issue 51 PECM

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15th & 16th Sept 2021 The NEC, Birmingham, UK PRE-REGISTER FOR FREE ENTRY!

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TOOLS & EQUIPMENT

HARNESSING PROCESSES DESOUTTER

Are customers paying the price for your process inadequacies? Process creation can be dull. It’s one of the most time consuming, yet critical, parts of a business. However, by getting bulky systems and arcane methodologies out of the way, you can focus directly on analysing and developing processes, offering a unique opportunity to improve quality and efficiency. It’s time to get a better grip of your data and see what an improved process control strategy can do for you, and more importantly, for your customers. Read on to learn more about the process control & data collection system from the experts at Desoutter. It’s easy to implement, ‘drag and drop’ configurable, and has the versatility to tackle any process, large or small.

WHAT IS PROCESS CONTROL?

is particularly pertinent as all too commonly, process non-compliance occurs in the gaps between systems. We can consider the following constituent parts: 1. Triggering of the process (Order received etc) 2. Gathering of required resources (Stock/Materials/Equipment) 3. Integration/Interlocking with process specific equipment 4. No faults forward completion of the process 5. Real-time recording of data Any process control system has to be able to handle these aspects in as efficient and reliable a manner as possible, but there’s more to it than that…

Process control takes many forms, and since its inception around the time of the first industrial revolution (and arguably even further back than that) it continues to evolve faster than ever. However, with so many methodologies and systems coming and going hitherto, the phrase can feel somewhat diluted.

WHEN CONTROL ISN’T ENOUGH.

In order to properly nail down a definition we need to step back from talk of Industry 4.0, big data, and dark factories, and instead we need to think in terms of what processes are, and how they should be properly managed. More broadly, we might define process control as “Activities involved in ensuring a process is predictable, stable, and consistent, operating at the target level of performance with only normal variation.” Which has a broad enough scope to encompass all manner of activities with a specified process. From controlling the assembly of goods in a factory, to managing the delivery of a script in a call centre, even the process of making a cup of tea! Processes, all easily encompassed within our aforementioned definition.

Industry 4.0 is the overarching term, and is characterised (by global management consultancy McKinsey) as a culmination of rising data volumes and computational power, the emergence of analytics and business-intelligence capabilities, new forms of human machine interaction (Augmented Reality, for example), and improvements in transferring digital instructions to the physical world.

Any sufficiently valuable process within an organisation has to be controlled within this framework, and where systems need to be implemented to ensure compliance, it pays to have a sufficiently flexible unitary solution to avoid a comparative patchwork quilt of mismatching equipment/methodologies. This

Industry 4.0, The Internet of Things, Big Data, Predictive Maintenance, and Dark Factories. These are all buzz-words & phrases one might encounter while trying to identify solutions in the process control sector, but what do they all mean, and what do they have in common?

The characterisation above is accurate and reflects the changes in industry, but the particular point it contains which binds all of those other buzz-words we mentioned earlier, is data. Without this massive shift towards data driven solutions, none of the other changes we see would be possible. It’s this data, coupled with 100 years of manufacturing expertise, which Desoutter is harnessing to benefit its customers and partners, allowing them flexibility, repeatability of process, reduced down-time, and with all those things combined, reduced cost!

UNRIVALLED VERSATILITY

Pivotware is the holistic process control and worker guidance solution from Desoutter. With Pivotware, you can easily master the wealth process complexity and process variation within your organisation, and help empower your employees to get the best from them. Long training periods, human error, and lack of traceability, are now things of the past!

COMPLETE INDEPENDENCE

You can easily configure your own production processes according to process variants using an intuitive drag & drop configurator. Making you independent, guaranteeing speed & agility, and saving the unnecessary expense of specialist programmers.

ISLAND-BASED ARCHITECTURE

All processes and work results are stored locally and provided globally. This unique island architecture is your bulwark to secure production against disruptions and network failures. Without reliance on a master PLC or server, Pivotware can be deployed in mobile applications where constant network signal can’t be guaranteed.

DEMANDORIENTED EXPANSION

With Pivotware being an entirely ‘off the shelf’ product, it’s easy to expand and enable new features at any time, without the expense and wasted time of bespoke version changes. Without the need for an expensive master/slave system, it’s easy and cost effective to start with one Pivotware station and expand as required.

