Process Engineering Control & Manufacturing - Issue 53 2021 by MH Media Global

Process

MANUFACTURING

Control &

Engineering

SOURCE ENGINEERING- 12

ELEMENT LOGIC - 56

Matrix goes back to Source to manufacture its innovative seating structure for wheelchair users

Deflating five myths around warehouse automation and robotics

PECM

Global Success Through Innovation Issue 53 2021 £3.95 www.pecm.co.uk

MITSUBISHI ELECTRIC- 54 Formulating innovation in chemical handling

Out of the Box Such is our confidence in this technology we offer an unparalleled 5 year full warranty on all models

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Process

MANUFACTURING

Inside... Sections Editors Choice

Control &

Engineering Inside Issue 53 4

Air gas and & Control / Connectors & Fittings 48 Control & Automation

Electrical & Electronics

Facilities Management

Fluid Handling

Food Processing

Gears, Drives & Motors Health & Safety Hydraulics & Pneumatics

Machining & Machinery

Measurement & Monitoring

Process Technologies

109

Pumps

112

Software & Systems

115

Storage, Handling & Distribution

120

Tools

122

Training & Recruitment

126

Valve & Flow control

128

3M COMMERCIAL SOLUTIONS DIVISION

A £70m global investment is set to help boost production capacity for 3M Commercial Solutions Division’s clients in the UK.

SOURCE ENGINEERING

MITSUBISHI ELECTRIC

Formulating innovation in chemical handling

ELEMENT LOGIC

Deflating five myths around warehouse automation and robotics

BRITISH SUGAR

Matrix goes back to Source to manufacture its innovative seating structure for wheelchair users

AUDI

BAUER GEAR MOTOR GMBH

World Class Sugar Producer Creates Factory of the Future with Infor EAM

The Audi Q4 e-tron: in its transition to electromobility, Audi is turning to synergies within the whole group

Eliminating the heat dissipation challenges of hygienic motors

LASTBASIC

Tailoring the motor to the application through appropriate coil selection

Digital prototyping platform allows ordinary inventor to turn mental health tech idea into a reality

FANUC

PORTESCAP

RENISHAW

Machine tool probing increases productivity for Australian machine shop

The key role of systems integrators in delivering automation

“The centre of excellence for strainer and ﬁltraaon technology”

www.bartonﬁrtop.co.uk Issue 53 PECM

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Process

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

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Issue 53 PECM

EDITOR’S CHOICE

£70M INVESTMENT 3M COMMERCIAL SOLUTIONS DIVISION

3M Commercial Solutions Division targets expansion A £70m global investment is set to help boost production capacity for 3M Commercial Solutions Division’s clients in the UK.

edge energy management systems and world class quality performance, including web inspection, defect identification and automatic converting connections.

The company, which helps customers build brands and transform spaces with total graphics and signage solutions, will now be able to meet growing demand by tapping into additional capacity at the state-of-theart facility in Hilden, Germany.

Engaging Six Sigma Black Belts to implement LEAN initiatives has allowed the plant to reach optimum efficiencies and deliver on its productivity targets, including automation and a focus on clean energy that will help the facility reduce its carbon footprint by 50% by 2022.

Two new graphic film production lines will be capable of delivering an additional five million square metres of film every year, ensuring lead times are maintained and growth expectations can be met. The site is being celebrated as an Industry 4.0 lighthouse plant, incorporating state-ofthe-art graphic film manufacturing, leading-

PECM Issue 53

With 2800 sq metre of manufacturing floorspace, the new building took 353 days to construct and reinforces Hilden’s position as the largest 3M production plant in Europe, reducing the shipping time to customers being serviced in the UK.

This investment further demonstrates our commitment to leadership in the Commercial Solutions world and boosts our capacity across key markets like the UK

excited that this is just the first step of a longer-term investment plan.”

“This investment further demonstrates our commitment to leadership in the Commercial Solutions world and boosts our capacity across key markets like the UK,” said Silvia Perez, President, 3M Commercial Solutions Division. “We are proud that this high-investment, next-generation site with global reach has been established in Europe and we are

The Grand opening was attended by key stakeholders from the 3M Commercial Solutions Division, the pioneers behind the development of the new facility, and key dignitaries from the German Government, who commemorated the momentous occasion.

3M manufactures graphic films‚ flexible substrates and inks used to create finished graphics that are consistent‚ reliable and durable. The company also holds training programmes for installers of all skill levels, to help them grow their businesses and build their reputations.

For further information, please visit www.3M.com Issue 53 PECM

EDITOR’S CHOICE

Example

Linear motors slash toan example within the handling and assembling sector. Linear Linear Motors energy Slash EnergycostsTake actuation is required on the horizontal plane to move items through to the Costs of Pneumatic Solutions next stage of the production process. A single LinMot Linear motor with 5%toof5%pneumatic solutions guide can replace a traditional 63mm diameter rodless air cylinder for this

Powering actuators directly with Linear electric motors rather than air cylinders can result in directly huge cost emission savings across board. owering actuators withand Linear electric motors ratherthe than air

task, ultimately reducing annual energy cost by over 10,000 EUR and CO2 emissions by over 26,000 kg.

cylinders can result in huge cost and emission savings across the board.

So much of our industry uses compressed air that is often regarded

asmuch the fourth afteruses electricity, natural gas andiswater. So of ourutility, industry compressed air that oftenHowever, regarded as the compressed air iselectricity, more expensive the other utilitiescompressed when fourth utility, after natural than gas and water.three However, on a per unit energy delivered airevaluated is more expensive than the other three basis. utilities when evaluated on a per unit energy delivered basis. Quin Systems, exclusive UK suppliers of LinMot Linear Motors for over 25 Quin Systems, UK suppliers of LinMot Linear over 25 years, can helpexclusive you calculate the predicted carbon and Motors energy for savings years, can by help you calculate predicted carbontoand energy savings achieved switching from athe pneumatic solution a linear motion solution. by switching from a pneumatic solution to a linear motion achieved

solution.

LinMot, one of the world’s leading manufacturers of industrial linear

LinMot, the world’s leading manufacturers of industrial motors motorsone has of released a new component of its LinMot Designerlinear software has released a new component of its LinMot Designer software that can that can quantify just how energy efficient its solution is, and the sizeable quantify justinvestment how energy efficient solution is,over andpneumatics. the sizeable return return on their motorsits can provide

on investment their motors can provide over pneumatics. Efficiency and CO2 results from Linmot Designer® for the worked example: Efficiency and CO2 Emission Moving mass: 5kg Friction Force: 100N

Total moving Distance per Cycle 4 m Total cycle Time: 6 secs

Motion Continuous: 8000h/year

Linear motor (Linmot) Electric Motor Power(1) [W]

Electric Power(2) [W]

143

Electricity Consumption per Year(3) [kWh]

CO2 Emission per Year(4) [kg]

1'145

573

Electricity Costs per Year(5) [EUR]

137

Pneumatic Cylinder Air Piston

Air Consumption

Electric

Electricity Consumption

CO2 Emission

Electricity Costs

Diameter

per Year(1)

Power

per Year(2)

per Year(3)

per Year(4)

[mm]

[Nm3]

[W]

[kWh]

[kg]

[EUR]

461'293

6'815

54'516

27'258

10'484

Combined with the extraordinarily long operation life of LinMot Linear Motors and the next to zero servicing requirements mean LinMot’s solution will continue working for years.

EXAMPLE Take an example within the handling and assembling sector. Linear actuation is required on the horizontal plane to move items through to the next stage of the production process. A single LinMot Linear motor with guide can replace a traditional 63mm Linear diameter rodless air cylinder for this task, ultimately reducing motor annual energy cost by over 10,000 EUR and CO2 emissions by < 5% Air over 26,000 kg.

Energy cost

The return on investment is significant. Energy saved by using a single electrically driven actuator over a basic traditional pneumatic cylinder has the potential to cover its higher initial outlay within a very short timeframe, typically less than a year. Combined with the the extraordinarily long life of LinMot This improves cost benefits andoperation environmental efficiency of your Linear Motors and to zero servicing production linethe by next a significant margin. requirements mean LinMot’s solution will continue working for years.

For more information, please contact Quin Systems, the LinMot

Thisdistributor improves the andon environmental efficiency of forcost UKbenefits & Ireland 0118 977 1077 or sales@quin.co.uk. your production line bywww.quin.co.uk/linmot a significant margin. Website:

For more information, please contact Quin Systems on 0118 977 1077 or sales@quin.co.uk. Website: www.quin.co.uk/linmot

The innovative Linmot Linear motor combined with a high stiffness linear guide provide high-speed and energy-efficient performance in a clean design.

Direct mounting of the load with absorption of

sales@quin.co.uk

PECM Issue 53

EDITOR’S CHOICE

Ergonomic handling solutions for all industries The Covid pandemic has brought new challenges to the logistics industry. Due to the dramatically increasing number of online orders and growth of e-commerce, and the pressures associated with staff health and safety, goods must now be picked more safely and efficiently than ever before. TAWI’s Mobile Order Picker (MOP) allows one person to do the job of two, while protecting them from injuries caused by lifting heavy objects. This increases productivity and health and safety levels at the same time. The MOP is compatible with any forklift or pallet jack, making it a highly versatile piece of equipment. With its adjustable tower height, operators can reach into pallet racks and other low headroom spaces giving them the ability to access otherwise hard to reach areas. Pete Wood, Key Account Manager for Logistics & Airports explains, “The growing concern to many companies is finding

that balance between providing manual handling aids for their operators and keeping up levels of productivity, and TAWI’s Mobile Order Picker does just that. The MOP removes 100% of the weight of the products that the operators must currently lift, and the ergonomic and user-friendly controls allow the operator to move at speed and meet their daily objectives.”

www.tawi.com

Issue 53 PECM

EDITOR’S CHOICE

TEN YEAR REVIEW 3DPRINTUK

Celebrating a Decade of Providing Quality 3D Printed Parts This month 3DPRINTUK is ten years old, which provides a great opportunity to look back at what the company has achieved and to look ahead to the next 10 years.

One interesting result of the knowledge vault at 3DPRINTUK came in October 2018, when it represented British manufacturing during the parliamentary review. This was an important step for the company, to be included in this important governmental review as an additive manufacturer, alongside some of the most successful companies in the UK.

This article highlights some of the major milestones across the last decade of 3D printing from 3DPRINTUK.

In November 2019, just as the pandemic was about to hit, but before the world understood what it meant, 3DPRINTUK completed its final move of the decade. This was a big deal, as it expanded into new and dedicated premises at Unit D9, Leyton Industrial Village, London.

10 YEAR REVIEW: It was September 2011 when founder and Managing Director, Nick Allen, officially opened the doors of 3DPRINTUK to provide a fast and efficient ‘rapid prototyping’ service. Back then, Rapid Prototyping — or RP — was the more widely recognised umbrella term for the range of additive, layer-by-layer processes that were slowly but surely penetrating into a range of industrial sectors as a way of speeding up product development. But Nick, who has always had his finger on the pulse, was convinced 3D printing was going to be an even bigger deal — both in terms of terminology and as a technology set for manufacturing — and he built it into the company name, and its DNA. The following year, in December 2012, with 3DPRINTUK as the parent company, Nick opened MAK3D, London’s first 3D printing co-working space in Brick Lane. MAK3D provided a range of 3D printing services and parts utilising an Objet (now Stratasys) PolyJet system. 2013 had a few memorable highlights. In April of that year, 3DPRINTUK moved to a new facility in Bermondsey, London and acquired its first industrial EOS Selective Laser Sintering (SLS) 3D printer utilising Nylon material. That same month, Nick featured on the BBC’s One Show, sharing his knowledge of 3D printing to a much wider audience. The passion for sharing knowledge and raising awareness pragmatically has never dimmed, and in October 2013 Nick delivered a memorable TEDx Talk. It’s definitely still worth a watch and holds great value today. Another major milestone came in September 2014, when 3DPRINTUK printed its 100,000th part. The company saw a notable trend as

Nick Allen, MD & Owner, 3DPRINTUK it started to scale up part volumes, with a wide range of applications. As Nick noted at the time, “We’ve sent stuff to the edge of space, to the bottom of the ocean and to the Dragons Den as well as many other places in-between.” This was only set to continue, and did. The start of 2015 really saw Nick’s vision for 3D printing coming to fruition. With accumulated knowledge and experience 3DPRINTUK really started to focus in on what 3D printing is really good at — low volume batch production applications. The company continued to provide the very best quality in prototyping services, and still do today, but the launch of the batch production service where 3DPRINTUK could demonstrate repeatability, on-demand manufacture, and tool-less manufacture of production parts opened up new business opportunities — for the organisation, obviously, but also for its growing number of clients. And just over two years from the time that it printed the 100,000th part, 3DPRINTUK was delighted to print its 1 millionth part in Nov 2016. This exponential growth of part volumes was significant, and is continuing year on year. It is not an accident, but rather comes from managing growth — and expectations — through acquiring knowledge, expertise, experience and, of course, more machines (capacity).

2020 was obviously the Covid Year. Nobody had it easy, but the company adapted and forged ahead, taking the opportunity to complete a £1 million internal investment into new AM systems and processes, new materials and new post-processing equipment and capabilities. This involved the introduction of the MultiJet Fusion (MJF) process, flexible materials, a wide range of colours & shot peening. These new dedicated facilities have enabled 3DPRINTUK to streamline its internal processes, further improving the quality, repeatability and traceability of parts. And for anyone interested in an update on that exponential growth — 3DPRINTUK has printed more than 1 million parts THIS YEAR alone! That just about wraps it up, and so, we have been in business for 10 years.

LOOKING AHEAD: Anniversaries are great for reflection, but also to place a stake in the ground for future planning. 3DPRINTUK already has some amazing plans set in motion to take it to the next level. None of them involve a move (thank goodness) – but who knows, there might be an extension. And the company’s capacity / part volumes will almost certainly continue on their upward trajectory. Thank YOU for being part of our history, here’s to the next 10 years…..

For further information, please visit www.3dprint-uk.co.uk

PECM Issue 53

Production Parts or Prototypes to your door in 3 working days.

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Order 1 - 10,000 parts on demand.

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EDITOR’S CHOICE

CUSTOMISED SUPPORT SOURCE ENGINEERING

Matrix goes back to Source to manufacture its innovative seating structure for wheelchair users A Plymouth manufacturer is playing a key role in helping develop a new seating system for wheelchairs that improves function and corrects body posture. Source Engineering, a specialist in pressed and machined components, has supported Matrix Seating with a complex stamped part that acts as a locking clamp for the unique micro modules that are shaped to deliver customised support. A 5-strong engineering team has worked with inventor Dr Steve Cousins to come up with a 11-stage progression tool capable of producing the ‘lock’ in spring steel – vital for delivering strength and flexibility at a unit price that works. 120,000 of the components have already been manufactured and delivered, with an

PECM Issue 53

increase in sales from the UK, Europe, the Middle East and the US set to result in a surge in volumes. “This is a really exciting project to be involved in and we are delighted to be able to use our design and manufacturing expertise to help people enjoy a longer and better standard of life,” explained Pablo Gutierrez, Technical Director at Source Engineering. “Steve approached us about coming up with a stamped metal part to replace what was previously a plastic and then hybrid component. He’d been to a number of other suppliers, but we were the only one prepared to invest the design time in trying to come up with a solution that worked.”

He continued: “There was a lot to consider. We had to deliver a critically strong part that still allowed the system, which looks like a robust mesh and is fitted in place of the usual wheelchair back, to move to deliver the potential orthotic spinal correction. “Initially, it was deemed to be just one part for the locking clamp, but after a number of prototypes and iterations we found that it was best to manufacture two components - a top and a bottom that would be connected with a bolt. Tolerances were really tight and also had to meet clinical specification.” Source Engineering has a long track record of taking projects from design and prototyping to volume production and this experience really came to the fore with this opportunity.

Pablo Gutierrez, Andrea Taylor and Ian Matthews

The 11-stage progression tool has been proven to deliver both parts successfully, with the firm’s wire erosion capabilities producing an accurate tooling insert that fits like a jigsaw to create the different circular and hex-shaped holes. Repeatable quality has been outstanding and stringent lead times have been met on the initial orders allowing Matrix Seating to fulfil current orders. Dr Steve Cousins, who spent 19 years at the Royal Hospital for Neuro-disability before founding the company, continued: “This is the fourth generation of locking clamp that holds our unique structure together and I believe we’ve found the long-term solution.

Our manufacturing is all completed in the UK and Source Engineering is a very welcome addition to our supply chain.

He concluded: “We feel that we finally have the right locking clamp and look forward to moving forward with Pablo and his team.” Source Engineering, which is approaching 30 years in business in 2021, employs 32 people across its two divisions on the Langage Business Park. Investment in a new high speed press line from Bruderer UK has given it additional capacity to secure reshoring contracts from abroad and support its desire to increase annual sales by 20% over the next twelve months.

“Our manufacturing is all completed in the UK and Source Engineering is a very welcome addition to our supply chain, understanding the potential of our product and going above and beyond to deliver parts that have come through a tough engineering challenge. “What was especially impressive was the ability to create parts that have a sharp edge in just the right place, so they dig into the nylon ball in the middle of the module. This was very technical and had to serve its main role, as well as not being exposed to the user of the chair.” Please visit www.source-engineering.co.uk. More details on Matrix Seating, can be found at www.matrixseating.com. Issue 53 PECM

EDITOR’S CHOICE

CHALLENGE EFFICIENCY SWEP INTERNATIONAL

The dawn of automation secures SWEP’s heat transfer advancement Industry 4.0 and automation is changing the production landscape for SWEP, world-leading supplier of brazed plate heat exchangers and prefabricated energy transfer stations. What started with two Swedish entrepreneurs in a garage more than 30 years ago is now an international corporation, still driven by the same spirit and conviction: to challenge efficiency and make a difference with Brazed Plate Heat Exchangers (BPHEs) that are part of a sustainable future.

A WILLINGNESS TO EXPLORE

SWEP has always been willing to test new technologies, and the manufacturing process is not an exception. Early in the company history SWEP choose their own way for the production equipment. One example is pressing steel plates together with the copper foil, something that a large competitor knew would never work. SWEP ignored that and made it work. Another example was the home-made stacking box that was an early automation equipment for press lines solving the straightening, turning, and stacking operations integrated with the press line with huge capacity and productivity increase to follow. Even if there have been automated functions linked to individual machines, like press lines and test equipment’s it is only in the last 5 years that the real automation journey has taken off, and

with quite some pace. Over 20 industrial robots built into automatic assembly lines with vision systems, advanced grippers, sensors, and conveyor systems have been commissioned and more is in the pipeline for the near future and the coming years.

A FOCUS ON AUTOMATION

The strategy behind this automation journey is a clear vision on the whole picture without losing focus on the individual parts. Try out in smaller scale, learn from mistakes, and use the experience in new projects to build up internal competence but continue to work with external partners in parallel. To design and own key components and all source code and build the robot cells in modules that can be scaled up and down is important for SWEP to be able to standardize, copy and implement to any of SWEP’s five plants around the world.

DESIGNING AND IMPLEMENTING A PROJECT

A typical automation project usually starts with internal brainstorming in a small technical group with resources from earlier automation projects and the future owner of the cell. The outcome are early visualizations and simulations models for discussion and comparison. Then external partners get involved with idea input and solution suggestions followed by defined work interfaces and formalized project team. Usually SWEP do the robot programming, design and manufacture key components like grippers, use external

consultants for PLC/safety program and external partners for most of the hardware. The philosophy is to build deep and wide internal competence but still utilize external partners that built and seen so many more installations in different industries. External partners also help keeping up the high pace and low prices on robots, for instance, as they source many more than SWEP.

LEARNING IS A CONSTANT BATTLE

Another learning in the automation journey is the importance of the planning, logistics and the whole picture. Only machines and automation cells forming islands in production will not give the expected productivity increase and this is where Industry 4.0 come into play, connecting the dots. Here new visualization and simulation tools or digital twins will play an important role. How to plan and balancing the flows, dimensioning the equipment correct, monitor, and communicate between the machines, robot cells and business systems. Building a model of a production flow as it is today can help optimize production output through machine utilization, changed order sequence and bottle neck analyses. Completely new scenarios of the future vision can be built up and analyzed to make the correct investment decisions, choosing the right technologies and dimensioning machines, robot cells, stock, buffers, and carrier capacity. This will be very valuable when entering the world of automated guided vehicles, AGV, which will be the next big automation step for SWEP.

For further information, please visit www.swep.net

PECM Issue 53

EDITOR’S CHOICE

TLV upgrades renowned cospect valve to ease installation and minimise process disruption Through a process of continued development and product enhancements, the renowned three-in-one COSPECT pressure reducing valve from steam system specialist TLV Euro Engineering has been upgraded and is now being offered with integrated pressure gauges as standard across the range. Commenting for TLV Euro Engineering, general manager Michael Povey says: “By upgrading and offering the pressure gauges as standard across the range, we have enhanced the COSPECT to make it even more of a unified steam system solution. The integrated gauges also mean no additional pipework modification is required before or after the PRV, which reduces installation time and minimises process downtime.”.

By eliminating the conventional arrangement and combining four separate components into a single valve, the COSPECT delivers numerous engineering benefits by incorporating fewer gaskets, spool pieces and fixings, improving moisture separation and providing accurate and stable pressure control. It is also more sensitive to downstream pressure fluctuations, is reliable in operation and its unified, modular construction facilitates easy, in-line maintenance.

Originally launched over 35 years ago, the COSPECT is a combined pilot-operated pressure reducing valve (PRV), cyclone separator, strainer and steam trap in a single component that overcomes the limitations and inadequacies of conventional PRVs and solves their many associated problems – including fluctuations in primary and secondary pressures and valve hunting and vibration – to provide improved-quality dry steam at a constant pressure and temperature.

In addition to the engineering benefits, the single component design of the five-model COSPECT makes it faster and easier to install, is lighter than the sum of using separate components, reduces the amount of insulation required and reduces the requirement for pipe support brackets, etc.

For further information call TLV Euro Engineering on +44 (0)1242 227223, email sales@tlv.co.uk or visit www.tlv.co.uk

The Lock-in Amplifier Explained and Reimagined

Work Together With You For Climate Control

Measurement of electrical signals, voltage, and current is one of the most important methods used by researchers to characterise electronic materials. But electrical signals are often at very low levels and in the presence of noise — which can be as large as or even larger than the signal itself. Because DC measurement instruments cannot easily extract the signal from the noise, AC measurement techniques are often used. They can modulate the signal with a frequency to measure the signal in the presence of less noise. The lock-in amplifier can perform such a measurement and is one of the best methods for measuring amplitude and phase of AC signals. The new app note discusses lock-in amplifiers in general and examines how the lock-in technology employed in the new M81 modular source from Lake Shore Cryotronics measures architecture deals with removing the effects of noise from the measurement. Contact QD-UKI their UK Distributor.

Not only will you stay warm with Snickers Workwear’s 37.5® Technology clothing, you’ll look and feel cool too. With styles for both professional tradesmen and women, they excel at ventilation to keep you cool and moisture transportation to stop you getting cold. They work together to keep you working comfortably wherever you are on site. The 37.5® Technology fabric is a very quickdrying material that captures and releases moisture vapour – like your sweat - for superior coolness and dry working comfort. It’s integrated into selected Snickers Workwear base- mid- and top-layer garments to keep you working at your best whatever the weather. After all, keeping a balanced work temperature is not just about staying cool and in great shape, it’s a matter of your wellbeing and job safety.

www.qd-uki.co.uk

PECM Issue 53

For more information visit www.snickersworkwear.co.uk alternatively, call the Snickers Workwear Helpline on 01484 854788.

Announcing the launch of Cargo Overseas innovative ACE technology across the Irish sea Cargo Overseas has developed an IT solution for UK importers and exporters to efficiently process their customs declarations and it is proud to announce the expansion of this technology to include automation of Irish customs entries. Currently, any UK company that imports from, or exports to, the EU is REQUIRED to complete a UK customs declaration for every shipment and if you need to import to or export from the Republic of Ireland, you would be required to complete a separate Irish customs entry. The ACE system, from Cargo Overseas, has the unique ability to run a combined joint entry automatically from one place without any duplication. Visit www.cargo-overseas.co.uk or email: ace@forwarding.digital today to find out how to set up your own digital dashboard on aCe

EDITOR’S CHOICE

AN EASY TO MAINTAIN SOLUTION NORTH RIDGE PUMPS

ATEX Peristaltic Pump for Solvent Slurry Adhesive Coating ADHESIVE HANDLING ISSUES

As solvent can attack cast iron the unit was coated in Halar. Halar is a type of plastic coating highly resistant to temperature fluctuations, chemicals and corrosion, protecting the pump in case of spillage or liquid escapement should the hose fail.

Solvent based glues are a mixture of polymer based ingredients mixed with solvent. Once the glue is applied and the solvent is exposed to air, it begins to evaporate until cured when the bond is at its strongest.

The ATEX (UKCA EX) Peristaltic pump was supplied with a motor suitable for operation via external variable frequency drive. The customer had existing 1¼ inch NPT fittings which we had fitted to the pump to enable plug and play operation.

Adhesives are available in various forms often utilising either Solvent or Water as a component to aid curing. Whilst water-based adhesives can be handled with a wide variety of materials, solvent based glues require handling differently.

The bond is more of an industrial bond and once applied is difficult to break unless a chemical such as acetone is used. These types of glues are very unforgiving, flammable and also more harmful to both personnel and the environment and so care must be taken during handling.

PUMP ISSUES

A customer contacted us who was experiencing issues with their vane pump handling a new blend of adhesive consisting of 3 parts -Solvent, Resin and Ceramic. They were experiencing high levels of wear with their vane pump with the mechanical seal repeatedly failing, allowing air ingress into the pump, hazardous flammable liquid would leak from the casing, and end product would fail to meet quality standards. At each breakdown not only did wearing parts have to be replaced, but the casing and any small parts would require a full clean using hazardous chemicals to remove any product set. When the seal leaked, product would ingress into the bearings, quickly rendering them useless. Maintenance required at least two people, and the downtime that the factory was experiencing was annualised at over £200,000 of lost product output per year. The Vane pump was feeding a batching line which would batch fill containers on an assembly line before bottles were packaged, and dispatched for delivery. Having to repeatedly disassemble the vane pump, change the seal, bearings and vanes meant repeated stoppages which the plant could no longer accept.

The customer received the pump within 3 weeks of order and is set to save over £200,000 in lost output with a payback period of less than 1 month. The capacity of the existing unit was between 5-15L/min with a discharge pressure of 4 bar. The glue had a viscosity similar to Ketchup (1000cps) but Various pump technologies were studied before finalising our specification for an ATEX (UKCA EX) roller Peristaltic pump controllable via Variable Frequency Drive. This design of pump which contains a single wearing part – a hose eliminates any chance of mechanical seal failure, and more importantly air ingress contaminating product.

The main difference in output flow from the Peristaltic to the vane pump is that vane pumps do not have a pulsating flow. To ensure accuracy within their liquid filling packaging machinery we supplied the pump complete with an inline pulsation dampener which eliminates up to 98% of pulsations during operation, meaning the customer receives a smooth linear flow important for flowmeter accuracy during dispensing, and that containers are not over or underfilled as an unintended consequence.

PROCESS IMPROVEMENTS, PAYBACK PERIOD, & OUTCOME The customer received the pump within 3 weeks of order and is set to save over £200,000 in lost output with a payback period of less than 1 month.

OUR LOW MAINTENANCE SOLUTION

Maintenance is far simpler requiring only one person with the pump kept in situ whilst work is undertaken. As there is only one wearing part – the hose, when this approaches the end of its useful life, it is removed from service, sent for disposal and replaced without any cleaning of parts using hazardous chemicals and added risk to personnel.

Hose pumps are of non clog design meaning there was no chance of blockages forming within the pump. They are of positive displacement design meaning the pressure will be constant, and flow rate proportionate to speed. This meant that the speed of dispensing and bottling could be altered according to line speed.

Furthermore as the plant had experienced some restructuring with team members who had expertise in pump overhaul and maintenance leaving the business, having such a simple to maintain solution accelerated training and meant outside expertise was not required.

For further information, please visit www.northridgepumps.com Issue 53 PECM

EDITOR’S CHOICE

EC MOTORS AXAIR FANS

Motor Efficiency & the Schematic Structure of EC Motors Paul Smith, Head of OEM at Axair Fans discusses the benefits of EC motors and the effects of electric motor efficiency regulations. Converting electrical energy to mechanical energy is not always very efficient so the fact that one of the biggest energy consumers of any product is the electric motor isn’t all that surprising. The most common type of AC motor, the induction motor, has been around for over 100 years but with government regulations such as the electric motor efficiency regulations demanding International Efficiency of IE3 and above on motors 0.75kW and above* EC motors, or electronically commutated motors, are now the preferred choice in many fields and applications. According to the International Energy Agency, electric motors account for approximately 45% of all global electricity usage and 75% of all industrial electricity usage. Efficiency is especially important in today’s climate, for reducing CO2 emissions but also for reducing the cost of a motor over its lifecycle. Based on the new regulations that came into effect in July 2021, Premium efficiency motors (IE3) should be specified in all new installations, when purchasing spares, on major updates to existing processes and when replacing oversized or existing IE2 motors. When calculating the IE classification, energy efficiency of an electric motor is calculated as the ratio of the mechanical output power to the electrical input power. EC motors may seem complicated, but these motors make manufacturing processes more efficient, more reliable and allow them to perform better, with the biggest energy gains coming from the ability to speed control them. Efficiency is the main reason for choosing EC motors over AC versions. With EC motors, the AC mains voltage is rectified in the commutation electronics reducing the losses internal to the motor. A downstream inverter provides the motor with the motor voltage depending on the position, like the principle of a frequency inverter.

On these energy efficient motors the intelligent EC commutation electronics decide how the motor phases in the stator are supplied with current (commutation) depending on the position, direction of rotation and speed specification. Permanent magnets generate the magnetic counter field in the rotor. The torque required for rotation is generated from the interaction of the stator and rotor fields. A mounting flange on the rotor is used for stable impeller mounting. The simple and quick electrical connection is made either via a terminal box with cable glands or a connection cable, depending on the motor series. The use of deepgroove ball bearings closed on both sides with specially matched greasing ensures maintenance-free and low-noise operation. The winding insulation corresponds to thermal class F. Using intelligent electronics, a wide variety of control and regulating functions can be taken over by the EC motor depending on the area of application, variable speed control, pressure control, volume flow control, temperature control, air quality control as examples.

Advantages: • High Efficiency • Low power consumption • Integrated monitoring function (motor temperature, locked rotor and many more) • Simple connection (Plug & Play) • Expanded functionality (pressure control and many more) • Compact design • Speed Controllable EC motors are ideal for integration into BMS systems such as Modbus, enabling maintenance engineers to monitor the status of individual fans and highlighting the need for retrofit or replacement. The Gen 3 motor from Rosenberg offers a range of benefits to the industrial fan market and complements all backward curved plug type impellers and modules making them a technologically advanced and innovative product for air handling units, containment applications and data centres where energy efficiency is a core consideration of the air movement system.

For further information, please visit www.axair-fans.co.uk

PECM Issue 53

Plug Fans with Generation 3 EC Motor * Scan with phone camera for info

The E Series range of Plug Fans produce significant increases in energy efficiency and a major reduction in operating noise in high flow and low-medium pressure applications. Available on short lead times, in multiple single & 3 phase EC variants.

Modular EC Plug Fans (GKHM) Compact, efficient and optimally designed, the GKHM range of EC modular plug fans feature a lightweight (1.22kg/m2) black UV stabilised, long fibre reinforced polypropylene impeller, therefore reducing the mass of inertia and start up resistance to a minimum. Designed with computer fluid dynamics, the profiled blades and diffuser wheel produces less vibration while significantly reducing noise levels.

Generation 3 EC Motor* The Generation 3 EC motor from Rosenberg is 30% more powerful than the previous generation. As standard, the motors input voltage range is 200-480 VAC (50/60Hz) and offers additional upgrades such as an integrated inspection LED to visualise the motors condition, improved ModBus RTU functionality, electronic quick change technology (EQC), IT network support. The maximum electrical input power is 4.7kW. *Featured on 3 phase fans only.

The E Wheel is geared for maximum performance and efficiency. The optimised inlet conditions reduce the motor interaction with the airflow path, resulting in an increased airflow and pressure.” Axair Fans UK Limited - Industrial Fan Integration Experts 01782 349 430 | sales@axair-fans.co.uk | www.axair-fans.co.uk Talk to our team of integration experts now on our LIVE online chat

EDITOR’S CHOICE

ENGINEERED HUCK FASTENERS ®

STAR FASTENERS

An alternative to welding For more than 60 years, the Huck® range of LockBolts and blind fasteners have been solving the problem of extreme stress and vibration in joints, providing strength and facilitating lighter, stronger, more durable structures... without loosening. Today the Huck product range, based on the original HuckBolt® design, has evolved to include small & large diameter LockBolts® medium & heavy-duty blind fasteners and the associated installation tooling, each specially engineered to offer superior performance”.

HUCK LOCKBOLTS Huck LockBolts BobTail®

C50L®

Diameters (mm) 6.4

7.9

9.5

12.7

15.9

19.1

22.2

25.4

Unique helical lock groove (upwards from 9.5mm): Holds pins and collar in place prior to installation* No pin-tail: Reduced wastage, low installation noise No pin-break: High corrosion resistance Semi-automatic tooling installation: Minimises installation time Pin head style: Brazier, truss, countersunk Collar style: Flanged Materials: Steel (5.8/8.8 up to 9.5mm, 8.8/10.9 12mm and above) Coating: High corrosion resistant coatings available

C6L® - The Original Huck Design

WHAT IS A HUCKBOLT AND HOW DO THEY WORK? Structural HuckBolts, also known as Lockbolts are available in a wide range of sizes (up to 1 3/8 inch) and materials, consist of a pin and a collar. These advanced fasteners are installed using a direct tension technique, in which the pin is pulled and the collar is simultaneously swaged into the locking grooves of the pin, deforming the collar into the grooves. Based on their design and unique direct tension installation, HuckBolts deliver consistent clamp for a strong, stable, and vibration-resistant joint. Huck Lockbolts provide direct metal-to-metal contact when installed, which eliminates the transverse vibration often found in conventional nuts and bolts. Engineered for a wide range of applications, Huck Lockbolts deliver superior joining strength, shear, and tensile strength for an unmatched fastening solution.

HUCKBOLT FASTENING TECHNOLOGY – ELIMINATING THE EFFECTS OF VIBRATION In addition to providing for faster, safer, and more accurate joining, there are several unique design elements of HuckBolts that ensure their ultimate resistance to the effects of vibration. Conventional nut and bolt installations, can loosen in high-vibration environments and need continual checking and maintenance, by comparison Huck LockBolts provide a consistent jointing solution.

HUCK BLIND STRUCTURAL FASTENERS For applications where only one side of the joint material is accessible, performance engineered Huck structural blind fasteners can often meet design requirements. These

PECM Issue 53

5.8 grade small diameter Lockbolt Made to British Standard B7805: Part 1: 1997: A mark of quality, safety and performance Wide flange collar available: Enables installation into nonmetallic materials Pin head style: Brazier, truss, countersunk, specific headstyle for palisade fencing Collar style: Standard, flanged, wide flanged and low profile Materials: Steel, stainless steel, aluminium

Diameters (mm) 4.8

6.4

7.9

Diameters (mm) 6.4

7.9

15.9

19.1

22.2

25.4

28.6

31.8

34.9

C120L®

8.8 grade small diameter Lockbolt High tensile strength version of C6L Pin head style: Brazier, truss, countersunk Collar style: Standard, flanged Materials: Steel Diameters (mm) 4.8

6.4

7.9

9.5

Huck 360® - Unique Lockbolt Solution

Magna-Grip®

4.8

Diameters (mm) 12.7

8.8 grade large diameter Lockbolt Made to British Standard B7805: Part 2: 1997: A mark of quality, safety and performance High tensile friction grip fastener Pin head style: Round, truss, countersunk, thread head Collar style: Standard, flanged, low profile Materials: Steel, stainless steel, aluminium Thread head variety available for rail track applications

Huge grip range: Accommodates wide variations in joint thickness - 14.3/23.9mm ** One pin and one collar cover a wide variety of applications: Reducing the risk of incorrect fastener installation Wide grip range minimises fastener inventory Flush pinbreak: No catching on clothes, skin or goods Pin head style: Button, truss, countersunk, rivet, broad truss Collar style: Standard flange, medium flange, wide flange Materials: Steel, aluminium

Diameters (mm) M10

M12

M16

M20

M27

M36

M18

No special tooling system required: Can be installed using a standard torque wrench Ideal for use where installation accessibility is limited for a standard Lockbolt Can be removed and re-tightened*** High speed installation: No prevailing torque All the performance benefits of a 10.9 grade Lockbolt

Imperial sizes available on request

9.5

Hucktainer® - Designed specifically for joining composite board in trailer applications. Will not crush or damage the composite board Integral seal around pin head prevents moisture ingress

Diameter (mm)

Low profile on both sides when installed: No catching on clothes, skin or goods. Not as grip sensitive as some competitor products

Pin head style: Standard low profile, encapsulated in plastic Sleeve style: Wide bearing, medium bearing, clearance Short grip version available Materials: Steel

9.5

* Special tab collar is needed to perform this function. ** Based on 6.4mm diameter. Two different grip lengths available. *** As long as the nut and bolt set remain free spinning after removal. Individual fastener benefits will vary depending on the application they are used in.

blind fasteners can deliver the shear and tensile strength to meet the demands of a number of demanding applications. Available in diameters ranging from 3/16 inch to ¾ inch, these fasteners offer a combination of strength and vibration resistance, easy installation, and a high level of safe operation.

WHERE ARE HUCK FASTENERS USED? Huck Fasteners are used in many industrial markets including truck, trailer, automotive, heating, ventilation and air conditioning, bus, coach, portable buildings, agricultural machinery, green energy and rail, but the

application possibilities are endless.

HUCK® LOCKBOLTS, AN ALTERNATIVE TO WELDING? HuckBolts and Huck structural blind fasteners have not been designed to replace all welds, but there are many applications where welding has been traditionally employed where Huck fasteners are a viable alternative. Engineered for easy installation, and long, reliable life, these direct tension HuckBolts and structural blind fasteners can be a faster, more cost efficient, and safer alternative to traditional welding processes.

HUCK BLIND FASTENERS Magna-Lok®

except 4.8mm Diameters (mm) 4.8

6.4

9.5

12.7

Wide grip range: Accommodates large variations in joint thickness Structural fastener: High shear & tensile strength Excellent gap closure capability Outstanding hole filling on the blind side: Excellent joint tightness and very resistant to water ingress Flush pinbreak: No catching on clothes, skin or goods. Quick and easy visual inspection Internal pin locking mechanism: Secure within the rivet body and protected from corrosion Headstyles: Protruding, truss, countersunk Materials: Steel, stainless steel, aluminium

Magna-Bulb®

Diameters (mm) 4.8

6.4

7.9

Extra large blind side footprint: Ideal for lower strength or thin sheet joint materials Structural fastener: Very high shear strength and high tensile strength Flush pinbreak: No catching on clothes, skin or goods. Quick and easy visual inspection Internal pin locking mechanism: Secure within the rivet body and protected from corrosion Headstyles: Protruding Materials: Steel

HuckLok

BOM® Very high strength/diameter ratio: Can be used in demanding structural applications as an alternative to threaded fasteners or welding Very high joint tightness when compared to conventional blind fasteners Very resistant to tampering, extremely hard to remove Excellent gap closure capability

4.8

6.4

7.9

12.7

15.9

19.1

9.5

Diameters (mm) 4.8

6.4

Headstyles: Protruding Materials: Steel

FloorTight - The flooring specialist fastener ®

Self countersinking head: Ideal for use on timber flooring and phenolic faced plywood Superior strength to conventional flooring screws: Reduces the number of fasteners required and number of drilled holes 3 Clamp strengths available to suit your joint. No crushing or pulling through the board

™

Diameters (mm)

Wide grip range: Accommodates large variations in joint thickness Structural fastener: High shear & tensile strength Large blind side footprint: Ideal for lower strength or thin sheet joint materials Flush pinbreak: No catching on clothes, skin or goods. Quick and easy visual inspection Internal pin locking mechanism: Secure within the rivet body and protected from corrosion, plus additional blind side pin locking for increased fatigue life Headstyles: Protruding Materials: Steel

Large blind side footprint: Ideal for lower strength or thin sheet joint materials

Diameters (mm)

7.9

Recessed pinbreak: No catching on clothes, skin or goods Headstyles: Standard flange and wide flange Materials: Steel

Penta-Lok™ - Specifically Designed for the Composite Panel Market Specifically for joining load restrain profiles to lightweight panel Penta-Lok “claws” unfurl and install inside the actual panel not on the blind side/back of panel High pull out strength: Due the load spread of the “claws” inside the lightweight panel of approximately 16mm.

Auto-Bulb™

Diameters (mm) 6.4

Purpose design blind side shape for easy hole location: Ideal for automated assembly Large blind side footprint: Ideal for lower strength or thin sheet joint materials Good blind side clearance: Less space required on the blind side prior to installation High pin retention: Prevents possibility of noise or vibration in dynamic assemblies Recessed pinbreak: No catching on clothes, skin or goods Headstyles: Protruding, Oval Countersunk Materials: Steel, Stainless Steel

No through hole required in the lightweight panel: Penta-Lok only needs a minimum 8mm of depth in the lightweight panel to insert the blind side of the fastener Diameters (mm)

Huck Fasteners offer benefits that other fastening methods cannot, including: • Quick and easy installation – minimal training & fast installation. • Will not loosen even under extreme vibration. • Maintenance free joints - eliminates checking / replacement, and ultimately cost reductions. • Superior, permanent and a reliable alternative to welding and nuts & bolts. • Tamperproof – once installed cannot be removed without specialist tooling.

Fasteners have a hire fleet for both short and long-term hire. IN-HOUSE TOOL SERVICE / REPAIRS We can help with that too! Every production environment, workshop and tool benefits from a regular maintenance program. Our inhouse service and repair workshop ensures: -

Materials: Steel

• fasteners are being installed properly. Magna-Tite™ - The roofing specialist fastener

Diameters (mm)

Reasons to specify Huck Fasteners into your next project?

Headstyles: Protruding

6.4

* Individual fastener benefits will vary depending on the application they are used in.

Today, HuckBolt fasteners doing the job in a wide range of applications that once solely belonged to welding, they can be effectively used with virtually any metal, and dissimilar metals with dissimilar coefficients of thermal expansion present no problems. Varying material thicknesses in a joint are readily accommodated, and surface finishes are not damaged. And most importantly, HuckBolts are proven to hold up over years of service in demanding high-stress, high-vibration environments.

In addition to providing for faster, safer, and more accurate joining, there are several unique design elements of HuckBolts that ensure their ultimate resistance to the effects of vibration.

4.8

6.4

Polymer watertight seal: Ideal for roofing or similar applications Extra large blind side footprint: Ideal for lower strength or thin sheet joint materials Low clamp load: Perfect for use in thin sheet material, composites and plastics Flush pinbreak: No catching on clothes, skin or goods. Quick and easy visual inspection Headstyles: Protruding, Low Profile, Shaveable, 100° Oval Materials: Aluminium

Each Huck Fastener has its own unique characteristics ensuring that there is a product for every application.

HOW TO INSTALL AND REMOVE HUCKBOLT AND STRUCTURAL BLIND FASTENERS

• Satisfy your health and safety obligations. • Keep production moving and makes sure that the tools are operating correctly.

STAR FASTENERS TECHNICAL SUPPORT Star Fasteners have been a Huck fastener distributor for over thirty years and are the UK’s largest stockists - we have a wealth of knowledge and experience gained from working in a wide variety of markets. If required, we can work closely with our customers to understand their applications and can help to introduce new products that might not have initially considered.

Star Fasteners offer a wide variety of quality tools that stand up to the rigours of a busy workshop environment, we can demonstrate the latest pneudraulic, battery, hydraulic and hand tools and offer advice on options best suited to both the application and the environment.

HIRE FLEET If your workshop needs additional tools, or a specialist tool is needed for a specific contract, Star

Huck 202 Tool Huck RangeForce Battery Tool

For further information…Tel: 0115 9324 939 Email: sales@starfasteners.co.uk Issue 53 PECM

EDITOR’S CHOICE

A DEPENDABLE SOLUTION IFM ELECTRONIC

ifm launches G 1/2 pressure sensors for hygienic applications The first hygienic pressure sensors on the market with a G 1/2 fitting, products in the new PM15 range from ifm electronic provide a convenient and dependable solution to the problem of measuring pressure in small pipes, such as those often found in dosing and filling systems. Thanks to their G 1/2 thread, the sensors can be installed quickly and easily without the need for expensive adaptors and, as they use oil-free ceramic sensing cells, they are ideal for applications in the food, pharmaceutical and other hygiene-sensitive industry sectors. PM15 pressure sensors feature I/O-link connectivity, which ensures accurate transmission of measurements even in electrically noisy environments and allows the sensors to additionally provide temperature measurements. In many applications, this eliminates the need for a separate temperature sensor, thereby saving money and reducing complexity. The sensors also provide a 4 to 20 mA analogue output for pressure measurements only.

CMY

Since they need no elastomer seal and incorporate a pre-mounted PEEK sealing ring, PM15 sensors are virtually maintenance free. All types have stainless-steel bodies with an IP67 or better ingress protection rating, depending on the method of installation. They are highly resistant to pressure and vacuum shock, and to the effects of abrasive substances. In addition, they are suitable for use with media over a wide temperature range of -25 to +125 ºC (<1hr: 150ºC). These features, together with their robust construction, make the new sensors ideally suited for use in even the most demanding environments. ifm electronic is currently offering the PM15 G 1/2 hygienic pressure sensor with ranges from 0 to 2.5 barg through to -1 to 40 barg and all have a minimum of 5 x measuring range overload resistance.

PM15 sensors are virtually maintenance free. All types have stainless-steel bodies with an IP67 or better ingress protection rating, depending on the method of installation.

For further information, please visit www.ifm.com/uk/pm

PECM Issue 53

Precise process monitoring

Hygienic pressure transmitter with IO-Link Interface

RANTY AR

years if m pr od

Whether food or beverage industry, milk production or meat processing: The ifm pressure transmitter, PM, reliably monitors your process, with a high accuracy of 0.2 percent! The excellent temperature compensation allows for rapid temperature changes in the process, eg. In CIP / SIP up to 150° C. This makes the pressure transmitter ideal for demanding applications in the food industry. A free factory calibration certiﬁcate for each sensor is available as a download. Interested? ifm - close to you!

Go ifmonline ifm.com / uk/pm

ifmnovation

Let’s make automation smart and simple!

EDITOR’S CHOICE

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

New electric desk TED from Treston suits industrial use Quick, silent and with wide reach. We could be describing a Big Cat, but these same qualities come with the new Treston Electric Desk TED. TED goes down as low as 630 mm and all the way up to 1270 mm quickly, at 22 mm per second, giving the user the possibility to easily adjust the table in a range of 64 centimeters. Accommodating a wide range of heights serves especially well in light-duty assembly work and manual packing applications, where the handled items can vary from big to small. A desk with a quick and wide adjustment range helps keep employees work comfortable and ergonomic throughout the workday. Have a look at this product in more detail on the Treston TED web page and ask us for more information. Phone: 01635 521 521 Website: www.treston.com Email: jemma.fowler@treston.com

PECM Issue 53

01926 512475

MasterTherm At MasterTherm we specialise in high efficiency heat pumps for commercial and industrial energy systems. For over 25 years we’ve been pioneering heat pump technology and our products have been used for projects all around the world including the cooling of supercomputers, heating of historic buildings and heat recovery for scientific research devices. Our ground source heat pumps are the most advanced in the UK and can offer outputs up to 92kW for a single fixed output heat pump, 7-45kW for a single inverter heat pump or up to 2MW in a cascade system. By developing and manufacturing both fixed output and inverter ground source heat pumps we can ensure the best possible solution is presented based on your business needs and building specification. Each of our heat pumps is constructed by hand using premium components, enabling us to offer customisation options, altering the performance of our heat pumps to specifically cater to your requirements. www.mastertherm.co.uk

gjw@mcs-corporate.com

Curtiss-Wright Surface Technologies Curtiss-Wright Surface Technologies (CWST) provides high quality surface treatments which will improve the life and performance of critical components through its global network of over 65 operating divisions and specialist onsite teams. Our surface treatments have been successfully used by OEM’s in major industries such as aerospace, automotive, oil & gas and power generation for many years. We are only too aware of the logistical challenges and costs faced by our customers and so we can offer a “One Stop Shop” solution providing a wide range of surface treatments including Controlled Shot and Laser Shock Peening, bespoke and trade Coating Applications, Thermal Spray Coatings and Parylene Coatings for metal, alloy, plastic and electronic components as well as Analytical Services. To find out more please visit www.cwst.co.uk.

Industrial Effluent Treatment & Utilisation

Helping our clients, save on their wastewater disposal costs using WEHRLE’s advanced biological treatment and filtration technologies. WEHRLE designs and builds turnkey wastewater treatment plants across multiple manufacturing sectors. Our clients achieve efficacy in their wastewater treatment by use of low energy technologies and by maximizing recycling and reuse of the treated effluent. WEHRLE’s modular design aids in reducing the installations footprint on the site, as well as futureproofing for changes in production and providing a sustainable approach to lowering the sites carbon footprint. WEHRLE’s wastewater treatment plants apply automation where possible and allow remote access, making them operator friendly. They are renowned for their reliability and this is demonstrated by more than 350 installations globally. Our comprehensive portfolio of services include: ► Concept design and pilot trials ► Detailed design engineering ► Manufacturing and assembly ► Construction and commissioning ► Service operation and maintenance ► Remote technical support WEHRLE are a 160-year-old family run business, located in Southwest Germany. Its UK division is based in Bloxham, Oxfordshire and has been operating for over 20 years. Should you require further information please contact: info@wehrle.co.uk or visit our website.

www.wehrle-werk.de/en/environmental-technology

EDITOR’S CHOICE

SUCCESS STORY AUDI

The Audi Q4 e-tron: in its transition to electromobility, Audi is turning to synergies within the whole group

Strong together: In its transformation to emissions-free mobility, Audi is relying on the synergy effects within the Volkswagen Group. During a media visit to the multibrand factory in Zwickau, Germany, Peter Kössler, Audi Board Member for Production and Logistics, and Dr. Stefan Loth, Chairman of the Board of Volkswagen Saxony GmbH, emphasized how intensely the sister companies are benefiting from their close collaboration. Thanks also to shared platforms like the modular electric drive system (MEB), Audi will have more than 20 fully electric models on the market by 2025. Starting in 2026, Audi will only launch new models with electric drive systems on the global market. The company will gradually phase out production of its internal combustion engines between now and 2033. In doing so, the premium

PECM Issue 53

manufacturer is clearly looking to electromobility and accelerating its own transformation. The main goal: to combine individual mobility and sustainability for its customers – and to increase its profitability as a company at the same time.

SYNERGIES ACCELERATE TRANSITION TO ELECTROMOBILITY The Audi Q4 e-tron and Q4 Sportback e-tron play a central role in the electrification strategy. In terms of price, they offer Audi customers an attractive point of entry into electric premium mobility. The Volkswagen Group’s platform strategy makes this possible: The Audi Q4 e-tron and Q4 Sportback e-tron are being produced in the multi-brand factory in Zwickau, where the Volkswagen ID.3 and ID.4 and, more recently, the Cupra Born are also manufactured. All these models are

based on the MEB, but they score points with their brand-specific strengths. “In the future, we will rely even more intensively on synergies within the Volkwagen Group,” says Peter Kössler, Audi AG Board Member for Production and Logistics. “This close collaboration makes the transition to emissions-free premium mobility affordable for our customers and economically presentable for us. At the same time, we make sure that all our vehicles unmistakably carry the Audi DNA within them and leave the assembly line in almost proverbially premium quality.” The next important electric model from the company with four rings, the Audi Q6 e-tron, is also based on a new group platform: the Premium Platform Electric (PPE) developed jointly by Audi and Porsche.

THE ZWICKAU VW FACTORY: A PIONEER IN THE EMERGENCE INTO THE ELECTRIC AGE At Volkswagen Saxony in Zwickau, approximately 8,500 employees are producing the group’s five current models – all carbon-neutrally. Dr. Stefan Loth, Chairman of the Board, says, “For us, it is a special joy as well as a challenge that we have transformed from an exclusively Volkwagen factory to a multi-brand location that will soon produce six electric car models. That makes significant demands of our employees, who are responding with tremendous engagement and skill.” Many novel and innovative technologies are being used in the assembly process. For instance, the head-up display is installed directly in the assembly line. Intelligent software assesses the test image projected on the windshield and autonomously makes fine adjustments.

THE Q4 E-TRON: UNMISTAKABLY A REAL AUDI Using shared platforms and technical modules has been a proven strategy in the Volkswagen Group for decades. “Teamwork across brands starts when a new platform is conceived,” says Fermin Soneira Santos, Head of Product Line for Electric Models from the A to C Segment. “It’s important to establish the right balance between distinctive brand character and maximum synergy.” For example, the Q4 e-tron is unmistakably a real Audi. This is not only apparent in the progressive design, but also in the standard Audi display and operation concept with a combination of

The benefits of crossbrand collaboration are evident not only in the technical platforms, but also among the employees. virtual cockpit and extra large MMI, the augmented reality head-up display, which brings the interface between the virtual and real worlds together for the first time in the compact class, and in Audi’s almost proverbial claim to quality and materials in the interior.Both models successfully started in all European markets in 2021; for US customers, the compact SUVs have been available since the end of September.

AUDI EMPLOYEES SUPPORT AND LEARN FROM ZWICKAU COLLEAGUES The benefits of cross-brand collaboration are evident not only in the technical platforms, but also among the employees: at the moment, approximately 350 Audi employees are engaged in manufacturing in Zwickau – primarily junior staff members who have just completed their vocational training. After their one-year assignment in Zwickau, they will bring their experience in

the emerging field of electromobility back to their original locations – for instance with the start of the Q6 e-tron in the Ingolstadt factory, which will be on the market starting in 2023.

ZWICKAU AND AUDI ARE UNITED IN A LONG TRADITION The roots of the company with the four rings are in Saxony: when he needed to expand his operation, company founder August Horch went to Zwickau, where he registered the company “A. Horch Motorenwagenwerke AG” in 1904. That laid the foundation for car manufacturing in Saxony. After disagreements with the board of directors, Horch left his company and founded the “August Horch Automobilwerke GmbH” in 1909, which was renamed the “AudiAutomobilwerke m.b.H.” in 1910. Then, in 1932, the company reached another milestone in its history: the four companies Audi, DKW, Horch, and Wanderer consolidated to form the Auto Union AG; the trademark became the four rings. Stefan Trauf, Managing Director of Auto Union GmbH, the company that is changing Audi tradition today: “Zwickau was, is, and will remain a very special city for Audi. Automotive history was written here – and, then as now, it was striking just how important and productive close collaboration between brands is.” Audi history and the history of the auto industry in Saxony live on in the August Horch Museum in Zwickau (www.horch-museum.