Visit us online to find out more: www.pivotware.com | www.desouttertools.com Issue 51 PECM

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Issue 51 PECM

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VALVES

ENHANCING RELIABILITY & SAFETY BÜRKERT

Bürkert valves update UK chemical plant to latest safety standards Chemical manufacturing, by its very nature, involves the use of potentially hazardous fluids. It is therefore imperative that chemical manufacturers choose process equipment that offers the utmost reliability to promote efficiency and safety. This was the approach taken when a major UK chemicals manufacturer decided to update one of its plants in Eastern England, where Bürkert valves and switch boxes were fitted to enhance reliability and safety. Control valves are a vital component of any modern chemical manufacturing plant. Open and closing to various degrees, the valves help to control flow, levels, temperature and pressure. Control valves play a crucial role in achieving the desired end product.

A CHEMICAL DELIVERY SYSTEM OVERHAUL A control valve usually consists of the valve body, an actuator and a positioner. Of course, control valves in the chemical industry must reach exacting safety and quality standards to ensure they are ready to take on substances that are potentially hazardous. To one chemical manufacturer, it was clear that the valves at its Eastern England facility had reached the end of their service life. The equipment was now outdated, with only basic safety systems in place to prevent solvents travelling into the incorrect tank. This was compromising confidence in the chemical delivery system and overall efficiency at the plant, especially as it was processing potentially flammable and volatile substances. Therefore, plant operators decided to completely overhaul the facility, to ensure that rigorous chemical industry health and safety measures were absolutely adhered to. The plant approached Process Instrument Sales, a high-quality instrumentation provider, to source new equipment for the overhaul. A priority was the provision of new control valves. To ensure the utmost

Produced from stainless-steel, the Type 2651 offers an innately high resistance to chemicals, which unlocks an extended service life. reliability and safety, Process Instruments recommended two Bürkert solutions.

bracket allowing it to be used with actuators of various sizes.

UPDATING THE VALVES

Once the central system was fitted by Lark Technology, any risk of leakage and spillage had been successfully minimised. Compliancy with all the stringent health and safety standards and insurance requirements was also achieved. Ultimately, plant operators now had total reassurance that the very best safety applications were now in place for the delivery system of volatile and flammable substances at the facility. This ensured increased efficiency and a greatly reduced environmental risk.

Bürkert’s Type 2651 flanged ball valves were selected to replace the outdated valves. Produced from stainless-steel, the Type 2651 offers an innately high resistance to chemicals, which unlocks an extended service life. Suitable for shut-off or distributing medium flows, a mechanical interface allows easy connection of pneumatic or electrical rotary actuators. All valves and actuators now fitted at the plant are SIL Safety certified. To ensure the correct opening and closing of the valves, Bürkert Type 1061 ATEX switch boxes with integral pilot solenoids were fitted. Suitable for use in potentially explosive application areas, the Type 1061 combines the function of a position feedback and a solenoid valve in one box. It is incredibly versatile, with multiple versions available and an adjustable

A plant operator from the UK chemical manufacturer said: “The total replacement and modernisation of our plant valves, solenoids and actuators has given us the reassurance that we now have the best safety applications in place. The supply of these high-quality Bürkert valves from Process Instrument Sales has been second to none with absolute attention to detail every step of the way.”

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

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VALVE & FLOW CONTROL

Eliminates cross port leakage

Pneumatic Control Console for a UK Nuclear Power station Click QR Code below to see this case study

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VALVES AND FLOW CONTROL

Use GEMÜ Plastic M-Block to Optimize Your Plant!

Flotronic pumps Ltd Founded in 1981 in West Sussex, Flotronic Pumps is a worldleading 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

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

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Lightweight, space-saving, quick installation and multi-functionality are becoming increasingly important for system components. In conventional plant design, complex control of liquids and gases is generally carried out by means of numerous individual valves. But this takes up a lot of space and assembly is time-consuming because of the much higher number of individual parts. The GEMÜ plastic multi-port valve block (M-Block) combines several valves and pipe sections in one compact unit. They can perform various functions for complex tasks in plant engineering while offering a host of benefits. When comparing to conventional designs, the block solution undoubtly has a smaller “footprint” as it requires a smaller number of pipework/fittings and connection points. This reduces not only the potential leakage points and deadleg, but also the operational safety risk. The installation process and time are reduced due to the simplicity of the integrated block. All these benefits increase plant reliability whilst significantly contributing to cost optimization. For more information, please click here. Youtube video: GEMÜ Plastic Multi-port Valve Blocks (M-Block): Space-saving, Multifunctional & Cost Optimizing

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

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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PIONEERS OF SPACE

For every room, there’s a Teknomek solution. Manage risk and meet the strict compliance standards demanded by your industry with our high-quality, hygienic furniture and equipment.

For more information get in touch today W: teknomek.co.uk T: 01603 788 833