For further information, please visit www.audi.co.uk/uk Issue 53 PECM

EDITOR’S CHOICE

SAVE SPACE, ENERGY & MONEY MICRONEL

Micronel reduce operating costs with decentralised compact dc blower solutions Micronel dc blowers save space, energy and money compared to other air sources such as bulky side channel blowers and compressed air systems. Saving energy not only conserves resources but is also good for the balance sheet. That is why machine and plant manufacturers as well as production companies rely on Micronel high-performance blowers in process control and automation applications. The reliable high-tech solutions enable new and more efficient application possibilities and promote independence in comparison with previous compressed air systems. Thanks to their very small compact sizes, Micronel blowers are suitable for decentralised installations and can be placed adjacent to the relevant process reducing pressure losses incurred in long air supply lines and allows flexible installation without the need to install or relocate air lines. Dynamic blower control allows air supply to be called up as on demand as required, increasing the efficiency of the application. Here is a simple example: compared to

a conventional Air-Knife compressed air application, with an annual consumption of 60000 m³ air volume, a Micronel Radial Blower U100H4 (pressure 165 hPa, flow volume 820 l/min) with a power consumption of 100 watts pays for itself in energy savings after only half a year.

and ease of use, M16 connector and has G¾ inch pipe threads for 32mm tight hose connections. The housing complies with protection class IP67 with connected suction and discharge ports. The 2 stage U100H4 can generate over 165 mBar (16,500 pascals) of pressure and achieve free blowing air flow over 900 litres per minute (54 metres cubed per hour) all from a very compact small size package of 107mm x 107mm x 118mm. With typical power consumption of 100 – 180 watts depending on working point they can pay for themselves in energy savings after only a few months. The performance and cost savings of the blowers is particularly evident in applications such as drying and cleaning processes, where high pressure and a considerable volume of air are constantly required.

Micronel blowers are also extremely advantageous in suction and extraction processes, such as pick & place processes or vacuum holding or conveying technology. A full range of accessories are also available including air knives, filters, and anti-vibration mountings. Micronel specialise in High Performance Blowers and Fans, their fan and blower products meet the needs of industries with special performance characteristics – Medical, Electronics Cooling, Personal Protection, Packaging, Gas Analysis, Laboratory, Transportation, Process Control and many more applications. Micronel offer customers the widest choice of standard ultra-slim fans, axial fans and high performance high pressure radial blowers from UK stock and provide technical design support for modified products and client specific designs.

The compact U100 dc blower family features a tough full aluminium IP67 housing, efficient brushless dc motor with integrated electronic driver for plug n run capability For further information, please visit www.micronel.co.uk

PECM Issue 53

MICRONEL MINIATURE FANS AND BLOWERS

BLOWERS FOR PRESSURISED AIR AND SUCTION APPLICATIONS

s reduce n o ti lu o s r e w lo b Decentralised ave energy! s d n a ts s o c g n ti opera PRESSURISED AIR IS EXPENSIVE!

ADVANTAGES OF MICRONEL BLOWERS

Compressing Compressing air air in in aa compressed compressed air air system system requires requires aa

•• Compact Compact design design and and flexible flexible positioning positioning at at point point of of use use

lot lot of of power power and and results results in in continuous continuous pressure pressure losses losses

•• Extremely Extremely small small sizes sizes –– Typically Typically 50 50 mm mm diameter diameter up up

during during transport transport from from the the point point of of generation generation to to the the point point

to to 100 100 mm mm xx 100 100 mm mm square square

of of consumption consumption -- This This makes makes compressed compressed air air one one of of the the

•• Lower Lower operating operating costs costs with with higher higher efficiency efficiency

most most expensive expensive forms forms of of energy energy of of its its kind. kind. For For this this reason, reason,

•• Work Work independently independently of of existing existing compressed compressed air air systems systems

Micronel‘s Micronel‘s powerful powerful compact compact blowers blowers are are becoming becoming

•• Robust Robust aluminum aluminum housing housing for for harsh harsh industry industry conditions conditions

increasingly increasingly utilized utilized in in the the market market for for pressure pressure and and vacuum vacuum

•• Maintenance Maintenance free free and and long long lifetime lifetime

applications. applications.

•• Quiet Quiet operation operation with with optional optional silencer silencer and and accessories accessories

Micronel Micronel UK UK Ltd. Ltd. Unit Unit 53, 53, The The Arches Arches Industrial Industrial Estate Estate Alma Alma Road, Road, Windsor, Windsor, Berkshire Berkshire SL4 SL4 3HY 3HY United United Kingdom Kingdom

Phone Phone +44 +44 1753 1753 641 641 412 412 info@micronel.co.uk info@micronel.co.uk www.micronel.com www.micronel.com

EDITOR’S CHOICE

CABLE INNOVATION HEATSENSE CABLES

Specialist High-Performance thermocouple and signal cable manufacturer continues to expand during lockdown CAPABILITIES

Heatsense Cables is the UK’s leading specialist high performance thermocouple and signal cable manufacturer. The company is highly customer focussed and offers a bespoke technical design and manufacturing service, rapid response times, short lead times, low MOQ’s and competitive pricing. The company is a technology leader in fluoropolymer extrusion, high performance taping and cable wrapping. Related processes include cover sintering, colouring, etching and the application of various specialist coatings. The range covers cables that operate in extreme environments; cables resistant to flame, oils & chemicals and which operate in ultra-high vacuum, cryogenic and high radiation environments.

INSULATION & BRAIDING EXPERTS

Insulation materials include; PFA, FEP, PTFE, ETFE, EFGLAS, SILICONE, PE, PU, PVC, Taped & Sintered PTFE, Polyimide, Aramid, PTFE impregnated yarns and Mica. Braiding materials include glass, quartz, ceramic fibre and other specialist yarns and various metals.

PRODUCTS

The company manufactures a broad range of cables including; thermocouple cables, RTD cables & PRT wires, sensor wires & cables, cryogenic cables, glass, quartz, ceramic fibre and pure nickel cables, the INTEMP® Range (250°C - 1250°C), radiation resistant cables, equipment wires & cables, high voltage cables, multicore cables, micro wires & cables, micro-coaxial cables, high-flex braided cables and PTFE yarns & threads. To support these activities Heatsense has its own specialist thermocouple calibration facilities and cable testing laboratory. Markets include, aerospace, nuclear, automotive,, medical, R&D, oil & gas and general industry. The company offers a range of approvals which meet internationally recognised specifications.

EXPANSION

Heatsense remained extremely active during the COVID lockdown period. Over the course of the last twelve months Heatsense acquired plant & equipment, including 16 additional high speed yarn braiders, a PTFE Paste Extrusion Line, a horizontal twin headed taping line, an additional corona etcher and refurbished and upgraded a number of manufacturing lines. The company also upgraded its internal manufacturing systems and ‘went live’ on a new fully integrated ERP system. The company continually strives to broaden its manufacturing capabilities

and improve efficiencies. The company continues to develop its digital strategy encompassing shopfloor data capture, ERP, CRM and machine automation. Heatsense is ISO9001:2015 and ISO14001:2015 Accredited and has F4N Status (Fit for Nuclear), awarded by the Nuclear Advanced Manufacturing Research Centre. The company is in the process of working towards AS9100D:2016 Accreditation and expects to be accredited by the end of this year. T: +44 (0) 1706 767070 W: www.heatsensecables.co.uk

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

PECM Issue 53

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

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

MARKET SPECIALISTS

Automotive

Aerospace

Nuclear

Medical

Industrial

Research

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

• Service international partners

• Short lead times

• Competitive pricing

• Based in the UK

• Low MOQ’s

*Registered owner of the world-renowned INTEMP trademark

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

EDITOR’S CHOICE

Brammer Buck & Hickman introduces innovative safety footwear Following the launch of the comprehensive GISS PPE product range in the UK, Brammer Buck & Hickman, the UK’s leading supplier of industrial maintenance, repair and overhaul (MRO) products and services, is pleased to introduce the GISS Linzor Safety Boot and GISS Luxsar Safety Shoe. Both GISS Linzor Safety Boot and GISS Luxsar Safety Shoe are innovative in design and performance. Incorporating Infinergy® for an increased level of comfort and Putek for extremely high levels of abrasion, the footwear offers all day comfort with extreme durability. The Infinergy® technology helps to maintain energy levels for longer than any traditional sole with the added benefit of lightness, freedom of movement, anti-fatigue and reduction of musculoskeletal disorders. For more information, please go to https://uk.rubix.com/giss.

Exalto Bearings UK Limited Exalto Bearings UK Limited are manufacturers of water lubricated bearings for the Pump and Marine Industries in a variety of materials and sizes. As an ISO 9001:2015 accredited company we adhere to strict quality procedures and continually strive to improve our products and level of service to our customers throughout the world. While standard bearings are stocked in a range of sizes for rapid despatch, Exalto also manufactures special non-standard sizes upon request. A modular tooling system means that Exalto can respond speedily to urgent requests for standard and custom-made bearings that are required for the highest standards passing even the rigorous requirements of the nuclear industry. Exalto Sales Department Exalto Bearings UK Limited +44 (0) 1332 340501 sales@exalto.co.uk www.exaltouk.com

End-of-Arm-Ecosystem

Any Robot | Any Gripper | Any End Effector • • • •

Standardised Interfaces Simple Installation Manual or Auto Tool Change Mechanical or Vacuum Grippers

Zimmer Group (UK) Ltd, Bretby Business Park, Ashby Road Bretby , Burton On Trent, DE15 0YZ Tel: +44(0)7891 204 306 | www.zimmer-group.com

PECM Issue 53

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

www.cistermiser.co.uk

PIONEERS OF SPACE Whether you want to improve line productivity, introduce automation, raise operator quality, save clean down time between lines or reduce risk of contamination and therefore clean down time, there’s a Teknomek solution.

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

EDITOR’S CHOICE

THERMAL IMAGERY QUANTUM DESIGN UK AND IRELAND

We offer one of the largest selections of Thermal Imaging Cameras to suit every application Quantum Design UK and Ireland (QD-UKI) have teamed up with the world leaders to provide an extensive range of imaging cameras, including thermal imaging, high speed, SWIR, CCD and EMCCD and X-Ray Cameras. We distribute cameras for Specim, Raptor Photonics and InfraTec. Below is just of some examples of the application areas they are working in and the latest news.

ADVANCING GEOLOGY WITH HYPERSPECTRAL IMAGING Hyperspectral imagery is a powerful technology to locate minerals that are exposed or weathered in areas of residual soil. The foremost airborne application of hyperspectral imagery provides mineral mapping for exploration clients in the mining, oil, gas, and geothermal sectors over large and often remote and inaccessible areas. Find out more about the SisuROCK workstation, a fully automated hyperspectral core imaging instrument for easy and high-speed scanning of drill cores and other geological samples.

• Integration into complex text solutions through interfaces to LabVIEW and MATLAB • Analysis instruments for fast-rotating objects, such as tires or brakes

(AGC) – Enables clear video in all light conditions

PRESTIGIOUS INNOVATION AWARD FOR NEW OWL 640T CAMERA - the World’s First SWaP Optimised ½” / VGA InGaAs Sensor with VIS-SWIR Response

• On-board Intelligent 3-point NUC – Enables highest quality photos

Raptor Photonics, a leader in innovative digital camera solutions has launched the OWL 640T camera. The 640T has already been recognised among the best in machine vision by the judges of the Vision Systems Design 2021 Innovators Awards program. • ½” Sensor Format – Better for optical design, ideal for OEM integration into Electro-Optic systems • 10μm x 10μm Pixel Pitch – Compatible with VIS-SWIR illuminators, markers & pointers • <50 Electrons Readout Noise – Enables a high VIS-SWIR detection limit • On-board Automated Gain Control

• Non-destructive testing allows precise and efficient quality control

THERMOGRAPHY IN AUTOMOTIVE INDUSTRY The ultimate marketing tool for presenting cars’ safety are, certainly, crash tests - one of the worst testing methods for engineers and controllers since, in the course of this process, the device under test will be destroyed. Thermal imaging helps to make defects visible without damaging the device under test on its testing. Therefore, functions of catalysts as well as electric systems of cars and motor assemblies can also be tested with the help of infrared camera systems. • Reconcile thermal behaviour of components with their standard behaviour

This is just one of the many applications that InfraTec cameras offer including Process Control, Automation and Aerial thermography.

HIRE A CAMERA FOR YOUR NEXT RESEARCH PROJECT.. We’re offering researchers the Opportunity to hire either our Specim IQ portable hyperspectral imaging camera or InfraTecIR 8300 high speed thermography camera for a week or month at a time. Use our camera for your upcoming research project without having to commit to buying one. Contact Luke Nicholls, luke@qd-uki.co.uk for more information.

CONTACT US QD-UKI have recently launched their new Company Magazine to coincide with their new Company Video. We welcome the opportunity to discuss your requirements in further details. Visit us at www.qd-uki.co.uk or email our technical expert, Luke Nicholls

For further information, please visit www.qd-uki.co.uk

PECM Issue 53

An imaging camera for every application

Hyperspectral imaging ■ ■ ■ ■

Forensics Food inspection Art conservation Vegetation and agriculture

Thermal Imaging ■ ■ ■ ■

Quantum Design UK and Ireland Ltd 1 Mole Business Park, Leatherhead, Surrey KT22 7BA Tel: +44 (0)1372 378822 | Email: info@qd-uki.co.uk

Automation Aerial thermography Process control Non-destructive testing

SWIR InGaAs Cameras ■ ■ ■ ■

Laser Beam Profiling Semiconductor Inspection Solar Cell Inspection Microscopy

For more information visit

qd-uki.co.uk/imaging

EDITOR’S CHOICE

Explosion-safe Air Conditioners FOR OFFICES, CRANE CABINS AND TLQ’S Suitable for Zone 2 environments Capacity up to 14 kW Cooling and heating 230 or 400 VAC Ambient temperature –27°C to 52°C II 3 G Ex ec h ic mc IIC T4 Gc

Artidor Explosion Safety B.V. | The Netherlands | artidor.com | sales@artidor.com

PECM Issue 53

EDITOR’S CHOICE

THE PEBBLE LASTBASIC

Digital prototyping platform allows ordinary inventor to turn mental health tech idea into a reality With the help of digital prototyping platform, LastBasic, UK-based councillor, Rob Middleton, has invented The Pebble, a wellbeing lifestyle product that uses Bi-Lateral Alternating Stimulation Therapy (BLAST) to help sufferers of anxiety alleviate day to day stress while promoting an overall sense of wellbeing. A sufferer of anxiety and panic attacks himself, Rob found that most treatments on the market were expensive, highly medicalised and inaccessible to the general public. After undergoing bilateral stimulation during EMDR (Eye Movement Desensitisation and Reprocessing) therapy, which is designed to alleviate anxiety associated with painful life events through rhythmic alternating stimulation, such as tapping alternating parts of the body, Rob came up with the idea of The Pebble, a pebble-shaped product that uses (Bi-Lateral Alternating Stimulation Therapy) to mimic rhythmic taps associated with bilateral stimulation. Rob turned to LastBasic’s innovative Product Development Marketplace, which allows anyone with a hardware tech idea to convert it into a functional prototype using a community of expert industrial designers and engineers. LastBasic provides a quick and cost-effective service, with a transparent approach allowing inventors to be guided through the prototyping process, whilst maintaining a high level of control over their product. Before discovering LastBasic, Rob had contacted several traditional consultancy companies in the UK, finding that attempts of contact were either met with silence, implying that these consultancies were not interested in doing business with individuals with a smaller budget, or had huge associated costs. With LastBasic, Rob was able to turn his idea into a reality in cost-efficient and accessible way. “LastBasic are a highly professional and approachable team, which makes them stand out to me. The payment process has

better value,” comments Alejandro Turell, CEO at LastBasic.

LastBasic are a highly professional and approachable team, which makes them stand out to me. been quite flexible, and I’ve saved tens of thousands of pounds by using LastBasic over an engineering consultancy. The latter just don’t cater to individuals who want to bring forward a solution. LastBasic was a much better choice. They help you to work out your own solutions in an empowering way,” says Rob. “Creating prototypes is critical to validating products and projects, but the traditional models for generating them can be complex, taking many months and sometimes costing tens of thousands of pounds. LastBasic’s platform is disrupting these traditional models, making prototyping more accessible, much faster, and providing

“By using LastBasic, inventors can access skills and knowledge of designers, engineers and Makers from different regions, who bring ideas, experience, and methods that are beyond the capability of many engineering consultancies,” Alejandro continues. Rob’s Pebble is in the final stages of production, and he is extremely excited to move onto the next stage of development. Mental health has become a significant topic in the UK, particularly following the pandemic, with 50% of people saying their mental health worsened. Solutions like Rob’s could have a significant positive impact on people suffering from anxiety, which there is clearly a need for LastBasic’s platform to help inventors like Rob bring their ideas to light. Whether you are a one-man band or an established company, everyone matters

For further information, please visit lastbasic.com Issue 53 PECM

EDITOR’S CHOICE

PHOTOCHEMICAL ETCHING PRECISION MICRO

Complex Metal Component Prototyping in as Little as 24 hours Photochemical etching offers the chance to prototype from the widest range of materials, with little to no set-up costs and delivery in as little as 24 hours. However, it’s almost the sector’s best-kept secret with most design engineers defaulting to “traditional” methods.

COMPLEXITY MADE SIMPLE Conventional sheet metal machining can face various issues when cutting certain metals, resulting in additional operations that can increase lead times. Chemical etching, by comparison, presents a more economical and efficient way to produce custom parts with complex designs and strict tolerances. This is possible by UV printing the part design through a phototool stencil onto sheet metal laminated with a light-sensitive polymer. The design is then selectively etched, offering a less intrusive and more delicate process for creating intricate components. The value of etching is truly found through the inexpensive and easily reworked phototools that ensure high accuracy and repeatability in production, perfect for providing OEMs with the critical components they need in short lead times for a great price.

TOP-QUALITY WITHOUT INTERVENTION Precision components are vital elements of many applications and even the slightest blemish can create significant disparities in the quality of the final product.

Thermal and cutting edge stresses are familiar factors that affect the quality of the components produced. Etching eliminates potential stress as there’s no heat or physical impact. Similarly, with no harsh cutting, there are no burred edges.

REDUCING TIME IN R&D Photochemical etching can simplify the development process as it eliminates stress and burring, allowing for products to be delivered to an exceptional standard in hours – rather than weeks or months. It also reduces tooling time and costs, with no expensive hard tooling required. While chemical etching provides simplicity, the process also allows even the most complex of parts to be created, opening more design avenues. It’s clear that chemical etching should be considered as a solution for cutting precision metal components, with reduced lead times, fewer costs and the ability to precisely cut even the most difficult metals in larger quantities. To discover more visit www.precisionmicro.com

PECM Issue 53

EDITOR’S CHOICE

CUSTOMER SOLUTIONS EXPROMET

How Expromet Technologies Group is putting the customer first Strengthening customer solutions: Less than five years after identifying the potential for a group of complementary precision engineering businesses to deliver high quality solutions for performance-critical applications, Chief Executive of Expromet Technologies Group Alistair Schofield says the group’s customer base is growing, along with its reputation. “Our Group businesses provide a wide range of complementary engineering and manufacturing solutions. We produce anything from simple cast components through to complex, precisionengineered systems, developing and utilising the best solution to meet individual requirements. That level of experience and understanding is proving to be a valuable resource for our customers.”

EXPROMET DELIVERS ON ITS CORE VALUES The Group is founded on delivering excellent service and value to customers across the defence, aviation, marine, medical, energy and process equipment sectors and other performance-critical industries. Three basic principles continue to drive growth:

The Group is founded on delivering excellent service and value to customers across the defence, aviation, marine, medical, energy and process equipment sectors and other performance-critical industries.

Operational excellence Expromet places engineering excellence, technological advancement and precision at the core of everything it does. Solutions from the Group’s four UK manufacturing locations range from investment, sand and gravity-die castings to precision machined and fabricated components and systems. Expromet also offers a wide range of castings, forgings and precision machined products sourced from international supply chain partners. Organic growth Each company under the Expromet umbrella has strengthened its position over the last two years. Investacast, Haworth Castings and Metaltech Precision have all seen investment in their facilities and made new appointments to their teams, providing a secure foundation for growth. Expromet Group companies continue to win new business and as they diversify into new sectors the Group’s global expertise continues to grow. Acquisition Expromet’s vision for the future is to continue development and investment in areas that bring additional technological and manufacturing advances for the benefit of its customers. “Our goal is to be a fully-integrated, leading-edge supplier of engineered solutions for customers on a global basis,” says Alistair. “We are always on the lookout for complementary businesses that can help us expand the breadth of capabilities that we are able to offer to our customers.”

Expromet Chief Executive Alistair Schofied (left) and Group Finance Director Dan Jones (right), with the Insider Media’s ‘Buy to Build Company of the Year’ award.

LOOKING TO THE FUTURE Expromet won ‘Buy to Build Company of the Year’ at Insider Media’s South West Dealmakers Awards in September 2021. Alistair Schofield says: “I was delighted to accept this award on behalf of Expromet Technologies Group. The award recognises the progress that we have made in growing the business over a relatively short period of time. The acquisition of Metaltech this year, combined with our focus on operational excellence and investment across the Group, sets the stage for the next phase of our development plans both in the UK and internationally.”

For more information please call + 44 (0) 1271 866200 visit www.expromet.com or email enquiry@expromet.com

PECM Issue 53

AV N AI OW LA BL E

EDITOR’S CHOICE

since 1849

All-in-one marking solution with touchscreen control • Pryor’s latest embedded software • 36V “all day” battery • Includes: 1x Bosch 36V batteries, 1x battery charger & mains charging cable (UK, USA, & EU options available) • Robust carry case for transport & storage

pryormarking.com

DESIGN

Feasibility, Model, Create

DEVELOP

Processes, Tooling & Cost saving

High Accuracy Digital pressure measurement solutions

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. 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.

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 sales@esi-tec.com | (0)1978 262255

PECM Issue 53

www.cybertoolsltd.co.uk

EDITOR’S CHOICE

WORLDWIDE GROWTH HRS HEAT EXCHANGERS

Combined companies have more than 100 years’ experience By Matt Hale, International Sales & Marketing Director, HRS Heat Exchangers The recent acquisition of HRS Heat Exchangers by Canada-based Exchanger Industries Limited (EIL) has created an international group with more than 100 years of combined experience in heat transfer technologies. Exchanger Industries was founded in Calgary, Alberta by Howard Thom in 1961 as Exchanger Sales and Services to manufacture tubular heat exchangers. By 1964 the company was also manufacturing air-cooled heat exchangers, sulphur condensers and waste heat boilers, which still remain core products to the present day. Exchanger Industries specialises in largescale fabrication and solving complex design problems, as well as offering alternative design solutions which lower the total lifecycle cost of projects. In particular EIL units are found in the petrochemical, industrial and clean power generation sectors. Over the years EIL has introduced a number of new applications and developments including new baffle designs and coatings. On the other side of the Atlantic, Heat Recovery Systems (HRS) was set up in the UK in 1981 by Steven Pither to sell heat exchangers. Within a few years HRS had taken on more design and selection work until eventually it began to manufacture heat exchangers, and the corrugated tubular heat exchangers for which it is best known. Over the years HRS has responded to a number of specific customer requests, which has led to the creating of a number of innovative products and systems including piston pumps, aseptic fillers, pasteurisers, evaporators, CIP skids, and solutions for treating and managing sludges and digestate. HRS clients come from a wide variety of industries, including food production, water and waste management, environmental, AD/biogas and industrial sectors. Both Exchanger Industries and HRS undertake all aspects of heat exchanger

design and construction themselves, from initial project assessment through to final delivery and commissioning. They understand that every job is unique and requires individual calculation of heat transfer and mechanical design. All products, from the smallest HRS pump to the largest EIL waste heat boiler, are manufactured to the strictest standards, such as those set by the Alberta Boilers Safety Association (ABSA), American Society of Mechanical Engineers (ASME) and the European Union. Each company also has proprietary and patented technologies, which have the potential to work together to bring new and improved solutions to market. For example, HRS, which is known for its unique corrugated tube geometry, has its patented Unicus Series of scraped surface heat exchangers and created its own heat exchange design software, while EIL has its EMbaffle® and Helixchangers™ and is well known for its development of a proprietary anti-fouling coating, which was commercialised in 2018. Heat recovery is a priority for both, as is increasing efficiency and reducing the environmental impact of their client’s and customer’s activities. Both antifouling coating technology and corrugated tubes provide similar benefits to the end user, albeit in different ways. Exchanger Industries’ proprietary antifouling represents a breakthrough in tackling

the issue of fouling, which affects heat exchangers used in multiple industries. The technology has taken ten years of R&D and seven years of field-scale evaluation in the oil and gas industry. HRS was the first company to introduce corrugated tubes to the UK market and over the years has continued to improve their design. Not surprisingly, understanding the science of heat transfer and thermodynamics is key to the success of both businesses. Individually both HRS and Exchanger Industries have made huge developments in the areas in which they operate and are each international companies in their own right. Together they now have a truly global footprint, employing some 420 people around the world, with manufacturing plants in four countries and sales offices in ten. Moving forward under the leadership of Mark el Baroudi as CEO, both Exchanger Industries and HRS will use their collective experience to share best practice and take key learnings from their respective business to see if they can be applied to new areas. Because of the different industry sectors they serve, this really is a case of two complementary companies coming together to further strengthen their differentiated customer offerings, identify opportunities for investment to drive international growth, and enhance their status as a worldwide leader in heat transfer solutions and technology.

For further information, please visit www.hrs-heatexchangers.com

PECM Issue 53

EDITOR’S CHOICE

1 HRS Heat Exchangers has operated at the forefront of thermal technology for forty years, offering innovative and effective heat transfer products worldwide, focusing on managing energy efﬁciently. Pasteurisation Sterilisation Heating/Cooling

Evaporation CIP/SIP Systems Process Skids

| +44 (0)1923 232 335 |

YEARS

Exchanger Industries has sixty years of experience, designing and manufacturing industrial heat exchangers to increase customer project proﬁtability for clients in a wide array of industries around the world. Air Cooler Shell & Tube Waste Heat Boilers

info@uk.hrs-he.com

Antifouling Sulfur Condensers Field Services

www.hrs-heatexchangers.com

Issue 53 PECM

AIR GAS AND ODOUR CONTROL / CONNECTORS & FITTINGS

O-Rings and Bonded Seals enhance existing product offering TR Fastenings’ comprehensive product range now includes an extensive selection of O-Rings and Bonded Seals, echoing commitment to the ongoing investment in components that customers demand. Selfcentralising Bonded Seals are available in a wide range of sizes. They’re used in high pressure systems to provide leak-proof seals. In addition, TR’s O-Rings are manufactured from either nitrile or fluorocarbon elastomer (FKM), and are available in more than 5,000 options. They can also be purchased in multisize kits, ideal for engineers who need fast and effective repairs and replacements. TR Fastenings design, manufacture and distribute industrial and Cat C components to more than 5,000 companies globally, with 34 locations including seven manufacturing sites and three Technical and Innovation Centres. Free phone: 08454 811 800 E-mail: sales@trfastenings.com Website: www.trfastenings.com/Home

Withstands the pressure Fluorinated gases have a very high Global Warming Potential and accordingly a large negative impact on global warming. HFCs accounts for the largest share of F-gas emissions. They are used in various sectors and applications, such as refrigerants. SANHA offers safe and economic piping systems to transport more environmentally friendly alternatives such as CO2 (R744). At the heart of these are our high-pressure solder fittings RefHP. Made from CuFe, they are compatible with all pipes currently available on the market, highly stable and suitable for pressures of up to 130 bar. For large piping systems, the dimension 2 5/8” was added to the range. RefHP offers noticeable advantages over both stainless steel welding and brass, making it an attractive and economic alternative. www.sanha.com/en/product-catalogue/ sa-copper-alloys/sanha-refhp-high-pressurefittings/

R PURIFICATION URIFICATION AIR PURIFICATION YHNDER ZEHNDER BY ZEHNDER

Efficient &filter patented filter solutions cient & 9patented solutions patented filter solutions High clean air delivery rate h clean9air delivery rate air delivery rate 9 Tailor-made to fit your individual needs lor-made to fit your individual needs e to fit your individual needs

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T IN TOUCH NOW UCH NOW

PECM Issue 53

The EXIN portable LED lighting range The EXIN portable LED lighting range is packed with great features and benefits whilst providing a maximum of 3200 lumens and runtimes up to 30 hours from a single charge. Widely used within the Rail and Construction Industries, the Emergency Services, Utility Companies and anywhere requiring a reliable and robust portable lighting solution. Two models are available: IN1600L and IN1600LB with the latter having a longer runtime but both having the ability to be used outdoors due to the IP65 rating. Supplied with a 240 volt mains charger and a 12/24 volt plugin car charger available as an optional extra makes it easy to charge on the go. A truly portable LED site light available to hire or buy from numerous outlets throughout the UK. Want to know more? Visit: www.hscgroupuk.co.uk

sales@lamonde.com

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Lamonde Automation Limited Quality Products: Expert Advice

CONTROL & AUTOMATION

ALS MECHATRONIC FANUC

The key role of systems integrators in delivering automation Tasked with bridging the gap between manufacturer and end-user, systems integrators are playing a crucial role in the delivery of automation systems. ALS Mechatronic is one such integrator, a specialist in bespoke factory automation and robotics systems for a number of the UK’s key industries, including pharmaceutical and FMCG. Here, we take a look at how ALS Mechatronic works alongside FANUC to help its customers improve production processes. “There’s a term we use to describe what we do – ‘solutioneers’, Andrew Steward, Managing Director at ALS Mechatronic explains. “That’s because we’re a team of engineers at heart, which means we have an understanding of how production processes work, and in particular automation. “But where we really add value is by providing solutions to problems, and helping manufacturers to figure out what they actually need to improve their workflow. It’s our job to be experts not just in automation, but all of the industries that our customers operate in.” Systems integrators play a critical role in helping businesses to overcome any apprehension and misunderstanding they may have surrounding automation. They serve as a key connection between manufacturers of automation solutions and end-users. Through its close working relationship with FANUC, Gloucestershirebased ALS Mechatronic has helped to boost productivity in factories across the UK and beyond. Andrew continues: “We primarily work in the packaging industry, with a number of customers in dairy, pharmaceutical, and household wares. A lot of what we do is dealing with bottles, from container handling and inspection through to when they get packaged up and sent off to be filled. It can be anything from house cleaning products through to pill bottle packaging, and it is heartening to see such a diverse range of customers looking to implement automation.”

PECM Issue 53

FINDING THE RIGHT SOLUTION 2020 was a challenging year for a number of industries, as social distancing measures put a strain on factory processes. One of the defining features of the manufacturing sector’s response has been a greater acceptance of the potential benefits of automation, particularly in facilitating a growth in productivity. With more businesses than ever before open to the idea, ALS Mechatronic witnessed an increase in people reaching out for expert advice.

Andrew explains: “Typically, we’ll get approached by a customer with a fairly open-ended question, such as ‘what is the best way to get my product to its final destination’? We then set to work on providing an answer, which means visiting the site and identifying the problems. From that point we can outline a solution – whether that’s a conveyor system or other machinery that will pick and place the product – and ultimately help them to understand if automation / robotics is right for them.

“It’s then a case of getting the ball rolling with designs and budgets. Once approved, we work alongside FANUC to provide the optimum machinery for that particular application.

WORK WITH FANUC With an extensive portfolio of robotics solutions, FANUC is a logical partner for ALS Mechatronic to work alongside. As Oliver Selby, Robotics Business Development Manager at FANUC UK explains, it is a working relationship that is built on a dedication to delivering the best results:

Andrew and the team at ALS Mechatronic work closely with their customers, which makes it much easier to identify which product is best for the end-user.

“Andrew and the team at ALS Mechatronic work closely with their customers, which makes it much easier to identify which product is best for the end-user. We’re always eager to ensure the most appropriate solution is provided, rather than simply specifying according to price. When you consider the significant impact that automation can have on a business, it is vital that you get it right, and this is something that both FANUC and ALS Mechatronic is committed to.”

minds at ease – especially if it is their first experience of automation. Ultimately, everyone benefits from this kind of thorough approach that delivers tangible results. It’s not just that one business that it positively impacts, but if we can help to change attitude to automation, then the manufacturing sector as a whole is stronger as a result.”

Andrew continues: “The other key aspect to working with FANUC is the name itself. They’re one of the leading automation companies, and that helps to put customers’

The latest chapter in the success story of ALS Mechatronic is the awarding of a prestigious Queen’s Award for Enterprise. Given in recognition of excellence in

QUEEN’S AWARD FOR ENTERPRISE

international trade, it is indicative of the role that the company has played in delivering automation solutions not just in the UK but worldwide. Andrew comments: “We’ve witnessed fivefold growth over the past three years, notably in the US market. We’re absolutely delighted to have been given the Queen’s Award because its representative of the direction that we, and indeed I hope UK manufacturing as a whole, is headed. The latest technology is there to help businesses grow, and our job is to help them take advantage of that.” Despite its international success, ALS Mechatronic remains a true British success story. With manufacturing and development set to remain in the UK, it highlights the appetite for high-quality British ‘solutioneering’ on the world stage. Andrew concludes: “Following a period of time that has created untold damage to many companies, it is great to see the signs of recovery in our sector. We firmly believe that automation is key to a strong manufacturing industry, and by working alongside FANUC we are confident in being able to deliver the best solutions for our customers.”

For more information, please visit: https://alsmechatronic.com/ and https://www.fanuc.eu/uk/en Issue 53 PECM

CONTROL & AUTOMATION

KJN Aluminium Profile Get the job done right with KJN Aluminium Profiles! We are one of the leading suppliers for aluminium profiles and components. Working with our own extruders allow us to provide high quality profiles with an anodised finish at competitive prices. Our range is ideal for the broadest spread of applications including tables, frames, machine guards, protective enclosures, test rigs, racking, conveyors and more. We have an extensive range which includes 20, 30, 40, 45, 50, 60, 80, 90, and 100mm, as well as accessories to complement your project. We offer two key ranges of aluminium profile and components: • BR range – compatible with Bosch Rexroth • IR range – compatible with ITEM Buy online: www.aluminium-profile.co.uk Get in touch with us today • 01455 823304 • sales@kjnltd.co.uk

PECM Issue 53

Spiroflow achieves carbon neutral status from emissions reduction action Leading bulk materials handling specialist, Spiroflow, has become one of the small percentage of UK manufacturing businesses to achieve carbon neutrality - a status achieved by calculating a carbon footprint and reducing it to zero through a combination of in-house efficiency measures and supporting external emission reduction projects. The company’s latest activity was a tree planting event held at Lancaster University’s Forrest Hills. Spiroflow was participating in Lancaster University’s ‘Forest of the Future’ initiative, an annual tree planting project held on universityowned land that provides the university and local SMEs with the opportunity to completely offset their carbon emissions for the year by planting a quantity of trees - the number depending on their carbon footprint. www.spiroflow.com

CryptoAuthentication™

Datakey’s new CryptoAuthentication™ tokens are ideal for embedded systems that: • Require ‘cyber robust’ removable memory devices for applications that include the transfer of passwords (or other data needed for user authentication purposes). • Need physical transfer of security keys, certificates, sensitive data or system configuration files. At the heart of all devices in the CryptoAuthentication™ line of memory tokens is a Microchip CryptoAuthentication™ high-security hardware IC. Its features include: • A unique and non-changeable 72-bit serial number (set by Microchip) • A 512bit one-time programmable (OTP) zone • A random number generator • A SHA-256 hash algorithm for data encryption. To understand how it could improve the security in your embedded system, we’re giving you a chance to win a CryptoAuthentication™ Development Kit! www.nexusindustrialmemory.com/land/ cryptoauthentication-devkit/

CONTROL & AUTOMATION

AN ADVANCED SETUP MITSUBISHI ELECTRIC

Formulating innovation in chemical handling Mitsubishi Electric has helped Labman Automation in the development of a compact, fully automated and highthroughput formulation system in under seven months. The innovative unit has been created for CPI’s National Formulation Centre and is built around two MELFA RV-series six-axis robots with CR800 controllers. These support processing, dispensing and handling activities for a wide range of materials. This advanced setup can enhance productivity by 5-10 times, improving CPI’s offering to companies bringing advanced paint, coating and battery formulations to the market. CPI is a leading independent technology and innovation centre that connects academia, businesses, government and investors with the aim to bring innovative ideas and research to the marketplace. Its Sedgefield-based National Formulation Centre provides the tools and expertise to support companies in the commercialisation of their next-generation formulations for active pharmaceutical ingredients, paints, coatings, detergents and batteries. As part of its continuous programme of investment in new equipment and technologies, CPI decided to develop a selfcontained, universal automatic formulation system with a glovebox enclosure that could address even the most ambitious processing needs. This would support the commercialisation of new formulations in a variety of markets and applications.

CREATING A FLEXIBLE PROCESSING SETUP To develop the new formulation system, CPI contacted its preferred specialist in lab automation and robotics, Labman. Dr. Lynn Donlon, Principal Scientist at CPI, explains: “Labman is a trusted partner for developing customised automation systems. We have collaborated with them on a number of projects across various applications and they have always delivered excellent solutions.” For this project, the two companies designed a compact, modular work cell that could fit three processing sections in an area of only 21 m2. In effect, the system can conduct processing, dispensing and

PECM Issue 53

The innovative formulation system is built around two MELFA RV series six-axis robots that support processing, dispensing and handling activities for a wide range of materials. measurements, as well as safe handling of volatile components, nanomaterials and other hazardous substances. In the first module, sample pots are loaded at high speed and moved to the dispensing unit after their lids have been removed. There, dispensers for solid, liquid and slurry applications quickly fill the pots with accuracies of ±1mg, ±10mg and ±25mg, respectively. The containers are then automatically moved to the processing section and loaded into a dual asymmetrical centrifuge that mixes their contents. At this stage, a pendant drop module can measure the surface tension of the formulations and perform spectral analyses using a multifunction probe station module. Samples can also be transferred to syringes to prepare coatings on a separate, CPI/Labmandesigned platform. The final module handles hazardous components by utilising powder feeders for nanoparticles and can also add a range of liquids and solvents to the formulations.

ROBOTISING THE UNIT Six-axis robots increase the throughput of the system by both handling samples quickly and by supporting continuous operations, processing out of hours and during weekends. They perform key

activities, such as removing or applying lids and caps, in the processing and glovebox units. It is important that these tasks are carried out reliably at high-speed and with high accuracy using robots that offer payloads and reach to fit the design of the setup. For this project, CPI requested a quick delivery and installation of the robots so that the system could be developed, installed and made operational as quickly as possible. To address these aspects, Labman contacted Mitsubishi Electric. Anthony Cumpson, Senior Engineer at Labman, comments: “We selected the MELFA RV series six-axis industrial robots as we knew that they could provide the performance required. Also, the responsiveness of Mitsubishi Electric’s team and the company’s ability to promptly deliver the equipment, were crucial for the quick turnaround of this project.” Furthermore, the six axes utilised make it easier to reach diagonally into key components, such as mixers. Dr. Lynn Donlon adds: “We are extremely happy with the RV robots. They are perfectly suited for performing the delicate operations within the unit, such as loading and unloading of pots and powder dispense units.”

two can continue their tasks without interruptions.

READY, SET, FORMULATE!

It is great to see our robots used in such an innovative application, supporting nextgeneration formulations.

The entire system was built in under seven months, half of the time that is typically required for similar projects. Since starting operations, the formulation unit has been widely utilised by CPI and its partners, raising considerable interest from specialists in different sectors. In effect, the solution can increase productivity by 5-10 times compared to conventional operations.

The project was further streamlined thanks to the compact CR800 robot controllers, which are easy to program and wire. These also enable CPI to implement any basic changes without requiring advanced programming skills. To optimise space utilisation and reduce the overall footprint of the system, particularly in the glovebox section, Mitsubishi Electric and Labman developed customised solutions that allowed the robots to pick the necessary equipment while moving within set limits. Placing the robotic arms on tracks, for example, was particularly beneficial to making the most of the room available. Such tracks use a Mitsubishi Electric HGSR52B motor and is linked to the CR800 controllers for accurate positioning.

Mitsubishi Electric has helped Labman Automation in the development of a compact, fully automated and highthroughput formulation system for CPI’s National Formulation Centre. The RV series also supports the creation of robot safety zones to enable cooperative applications. Human operators can access one of the three sections, stopping any automated activity there, while the other

In addition, the flexible and modular build has been designed to support further expansions. Dr. Lynn Donlon explains: “We are extremely happy with the solution that has been developed and technical support provided by both Labman and Mitsubishi Electric. Since building this formulation system we have expanded the scope of our collaboration by adding further modules to the unit. We are working on plans to develop the capabilities of the system even further in the near future.” Ian Patterson, Key Account Manager at Mitsubishi Electric, concludes: “It is great to see our robots used in such an innovative application, supporting next-generation formulations. We’ve had brilliant feedback and look forward to continuing our work with Labman and CPI.”

To operate successful in a compact workcell, the robots were placed on tracks and programmed accordingly to pick the necessary equipment while moving within set limits. Safety zones were also set to enable cooperative applications. For further information, please visit gb3a.mitsubishielectric.com Issue 53 PECM

CONTROL & AUTOMATION

AUTOMATION MYTHS ELEMENT LOGIC

Deflating five myths around warehouse automation and robotics

Gavin Harrison, UK Sales Manager, Element Logic

Here, we debunk the five of the biggest myths.

To maintain competitiveness in their respective markets, many companies are now looking at automating their warehouses for faster order fulfilment.

1. AUTOMATION IS COMPLEX AND DIFFICULT TO USE

However, despite being a rapidly maturing market, the business case for automation often gets shot down by boardroom sceptics. This barrier to adoption is usually based on misperceptions around warehouse automation and robotics.

PECM Issue 53

Some believe that the automation of logistics infrastructure involves impossibly complex technology. It is, in fact, much more intuitive and easy-to-use than you might think. Integration is always supported by training, and your employees can get acquainted with their new workflow within hours.

Automation comprises different levels – from basic picking machines to entirely data-driven warehouse systems – and should be tailored to support specific needs and overall business performance. With the right automated system, you’ll have a flexible and scalable solution that lets you make adjustments easily whenever your operational needs change.

2. IT’S TOO EXPENSIVE Like any other major investment, there are certain aspects to consider before signing on the dotted line.

However, you don’t have to go all out at once but can gradually transform into an automated warehouse. A key point to remember is that automation helps streamline processes by reducing costs in the long run. Whether you want to scale up during peak seasons throughout the year or maintain a competitive advantage in the market, robotic automation will make your operations more flexible. It will help you control your budget more efficiently by generating higher rates of accuracy and efficiency, thereby lowering your warehouse’s cost per error.

their value chains to meet new customer demands.

A key point to remember is that automation helps streamline processes by reducing costs in the long run.

5. ROBOTS ARE BAD FOR SUSTAINABILITY The right robots are extremely energy efficient. For example, the AutoStore robots used by Element Logic run on rechargeable batteries and generate much of their own energy – in fact, 10 of these robots use the same amount of energy as a single vacuum cleaner.

3. ROBOTS ARE ONLY FOR BIG INDUSTRY PLAYERS Automation enables businesses to process tasks quicker and expedite orders more efficiently, improving customer service across the board. This is a competitive necessity for both smaller and bigger companies. Also, customer demands do not differentiate, so size doesn’t matter as no automation solutions are the same – the solution is fitted to your business model. In fact, being small may count in your favour, as it allows you to adapt faster to change. With the help of a strong intralogistics provider, a scalable solution also allows smaller businesses to test advanced tech without the associated cost of commitment.

Because of automation’s flexibility, some businesses use robots to handle parts of their product line-up while continuing to handle larger items or hazardous products manually. If automation can make the day-to-day handling of your products more efficient, you should strongly consider a tailored solution.

4. IT’S NOT SUITABLE FOR OUR BUSINESS OR INDUSTRY Automation is designed to efficiently handle all kinds of products, from healthcare and consumer electronics to sports and apparel, including the 3PL segment. The only prerequisite is that you must have a warehouse and products that fit into bins. As a result, more and more industries are adopting automation to streamline

They regenerate the energy by slowing down and lowering bins and don’t waste energy through friction and resistance associated with traditional braking. Another sustainable aspect is that robots can work in the dark, unlike humans. This reduces the need for heating and lighting and maximises the use of space, thus cutting down on emissions. With these myths now debunked, isn’t it time to make an informed decision about the future of your warehouse?

For further information, please visit www.elementlogic.co.uk Issue 53 PECM

ELECTRICAL & ELECTRONICS

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Quality Passive Alternatives... on short lead times Many manufacturers currently have lead times of 18-26 weeks with product allocation policies. Through franchised distribution agreements, BEC can offer cost-effective alternatives with 8-10 weeks delivery. BEC offers quality alternatives to 95°/o of all passive components including TOKO/ Murata, Sumida, TDK, Coilcraft, Cooper, Molex, Bourns, Tyco,

PECM Issue 53

Vishay, Warth, Panasonic and many others. Capacitors, Transistors, Varistors, Diodes, Rectifiers, Inductors, Coils, Chokes, LAN Magnetics, Transforms and Terminal Blocks BEC Dsitribution Ltd T: 01844 275824 E: johnd@bec.co.uk www.bec.co.uk

ELECTRICAL & ELECTRONICS

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Issue 53 PECM

ELECTRICAL & ELECTRONICS

PanelPilotACE Display: Scientific Air Management Hospital Air Disinfection System Compromised air quality in hospitals can increase the severity of infections in patients and negatively impact staff. There is no overstating the importance of air quality in hospitals and medical centres as these facilities need to be sterile and clean to allow patients to recover and employees to work safely. According to significant research articles, over 35% of infections can be transmitted through the air. These types of infections can leave particles suspended in the air for extended periods of time. Scientific Air Management, a Florida-based company, created the S400 to reduce these transmissions in critical areas. The S400 is a mobile air disinfection unit designed to remove airborne contaminants, pathogens, and odours of all types. The S400 unit utilizes Lascar Electronics’ SGD 43-A programmable TFT panel meter. Scientific Air Management chose the SGD 43-A display primarily for its programmable interface and ease of use. The free configuration software supplied with the panel meter enabled Scientific Air Management to design and create a multipage user interface. The design utilized two PWM outputs to control fan speed and

illumination of the UV bulbs. The SGD 43-A also displays the HEPA filter runtime to ease maintenance and ensure efficient operation. Lascar recently designed and manufactured a PCB that eases the assembly process and greatly speeds up the production time of the completed assembly. Lascar Electronics was proud to help Scientific Air Management meet the high demand and supply hospitals with the S400 during the COVID19 crisis. Lascar Electronics Module House Whiteparish SP5 2SJ 01794 884567 sales@lascar.co.uk

www.lascarelectronics.com

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PECM Issue 53

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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 Issue 53 PECM

FACILITIES MANAGEMENT

STEGO CONNECT

Grant Handling

STEGO CONNECT is the latest contribution to the Industry 4.0 technology. The new Software-as-a-Service provides user-friendly access to network and control sensors and actuators based on the IO-Link protocol. Data storage and software functionality are centrally organised in the STEGO CONNECT cloud. Freely configurable dashboards, alerts and workflows give users full control of their digitalisation projects. STEGO is launching its new IIoT platform: STEGO CONNECT.

Grant Handling is the sole distribution partner of Heli forklifts and warehouse equipment for the UK. Our product range comprises of Three and Four-Wheel Electric (Lithium-ion & Lead acid) trucks ranging from 1.0 to 5.0t, LPG and Diesel Counterbalance forklifts from 1.5 to 10t as well as a full range of Warehouse Equipment. This comprehensive range allows us to specify the right truck for any engineering application. But it’s not just about the truck, our nationwide service and support are simply designed to make your materials handling more efficient and cost effective and ensure maximum uptime throughout the year.

The cloud service is a springboard into Industry 4.0 for small- and medium-sized enterprises (SMEs). The IIoT-based solution promises to reduce the initial hurdles in individual digitalisation projects, particularly for SMEs. STEGO uses IO-Link technology to achieve this. And STEGO CONNECT provides its integrated edge computing for fast, seamless data exchange with the cloud – a vital feature to ensure independence from constant internet connection. www.stego-connect.com

Our Services: • New & used forklifts • Contract hire, outright purchase, sale & re-hire • Preventative maintenance • Fast track parts • Short-Term Rental • Operator Training info@granthandling.com or 0845 0739407 www.granthandling.com

bio-cleanseal® Sealing System for Clean Rooms The new bio-cleanseal® product line from liquitec ensures the sealing of pipe systems in controlled clean room environments. The system is based on a smooth stainless steel sealing element with an elastomer mono seal for the penetration of pipes between controlled environments. The system is designed for use under various conditions and can also withstand problematic environmental conditions. For example, it is chemical-resistant and Atex-compliant. The installation of the sealing element for pipe penetrations and the orientation of the penetration is very flexible. The sealing element can be attached to ceilings, walls or floors and compensates a slope of the pipe segment of up to 5 °. The sealing system is designed to completely dampen vibrations and also acts as a noise reducer. It also has smooth surfaces, a hygienic design and is manufactured in accordance with regulations and GMP guidelines. www.liquitech.co.uk

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PECM Issue 53

FLUID HANDLING

Swivel joint solutions for all the engineering industries Through design and in-house manufacture Rotaflow Swivel Joints 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 cross-contamination 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 associated downtime. By fitting a quality designed swivel you are improving your production capacity. Our swivels are regularly utilised in the following engineering sectors with tailored or stock designs for specific needs : Brewery, Chemical, Dairy & Farming, Food & Drink, Nuclear,

Process & Plant, Drilling & Mining, Oil & Gas, Subsea, Water & Waste. And with over 35 years in our field, Rotaflow, are specialists in taking your bespoke requirements and being able to design a solution that can fit your budget, dimensions, materials, FAT/witness testing; hygienic and pressurised environments. To find out more please visit our website and/or give us a call. Tel: +44(0)1663 735003 sales@rotaflow.com

www.rotaflow.com

Bulk liquid dispensing skids for mobile and static applications Self-contained mobile demountable skids for IBC delivery vehicles Land based skids for loading and unloading of road tankers with fuels, oils and chemicals

Dispensing systems designed to suit customers specific requirements in terms of liquids and flow rates

IBC and barrel filling

Electric, hydraulic or donkey engine drive options

PD or centrifugal pumps for handling all types of petro-chemical liquids

Optional transfer methods, hose reels, loading arms custom hoses and couplings

Highly accurate LC flow meters with mechanical or electronic registers

Galvanized or stainless-steel framework for protection against the elements

Liquid handling solutions for the petro-chemical industry

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PECM Issue 53

Alpeco Limited | 66-69 Rabans Close | Aylesbury | Bucks HP19 8RS

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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

FOOD PROCESSING

HITTING THE SWEET SPOT BRITISH SUGAR

World Class Sugar Producer Creates Factory of the Future with Infor EAM ABOUT BRITISH SUGAR The sole processor of the UK’s beet sugar crop, British Sugar works in partnership with around 3000 growers to deliver a range of world-class products made to the highest standards for its customers. With factories that were first built more than 100 years ago, British Sugar processes around eight million tonnes of sugar beet and produces around 1.2 million tonnes of sugar each year to the British and Irish markets as well as exporting to Europe and around the world.

CREATING A FACTORY FOR THE FUTURE British Sugar has invested £250 million over the last five years into transforming its four sugar factories into digitally enabled manufacturing plants. Its Factories of the Future deliver over 50% of the UK’s demand for sugar. In fact, it manufactures more sugar than the 18 factories operated by the company in the 1970s. Sugar processing is complex, energyintensive and takes place across 42 weeks of the year from September, following once the sugar beet harvest from across East Anglia and the East Midlands, UK. Once harvested, crops travel to one of four sites in Bury St Edmunds, Cantley, Newark or Wissington, before being washed and processed. The sugar beet is then sliced into thin strips called cossettes and mixed with hot water to extract the sugar, while lime solution removes any impurities, creating a syrup. The syrup is then filtered, heated, concentrated and seeded with tiny sugar crystals, which then grow into the required size prior to being washed, dried and cooled.

ASSET PERFORMANCE MANAGEMENT The scale and specialist capabilities of equipment involved in this process means that effective maintenance is crucial to optimise availability throughout the Autumn/ Winter processing window. British Sugar has relied on Infor EAM for many years to support its maintenance operations, and recently embraced the

PECM Issue 53

benefits of multi-tenant cloud to enhance safety, reliability, productivity, efficiency and engineering productivity across the entire business.

benefits, and deliver against Industry 4.0 and IIOT principles, including sensorderived insights, connectivity across the company’s core systems is paramount.

The shift helps British Sugar move from a planned maintenance model to a predictive maintenance one, whereby monitoring takes place to identify where equipment is falling short of performing optimally, so that remedial action can be taken before it breaks. In turn this reduces downtime, maximises quality and minimises risk.

Because British Sugar’s sites are all in rural areas, network reliability represented a barrier to achieving a truly connected enterprise as the digital enablement was deployed. In addressing this challenge, the company is installing private mobile networks in order to ensure secure, high performance, robust connectivity.

CONNECTED MAINTENANCE In order to realise the potential of a predictive maintenance model, optimise

These networks are crucial as British Sugar deploys Infor Mobile, which allows Infor EAM to be used by those on the shop floor, irrespective of site or location.

Having access to the depth and breadth of maintenance-focused insights within Infor EAM at the source, or machine, means that British Sugar plant employees can observe, record, input and retrieve insights in the moment. Previously, they had to make notes manually, risking time lags and errors pending a return to a desktop in an office. “As a large site, the time taken to walk around a plant, make notes and return to an office is not insignificant,” comments Nick Smalley, Programme Manager, British Sugar. “Running Infor EAM on mobile devices not only provides us with a modern, realtime way of working, but can save hours potentially in a single day. “We can also use mobile applications to contact remote specialist support at the site of respective equipment, which helps to demonstrate the specifics of the issue and expedites fault resolution. “Through being able to access high quality information, such as a full equipment record, comprising work orders, plant history and supporting information, we can quickly complete details and take action immediately.” Not only does the software improve accuracy, efficiency and reduce risk, it also helps British Sugar to attract new talent. “It stands to reason that young talent is unlikely to be motivated by the prospect of working with older, manual systems, so while it’s hard to identify a bottom line benefit, the ability to compete for the best talent is hugely important for us strategically,” Nick explains.

SUSTAINABILITY Sustainability is at the forefront of British Sugar’s strategy. Sugar beet travels on average just 28 miles from farm to factory. As part of its Factory of the Future investment, supported by Infor EAM, its operations are incredibly efficient, as illustrated by less than 200g of waste for every tonne of sugar produced. This is because process outputs are used to make products including aggregate, topsoil and animal feed, thus making the best use of all available resources to minimise cost and operate efficiently and responsibly.

It stands to reason that young talent is unlikely to be motivated by the prospect of working with older, manual systems consolidate our predictive maintenance model, and use EAM as a springboard from which to capitalise on new technologies. There are a million different ways to use the insights Infor EAM provides us with. Specific initiatives we’ve earmarked as having a great deal of potential include

using AI to analyse sensor information and raise work orders automatically; supporting resource planning to refine skills utilisation and uphold stringent safety parameters; and integration with British Sugar’s ERP system to automatically order spare parts, streamline inventory and assume greater control of stock,” Nick concludes. “As our Factory of the Future evolves, we look forward to Infor EAM evolving with us. Twenty years ago, our maintenance was reactive, and for the last 20 it has been planned. Today, we’re excited to embrace an era where sensors and AI can help us to realise a truly proactive, predictive maintenance model which not only helps us to maximise uptime and quality, but also capitalise on IIOT and Industry 4.0. Infor EAM will help ensure that we make the right capital investments to avoid unnecessary spending.”

REALISING THE VISION Looking ahead, British Sugar is looking forward to leveraging its Factory of the Future to explore more ways in which to drive performance improvement and enhance sustainability activities. “Infor EAM is one of our core pillars moving forward, helping us to take our maintenance practices to the next level, For further information, please visit www.britishsugar.co.uk Issue 53 PECM

GEARS, MOTORS & DRIVES

The UK’s laboratory equipment experts The new LabBox® by HiTec Zang provides an entryway into the digital laboratory, using automation to increase quality and productivity while reducing costs. Especially designed for preparative and analytical workstations in laboratories or pilot plants, you can easily automate experiments and processes and gain time for more runs. The advantages at a glance: • Suitable for your application – Benchtop, Batch or Continuous operations. Simply define automated test sequences and let the LabBox® measure and control all processes accurately. • Flexibility - Connect to any sensors and devices, thanks to the many possible protocols and interfaces. • Central user interface - You

Stainless Steel Laboratory Furniture

can freely design your display and user interface. For repetitive processes, you can use many of our preconfigured routines and define your sequences, e.g. by drag and drop. • Document or export test data - Observe your measured value progressions live, monitor them remotely (Microsoft Windows® 10 or Android®) and/or transfer all values to other programmes. Discover more about LabBox at www.labtex.co.uk/

manufacturers/labboxhitec-zang-laboratoryautomation/ or call Labtex on 01484 600200.

Implementing customers’ ideas for the future Introducing QualCoil H Preformed Windings are very pleased to announce the launch of ‘QualCoil H’, the first resin rich diamond coils suitable for class H motors and generators. QualCoil H has successfully passed 1,000 hours on VE test. Preformed Windings are a high-quality supplier of high voltage diamond with customers including ABB, Siemens and GE who say: “Preformed Windings have supplied many sets of high voltage coils to GE Renewables over the years. The quality of product and service is exceptional, and they are a trusted partner in our supply chain. We enjoy collaborative and cutting-edge research and development with Preformed Windings, which positions both organisations as thought leaders in the hydro industry. Their products offer significant benefits such as very low partial discharge and a long service life” coilshop@preformedwindings.com www.preformedwindings.com

PECM Issue 53

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.

GEARS, MOTORS & DRIVES

A global leader in coil manufacturing for over 50 years Providing superior quality, high voltage coils with the lowest Partial Discharge levels and best Tan Delta Results in the industry. As an independent coil manufacturer we are a trusted partner to the largest OEM’s and rewind shops around the world.

E: coils@preformedwindings.com | T: +44 (0) 114 248 4391 www.preformedwindings.com

Motion Control Products Motion Control Products, the southern UK based solutions provider for the automation market, launches the IMA-S stainless-steel integrated servo actuator from Tolomatic, which is designed for the most demanding of food and beverage processing applications. The IMA-S integrated electric servo actuators are designed to hygienic standards for eliminating ingress points and preventing bacterial growth. The 316 stainless-steel construction provides excellent corrosion resistance and withstands high pressure, high temperature and caustic washdown processes. With its hygienic design and IP69k ingress protection rating, the IMA-S meets clean-in-place requirements, allowing machine designers to achieve open machine designs and eliminate shrouding required to house standard actuators. For more technical information, please visit our website or contact our sales team at enquiries@motioncontrolproducts.com or call us at +44 (0)1202 599922. www.motioncontrolproducts.com

Issue 53 PECM

GEARS, MOTORS & DRIVES

COOL AND CLEAN HIFLEXDRIVE BAUER GEAR MOTOR GMBH

Eliminating the heat dissipation challenges of hygienic motors It is critical that any equipment operating on a food and beverage production line is designed to hygienic criteria. This includes motors driving conveyors. However, the features required to achieve a hygienic motor design can present heat dissipation challenges that can affect the reliability of induction units and threaten uptime. Bauer Gear Motor offers a solution with its HiflexDRIVE range of aseptic coated and stainless-steel hygienic motors, which feature permanent magnet synchronous motor (PMSM) technology to ensure the problems of heat are solved effectively.

HYGIENIC MOTOR DESIGN FEATURES Motors in hygienic applications must offer several innate features to operate within a highly regulated environment. Washdowns are common across food and beverage production lines to safeguard product quality and legislative compliance. As a result, the exterior of the motor must be smooth to expediate this cleaning and remove areas where contaminates and bacteria could propagate. Naturally, a high ingress protection rating is also key. As a result, the traditional design features which facilitate cooling in standard induction motors must be omitted. Cooling fins present areas that are harder to clean during washdowns, providing bacteria with additional purchase. Fans further compromise the smooth exterior design, while also presenting a risk of spreading contaminates in operation. Choosing a construction material that is a good conductor of heat could be a solution. However, hygienic material options are limited. Stainless-steel, a material often selected for the exterior of hygienic motors, is poor at heat dissipation - compounding the issue. Upsizing the motor could improve the dissipation of heat, but in the case of stainless-steel, this would greatly increase weight with little benefit. For induction motors which naturally produce heat in operation, the requirements of hygienic design present a real reliability risk due to insufficient cooling.

HOUSING PROBLEMS A solution to this induction motor heat issue could be to place the motor inside a separate, hygienic containment housing. The installation would therefore by compliant with washdown regulations, while the motor itself would still benefit from traditional cooling methods. However, this is counterproductive over the long term. While the containment housing will receive regular external cleaning, it will collect grime internally during long-term operation which will require additional washing. Consequently, the containment housing will need disassembling to carry this out, causing more risks in terms of germ distribution and product contamination. Increased cleaning requirements will also reduce productivity. Space is at a premium at any food and beverage production facility. To ensure an efficient use of space and ease of access to the line, choosing compact equipment is important. However, a motor within a large containment housing takes up unnecessary space. This compromises both the design of the production line and overall space efficiency at the plant. Ideally, a hygienic motor needs a compact, easy to clean design that eliminates heat dissipation issues.

COOL AND CLEAN Bauer Gear Motor, a leading brand of Altra Industrial Motion Corp., has tackled the unique challenges of motor design for hygienic environments by eliminating the need for induction motor heat dissipation entirely. The HiflexDRIVE utilises PMSM technology to eliminate heat losses from the rotor by

100% and reduce total losses by 25%. This removes the necessity for the cooling fans and fins that keep a traditional induction motor cool. Therefore, the smooth exterior of the HiflexDRIVE has no heat dissipation penalty, while offering exceptional hygienic performance. As well as benefitting the aseptic coated design, this elimination of heat losses also ensures that the stainless-steel material option needn’t contend with heat dissipation problems. The inherent benefits of PMSM technology and a smooth, hygienic motor exterior means that the HiflexDRIVE needs no additional containment housing. The HiflexDRIVE doesn’t require any specialised cleaning beyond usual washdown routines, which helps to improve production uptime. An ingress protection rating up to IP69K ensures suitability for even the most rigorous washdowns. With no containment housing to disassemble for cleaning, contamination risks are further reduced. A compact design with high power density also ensures the HiflexDRIVE doesn’t take up excessive space on the production line, improving space efficiency and optimising equipment design. Efficiency is another feature of the HiflexDRIVE. Offering a total efficiency improvement of 10% or more, the HiflexDRIVE unlocks reduced energy costs and contributes to a lower carbon footprint for food and beverage production operations. Furthermore, it helps operators offset future increases in energy costs. Motors up to IE5 efficiency ratings are available. With the quantity of conveyors required for food and beverage manufacture, this efficiency improvement becomes a sizable cost saving.

NO LONGER OPPOSING AIMS Thanks to decades of experience delivering hygienic motors to meet the needs of food and beverage manufacturers around the world, Bauer Gear Motor has challenged the paradox of adequate heat dissipation and a smooth hygienic exterior within the same motor. The HiflexDRIVE delivers cool, efficient operation with an easy clean design that means food and beverage production managers needn’t worry about things getting too hot on the production line.

For further information, please visit www.bauergears.com

PECM Issue 53

GEARS, MOTORS & DRIVES

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 MoldedOil 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 53 PECM

GEARS, DRIVES & MOTORS

THE MOST EFFICIENT SOLUTION PORTESCAP

Tailoring the motor to the application through appropriate coil selection During the selection of a miniature DC motor, the design engineer will of course consider the dimensions needed to fit the desired space as well as the working point (the torque and speed at which the motor is required to operate). This information will be readily available in most motor product catalogues. Alongside this information there will also often be a choice of coils.

The number of options tends to be greater if a current source – a given maximum current across a range of supply voltages – is available instead of a voltage source to achieve the same working point. Now we might have a higher number of possible coils to meet the application requirement, and the design engineer can really begin to tailor the application.

Valentin Raschke, application engineer at Portescap, examines how choice of coil impacts on the motor specification, making it possible to adapt the motor to the available power source to create the most efficient solution for a given application.

If total efficiency is the prime consideration, that might lead us in one direction. In other applications, the coil with the lowest current consumption might provide the best choice, as it will result in a longer lifetime of the commutation system and increase the number of cycles with a single battery charge for battery-powered applications.

Regardless of its construction, a DC motor is always performing the same job – converting electrical energy into mechanical energy. For any given application, there might be a whole range of motors available that could potentially do the job, with the designer making the eventual selection based on parameters such as size, weight, efficiency, torque & speed requirements, lifespan and cost. Taking those factors into consideration might lead the designer to a single, best choice of motor. But what is not always appreciated is that there might be the opportunity to tweak motor design – and therefore boost efficiency – by selection of the most appropriate coil. So how does the coil impact on our design considerations? The torque produced by the motor will be determined by the current consumed and the torque constant. The torque constant, in turn, is defined by the radius of the coil, the magnetic flux density, the length of the motor and the number of turns of the coil. The first three of these parameters are fixed by the chosen motor and its diameter. Adjusting the number of turns of the coil, though, can impact the torque constant for a given size of motor. This is important because, for a given motor and neglecting friction, the no-load speed of the motor is defined by the available supply voltage and the torque constant of the coil. If we look at a motor manufacturer’s

catalogue for a suitable product to meet a specific operating point and power, we might find a choice of several coils that meet our needs, but with different supply voltages and different current requirements. The coil is therefore chosen to adapt the motor to the available power supply. Choice of coil also impacts on the motor efficiency in the application. Look for example at ironless DC motors: these are renowned, among other things, for their high efficiency. Where there are losses, aside from friction, it tends to be heat generated by the current running through the copper wile of the coil. These losses are proportional to the coil resistance multiplied by the square of the current. Motor efficiency is higher at lower torque due to the lower motor current, so here again choice of coil can have a big impact.

MAKING THE CHOICE If we were to consider an application requiring continuous operation at a fixed speed and torque – perhaps something like a medical infusion pump – then we might find a number of coils in the motor manufacturer’s catalogue that would seem to meet our needs at the required working point and power. If the available power supply for our application is a voltage source, supplying a fixed voltage, that will narrow down the choice of coils further, and the designer can select the one that is the best fit to optimise the application. With a voltage source, it is typical for a reduced number of options of coils, and indeed, there may only be one option for a given application. For more information, visit www.portescap.com

PECM Issue 53

CUSTOM MANUFACTURED COILS The availability of a number of standard coils can take us a long way towards tailoring the motor to the application, but even so there may be instances where the design engineer needs something even more optimised. In a critical application where cost pressures are less of a consideration than ultimate performance, and where the design engineer doesn’t have the freedom to adapt the power supply for a standard coil, then a custom designed coil could provide the best solution. We can see, then, that the choice of coil based on the required motor working point and the power supply has a big impact on the optimisation of the application. For a given task, there may be different standard coils which can achieve the same working point with different voltage and current requirements, with each having different applications for efficiency, current consumption and lifespan. Or it may be desirable to ask the motor supplier to manufacture a custom coil if the application warrants it. But the coil considerations also emphasise the advantages of engaging with a with knowledgeable motor manufacturer such as Portescap at the earliest stages of a design, before critical parameters are set in stone, and when there is the greatest opportunity to truly tailor the motor to the needs of the application.

ALWAYS AN EYE

ON YOUR SAFETY

HEALTH & SAFETY

REMBE GOES WEST REMBE INC.

New Premises in Fort Mill, South Carolina, USA

REMBE Inc., the American Branch of REMBE GmbH Safety + Control, headquartered in Brilon, Germany has just moved into its new premises in Fort Mill, South Carolina. The brand name REMBE is worldwide renowned for superior quality and performance in industrial safety solutions such as Turn-Key Dust and Gas Explosion Protection Systems and Pressure Relief Devices like rupture discs or breather valves. REMBE has successfully protected numerous sites across the U.S. and Canada ranging from wood manufacturing factories to critical processes in chemical, food and pharmaceutical industry. „When we started our operations in 2006 we faced tough times to convince American Prospects to rely on a non-American product“ reflects Stefan Penno, CEO of the parent company in Germany. „However, the REMBE Quality convinced not only multi-nationals but local producers as they quickly recognized how much money they save with a tailor-made solution that keeps their process running without

unwanted interruptions“ adds Stefan Penno. REMBEs approach is not just selling commodity items but develop bespoken solutions and engineer total safety concepts including full service from Start-up to regular maintenance. The company had a first breakthrough end of the 80s when introducing the technology of flameless venting. Most famous product those days was the Q-Rohr, a quench pipe with incorporated vent panel that retards not only explosion flames but reduces heat emission. Allowing operators to vent an explosion wherever they want allowed OEMs to position their equipment according to efficiency criteria rather than placing filters, hoppers or bins close to a wall to vent the explosion to outsides but compromising with unnecessary pipe length. “Guaranteeing both, a safe process and maximum business continuity is worth a few bucks more than just installing something and hoping for the best“ underlines Dr. Gerd Mayer, President of REMBE Inc. Today REMBE also offers a complete

range of rupture discs. Applications such as FPSOs or infrastructure critical Power Supply Stations like Transformers are protected by the German engineered products named STAR or SFD, so-called forward acting rupture discs that are produced from noble alloys and with the REMBE typical passion and precision. With office, Assembly, Warehouse and Manufacturing Space of more than 1000 sqm and a total 23,000 sqm Ground, REMBE Inc. has enough room for expansion over the next years. Currently employing 17 Engineers and Workers the company is constantly exploring new fields of Business in North America whilst serving its existing Customer Base. Located only 20 Minutes away from Douglas International Airport in Charlotte, NC and with mobile Senior Consultants all over the continent, REMBE Inc. is ready to support their clients with on-site Consultancy and Engineering within hours. Spare parts are stocked in Fort Mill and same-day delivery now is just another Pro to protect equipment with REMBE Technology.

For further information, please visit www.rembe.us

PECM Issue 53

T +49 2961 7405-0 hello@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

Is your Hearing Protection compliant with the new PPE Regulation? From 21st April 2019 all hearing protection products used in the workplace must comply with the new Personal Protective Equipment (PPE) Regulation (EU)2016/425.

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

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

Setting the standard in custommade and universal-fit hearing protection since 1994, ACS is one of the first UK companies to achieve compliance to the new regulation and is ready to serve the market beyond April 2019. ACS has become the trusted provider of hearing protection and communication solutions to a diverse range of industrial and aviation sectors across the world. All products are fully certified to EN 352-2 and EN352-6 and PPE regulation (EU)2016/425. ACS ambient noise filters offer a choice of 6 SNR’s between 15dB and 28dB which ensures the correct amount of sound reduction can be achieved in any environment:

communicating safely, hearing warning alarms without causing muffling and allowing ears to breathe. Other key benefits of using ACS products include reducing your HPE costs, environment waste and highlighting your corporate social responsibility. Find out what your cost saving could be on certified and compliant hearing protection by contacting ACS at: info@hearingprotection.co.uk 01295 266665 www.HearingProtection.co.uk

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

PECM Issue 53

“THESE THINGS ARE THE NUTS. #BUCKBOOTZ” BBZ8000 BK OR

BBZ8000 BL OR

BBZ8000 BK YL

To find out more about BBZ 8000 go to www.buckbootz.com To find your nearest stockist call 01382 82 82 00 or email info@buckbootz.com

@laurencek86

Which consumer-product relies most heavily on precision engineering? The first product to come to mind should be daysoft daily-disposable contact lenses Let me explain; daysoft relies on the skilful application of the most advanced manufacturing processes in the world to produce millions of identical contact lenses, time after time. Our unique process produces lenses at half the

cost whilst only using half the plastic compared to any other daily-disposable contact lens manufacturer. All this has been made possible by the development of a unique process

of manufacture based on incredibly advanced precision engineering where the lens is made entirely inside a concave mould of exceptionally high precision.

INPAC TECHNOLOGY The mould precision relies on the absolute accuracy of metal formers which have been cut to give outstanding accuracy and a ‘mirror’ finish using diamond tipped tools in air-bearing lathes to eliminate all polishing. The highest level of precision is not just to ensure the lenses provide great vision but so that they sit comfortably and safely on the human eye making …

every day a comfortable daysoft day Kind regards Ron Hamilton CBE, Engineer, Contact Lens Inventor and Daysoft Founder

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comfortable, affordable, daily-disposables

Shipped direct to your door by the daysoft Team who made them for half the price using half the plastic and a fraction of the water used by other manufacturers and for just:

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Data on file showing successful replacement of all major daily-disposable brand covering 700 million daysoft lenses sold into over 90 countries

DAYSOFT.COM

HYDRAULICS & PNEUMATICS

CONNECTING THE UK SINCE 1972 TOM PARKER

A big year ahead for Tom Parker Ltd

Tom Parker Ltd

2022 will soon be upon us and there are many things to look forward to – not least the Fluid Power & Systems show! It also promises to be an especially special year for all the team at Tom Parker Ltd. as they will not only be launching their 2022-2023 product catalogue, enhanced user-friendly ecommerce website but also celebrating the company’s 50th anniversary.

SPONSORS & EXHIBITORS AT FLUID POWER & SYSTEMS 2022 Tom Parker Ltd. have gone from strength to strength over the past 5 decades and are now the leading independent fluid power distributor in the UK. To help mark this auspicious milestone they will be a primary sponsor of the eagerly awaited Fluid Power & Systems show being held at the NEC, from the 5th to the 7th April in 2022, exhibiting on stand D4. The whole team are proud of the company’s history, their close relationships with suppliers, wide range of market-leading brands and all they have achieved to date. Many of their highly skilled workforce are long serving employees who have a wealth of expert knowledge and will be available to offer technical advice on their stand D4. The team are looking forward to being able to meet with many of their customers and national UK product distributors who are regular visitors to the show, interacting with many potential clients face-to-face and helping visitors to the show to source complete turnkey product solutions to the most challenging of fluid power projects.

CUSTOMERS ALWAYS COME FIRST UK Sales Manager and BFPDA Board Member, Seb Cole shared his thoughts on why it is important to be a part of the show: “Everyone at Tom Parker Ltd is committed to providing the highest levels of service to all our customers and this is one of the many reasons for our ongoing success. Our focus has always been on supplying high quality, competitively priced product ranges. We now have more than 36,000 product lines in our 2022-2023 product catalogue and distribute more than 80 brands that span

pneumatic, hydraulic, industrial and process markets. The FPS show provides us with a great opportunity to meet our customers in person, further strengthen relationships and exhibit many of our innovative products directly to the decision makers in the fluid power market. Visitors to our stand can raise any technical issues they may have, and we will provide impartial, expert advice and product solutions. We pride ourselves on being friendly, approachable and going the extra mile for our customers and we particularly relish a challenge so why not put us to the test?”

WORKING DEMONSTRATIONS Stand D4 will have an exciting array of products displayed. Tom Parker Ltd. will have working demonstrations of key product ranges to make it clear to see and feel how high-quality, durable, safe and reliable they are. They will also be showcasing products from their core brands who include Camozzi, CDC, CEJN, CPC, E.MC, John Guest, Festo, Fitok, Master Pneumatic, Parkair, and Sicomat. They will also be launching the innovative Sharkbite fittings and ring main system from RWC (a partner of market leader John Guest) and new brand fire sleeve stainless steel overbraid and Flex guard hose burst from Sleeve-it.

01772 255109

PECM Issue 53

sales@tom-parker.co.uk

Product range additions include the new BLQ6 & BLQ2 Series from CPC, new BH Series from Rotoflux, the new EA Range filter regulators and SR Series integrated manifold assemblies from E.MC, new advanced pressure switches from Camozzi and an even larger range of CDC fluidfit fittings. Also, on display will be products from more recent brand additions, who include Camloc, Hydrotechnik, JORC, Lubetec UK, Rötelmann, and UK Flowtechnik.

PUTTING CUSTOMERS FIRST With their head office in Preston and second branch in Basingstoke, Tom Parker Ltd.’s network of Area Sales Managers serve the entire UK to help provide full turnkey product solutions to each individual projects or applications needs. Both premises have stocked trade counters, highly skilled engineers and on-site workshops where the expert team can design, certify and test pneumatic hose assemblies up to 500 psi and hydraulic hose assemblies up to 30,000 psi. They also offer a 24-hour bespoke cylinder build service and are independently assessed by the BSI to BS EN ISO 9001:2015 and BFPA Q mark hose accredited. Everyone at Tom Parker Ltd. hopes 2022 will a great year for everyone in the industry and look forward to welcoming people to their well-stocked premises and onto stand D4. Their new 50th anniversary edition 2022-2023 product catalogue and enhanced website will launch in January 2022! Please email marketing@tom-parker. co.uk to request your copies, printed or digital, now.

tom-parker.co.uk

Your Partner for Fluid Power High Stock Levels & Same Day Dispatch Exclusive & Market Leading Brands 35,000+ High Quality Catalogue Products Technical Support Team Hose Assembly & Test Facility COMING SOON: New Tom Parker Catalogue!

Trade Counters at Preston & Basingstoke

Jan 2022

Connecting the UK& Since 1972 Our History

Next year 2022 will be a very special year for us as we will be celebrating our 50th anniversary. We are immensely proud to remain a family run business and of earning and maintaining our place as one of the leading fluid power distribution companies in the UK.

Our People

Many of our team have been with the company and working in this industry for a long period of time. Our Internal Technical Support Team and External Area Sales Managers have extensive experience and training, which enables them to provide advice when needed.

Our Exclusive & Market Leading Brands

Our focus has always been on supplying innovative, high quality, competitively priced product ranges. We now offer more than 80 brands and application solutions that span the whole fluid power market.

Our Northern & Southern Locations

With our HQ situated in the North West of England (Preston, Lancashire) and our second branch located in the South (Basingstoke, Hampshire), we can ensure a quick and reliable supply network to the entire UK.

Our Trade Counters, Hose Assembly & Testing Facilities

Both premises have stocked retail units, engineers and on-site workshops where we can design, certify and test pneumatic hose assemblies up to 500 psi, hydraulic hose assemblies up to 30,000 psi.

Carefully Selected Products

Produced biennially, our new catalogue will launch in January 2022. Core and market leading brands include Aignep, Cejn, CPC (Colder Products Company), CDC Pneumatics, Master Pneumatic, E.MC, John Guest, Festo, Fitok, Sicomat and Camozzi.

Our Stock Levels, Same Day Dispatch & Flexible Delivery

Our highly stocked warehouses enable us to provide a variety of delivery options (complete with tracking details) which include next day delivery before 9 am on stock items, Saturday morning delivery and no minimum order charge.

Our Customers’ Come First

We regularly review our systems, product offering and services to ensure we keep evolving and are where we plan to be in the future. Our entire team are committed to providing a first class service to all our valued customers.

Our Supporting Credentials

Proud to be members of the BFPDA; we are also independently assessed by the BSI and accredited to BS EN ISO 9001:2015. Close relationships with our suppliers also mean that we can solve the most challenging of problems. Call today to see how we can help.

Buy Online

35,000+ Products Next Day Delivery

Tom Parker Ltd 01772 255109 sales@tom-parker.co.uk tom-parker.co.uk

HYDRAULICS & PNEUMATICS

SPECIALIST

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

Unrivalled UK stock of Aeroquip Interlock fittings To offer replacement hoses for mobile plant including all common machines Jump sizes, various angles and long drop 90s ¾” to 2” Same day/next day delivery service available

For sales and service

01709 378 999

Tel

07710 345 260 info@carlton-hydraulics.co.uk

24hr Call Out Email

Our Address Carlton Hydraulics Limited, Eastwood Trading Estate, Rotherham, South Yorkshire S65 1SU

This includes smart connecting lines with information flow, automatic jumpers, easy positioning of items between the connecting lines, the straightforward changing of solenoid properties, automatically generate Bill of Materials, and much more. Get your free one month trial: www.paro-nl.com PARO offers the complete hydraulic software package for design and production of hydraulic manifolds with HydroMan 3D design and with HydroCAM automatically program your CNC machine.

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

8289

PECM magazine advert ONE.pdf 1 21/10/2021 12:16:00

Bespoke Mechanical and Electronic Equipment

Drallim Rotary Selector Valve

Water treatment Controls for UK Nuclear Power station

Electrical | Electronic Pneumatic | Hydraulic Mechatronics Remote monitoring stations for power cables in Hong Kong Prototyping Manufacture / Build to print

CMY

PCRID (Permanent Current Rail Indicating Device) London Underground. Remote Monitoring Systems

Waveguide and Radar dehydrators

Torpedo Purge and Leak Test Set

ACCREDITATIONS: BS EN ISO 9001:2015 | BS EN ISO 14001:2015 | BS EN ISO 45001:2018 | AS9100D: 2016

PECM Issue 53

Drallim Industries Limited

Millwood House, Drury Lane, Ponswood Industrial Estate, St. Leonards-on-Sea, East Sussex, TN38 9BA Tel: 01424 205140 | Sales@drallim.com

www.drallim.com

MACHINING & MACHINERY

Solving complex dry air supply and control problems Drallim are specialist equipment manufacturers and offer a wide range of bespoke products and services. One area of increasing activity has been designing and building custom dehydrators to suit a variety of telecom applications from copper cable pressure systems to television, satellite, and radar systems. There currently exists a large installed base of older equipment that is often found obsolete whereas we have successfully provided a full range of services to maintain, monitor replace equipment of any brand. Maintaining an extremely dry air supply is essential to these applications and in recent years we have developed sophisticated remote monitoring solutions for telephone exchanges and waveguide tower installations providing an early warning of potential issues on often highly critical services. This monitoring capability has also spilled over into offering monitoring for cable theft, cable integrity and unauthorised access.to manholes and cabinets.

We have a range of standard units to suit most applications but often our customers need something rather unique. We will work with clients and their customers to understand the needs of their application(s) and look at how best to provide a solution. We offer a professional service from site survey, customer design, manufacture and installation and we’re not always finished then. We offer full training on all products which makes servicing and maintaining

the unit an inhouse option for the client if preferred. If you operate any kind of installation requiring a supply of dry air, we have over 50 years’ experience with this type of equipment and supply the Koganei range of quality Japanese pneumatics alongside our own specialist Rotary Selector Valve that is widely used to control complex pneumatic switching applications.

www.drallim.com

New High Precision Roller Chain Developed for the UK’s After-Market The new EXL Chain from Donghua Limited offers superior quality and durability. Aimed at the UK’s after-market, EXL Chain is designed, manufactured and tested for unbeatable accuracy and performance, offering enhanced wear & fatigue resistance and greater precision than their standard Roller Chain. EXL Chain incorporates unique Easy Break Technology enabling it to be cut in the field using Donghua’s plate extractor tools. Supplied pre-loaded with 40-50% of the breaking load, it can be matched in pairs, is pre-lubricated as standard, and available in standard packs or cut to length. The new EXL Chain offers the best possible quality/price ratio and is the new Roller Chain solution of choice for UK stockists.

www.donghua.co.uk/exl-chain

Issue 53 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 +44(0)1527 520 580 sales@threadtools.com www.threadtools.com

For further information, please visit www.threadtools.com

PECM Issue 53

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 +44(0)1527 520 580 sales@threadtools.com www.threadtools.com

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

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

MACHINING & MACHINERY

IMPROVED PRODUCTIVITY RENISHAW

Machine tool probing increases productivity for Australian machine shop When Australia-based machine shop, Hammond Engineering, found that manually setting workpiece positions was time consuming and difficult to repeat, it looked to the potential of on-machine probing. Since using Renishaw’s OMP40-2 optical transmission probe, the company has experienced faster set-up times and higher levels of productivity.

BACKGROUND Hammond Engineering is a machine shop based in Bairnsdale. Its services include computer aided design, CNC milling and turning for production sizes ranging from

PECM Issue 53

prototyping to large industrial runs. “I started Hammond Engineering to combine my passion for metalwork with my love of IT,” explained Travis Hammond, Founder of Hammond Engineering. “After completing my First Class Machinist apprenticeship, I found myself a second hand CNC lathe and went from there. Now, we’re a team of three working to provide a more technology focused engineering service than the area has had in the past.” The company primarily works with customers in the food and aftermarket

automotive parts sectors, but also offers general manufacturing and repairs for local industrial businesses.

CHALLENGES “When doing general ‘job shop’ type work, our team must change machine set ups several times during the day,” continued Hammond. “Time taken to make changes, for example to align a vice or set up a workpiece, means time that the machine is not running. In such a small business, lost time is costly, so we started looking for a way to increase productivity, reduce turnaround times and reduce human error.”

SOLUTION “As we’re a very small business looking to reduce costs, we often buy machines second hand,” continued Hammond. “When we purchased our latest machining centre, it came with a Renishaw probe attached, so we began to use it for part set-up to see if we could improve accuracy and productivity.” Hammond Engineering’s machining centre was fitted with an OMP40-2 probe. This ultra-compact 3D touch-trigger probe with optical signal transmission is primarily used for workpiece set-up and inspection in machining centres. It offers users up to a 90 per cent reduction in set-up time, as well as a reduction in scrap and fixture costs.

RESULTS Since using the OMP40-2, Hammond Engineering has experienced faster set-

Now that I can see how user-friendly and accurate the OMP40-2 is, it would be hard to convince me to use anything else. up times. For example, before using the equipment, aligning a vice would typically take around five minutes to complete — with the OMP40-2 this task takes less than

a minute. The benefits will add up over time — if the team uses the probe to help align one vice a day, the company will save 17 hours a year. Using the probe also reduces the chances of human error impacting production because it can calculate angles without the need for human intervention. “I can’t believe it took me this long to realise how valuable probing is in my work environment,” said Hammond. “Now that I can see how user-friendly and accurate the OMP40-2 is, it would be hard to convince me to use anything else.” In the future, Hammond Engineering plans to use the OMP40-2 for in-process measurement on repeat parts to ensure correct positioning and alignment. The company also plans to use tool breakage detection to improve process reliability and confidence.

For more information visit, www.renishaw.com/hammond Issue 53 PECM

MACHINING & MACHINERY

GUNDRILLS UNISIG

UNISIG Drills Down to the Smallest Diameters By Eric Krueger and Ryan Funk, Engineering Team, UNISIG The modern gundrill is an engineering marvel, a well-designed piece of equipment that does one thing exceptionally well. A new gundrill will produce round, straight holes with enhanced cylindricity even at its deepest points. And it does all this while simultaneously providing a fine I.D. finish and excellent tool life. Like all tools, gundrills wear out, typically after drilling around 1,000″. While a talented operator can still drill a hole with a worn gundrill, it will more often result in a loss of hole tolerance and finish at best. As gundrills wear, they require more thrust and torque while producing more run-out and experiencing greater drift. A dull cutting edge will produce irregular chips, which in turn cause spikes in coolant pressure – sure signs that failure is imminent. Unlike some tools, gundrills are excellent candidates for resharpening. When performed correctly, the same gundrill can be resharpened to perform as well as a new drill as many as 8 to 10 times. The only significant difference between a resharpened gundrill and a freshly produced tool from the OEM is a slight back taper, an issue only for shops that require tolerances far beyond most manufacturers’ needs – all other shops can simply account for the everso-slightly reduced tool diameter. Otherwise, the only visible difference will be seen in the length of solid carbide on the gundrill’s tip. Even coated drills can be sharpened. Naturally, this will reveal the raw carbide on the face, but this does not impact performance. The coating will remain on the wear pads and continue to improve the gundrill’s size control and ability to leave behind a finished surface. Tool life will be impacted, but the only other option is having it fully resharpened and re-coated by the OEM, which will likely be less cost effective. Manufacturers have several options for resharpening their gundrills. For specialized gundrills, such as twin-flute tools and those intended for ultra-high-

leaves behind a gradual transition between elements of the tip’s geometry, while facet grinding creates distinct geometry. UNISIG typically recommends facet grinding, because the slight increase in tip strength produced by a versatility sweep grind is outweighed Increase your mold manufacturing by the repeatability and greater ease of using the power of gundrilling with theby facet grinds. inspection offered

leaders in deep hole drilling, UNISIG. Oﬀering The final piece of advanced gundrill grinding complete solutions for everything from systems involves a digital inspection camera feed applications with chipbreakers below capable of viewing and storing magnified a coating, resharpening is something mold components, UNISIG simple to complex images. Ideally, this will allow the user to that only a gundrill’s OEM can do. A local perform measurements and identify flaws machines help moldmakers improve sharpening service will likely have the without taking the tool out of the fixture. proper equipment, but this requires having and precision with eﬃciency, throughput In addition to allowing for highly precise redundant tooling and factoring in lead time grinding, this inspection is vital for process outstanding and transportation costs. part-processing versatility at an optimization. exceptional value. However, both of these methods result in Process optimization capability is the real a loss of process intelligence. The grinding added value conferred by performing process can offer valuable information gundrill resharpening in-house. Frequent manufacturers use to optimize their TAKEcan YOUR MOLDMAKING OPERATIONS inspection allows for the maximization of gundrilling applications. As a result, more tool life. Shops become familiar with the FURTHER WITH UNISIG TODAY. manufacturers that use gundrills are wear patterns created by a given application choosing to resharpen their tools in-house. and may find they are replacing gundrills too often. If a gundrill tip has even wear The main risk of performing resharpening across its entire cutting edge, it could easily operations in-house is poorly sharpened have many hundreds of inches of life left, Find out more at www.UNISIG.com gundrills. Without the correct tip geometry, something that will only become apparent gundrills do everything worse: size control, with repeated inspections. roundness, cylindricity, finish, chip control, straightness and depth all negatively In-house gundrill resharpening also ensures impact workpiece quality and result in that shops can obtain the best tip geometry significantly diminished tool life. This will for their given applications. Whether it is cause operators to reduce feedrates or uneven or unexpected wear, or the sudden change out tools more frequently to achieve appearance of chips in the cutting edge, the necessary tolerances and out of fear of once a shop identifies an irregularity, catastrophic tool failure. they can then adjust speeds and feeds to optimize the process. The inspection Modern gundrill grinding systems make equipment even makes working with tooling it easy to avoid these consequences. OEMs easier, since shops can send them a For the greatest advantage, one needs measurement set and picture of a tool when the full system. That means a grinder, the asking for advice on how to improve the appropriate gundrill fixture and equipment geometry. for calibrating and inspecting the drill tip. Further information on all machines and A basic, high-precision manual tool grinder the complete UNISIG machine program is is used as a platform for these systems, available at: www.unisig.com or follow the company on LinkedIn and Twitter (@UNISIG). though the length of some gundrills necessitates a reinforced table for sufficient accuracy. Choosing a fixture can be more You will also meet us at the EMO 2021 complicated, as gundrills can be ground show in Milan, Italy in Hall 2, E38 from 4.–9. in two different ways. Sweep grinding October.

For further information, please visit www.unisig.com

PECM Issue 53

UNISIG.COM

UNISIG TAKES YOUR GUNDRILLING PRODUCTION FURTHER

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

4 - 9 October • Hall 2 - E38

MACHINING & MACHINERY

VIBRATION ISOLATION MASON UK

The benefits of inertia bases and bespoke engineering What is the most effective anti-vibration technique for machinery? In high precision manufacturing, getting vibration isolation right is especially important as even a relatively small amount of vibration can disrupt the working of sensitive equipment. Here, Adam Fox, director of vibration isolation specialist Mason UK, explains the benefits of inertia bases. Inertia bases are primarily used to support mechanical equipment. They are generally steel frames which are filled with concrete and supported by spring mounts to provide a large stable mass on resilient elements with a low natural frequency to provide a high level of isolation. Different types of bases are used depending on the application. Larger bases might be used for pumps for example, while smaller bespoke bases might be installed for sensitive scientific equipment.

GETTING THE ENGINEERING RIGHT In many applications, vibration isolation is not simply a case of picking a particular product off the shelf. In many instances, the product needs to be specifically designed for the unique demands of that project. You also need expert engineers who can assist with installation and onsite support. This is especially so in precision manufacturing, or in applications involving the use of sensitive equipment such as bluechip production, scientific laboratories or medical facilities. In these situations, a good level of vibration isolation is not enough. You often need above 98% isolation efficiency from the disturbing to make sure sensitive equipment performs as it is designed to do. We’ve been involved in a number of such projects. For example, we had to isolate a vertical boring machine to prevent its operation from interfering with precision manufacturing facilities that were located nearby. We designed the bases, which were supported by Mason SLF spring isolators, and handled the installation. On this occasion, we also provided rubber dampers under the slab as part of a bespoke solution.

Inertia bases are especially effective at isolating disturbances caused by pumps and to isolate sensitive manufacturing equipment from external vibration sources. In another instance, we worked on a project where we needed to isolate sensitive ultrasonic equipment being used in pioneering cancer research. Vibration caused by nearby construction work was seriously impeding the use of this To find out more visit www.mason-uk.co.uk

PECM Issue 53

equipment, which operated at very high levels of precision. We had to design and install a steel base support by Mason MT Air Springs. Again, this was a bespoke design to fit the legs of the equipment precisely, as well as fitting within the existing raised access floor. Inertia bases are especially effective at isolating disturbances caused by pumps and to isolate sensitive manufacturing equipment from external vibration sources. However, it is important that they are partnered with the right acoustic isolation products and in many cases, as we have seen, you need a solution that is bespoke. A good acoustic consultant can advise you on this, so make sure you get them involved in your project at the earliest possible stage. Mason UK provides specialist isolation products for a wide range of applications, including mechanical and electrical systems and HVAC isolation.

MACHINING & MACHINERY

Introducing the 2060 Process Analysers MAXIMUM FLEXIBILITY FOR THE TOUGHEST CHALLENGES IN PROCESS ANALYSIS The 2060 Process Analysers are the most versatile analysers in the Metrohm Process Analytics product portfolio and on the market. They enable 24/7 online or atline monitoring of chemical industrial processes, water, wastewater or other liquids. • Monitor and safeguard your process 24/7 • Optimise process efficiency • Increase plant safety • Improve the profitability of your operations

www.metrohm.co.uk

MEASUREMENT & MONITORING

UNIQUE PAINT PROCESS SYSTEM PHOENIX TM

Painting a complete picture of your coating process! PhoenixTM has developed a unique new Paint Process monitoring system, allowing for the first time, not only the traditional temperature profiling of the product temperature through the oven but also optical profiling of the products journey. The newly developed TS64 thermal barrier permits in a single barrier the facility to both protect the PhoenixTM data logger and also the PhoenixTM Optic system (video camera with independent illumination) with a thermal performance of 3 hours at 200 °C. The thermal barrier, incorporating a specially designed heat sink, can be adapted to allow either temperature profiling or optical profiling runs to be performed. Although it is most likely that the different monitoring operations will be best performed sequentially due to different set-up / mounting requirement the system can be used to perform simultaneous product temperature monitoring and optical profiling in a single pass through the oven if required. For the first time ever, you can potentially not only determine oven temperature uniformity problems from the temperature profile graph but complement this data with video evidence from inside the oven as to the possible root cause of the temperature problem. With a single system you can not only highlight hot and cold spots from the temperature data, which may affect the quality of the paint cure, but quickly and efficiently identify the physical oven fault causing the problem. Use the Optic system to discover oven problems such as faulty fans, blocked ducting or even damage to the internal oven structure or insulation. The PhoenixTM Optic system allows thru-process paint defect detection using Optical Profiling. The high-resolution video camera can safely travel through the paint oven with an independent torch recording video footage of what the product sees. The system is just like your car ‘Dash Cam’ the only difference being that the journey is through a cure oven operating up to 200 °C. The Optic system can be mounted on a test body allowing monitoring of the exterior of a separate production body shell or potentially directly on a production body itself.

PhoenixTM TS64 Optic system. Thermal barrier is shown configured with a PTM1220 20 channel data logger and finishing thermocouples, including the new compact MiniMag magnetic thermocouple.

The PhoenixTM Optic system allows thru-process paint defect detection using Optical Profiling. During the journey through the oven the painted car body can experience many problems that are not temperature related that can affect the quality of the cured paint. Employing the Optic system, problems such as paint sags or curtains, paint or rinse entrapment or condensate contamination can be detected and sources identified, allowing informed corrective action strategies to be reached. Complementing the monitoring system is the PTM1520 Epsilon-x a unique intrinsically safe 20 channel data logger. The PTM1520 is certified against the ATEX European standards as Group II category for safe operation in gaseous and dust environments www.phoenixtm.com

PECM Issue 53

(ATEX Zone 2 and 22 respectively) allowing safe operation of automotive paint and powder coating applications. Choose from magnetic thermocouples for traditional steel or clamp thermocouples for Aluminium. New to the PhoenixTM thermocouple range is the MiniMag thermocouple designed to fit in the tightest of spaces extending your monitoring capabilities. The Thermal View Finishing software allows paint process conclusions and actions to be made quickly but with confidence. Including the new Phoenix Factor index of cure analysis tool, accurate cure confirmation against paint supplier specifications for all your different coatings is now possible. The final profile report gives you the comprehensive certified monitoring record to allow fully traceable validation of your paint operation. Whether temperature or optical monitoring PhoenixTM your Finishing Oven to find, fix and forget those paint cure problems. For more information: Contact Dr Steve Offley - Product Marketing Manager; PhoenixTM Ltd UK; tel: +44(0)1353223100; e-mail: Steve.Offley@phoenixtm.com;

Innovation in Thru-Process Automotive Paint Monitoring Safe ATEX Certified Temperature Profiling

Intrinsically Safe

•• 20 20 measurement measurement channels channels •• Paint Paint & & Powder Powder coating coating •• Includes Includes Phoenix Phoenix Factor Factor cure cure index index calculation calculation

New Optic Video Profiling System During Production •• Detect Detect paint paint runs, runs, drips drips and and defects defects •• Spot Spot transport transport problems problems •• Identify Identify oven oven damage damage

Phoenix Temperature Measurement T:01353223100

E:sales@phoenixtm.com

www.phoenixtm.com

MEASUREMENT & MONITORING

WaveCapture FBG Analyzer Series Precise, reliable, and compact spectral analyzer for Fiber Bragg Grating (FBG) sensing Advanced Energy’s WaveCapture Fiber Bragg Grating Analyzer (FBGA) is an integrated spectral engine that serves as the heart of precise, fast, and reliable FBG interrogator systems. The FBG Analyzer employs a proprietary optical design that features high-efficiency dispersive optics, an ultrasensitive detector array, and innovative numerical algorithms to provide high speed, high-resolution spectral measurements in challenging environments. A broadband light source illuminates an optical fiber which features an array of “N” fiber bragg grating sensors. The FBG array reflects “N” spectral bands of light back down the fiber, where an optical circulator directs the light to the FBG Analyzer. Inside the analyzer, the light is dispersed and the diffracted spectrum is measured by a detector array. Numerical algorithms are used to extract each “Bragg wavelengths” from the raw data, which are sent to the host and converted to temperature, strain, acceleration, or other measured parameter. Both raw and processed data are available to the host.

Above, WaveCaptue FBG Analyzer Series . Top right, WaveCapture FBG Interrogator

Advanced Energy’s WaveCapture™ Analyzer Series offers excellent performance in real-world applications. Its innovative highefficiency optical design provides excellent wavelength repeatability, resolution, long-term stability, ultra-low power consumption, sub-ms. response time, no moving parts, and lifetime

calibration. The WaveCapture FBG Analyzer is field-proven, with thousands of units serving as the heart of FBG sensing systems worldwide. Applications for this sophisticated measurement solution are in Medical, Energy, Aerospace, Oil and Gas markets as well as in Civil structures.

info@aei.com | www.advancedenergy.com | View product

CTL Continuously Tunable Laser family: Measurements at the quantum limit Lasers of TOPTICA’s CTL product family are made to be ideal tools for exciting microcavities or quantum dots, for pumping micro combs, as well as for component testing and spectroscopy. Their most important property is providing wide and continuous tunability without any mode-hops. They have high power, a narrow linewidth and low drift. Scans can be performed with highest resolution. This unique combination of features makes them outstanding in their field and enables researchers to perform measurements at the quantum limit. The latest addition to this family is called CTL 900. It is tunable between 880nm and 950nm. The long-awaited wavelength range is especially useful for resonantly exciting quantum dots, for spectroscopy or addressing e.g. rare earth ions or the Caesium D1 line. www.toptica.com

PECM Issue 53

Simplifying access to data The TR-7wb WLAN data logger with Bluetooth feature is ideal for temperature and humidity monitoring, and designed for those who require a broad range of measurement tasks. Recorded data can be automatically uploaded to T&D’s free of charge WebStorage Service, which is accessible anywhere and any time by computer or mobile devices. The App “T&D Thermo” enables the use of mobile devices for viewing data recorded by TR-7wb/nw (wireless and wired LAN) series data loggers, as well as direct communication and operation with the TR-71wb, TR-72wb and TR-75wb via Bluetooth. These applications allow uncomplicated and cost-effective protection of various goods and processes in public buildings, warehousing of sensitive products, and the supervision of laboratories and refrigerators. www.tandd.com www.webstorage-service.com www.facebook.com/ TandDCorporationEurope

On-line, Real-time Process Elemental Analysis for Liquid Stream Applications 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. 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. www.rigakuedxrf.com/nex-ol.php

POSITIVE MATERIAL IDENTIFICATION

THE THERMO SCIENTIFIC NITON XL2 PLUS FAST, ACCURATE, VERSATILE XRF

The Niton XL2 Plus is perfect for verification of metals and alloys in manufacturing as well as quality assurance testing for positive material identification. o Rapid real time results with high accuracy. Nondestructive analysis. o Compact, ergonomic and rugged design for real-world industrial environments. o Wider alloy coverage and lower limits of detection allow operators to scan a broader range of incoming or installed materials more quickly. o A dedicated UK based service centre and loan fleet will keep you running smoothly with full ISO 9001 accreditation.

CALL: 01256 397 860 Email: SALES@nitonuk.co.uk WEB: www.nitonuk.co.uk

RECENT FEEDBACK: “The whole service was carried out professionally, and arrangements for loan equipment to cover us over the service period was very professional brilliant. Thank you. David” Crane Chem Pharma Energy

SCAN THIS QR CODE NOW: FOR THE FULL XL2 SPECIFICATION.

MEASUREMENT & MONNITORING

MAXIMUM EFFICIENCY VEGA

VEGA level switches Ask any operator in a food processing plant - some of the smallest parts of the process, like the sensors doing the ‘simplest’ detection and switching, can cause problems, overspills, feed supply run-outs or long hold-ups – especially when they can’t keep up with the demands of modern production and recipe variants.

Figure 1 VEGAPOINT 24 Flush hygienic point level switch suitable for all media out of the box

NEW VEGAPOINT 24 LEVEL SWITCHES MASTER THE STICKY AND VISCOUS Many food products are developed with a distinctive texture in mind, whether they are “melt-in-your-mouth” like some chocolates, grainy like hummus, tough and chewy, super-sticky, satisfyingly crunchy or intensely super-soft and creamy. As a result of producing all these various textures and tastes, it in-turn increases the demands on the level measurement technology necessary for the consistent production of our favourite flavours and foods.

LIGHT UP YOUR LIFE VEGA has developed the new frontflush point level and interface switch VEGAPOINT 24, designed especially for use with challenging switching duties required on very sticky, viscous or abrasive products. Its focus is to provide the greatest possible robustness and reliability in the face of all these diverse ingredients. Even with the strongest build up, you can depend on its effectiveness at detecting the point level, it indicates the process status with a super-bright 360° LED ring, that is easily visible from afar.

Figure 2 VEGAPOINT 24 Features a superbright 360 LED Users can select colours and flashing status to suit their process

OUT OF THE BOX THINKING Thanks to this robustness, VEGAPOINT 24 is really quick to deploy, as a plug-&-play sensor it can be installed very easily in just a few simple steps. Flexible production systems with frequent and fast product changes really benefit from the fact that it can detect all media utilising the ‘out of the box’ setting, without any adjustment. Users can also take advantage of its extra functions and capabilities with a simple to use, smart phone Appbased Bluetooth wireless connectivity, to access and configure settings like liquid/liquid interface detection or ignoring/detecting foam (VEGA Tools App free on iOS or Android). This is also where you can also customise LED colours and/ or flashing combinations for process status notifications.

LASTS 4 TIMES LONGER “With this device, we are specifically targeting the food, beverage and also the pharmaceutical sectors. Here, mixing, conveying and filling are all about efficiency and safety, even with demanding liquids and bulk solids like molasses or homogenised creams,” explains Volker Allgaier, Product Manager at VEGA. The front-flush design of VEGAPOINT 24 especially ensures its universal application possibilities. “It means that it can even be installed and operate alongside pigging cleaning systems that can pass safely past its flat measuring tip,” Allgaier emphasises, “we made sure the measuring sensor face is more durable too, we tested this and it even copes with abrasive sandblasting.” This is because the ‘wetted’ measuring part in the process is mainly metal in its construction. “Compared to all-plastic measuring tips”, he concludes, “our

extensive tests have shown the service life can be extended by a factor of 4.”

FITS LIKE A GLOVE Another decisive factor is flexibility of use through its versatile process fittings and adaptors. This is a level switch designed to fit in your existing process systems like a glove. This means users can achieve optimum visibility of their processes with the new VEGAPOINT 24 - the relationship between durability, low life-cycle costs, partnered with ease of use and ‘easy to see’ indication, makes it truly groundbreaking for reliable point-level switching. If you would like to test or try a device for yourself, or just get more information e-mail demo.uk@vega.com

More information available at www.vega.com/vegapoint

PECM Issue 53

We bring colour into view! Compact capacitive level switches with 360° custom-colour status display

256 colours Individually selectable: Measurement in progress Sensor switching Process malfunction

15 cm

Compact design

Hygienic adapter system

Adjustment via smartphone

£282 VEGAPOINT 24 G½"

www.vega.com/vegapoint

NEW!

Absolut ely front-flu sh design

MEASUREMENT & MONITORING

THICKNESS MEASUREMENT MICRO-EPSILON

Factors to consider when measuring thickness in battery production Energy storage devices such as lithium-ion batteries play a crucial role in electromobility and energy transition. In order to optimise battery production, sensors are required to monitor the production line, including thickness measurement sensors. But what are the challenges in making reliable thickness measurements, asks Glenn Wedgbrow, Business Development Manager at MicroEpsilon UK. The growing demand for energy storage devices such as lithium-ion batteries and fuel cells are being met by Giga factories that are equipped with efficient, highly automated production technologies. In order to optimise battery production, sensors are required that monitor the production line to the highest accuracy and dynamics. These sensors include high precision distance sensors, infrared temperature measurement technology,

PECM Issue 53

as well as 2D/3D profile sensors for the many measurement tasks involved in battery production such as electrode manufacturing, assembly and forming processes. In battery production, one of the key quality control parameters is the thickness (and width) of film and strip materials, wet layers and electrode coatings. These require sensors that measure thickness reliably as the material is being processed (inline), helping to optimising production yields while minimising waste. All manufacturers will have a process specification that they will need to meet in order to satisfy their customers. But in reality, how can a manufacturer be sure that they are meeting these specifications at all times and what are the challenges they face? A number of different measurement systems can be used to measure the thickness of a material. Some of these are used offline, i.e. random samples of the material are removed from production and measured to verify that they meet the specification. A more effective approach is to install an in-process or fixed, inline

non-contact measurement system that continuously measures the thickness of the material as it is processed. If measurements from these systems move towards the outer limits of the specification, machine and process control parameters can be altered to bring the thickness back into acceptable limits.

REAL WORLD ERRORS A key factor to consider when selecting a suitable system from a supplier is to understand the combined real-world errors that can occur when using a non-contact thickness measurement system and how these errors can be eliminated or compensated for. While many suppliers state on their datasheet that the measurement system meets a certain resolution and linearity, in the real world, this performance is affected by a number of environmental influences. Errors associated with real world thickness measurement are not always so obvious, but can combine to create significantly large errors. It is therefore critical to select a system based on system accuracy, not just sensor accuracy.

Special attention must be paid to the alignment of the sensors, which are typically installed opposite one another.

ALIGNMENT & TARGET MOVEMENT

SYNCHRONISATION

Special attention must be paid to the alignment of the sensors, which are typically installed opposite one another. No misalignment, tilting or inclination of the sensors relative to the target object is permissible in order to ensure the sensor spots are measuring at the same point all the way through the measurement range. For example, for a misalignment of 1mm and an inclination of 2°, there will be a thickness measurement error of 35µm. In the case of a 10mm target thickness, this error increases to 41µm.

In order to avoid thickness calculation error due to movement of the target, both sensors must be perfectly synchronised so that they perform the measurement at the same time, at the exact opposite point of the target. If synchronisation does not occur, inaccurate measurement data is produced. For example, if measurements are taken at different time intervals, micro-vibrations of the target or of the sensor mechanics will result in a thickness measurement error. For example, for a time-delayed measurement of 1ms, a deviation of 125µm is produced (assuming 1mm vibration at 20Hz).

Combined linearity errors of up to 8µm, for example, can be seen with a vertical target movement of just 200µm of the target in the measurement field even if the target has the same thickness. The combined error of non-linearity from both sensors must therefore be compensated for. As a supplier of non-contact inline thickness measurement systems, Micro-Epsilon has developed its own methods of precise sensor alignment and patented algorithms for this process.

INDIVIDUAL SENSOR ACCURACY/ LINEARITY Each measurement sensor has its own measurement uncertainty, often referred to as ‘linearity’. This means that at any given point in the measuring range, the actual reading from a sensor can vary by

a percentage of its measuring range. The challenge is that no sensor is the same, so errors caused by non-linearity can add or subtract in the final result. Micro-Epsilon has overcome this challenge by performing a combined, patented calibration of both sensors to create a new significantly improved thickness measurement linearity.

THERMAL BEHAVIOUR OF SENSORS AND/OR MOUNTING FRAME It is extremely important to design a mechanically and thermally stable sensor mounting frame. The mounting mechanism should be isolated from process or machine vibration as best as possible. Mounting with an O-frame is more stable than using a C-frame. Thermal expansion of mounting materials is often overlooked as a source of large errors in precise thickness measurement. Therefore, selecting materials with as low a thermal expansion coefficient as possible is very important. For example, mounting sensors on a typical aluminium or stainless steel extruded profile, with a thermal expansion coefficient of ~16ppm/K, experimental testing has shown that just a 5°C change in ambient temperature can move the sensors by >80µm! In contrast, using a standard grade Invar mounting frame with a thermal expansion coefficient of typically 1.2ppm/K reduces this to 6µm. Specialist Invar grades can reduce this error by half again, but can result in a very expensive solution and does not solve the problem when the manufacturing tolerances can be single microns, as is often the case with battery production. Micro-Epsilon has solved this issue with integrated automatic thermal compensation to eliminate measurement errors due to thermal expansion. In addition, Micro-Epsilon inline thickness measurement systems provide automatic calibration features built into their system as standard, which provide gauge capability results at the touch of a button. This also means the operator does not have to spend time calibrating and checking the system.

For more information, please call the Micro-Epsilon sales department on +44 (0)151 355 6070 or email info@micro-epsilon.co.uk Issue 53 PECM

MEASUREMENT & MONITORING

MMS® INSPECTION SERIES FISCHER INSTRUMENTATION

Nace: Corrosion costs $2.5 trillion annually Every year, corrosion causes an economic damage of more than $ 2.5 trillion worldwide. Therefore, the prevention of corrosion, is an issue that plays an important role in many areas. The new MMS® Inspection series that is optimized for corrosion protection reliably supports the inspector in assessing corrosion-exposed components and in jobs that involve checking of corrosion protection. Corrosion is the deterioration of a metal as a result of chemical reactions between it and the surrounding environment. This leads to a functional impairment of the metallic component over time. Accordingly, rust formation on a railroad track is not harmful, since the function of the rail is not diminished. However, a pipe which has become leaky due to pitting corrosion is clearly defective, since the safe transport of liquids is no longer guaranteed. The same applies to the maritime sector, where material surfaces attacked by corrosion on ship walls can quickly become a safety risk. There are serious consequences caused by corrosion in engineering structures such as bridges. If the steel structure corrodes without any control, a bridge can quickly become a threat to those who move on it. Furthermore, there are economic advantages to implementing proper corrosion prevention methods. In order to protect metallic materials against environmental influences and thus corrosion, in most cases coating with suitable corrosion protection material is sufficient. The expense for this – passive – corrosion protection is relatively low in relation to the costs caused by corrosion such as loss of value, downtime, dismantling, etc. For companies and institutions saving on corrosion protection, it usually becomes expensive to repair the damages afterwards. This is especially so for structures that are very difficult to access after installation, such as offshore wind

turbines. Corrosion protection involves regular inspection and checks for proper functioning. This means that inspectors and service personnel need to use targeted measurements to inspect if the quality of the corrosion protection coatings still meet specified standards. With regard to coating thickness gauges used here, both magnetic induction method and eddy-current testing have established themselves as standards worldwide. 1) NACE International, impact.nace.org (2016) Rusting, the formation of iron oxides, is a wellknown example of electrochemical corrosion. Magnetic induction is the method of choice for measuring the thickness of non-magnetic layers on magnetic base materials, e.g. layers of paint, plastic, galvanized or hot-dip galvanized layers on steel and iron. The eddy current method is suitable for electrically non-conductive layers on non-ferrous metals, such as e.g. paint, lacquer or plastic on aluminium. Depending on the version, modern gauges such as the newly developed MMS® Inspection series from Helmut Fischer offer both measuring methods. Helmut Fischer has made every effort to ensure the convenience of the user. For this reason, international measurement standards such as SSPC PA2 (Level 1-5), IMO PSPC, ISO 19840, Australian AS 3894.3-2002 or Swedish IS 1841 60 are firmly integrated as

MMS® Inspection DPM (Dew Point Meter)

MMS® Inspection SPG (Surface Profile Gauge)

pre-configured batches or measurement specifications via the software. The dew point measuring device MMS® Inspection DPM, which belongs to the same series, measures the dew point before the corrosion protection paint is applied. This helps to ensure that the coating is applied under proper environmental conditions. If the conditions are not suitable, premature corrosion may occur or the paint may peel off as a result of poor adhesion. Inspection SPG. This gauge measures according to the “Peak to Valley” method, meeting ASTM D 4417-B and US Navy NSI 009-32 standards. The surface profile depth influences the amount of paint needed. If the peak to valley distance is too big, the applied paint layer may not be thick enough on the peaks. Additionally, the profile infuences the adhesion of the paint on the surface. The MMS series is offered as a set of three to enable better corrosion protection. They are the only device on the market that meet IP 65 protection requirements which include dust protection and water proof. The MMS Inspection offers one-handed operation and provides immediate feedback by means of light, vibration and sound. The auto rotate function allows the corrosion inspector to view measurement results at all important angles. Intuitive user interface for all systems. The software guides the user step by step through the individual measuring programs and shows him how to proceed with each measurement. Thus, the devices can be handled reliably even by untrained personnel.

MMS® Inspection DFT (Dry Film Thickness)

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

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The MMS series offers a third model, the MMS Inspection SPG. This gauge measures according to the “Peak to Valley” method, meeting ASTM D 4417-B and IssueUS 53 Navy NSI 009-32 standards. The surface profile depth influences the amount of paint needed. If the peak to valley distance is too big, the applied paint layer may

A big advantage of the MMS® Inspection series is the intuitive user interface for all systems. The software guides the user step by step through the individual measuring programs and shows him how to proceed with each measurement. Thus, the devices can be handled reliably even by untrained personnel.

Helmut Fischer has designed this series of gauges to make corrosion protection inspection considerably easier. This enables many companies around the world to avoid corrosion damage and the resulting loss of value.

Adverta4.indd 1

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

Quality Robust Process Instrumentation

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

01623 427701

MEASUREMENT & MONITORING

Ultrasonic Flow Meter Ideal for Ultra-Pure Water Applications Clean bore flow measurement devices such as Titan Enterprises’ Metraflow® ultrasonic flowmeter, offer the ideal solution for dispensing applications requiring a high degree of cleanliness. Typically used in production and cleaning processes within pharmaceutical, medical and semiconductor industries, ultra-pure water (UPW) is an important component where impurities can cause product contamination or impact process efficiency. Neil Hannay, Senior R&D Engineer with Titan Enterprises, says: “Ultra-pure water can become easily contaminated. Metraflow’s high performance PFA polymer tubing offers excellent chemical inertness and an ultra-high grade of purity.” The Metraflow® uses Titan’s patented ultrasonic ‘timeof-flight’ technology to accurately measure liquid

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Innovative Liquid Flow Measurement Solutions Titan Enterprises supplies international markets with their advanced flowmeter technology. Titan is a leading design and manufacturer of innovative end user and OEM highperformance liquid flow meters used within a wide range of environments and applications. travelling through the clear, single flow tube. Non-intrusive with no internal moving parts, Metraflow® gives an accuracy of +/-0.5% FSD and repeatability across flow ranges from 20 to 5000 ml/ min. Its wide flow range and PFA (FDA approved) tubing makes this ultrasonic flow meter also highly suited to aggressive chemical flow measurement.

www.flowmeters.co.uk www.metraflowmeter.com T: +44 (0)1935 812790 E: sales@flowmeters.co.uk

Ultrasonic Turbine Oval Gear • Compact, robust and reliable • Excellent accuracy and repeatability • Measure low to high flow ranges • High chemical resistance • OEM bespoke design capability For your specific liquid flow meter applications, contact: T: +44 (0)1935 812790 E: sales@flowmeters.co.uk W: www.flowmeters.co.uk

MEASUREMENT & MONITORING

DRIVING THE FUTURE CREAFORM

Creaform Introduces Three New Solutions to the R-Series Suite of Automated Dimensional Quality Control Solutions

Creaform, the worldwide leader in portable 3D measurement solutions and engineering services, has announced the latest additions to its R-Series lineup, including a new MetraSCAN-R BLACK | Elite HD with improved performance as well as a new edition of VXelements designed for long-term support (LTS). This state-of-theart set of solutions also includes a new version of VXscan-R module specially made to accommodate custom automated 3D scanning cell layouts, while keeping the ease of use of its digital twin programming software.

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Discover Creaform’s high speed and highly repeatable automated quality control solutions. • Speed and repeatability: MetraSCAN-R BLACK Ι Elite HD offers an optimized field of view for increased performance levels during challenging applications, such as 3D measurements on sheet metal parts. • Ideal for the automotive market: With its 69 laser lines and 3,000,000 measurements/s, this specialized 3D scanner is perfect for parts with many edges, trims, and boundaries.

• Personalized solution: The intuitive VXscan-R software module makes it possible to include the custom features of your 3D scanning CMM (enclosure, robot base, turntable, etc.) for fast and easy programming. • Long-term support: Exclusive to the R-series products, the new VXelements LTS version extends the period of software maintenance while also increasing software robustness and dependability by limiting the number of new feature releases.

For better decisionmaking to get better quality parts, they also need fast and precise data. • Operational simplicity: With its compatibility with major 3D metrology software, off-line programming, and seamless integration within any production workflow, the R-Series is accessible to all, regardless of the expertise or experience level. “In the quest to gain efficiency, manufacturers require QC solutions that can adapt to their workflow and environment, while being easy to use. For better decision-making to get better quality parts, they also need fast and precise data,” explains Jérôme-Alexandre Lavoie, Product Manager at Creaform. “With these latest innovations, there has never been a better time to easily move to automation.”

For further information, please visit www.creaform3d.com Issue 53 PECM

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GIVAUDAN

OMNIFLEX

How the fragrance and flavours giant enhanced its safety critical processes Once the artistic work of creating a fragrance is complete and the formula has been signed off, the process of extracting the raw materials and blending begins. Safety and compliance are a priority during the manufacturing process and so, when flavours and fragrances giant Givaudan wanted to strengthen its safety critical alarm systems at its Kent facility, it partnered with Omniflex to upgrade its fleet of annunciators. Located in Ashford, Kent, Givaudan’s UK plant is where the company creates fragrances and oral care flavours. Here, the company brings together the various ingredients to create the finished formula that gives consumers their favourite scent or oral care flavour. In this process, the facility uses a variety of plant machinery and equipment to carefully monitor variables such as atmospheric quality, oxygen levels, temperature, pressure, well-levels, ventilation, pump operation and extraction processes. The ingredients being processed are carefully chosen from a palette of many thousands and include powders and liquids. A typical batch could contain anywhere from just two or three up to 120 ingredients at a time, at various weights and volumes. These raw materials arrive on site in packages weighing anywhere between 0.5 kg to 20 tonnes, and are tested to ensure they meet the high-quality standards before being used. The facility uses onsite labs to carry out quality assurance (QA) on samples. Nitrogen and hydrogen-based gas chromatography equipment is used to ensure the materials have not been exposed to air. To ensure worker safety and to maintain compliance with the UK’s Control of Major Accident Hazards (CoMAH) regulations, the QA areas are fitted with sensors to detect safe oxygen levels. To meet these safety regulations, and to ensure that the materials are kept within containment guidelines, the plant uses safety instrumented systems, including alarm annunciator panels, that alert plant staff if the

UK. The two key points in the brief were to add networking and a way of prioritising critical and non-critical alarms, so that in an emergency the operator can start at the top and work down a list of alarms in order of severity. This makes for a comfortable environment for the operator and drastically reduces response times.

process measurements deviate from safe parameters. “As part of our continued drive to meet the highest levels of safety on site, we review equipment regularly, and one of the areas we decided to upgrade was a range of our legacy alarm annunciators,” explains Stuart Brazil, electrical project manager at Givaudan. “Our goal was to add networking functionality to our alarm system and reduce the amount of physical wiring on the network that spans around eight-hectares. Not only would this make the process of adding new alarms more efficient, it would ensure the system met the latest IEC 61508 safety integrity level (SIL) rules.” The site was already using Programmable Logic Controller (PLC) technology — in fact, it was originally one of the first sites of its kind to move away from traditional relays, towards a digital system that made it easier to add switch points and alarms. “To consolidate our operators’ alarm sheets and deliver even faster response times, we partnered with Omniflex on the upgrade project,” says Brazil. Based in Greater Manchester, in the UK, with operations in Australia and South Africa, Omniflex specialises in industrial networking, remote I/O systems, utilities monitoring, process automation systems, signal conditioning and alarm and event management. “We worked with Givaudan’s Ashford facility to upgrade the site’s legacy Highland alarms, while keeping engineering costs down,” says Gary Bradshaw, director at Omniflex

“We also enhanced the layout of the alarms to ensure that they are displayed to the right person, in the right area, at the right time,” continued Bradshaw. The project began in October 2019 and was completed by November 2020. Omniflex delivered several OMNI 16C alarm annunciators, as well as the necessary HMIs and signal conditioning units required to work alongside the existing system. “These 16-point modules allow users to create up to 256 alarm points using a panel mounted LED-backlit display,” says Bradshaw. “Crucially, the units also provide connectivity to interface with a PLC, DCS or SCADA system.” “We’re really happy with the upgrades to our safety-critical alarm system,” says Brazil. “It’s faster, more responsive and less complex, allowing easy alarm prioritisation and the ability to control it centrally. “The team at Omniflex has also been brilliant in helping us through the process. Despite social distancing constraints, their engineer successfully carried out the factory acceptance test on-site. This allowed us to do a dry-run and test all the system before it was installed and commissioned. “Additionally, the team also provided the ongoing training session via video calls due to the pandemic. This really showed how flexible they are at a time when most companies were closed during lockdown.” While this project was designed to consolidate alarms at Givaudan’s Ashford site, it highlights the drive to maintain the highest levels of safety in industrial plants across the sector, especially safety-critical alarm systems.

For further information, please visit www.omniflex.com

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PROCESS TECHNOLOGIES

SEPURA™ brings environment to the fore Bowman Stor is renowned globally for its groundbreaking range of filtration solutions. But each time a customer places an order for their instantly recognisable blue SEPURA™-branded filtration units, or purchases one of their third party service kits they are investing in something that is worth far more than the sum of those parts.

SILEXA is 20% more adsorbent, cleaner, lightweight, and requires no pre-soaking making installation even easier and allowing rapid servicing. What’s more, SILEXA enables users to remove exceptional levels of oil content, achieving outlet quality discharges as low as 5ppm.”

SEPURA products contain SILEXA™ - a revolutionary patented media developed through years of research in Bowman Stor’s own laboratories.

The SILEXA material has major environmental benefits; it is produced from a readily available recycled waste product, unlike similar products which are made from virgin materials with huge carbon foot prints. In addition, SILEXA media has the added benefit of being super lightweight and further reduces shipping/ delivery impacts compared with traditional, heavier materials.

“Only SEPURA products contain SILEXA media,” says Managing Director Richard Potts. “Our comprehensive range of filtration units and service kits gives customers the peace of mind that they are not only complying with the current regulations, but they have the best available equipment for treating condensate and keeping environmental impacts as low as possible.” To place an order or for further information on SEPURA’s unique range of filtration products contact: Multi Factor Europe Ltd., t: 01978 855995 e: sales@mfeuk.co.uk or visit our website: sepura-technologies.com

sepura-technologies.com

Issue 53 PECM

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LASER DIODES FRANKFURT LASER COMPANY

High-quality, cost-effective laser modules beam has a sharp rectangular shape with homogenous power distribution along the line. The housing is electrically isolated and keeps the protection class IP65 (IP67 optional) conditions. TTL modulation up to 1MHz and analogue modulation up to 100kHz are optionally available. The power stability is <1% over 24 hours.

COMPACT LASER DIODE LINE MODULES HSML-E WITH ULTRA-THIN LINES

The new HSML-E is a series of laser diode line modules which are very compact and deliver an ultra-thin line. Laser head and laser driver are separated which allows a very compact size of the laser head of just Ø12.6mm x 44mm. The laser driver is 200mm away from the laser head with dimensions of Ø12.6mm x 40mm and can be operated at 24V. The beam line can be focussed to e.g. a thickness of just 10µm at 40mm distance. Standard fan angles are 10° - 90°. The wavelength range is from 405nm to 1060nm with output powers up to 50mW. The power stability is typically <±5% over 8 hours at an operating temperature range from 10°C to 50°C. As an option these modules are offered with potentiometer for power adjustment, external TTL modulation up to 1MHz and analogue modulation up to 100kHz. The housing is electrically isolated and satisfies the protection class IP67 which makes these modules ideal for the use in industrial applications with harsh environmental conditions. The major applications are machine vision, scanning, profiling and laser triangulation.

Applications include, but are not limited to, roof tile alignment, railway conditions control, steel parts production, subsea robotics, traffic control, long distance pointer in defense applications. LASER DIODE MODULES WITH SINGLE MODE FIBER OUTPUT

The new series ML1xxFC are laser diode modules with a single mode fiber output. The wavelength range is from 405nm to 2500nm. The power out of the SM fiber can be up to 100mW. The operating temperature range is from -10°C to +50°C. With dimensions of 12.6mm to 15mm in diameter and 40mm in length (without connector) they are very compact. As an option these modules are offered with potentiometer for power adjustment, external TTL modulation up to 1MHz and analogue modulation up to 100kHz.

HIGH POWER LINE LASER DIODE MODULES

The ML2540-Series laser modules deliver high output power up to 2W and are ideal for the use in industrial applications with harsh environmental conditions. The offered wavelengths range is from 405nm to 1060nm. Apart from round and line beam, other beam shapes like grids, circles or line and dot arrays are available. The line

LASER LINE MODULES WITH EASY FOCUS ADJUSTMENT

It is eminently necessary in machine vision, especially in 3D vision systems, to have a laser illumination source that delivers uniform and stable line beam. FLC offers line laser diode modules from the HAML-F series for those applications. They are very compact, reliable and the focus can easily be adjusted by rotating the upper www.frlaserco.com | sales@frlaserco.com

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part by hand. Additionally it fulfills the IP67 requirements, which make it the right product for the use in harsh environmental conditions at production facilities. The wavelength range is from 405nm to 1060nm and the output power can be up to 200mW. N:\Documents\T-Online Documents\ SHOWS\VISION\VISION 2018\ Pressebooklet\HAML-Modul-17-2w 1.jpg NEW HIGH POWER LASER ILLUMINATORS

Frankfurt Laser Company now offers a new series of highpower laser illuminators based on high quality VCSEL chips and excellent optic design. With an optical output power of up to 25W it is possible to achieve an illumination range of more than 5000m. The illuminators of the FLTT series have a large dynamic beam angle zooming range and match the field view angle of most standard cameras. The customer can choose between RS232, RS422; RS485 and TTL interface and they are compatible with major lens and cameras, integrated with the protocols of Pelco D. It is easy for users to implement the illuminators in their systems. Simultaneously, position can be pre-set via serial port, and users can call the instruction to operate conveniently in use. Due to uniform power intensity of the beam, users can obtain high quality videos and easily recognize gestures. Applications • Security Surveillance • Automobile Night Vision (ADAS) • Machine Vision • Gesture Recognition • Display Applications • Medical Applications • Military Applications • Port Terminal Monitoring • Border and Coastal Defense Monitoring • Forest Fire Monitoring • Commanding Height Monitoring • Highway Monitoring

Line Laser Modules for Machine Vision and

Laser Triangulation HAML-F Uniform Line Laser Diode Module Wavelength: 405nm – 1060nm Output power: 100mW – 200mW Line uniformity: up to +/- 10% Industrial protection: IP67 Easy manual focus adjustment

ML2540 High Power Line Laser Modules Wavelength: 405nm – 1060nm Output power: 0.5W – 2.0W Temperature stabilized Industrial protection: IP67 Market smallest footprint: 130mm x 40mm x 25mm

HSML-E Ultra-thin Uniform Line Laser Diode Module Wavelength: 405nm – 1060nm Output power: up to 50mW Line width: 10 μm Line uniformity: up to +/- 10% Industrial protection: IP67 Separate electronic driver to use in limited space devices

See technical details on

frlaserco.com

See us at Hall 10 Booth 10E90 Oct 05 – 07, 2021 Stuttgart, Germany

PUMPS

NOT ALL PUMPS ARE EQUAL SEEPEX

How Pump Selection Can Affect Total Cost of Ownership While considerations should be made on the total cost of ownership (TCO) when specifying a pump, the most important criteria should be that it is fit for purpose, to ensure optimal productivity. Selecting the wrong pump can prevent the pump from performing to its full potential and lead to unnecessary downtime, wear, maintenance and energy consumption, product damage or reduced uptime of the process. When selecting a pump, factors such as the viscosity of the product being conveyed, flow rate or the operating temperature should also be considered. Not all pump technologies are equal. Some are designed to handle low viscosity, others for highly viscous and high solids content products. Shear-sensitive media, for example, requires a pump with low shear action. In wastewater treatment processes, polymers are used to thicken sludge by attracting all suspended fine particles to produce larger groups of solid materials through a process called flocculation. These flocculants are often extremely viscous and shear-sensitive once hydrated. Incorrect pump selection can affect the metering accuracy, damage the polymer structure and potentially the efficiency of the thickening process.

WRONG SELECTION AFFECTS PROCESS PERFORMANCE A Water Company was using two multistage vertical centrifugal pumps to handle polyelectrolyte for use as a flocculant agent and transfer it from a ‘make-up’ tank where the powdered polymer was mixed with water to their daily service tank. However, build-up around the volute casing and impellers in the pumps severely affected the flow which required the pumps to be dismantled and cleaned – a process which took 2-3 hours per pump, and the pumps being replaced every 6 months. The use of centrifugal pumps to transfer viscous media reduces their performance due to factors such as the effect of viscosity on the impeller, reduction in flow and the increase in horsepower required. But also their pumping action generates high shear,

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SEEPEX transfer pumps offer reliable performance, and ease of maintenance due to their simple pump design

Build-up in the pumps severely affected the flow, requiring 2-3 hours to clean each pump and equipment being replaced every 6 months making them unsuitable to handle shearsensitive products. To address these challenges, SEEPEX was engaged to offer a cost-effective pumping solution.

Not all pump technologies are equal. Some are designed to handle low viscosity, others for highly viscous and high solids content products.

THE RIGHT PUMP FOR THE DUTY To meet the application’s requirements, SEEPEX selected progressive cavity pumps from their BW range for transferring the viscous polymer. Simple and compact for quick and straight forward maintenance. Progressive cavity pumps have a low shear pumping action. Their flow rate is directly related to pump speed and have

minimal pulsation, producing the lowest mechanical stress and minimising product shear damage. Additionally, in a PC pump the stator is cleaned by the action of the rotor, eliminating any chance of product build-up and subsequent blockages which would otherwise affect pump performance.

NO ONWARD COST SINCE INSTALLATION SEEPEX’s intervention has resulted in costsavings for the customer as the new PC pumps have not suffered from blockages, used any spare parts or required maintenance since they were installed in 2018.

For further information, please visit www.seepex.com Issue 53 PECM

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SEEPEX Big Pumps with Maintain-in-Place Technology: Smart Maintenance. Fast and Simple. SEEPEX, global leader in design, manufacture and applications of progressive cavity (PC) pumps, macerators and digital technology, continues to extend its world class portfolio of maintain-in-place pump technologies. The new patented BNM range of pumps with capacities up to 300 m3/hr and discharge pressures up to 48 bar can handle flowable to highly viscous products with a high dry solids content. The design features a suction casing that enables quick and easy access for rotor and stator removal without having to dismantle the rotor side joint. As a result, maintenance time can be reduced by up to 80% with a significant reduction in maintenance costs. The suction casing and pressure branch remain in place, eliminating the need for pipework dismantling. The pump drive can then be quickly removed complete with mechanical seal, drive side universal joint and coupling rod.

UNIQUE PATENTED SOLUTION SEEPEX new ease of maintenance solution for big pumps complements our Smart Conveying Technology (SCT), launched in 2008 and still setting standards in the maintenance of

Above, SEEPEX Rotor Joint Access technology provides quick and easy access to the rotor-side joint. Below, With SEEPEX Drive Joint Access, the complete drive and coupling rod assembly can be easily removed from the back of the suction casing to service the mechanical seal or joints. smaller standard progressive cavity pumps, and Drive Joint Access (DJA) technology for open hopper pumps. All of these patented solutions increase uptime and plant availability.

www.seepex.com

Wanner announces new Hydra-Cell heavy duty, high pressure, multidiaphragm seal-less pump Wanner has launched the HydraCell® T200 Series Medium Pressure, multi-diaphragm pump range, which in terms of flow rate and pressure are the highest performing pumps in the Hydra-Cell range and the biggest pumps ever produced by the Company. They feature a seal-less design that eliminates leaks, hazards and the expense associated with seals and packing; lowering the cost of ownership and giving a longer service life than competitive pumping technologies. There are two models, currently, in the T200 Series, rated at 207 bar (3000 psi) and 241 bar (3500 psi) with maximum flows of 387 l/min (102.2 US gpm) and 349 l/min (92.4 US gpm) respectively. The new pumps are ideal for oil and gas production, mining operations, boiler feed and high-pressure cleaning, along with chemical and petrochemical process and transfer applications.

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No Problem Metering Non-lubricating Liquids with Hydra-Cell Hydra-Cell API 675 Metering Pumps have solved a problem for one of the world’s largest suppliers of polyurethane automotive foams

Hydra-Cell pumps have no dynamic seals, cups or packing to leak, wear or replace, eliminating seal maintenance costs while hazardous materials and VOCs (volatile organic compounds) are fully contained. The seal-less design, combined with robust check valves, also enable the pump to handle abrasive particles up to 800 microns in size and with less wear than gear, screw or plunger pumps. The Hydra-Cell T200 can operate with a closed or blocked suction line and can run dry indefinitely without damage, eliminating downtime and repair costs.

The external gear pump used to pump nonlubricating, water-based catalyst were prone to wear, exhibited low efficiency and caused unacceptable high shear within the product. Hydra-Cell API 675 diaphragm Metering Pumps, with their inherently low shear pumping action, provided the ideal solution to the problems. Since the application could not risk contamination by the hydraulic fluid, extensive testing with Mesamoll® oil, was conducted before a Hydra-Cell Metering Solutions model P200 was installed for evaluation. This first P200 pump performed exceptionally well, eliminating the low-efficiency, high-shear, and nonlubricating pumping problems. Hydra-Cell P200 pumps are steadily replacing the gear pumps on the customer’s systems installed in automotive plants around the world.

www.hydra-cell.eu

www.hydra-cell.co.uk

SOFTWARE & SYSTEMS

FUNCTIONAL SAFETY DELKIA

The steps for assessing cyber-risk in nuclear plants Malware in standard Information Technology (IT) systems is, at most, disruptive but not generally life threatening. However, what happens when this malware is transmitted to thousands of sensors in a nuclear plant, causing a major incident and putting people, assets and the environment at risk? Here Gareth Powell, systems integration manager at industrial control systems specialist Delkia, explains how cybersecurity affects functional safety and why certain defensive measures are needed to ensure a system’s integrity. Stuxnet and Industroyer are two examples of malware attacks in recent years that targeted the industrial control systems of two facilities. In both cases, the malware was used to compromise SCADA, PLC or DCS systems with the intent to cause catastrophic failure. In the first case attackers targeted the centrifuges in Iran’s nuclear programme. The Stuxnet malware altered the PLC programming, resulting in Iran’s nuclear centrifuges spinning too quickly and for too long. This caused irreparable damage to delicate equipment. In the second example, the electrical substations in the Ukrainian capital, Kiev were hacked, leaving 230,000 residents without electricity for up to six hours.

quickly to potential threats to functional security. If a cyber-threat is detected early enough, and the relevant personnel are informed immediately through Human Machine Interfaces (HMIs) connected to the PCS, action can be taken to prevent costly damage. For a nuclear power plant, subversion of a system could result in the dismantling of safety-critical measures. To this end, it is vital action is taken quickly.

SUPPLY CHAIN SECURITY

According to the National Cyber Security Centre (NCSC), one of the most important steps in protecting your control system against cyber-attacks is collaborating with suppliers and partners. additional security measures that may be required. Following the security standard IEC 62443, this involves picking holes in the work protocols, countermeasures and employee behaviours, as well as the technology comprising the control system itself, to ensure full functional safety. Often after installing a system, penetration testing is carried out to check its robustness and integrity before it is installed in a facility.

Engineers now need to be cognisant of how they design systems and maintain procedures, policies and behaviours so industries are not blind to extra risks. These risks are multiplied as mission-critical businesses increasingly adopt wireless technologies, use offsite data centres and trial technologies such as drones.

After installation, physical security measures can be put in place to ensure cybersecurity. This could be as simple as managing user permissions or installing the latest hardware, software or firewalls to continuously monitor cyber-threats. Firewalls are most effective when only specific users can access the system, and when any ports that are not needed to support the control system connections outside the corporate LAN are blocked.

MANAGING VULNERABILITIES

IMPORTANCE OF DATA MONITORING

Cyber-threats need to be considered at every stage of the functional safety lifecycle. During the design stage, it’s important that engineers eliminate blind spots by clearly identifying each element of the control system as well as the security breaches that are likely to occur and how to tackle these. Plant managers should carry out cyberrisk assessments of their operational technology (OT) systems to identify

Logging, monitoring and analysing your data via a Process Control System (PCS) is also a critical step to ensure cyber-security because it enables businesses to detect malicious activity. Because not all sensors and equipment produce security logs, it’s vital to focus efforts on the instrumentation in the path of an intruder that can give you data. Being able to monitor data in real-time is also important for operators responding

With the right partnerships in place, companies can pick holes in a system’s cybersecurity from the get-go, reducing downstream time, effort and costs. What you want to avoid however, is over-thinking hypothetical threats, which may lead to over-complex, costly control systems. With the right team of cybersecurity experts and systems integration engineers, Delkia is well positioned to advise, deploy or support on functional safety practices affected by cyberthreats. This includes undertaking risk and vulnerability assessments, installing antivirus software, firewalls, intrusion detection systems and alert logging and monitoring capabilities. What’s more, Delkia’s team of certified functional safety practitioners can advise at the early stages of the design. This is more time and cost effective than trying to retrofit functional safety management requirements at the later stages of implementation. By aligning cybersecurity and functional safety together, the nuclear industry can benefit from cost-effective and intrinsically safe control systems. For more information on how Delkia is positioned to provide you with the latest cyber support, visit www.delkia.co.uk/cyber-security or contact one of our engineers on +44 (0)1946 812288.

For further information, please visit www.delkia.co.uk/cyber-security Issue 53 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 both Sage50 Manufacturing and Sage200 Manufacturing are End Of Life Solution Sapmanv12 More Features – Less Cost – Sage Developer Fully Supported – Continuous Development Sapmanv12.co.uk COME OND VISIT US AT THE SOUTHERN MANUFACTURING SHOW, FARNBOROUGH: 8-10 FEBRUARY 2022 ON STAND E105 Issue 53 PECM

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SOFTWARE & SYSTEMS

THE GREAT HACK FORTNET

How secure is your supply chain? By Steve Mulhearn, Director of Enhanced Technologies at Fortinet Hiding within the machinery, the sensors, the robots and the computers is a vital IT infrastructure responsible for the smooth running of the entire production and process of manufacturers. Yet it also exposes the vulnerability of vendors in the supply chain to cyber invasions via the long tail of IT services they lean on. In this environment, a “supply chain” attack also takes on a very literal meaning because most of these companies have long, multi-party supply chains for producing their products. These suppliers and partners often have links into the organisation’s ERP and business process systems, so ensuring that all partners are as well protected as they themselves has become a big topic of discussion. Using the latest innovations, cyber criminals creep around in email services, pretending to be employees to access or manipulate data. Or they might introduce a nasty code into IT software requiring a system update that unwittingly opens the back door for attackers to enter. Once in, the malware can transfer files, reboot computers and disable system services, sabotage infrastructure operators – the list is encompassing and endless – and it’s difficult to ask the unwanted guest to leave. Securing the supply chain is the hardest nut to crack because there are so many links. This is compounded by ever more sophisticated and aggressive methods of today’s hackers. Operators are shifting their strategy away from email-initiated payloads to focusing on gaining and selling initial access into corporate networks further showing the continued evolution of Ransomware-as-a-Service (RaaS) fueling cybercrime. Recent data from Fortinet’s FortiGuard Labs shows that the average weekly ransomware activity in June 2021

was more than 10x higher than one year ago. This shows us a consistent and overall significant increase over a one-year period. According to Fortinet’s State of Ransomware survey, it has become the top threat of concern for many organisations today, including manufacturers, with ramifications that extend into the fields of geopolitics, espionage and national security. Hackers want to steal the secrets and money as well as damaging the reputation of their targets.

CYBERCRIME IS A BUSINESS TOO Cybercrime is a lucrative industry too, complete with call centres that assist their victims to pay ransoms, tech support, money laundering partners, and Dark Webbers who build code for sale. Take for example RaaS, a subscriptionbased model that allows partners (affiliates) to use Ransomware tools that have already been developed by someone else to execute attacks. The affiliates earn a percentage of the profits sometimes up to 80% if the attack is successful, and everybody else gets their cut. The booming cybercrime ecosystem has therefore grown into its own supply chain, generating more than a trillion dollars of revenue every year. That supply chain is growing as well because the bad actors are becoming better funded, they are using new elements and service models, and they keep changing their tactics and upping the game. In most sophisticated manufacturing ecosystems, multiple people and functions work together and it is no different with cybercrime. For example, suppliers create and produce malware and zero-code exploits, then they license, sell, and share their technology with distributors and affiliates, who then sell their solutions to clients who target those solutions at victims— effectively using their supply chain to better infiltrate their victims’ supply chains.

DISRUPT THEIR SUPPLY CHAIN At Fortinet, our researchers and threat hunters follow these criminals’ moves

and study their tactics and playbooks to replicate and detonate their attacks. We use heat maps to uncover recent techniques, so we know what they are thinking and what they have implemented which is key — their heat maps turn into roadmaps that lead us in the right direction. Because many cybercriminal organisations operate like a business, defenders can use a combination of their own tactics, real time data, and high-resolution intelligence against them; by disrupting their supply chain, making it more expensive for them to operate and thereby forcing them to shift tactics. Several events thus far in 2021 count as important wins for the defenders. Take TrickBot, for example—its original developer was arraigned on several charges in June. Likewise, the coordinated takedown of Emotet, one of the most prolific malware operations in recent history, as well as actions to disrupt Ransomware operations, such as Egregor and NetWalker. These wins signify the momentum of cyber defenders, including collaboration among global governments and law enforcement.

TAKE AIM AT CYBER SECURITIES By educating manufacturers on bestpractice cyber hygiene, collaborating with other defenders, and leveraging tools like artificial intelligence (AI) to detect and implement countermeasures, they can stay one step ahead of the bad guys. It’s safe to say that cybercrime isn’t going away any time soon, but as cybercriminals become more sophisticated and creative, so must businesses. The collaboration and sharing of threat intelligence among enterprises, law enforcement, and government entities helps to shine a light on the bad actors. Ultimately when they are taken down, it’s taking them longer to recover. Some affiliates are abandoning their criminal organisations altogether because they too have become targets of law enforcement. So, there have been promising dips in threat activity amongst manufacturers, but there is still work to do. We are at a critical inflection point when it comes to combatting cybercrime.

For further information, please visit www.fortinet.com

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FARNBOROUGH | Hants | GU14 6TQ

8th | 9th | 10th FEBRUARY

9.30am - 4.30pm (3.30pm close Thurs)

Where Industry and Innovation converge Over 600 national and international suppliers come together to exhibit at Farnborough International Exhibition and Conference Centre this February for Southern Manufacturing and Electronics (inc AutoAero) 2022. Meet the power behind UK manufacturing industry and see live demonstrations and new product launches of machine tools & tooling, electronics, factory & process automation, packaging & handling, labelling & marking, 3D print technology, test & measurement, materials, composites & adhesives, rapid prototyping, ICT, drives & controls and laboratory equipment. Free industry seminar programme online @ www.industrysouth.co.uk The exhibition is free to attend, free to park and easy to get to. Doors open at 9.30am on Tuesday 8th February.

FREE SEMINARS FREE PARKING

AUTOMATION DEFENCE FOOD & DRINK AUTOSPORT MARINE AEROSPACE TRANSPORTATION PACKAGING ELECTRICAL & MECHANICAL ENGINEERING ADDITIVE MANUFACTURING LOGISTICS ELECTRONICS ENERGY SPACE ENGINEERING R&D MEDICAL COMPOSITES CONSTRUCTION

PRE-REGISTER TODAY

SOUTHERN MANUFACTURING & ELECTRONICS

www.industrysouth.co.uk

Tel 01784 880890 · email philv@etes.co.uk

for your Fast Track Entry Badge, Preview Magazine and Event Catalogue at

is an ETES event organised by European Trade & Exhibition Services Ltd

STORAGE, HANDLING & DISTRIBUTION

idea for pecm magazine-version 2.pdf 1 16/08/2021 12:23:53

Bespoke Lifting and Handling Equipment

Rotor-craft Steering Arms

Engine Cover Lifting Beams and Bespoke Trolleys

CMY

Concept Design Reverse Engineering Obsolescence review Prototyping Manufacture / Build to print Qualification

Nose Cone Cover

Bespoke DMRT Lashing for the QEC Wheel Dipping Frame

Drallim Industries Limited Aircraft Door Barrier (Safety Nets)

Aircraft Wheel Trolley

Watchkeeper Stowage Trolley

ACCREDITATIONS: BS EN ISO 9001:2015 | BS EN ISO 14001:2015 | BS EN ISO 45001:2018 | AS9100D: 2016

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Millwood House, Drury Lane, Ponswood Industrial Estate, St. Leonards-on-Sea, East Sussex, TN38 9BA Tel: 01424 205140 | Sales@drallim.com

www.drallim.com

STORAGE, HANDLING AND DISTRIBUTION

ADDING GENUINE VALUE CROCODILE

Designing bespoke packaging solutions to perfectly fulfil clients’ needs Crocodile began as a family company back in 1991 in response to a growing demand for innovative and versatile industrial packaging solutions. To this day Crocodile remains entirely family owned and run and the goal of providing high quality sophisticated packaging solutions that add genuine value to clients has not changed. Crocodile has a truly global outreach, with manufacturing partners in China, Germany and the USA. But the key to Crocodile’s success is it’s commitment to quality, which is why all aspects of the business from design to manufacturing, right through to delivery of the product is managed under the same roof in Swindon. By controlling every aspect of the business Crocodile ensures that only the best product and customer service is delivered.

SPECIFIC TO CUSTOMERS NEEDS Crocodile does not sell from a catalogue, but custom designs bespoke packaging solutions to perfectly fulfil clients’ needs. We visit prospective customers and listen to them in order to ascertain as much information as we can about exactly what they want and need from their packaging. Our team of CAD Engineers will then design a packaging solution based around these needs, which we will then present to clients for approval or feedback.

CLIP TOGETHER SYSTEM Crocodile’s unique clip system means that packaging can be flat packed and reused, which dramatically cuts customers’ total costs and provides a sustainable, environmentally friendly way to ship goods.

COST EFFECTIVE Our aim is to win customers by delivering a first class but cost effective solution and performance. We then passionately wish from then onwards to continue supplying the customer every time they need

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

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

01793821555 ISPM 15 COMPLIANT

For further information, please visit www.crocodile.uk.com

TOOLS

DATA-DRIVEN SOLUTIONS DESOUTTER

It’s time for your digital transformations As businesses at varying stages of their digital transformations grapple with data management, it pays to use a unifying system allowing central analysis and control. Organisations entrenched in the world of big data or those just taking their first steps into industry 4.0, will benefit from Desoutter’s data-driven solutions. It’s now very easy to manage and analyse data gathered from the widest possible array of sources. Never before has there been an opportunity to gather such an abundance of data from the tools and processes used day-to-day, from machinery and test equipment in manufacturing environments, software systems in warehouses or manual entry from operators in the field. Empowering? Yes! But, on closer inspection it’s too often left untouched, unobserved and untapped. Data for data’s sake is no good to anyone.

Organisations entrenched in the world of big data or those just taking their first steps into industry 4.0, will benefit from Desoutter’s datadriven solutions.

CAN YOU WIN THE DATA COLLECTION BATTLE? With sensible planning, yes! Desoutter’s ‘Pivotware’ process control software provides operator guidance as well as automation of equipment and tests. Pivotware processes can be created quickly and easily, whilst also allowing the integration of our intelligent tooling and

a wide variety of third-party equipment. This allows the data from all relevant equipment or sources to flow through one system, eliminating the requirement for separate databases or traceability systems.

LET YOUR HISTORY HELP SHAPE YOUR FUTURE… With the ability for data to be recorded through one system, it can be stored centrally. Therefore, it’s simple and intuitive to perform analysis of historic data by searching for specific builds, events or time periods. Data can be viewed in its original state for quick reference or exported into various formats for advanced analysis and concise sharing.

BE MORE INSTANTANEOUS, IT’S EXPECTED! Traditionally, data is used reactively as required. These days society is more connected and our business increasingly fast-paced. This means it is critical to proactively use data which drives daily decision-making within an organisation and prevents issues ahead of time. Desoutter’s ‘Demeter’ real-time data monitoring and analysis software allows easy viewing of key data in a tailored format, accessible from any web-browser equipped device. A proactive data strategy = reduced risk and increased productivity. Don’t risk your company’s data being left shelved with its valuable lessons unlearned.

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Worldwide Diamond Tooling Solutions Manufacturing Resin bond and Electroplated wheels in the U.K for over 60 years

TOOLS

GO-TO MACHINE SPECIALISTS KM TOOLS

Rail OEMs can benefit from KM Tools on the line A railway pioneer, the UK has a long and proud history in the train manufacturing industry. Nowadays, leading rail OEMs operate state-of-the-art UK-based production lines, each designed to manufacture the next generation of trains. KM Tools is helping OEMs to meet the demand for advanced rolling stock with a turnkey, bespoke engineering service for production machinery. Based in Cheadle, Staffordshire, KM Tools has rapidly built a reputation as the go-to machine specialist for the rail industry. A turnkey engineering business offering design, prototyping, testing, manufacturing, fabrication, installation and maintenance services – KM Tools has supported leading rail OEMs such as Alstom and Hitachi.

The company’s full electromechanical engineering capability ensures that all aspects of machines, from frames to control systems, can be designed and delivered in-house.

SMARTLINE JIGS A popular KM Tools innovation is the SmartLine Jig. These jigs are designed to allow welding, assembly and preparation of rolling stock as part of a lean production flow. Onboard hydraulics, custom fixtures and controls allow for multiple processes to be carried out with a reduced footprint. This maximises production efficiency and minimises the movement of parts and personnel. The jigs are enabling rail OEMs to follow the lead of the automotive industry

in implementing lean production strategies. Neil Harrison, Sales Manager at KM Tools, expands: “Our SmartLine Jigs are currently operational at Alstom’s Litchurch Lane site and Hitachi Rail’s Newton Aycliffe production facility. The jigs are directly supporting the production of modern rolling stock destined for the UK rail network and beyond. “Our turnkey, bespoke engineering service means that we can deliver custom designs to meet the requirements of each OEM production line and process. Rail OEMs can therefore optimise their machinery to unlock new production efficiencies, improving productivity and adding value.”

KM Tools is a turnkey engineering business offering design, prototyping, testing, manufacturing, fabrication, installation and maintenance services.

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KM Tools reverse engineered a welding gantry for the manufacture of train underframes as well as roofs.

Our turnkey, bespoke engineering service means that we can deliver custom designs to meet the requirements of each OEM production line and process. REVERSE ENGINEERING AND 24/7 MAINTENANCE SUPPORT As well as delivering new machines, KM Tools also offers reverse engineering services. If customers require a legacy machine to be reproduced, KM Tools can create one to modern standards whilst increasing efficiency and reliability. Recently, KM Tools reverse engineered a welding gantry for the manufacture of train underframes as well as roofs for Alstom and ensured that it could be integrated into the existing production line. The new machine even featured a matching control system and user interface, ensuring that operators had instant familiarity with the new unit. Highly responsive on-site maintenance support is another key service of KM Tools. To ensure maximum uptime for production equipment, KM Tools can station specialists on-site 24/7 to provide a fast reaction to any maintenance requirements. Furthermore,

KM Tools has supported leading rail OEMs such as Hitachi. the business offers a planned preventative maintenance (PPM) service to ensure continued machine reliability.

A TAILORED APPROACH “Our experience working with leading rail OEMs in the UK means that we can support

the machine requirements of any train production line,” Neil explains. “We can offer our services as a complete package or individually depending on customer preference, which ensures we can deliver not only a bespoke machine, but a tailored service to match.”

For further information, please visit www.kmt.tools Issue 53 PECM

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TRAINING & RECRUITMENT

PLANT & ASSET MANAGEMENT PRO-RELIABILITY SOLUTIONS LIMITED

Helping you and your business achieve long term sustainable reliability Pro-Reliability Solutions Limited (PRS) is a leading provider of asset management, maintenance and reliability engineering consulting and training services, who help and support companies to reach their potential by improving the way they perform and deliver reliability and maintenance from an engineering and organizational perspective.

Offered as a single program, or as individual modules based on customer needs, ReliabilityFocus™ provides a comprehensive framework for asset reliability improvement and the development of a strong reliability culture, releasing hidden plant profit and driving other benefits such as:

Setting out to find ways to harness the power and potential of reliability to industry, Pro-Reliability Solutions has developed a framework for achieving reliability success. This framework is called ReliabilityFocus™.

ReliabilityFocus™ Maturity Self-Assessment: Where are you now versus where you need to be?

• Improved safety performance • Increased operational performance • Increased maintenance effectiveness • Proactive risk mitigation and elimination of unplanned events • Greater teamwork and motivation

If you are an existing plant, a new facility or still in the design phase and looking to evaluate or start your reliability improvement journey, Pro-Reliability Solutions offers a facilitated reliability maturity self-assessment to help companies understand reliability maturity within their organisations. This collaborative exercise aids in exposing gaps and provides companies with a deep insight that helps them to move forward, or indeed take those first few steps.

Facilitated by an expert Reliability Coach, the assessment output will consist of a comprehensive report identifying the ‘Gap to Potential’ and recommendations targeted for continuous improvement. With offices in the U.K., Ireland and the U.A.E., Pro-Reliability Solutions can support your team and your asset management program to deliver optimum plant performance that will lead to direct results for the operation both in terms of cost and risk reduction and would be happy to discuss your needs and requirements at any time.

Introducing a FRAMEWORK for Success – How to create a Reliability CULTURE

FIVE ESSENTIAL STEPS – YOUR FRAMEWORK FOR RELIABILITY SUCCESS.

KEY ENABLERS –

MODULES TO UNLOCK YOUR RELIABILITY POTENTIAL.

STEP 01: AGREE

Leadership agreement and buy in to cultural transformation.

STEP 02: ALIGN

Create a Reliability Mindset across the entire organisation.

STEP 03: ADOPT

Make reliability available to everyone.

STEP 04: APPLY

Grow your culture. Implement your master plan. Make it happen.

STEP 05: ADVANCE

Reliability for life, day in, day out. Contact Pro-Reliability Solutions to discuss your Reliability needs.

E: info@pro-reliabilitysolutions.com | W: www.pro-reliabilitysolutions.com | T: +44 1484 941068

Reliability is our passion

BENEFITS –

WHY YOU SHOULD CARE ABOUT GROWING YOUR RELIABILITY CULTURE?

Because you grow a culture where it is normal for everyone to be engaged in the process of continuously improving your business as part of everyday life, delivering: • Greater Stability • Reduced Production Losses • Reduced Maintenance Costs • Highly Engaged Workforce www.pro-reliabilitysolutions.com

E: info@pro-reliabilitysolutions.com | W: www.pro-reliabilitysolutions.com | T: +44 1484 941068

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2022 Reliability Training Courses

Reliability training designed to increase individual and organisational productivity Pro-Reliability Solutions is offering a range of Reliability training programs for online and public delivery throughout 2022. From our popular Reliability Elements course, to our essential Root Cause Analysis Course, and our highly advanced RAM Modelling course we look forward to helping build your teams Reliability knowledge and skills in 2022.

Book your 2022 Training enquire now at: info@pro-reliabilitysolutions.com

2022: Remote Online* Training Courses

PRS is delighted to offer the following online training courses in 2022. COURSE

LOCATION

Reliability Elements

Online

Feb 7

May 9

Root Cause Analysis

Online

Introduction to FMECA Introduction to Motor Management

Online

2022 DATES Jul 4

Oct 3

Dec 5

* All online training courses are delivered in person by our qualified training staff in an interactive environment. Each course consists of 2 x 3-hour sessions.

2022: Public Training Courses

PRS is delighted to offer the following public training courses in 2022. Public courses will be held in Manchester, Dublin and Dubai through out the year. COURSE Root Cause Analysis (Masterclass)

Reliability Centered Maintenance

FMECA (Masterclass)

LOCATION Manchester

Jan

Feb

11, 12

Apr 5, 6

Oct

Nov

11, 12

8, 9

12, 13

15, 16

18, 19

21, 22

Manchester

13, 14

7, 8

13, 14

Dublin

10, 11

14, 15

17,18

Dubai

16, 17

20, 21

23, 24

Manchester

22, 23

Dublin

13, 14 22, 23

20, 21

28, 29

12, 13

Dublin

24, 25

22, 23

Dubai

30, 31

14, 15

24, 25

15, 16

24, 25, 26

Dublin

26, 27, 28

Dubai

Reliability Elements (Masterclass)

Sep

14, 15

Manchester

Reliability Leadership

Jul 5, 6

Dubai

Work Management

2022 DATES May

Dublin

Manchester RAM Modelling

Mar

Manchester

2, 3, 4 29, 30, 31

Dublin

11, 12, 13

Dubai

24, 25, 26

Manchester

22, 23, 24

Pro-Reliability Solutions are available to custom develop training courses to meet the specifics of your personnel development needs. All of our standard training courses can be customized to incorporate topics, elements or subjects specific to your facility. With offices in the U.K., Ireland and the U.A.E., we are here to support your reliability journey and would be happy to discuss your training needs and requirements at any time.

Contact Pro-Reliability Solutions to discuss your Reliability training needs. E: info@pro-reliabilitysolutions.com | W: www.pro-reliabilitysolutions.com | T: +44 1484 941068

VALVES AND FLOW CONTROL

ARI-Armaturen – your answer to all your valve ARI-Armaturen – your answer toneeds all your

valve needs

® Introducing ENCOsys ® Introducing ENCOsys Introducing ZETRIX® A COMPLETE SOLUTION FOR STEAM THE PREMIUM PROCESS VALVE

A COMPLETE SOLUTION FOR STEAM TO WATER HEAT EXCHANGE TO WATER HEAT EXCHANGE

Designed to provide hot water instantaneously whatever thetoload conditions, Designed provide hot water instantaneously whatever the load up to 2100kW without the conditions, up to 2100kW without the need for water storage. need for water storage.

Reliable, Efficient and Cost Effective Reliable, Reduced Heat Loss Efficient Improved Temperature Control and CostEfficiency Thermal Effective Operational Savings • Reduced ARI-Armaturen UK Ltd specialises in pipeline equipment for Heat Loss steam systems, thermal oil and hot water and is a subsidiary • Improved of a large German engineering company, reputed to have the Temperature largest valve stock in Europe. Control • Thermal Efficiency

Reliably tight, durable and versatile triple offset valve with zero leakage, even in harsh industrial environments. Changing from single to double isolation made easy with the small face-to-face dimensions of the ZETRIX® ZETRIX® Double block and bleed arrangement

Contact salesoffice officeon on 01684 01684 275752 Contact thethe UKUK sales 275752 Email: marketing@ari-armaturen.co.uk inquiries@uk.ari-armaturen.com ororEmail:

• Operational Savings

www.ari-armaturen.com

ARI-Ad-UK-ENCOsys-182-129.indd 1

23.06.2021 14:21:36

GEMÜ 567 BioStar: Aseptic and Precise Control Valve

Valves for a Sustainable Future For more than four decades the Oliver family of companies including Oliver Valves, Oliver Twinsafe and Oliver Valvetek have designed, developed and manufactured cutting edge, products for traditional oil and gas industries, however, times are changing… Since the dawn of the industrial revolution our energy demands have been met by the combustion of fossil fuels, the greenhouse gas emissions created have rapidly accelerated the global warming effect. Recognising that must now transition to net zero emissions, Oliver Hydcovalves Ltd became the latest addition to the Oliver family. Incorporated with the primary objective of providing valve technologies that support the net zero emission targets of industrial users, the company will build on the decades of expertise held within the Oliver companies. Contact us at rporter@valves.co.uk or our website www.valves.co.uk

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PECM Issue 53

Aseptic diaphragm valves are frequently used to control sterile applications. However, diaphragm valves soon reach their limits when a fine batch is required. Although globe valves with flow restrictors offer precise control, they are not aseptic. Born from a need for precise and aseptic control valve applications for small volume dosing in the pharmaceuticals, biotechnology and food/ beverage industries, GEMÜ developed a diaphragm globe control valve, the GEMÜ 567 BioStar. The valve allows small volume to be regulated extremely accurately under aseptic conditions from 80 l/h to 12,500 l/h. Using innovative sealing via GEMÜ PD (Plug Diaphragm) made from an FDA-compliant PTFE diaphragm guarantees a hermetic separation of fluid from the actuator, whilst simultaneously achieving excellent valve control characteristics. Available

with manual, pneumatic and motorized actuators, the GEMÜ 567 BioStar is CIP/SIP capable and can also be integrated into GEMÜ stainless steel multi-port valve blocks. For more information, please click here. Tel: 01925 824044 Email: enquiries@gemu.co.uk

Web: www.gemu.co.uk

VALVES & FLOW CONTROL

MULTI-PORT VALVE BLOCKS GEMÜ

Dosing Installations for Detergent in Industrial Laundries: Extendable GEMÜ Plastic Multi-port Valve Blocks In a successful industrial laundry applications, the GEMÜ plastic multi-port valve blocks are used to produce a wide variety of detergents and automated systems for dosing these detergents. The compact GEMÜ plastic M-Blocks are the key element in these systems as they make the corresponding dosing, distribution and ﬂushing functions possible.

OPERATION OF DETERGENT DOSING INSTALLATIONS Automated detergent dosing installations provide industrial laundries with ﬂexibility, allowing them to adjust the required detergent composition individually to each speciﬁc cleaning programs. Depending on the hardness of the water and the type and level of soiling, the cleaning agents, special additives and care products can be dosed to match the type of textile being washed. In the case of conventional dosing installation designs, a separate dosing pump is required for each washing machine and medium. The resulting large number of pumps, hoses, unions and distribution components makes extensive maintenance and calibration work necessary.

COMPACT DESIGN IMPROVES PLANT RELIABILITY The use of GEMÜ multi-port valve blocks allows the number of pumps, hoses and ﬁttings to be kept to a minimum on modern dosing installations. Only one pump is required per medium and multiple washing machines can be supplied with

Extendable multiport valve block

Dosing cabinet one dosing installation. A smaller number of connection points improves plant reliability as it reduces both potential leakage points and deadleg. Less connections mean less time required to assemble the customized units. All these benefits make a significant contribution to cost optimization of the plant.

MULTIPLE FUNCTIONS IN ONE MULTIPORT VALVE BLOCK In order to achieve a more compact design, all dosing, distribution and flushing functions are combined in one multi-port valve block. The dosing pump for each medium is connected to a variable area flowmeter each of which is connected directly to the multi-port valve block. The valve block consists of 3 rows of pneumatically actuated diaphragm valves. The first valve row at the bottom is used to dose the medium. Depending on the requirements, quantities of 10 – 200 ml are metered out. The valves in the second row control which washing machine the medium is sent to and the upper, third row of the valve block is used to flush the unit with water after every dosing process.

Multi-port valve block with ﬂowmeter for detergent dosing and distribution

EXPANDABILITY OF EXISTING PLANTS The multi-port valve blocks are also able to be extended. If an industrial laundry adds washing machines to its plant, the existing dosing unit can be extended by the required number of valves with just a few simple modiﬁcations without the need for additional piping, solvent cemented joints or welds.

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

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PECM Issue 53

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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