PECM - Issue 56 2022 by MH Media Global

Process

MANUFACTURING

Control &

Engineering

BABCOCK WANSON - 6

PORTESCAP - 20

the innovative development of Supercritical CO2 technologies in industrial waste heat recovery

Portescap's new miniature motor R&D facility increases customisation capability

PECM

Global Success Through Innovation Issue 56 2022 £4.95 www.pecm.co.uk

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Process

MANUFACTURING

Inside... Sections Editors Choice Boilers & Maintenance CHEM UK Show Preview Coatings Control & Automation Electrical & Electronics Facilities Management Fluid Handling Gears, Drives & Motors Health & Safety Hydraulics & Pneumatics Machining & Machinery M&E Week Show Preview Measurement & Monitoring Packaging Innovations Show Preview Packaging Process Technologies Pumps / Software & Systems Subcon Show Preview Switches & Sensors Tools Valves & Flow Control

Control &

Engineering Inside Issue 56 4 48 49 54 55 68 73 74 75 78 88 90 100 102 110 112 116 120 124 126 128 129

FILTERMIST

IDS

KOL

EMS LTD

XAAR

ACTIVE ROBOTS

Filtermist has reported a 60% increase in enquiries at this year’s MACH show compared with the 2018 exhibition The benefits of becoming a freelance engineer Xaar’s guide helps new users explore the possibilities of inkjet

BURCKHARDT

Well-planned maintenance of any equipment is essential for long-term reliability and efficiency

PP CONTROL & AUTOMATION

PP C&A boss urges UK manufacturers to make the most of a ‘once in a generation’ reshoring boom

Autonomously driving robotic assistance system for the automated placement of coil creels How manufacturers can increase productivity to meet growing demand Specialists in the smarter application of robotics technologies, industrial automation and system integration solutions

HERGA

Herga Technology’s 6256 heavy-duty industrial footswitch has AC15 utilisation category rating

TEEPEE ELECTRICAL

Teepee harnesses electrification dreams for fire and rescue appliance specialist

Cover photo: KHS

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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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Engineering MANUFACTURING

Control &

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Issue 56 PECM

EDITOR’S CHOICE

WASTE NOT, WANT NOT BABCOCK WANSON

Chris Horsley, Process Engineering Director at Babcock Wanson, looks at the innovative development of Supercritical CO2 technologies in industrial waste heat recovery Heat recovery has become increasingly popular within industry, driven by high energy prices, environmental regulations, and a desire to reduce carbon footprint. However, sites and processes vary dramatically, so heat recovery systems are frequently bespoke in nature or, at the very least, require extensive modification of existing equipment and expert installation. To truly make heat recovery appealing to users, the energy efficiency of these systems needs to be improved to reduce ROI time, and installation made far simpler. The EC Horizon 2020 grant funded I-ThERM project, coordinated by Brunel University London, set out to do just this. The project was divided into three areas, with Babcock Wanson involved in the recovery of heat from temperatures above 300°C using a Supercritical Carbon Dioxide System. When Carbon Dioxide is held at, or above, its critical temperature (31°C) and critical pressure (73.8 bar) it turns into a fluid state, known as Supercritical Carbon Dioxide (sCO2). sCO2’s thermal stability and non-flammability, makes direct heat exchange from high temperature sources ranging between 350°C - 800°C possible. Furthermore, its physical footprint is simple and compact, and it has a low toxicity and environmental impact. All of which make it potentially appealing when it comes to heat recovery systems. Designing and building a Supercritical Carbon Dioxide Heater presented a host of new challenges, as not only does the heater have to contend with very high temperatures, it would also be used for testing so needed to be adaptable. Following several briefings and learning more about the process and the testing regime, we built a specialist Direct Process Air Heater, using our MIXBLOC Heater as the starting point as it is designed to provide high temperature air with no flue gas losses. MIXBLOC can operate using the process air flow as the source

PECM Issue 56

The innovative heat recovery technology developed by the I-ThERM project has already received significant interest across Europe from industrial organisations of combustion air, or an independent combustion air fan. The heater was designed for operation at up to 780°C air temperature with heater lockout set at 800°C. Burner turndown ratio was retained at 5:1. The process fan size was specifically selected to account for the higher head loss associated with operation at higher working temperatures and with a

heat exchanger located close to the heater outlet. A final discharge cooling system was included, comprising of air cooler with variable speed fan to allow the final exhaust to be cooled to around 350°C irrespective of the heat absorbed into the sCO2. As the heater was being designed for a test site, we manufactured and supplied a 2m

“dummy” section between the combustor and cooler to allow the system to be fully commissioned and operated without the very specialist heat recovery unit being in place. This means the system can be tested at varying heat load/temperature and air flow settings without the heat recovery unit being present to allow for the test protocol to be formalised and proved without risk to the heater battery. A further adaptation to accommodate the test conditions included the mounting of the combustion chamber section on roller type feet to allow it to be moved to ease the installation of the differing heat exchanger sections. Both the heater and cooler unit are made of carbon steel construction throughout and are fully ceramic lined (including the dummy section) to cope with the high operating temperatures. The system is natural gas fired and we also supplied a gas booster to provide up to 70 mbar of lift, plus a suitable in-line gas meter with analogue input to the MIXBLOC heater control system to display and re-transmit the gas consumption under test conditions. The final unit consisted of a fully packaged plant complete with all controls and interfaces for both local and remote monitoring plus remote adjustment of set parameters prewired and mounted to the heater. Control is via Siemens PLC with touch screen HMI.

The innovative heat recovery technology developed by the I-ThERM project has already received significant interest across Europe from industrial organisations – especially those within the steel, cement, glass and petrochemical industries - looking to reduce their energy consumption and emissions whilst also increasing their global competitiveness. With an electrical power output of 50 kilowatt-electric (kWe), the sCO2 system is expected to deliver energy and GHG emission savings in excess of 15% and ROI of under three years. The technology has been recognised

by the EC’s Innovation Radar, which identifies the most promising innovations. Professor Savvas Tassou, I-ThERM project coordinator and Director of the Institute of Energy Futures, Brunel University London, states: “The supercritical CO2 waste heatto-power cycle is a unique technology and the first complete system to be operational in Europe.” The project has further funding to develop advanced heat exchanger and controls for full scale industrial sCO2 heat to power systems. Babcock Wanson offers a complete range of products and services for boiler houses and other process heating needs.

For further information, please visit www.babcock-wanson.com Issue 56 PECM

EDITOR’S CHOICE

Shrink energy costs by using Linear Motors instead of Pneumatics Powering actuators directly with Linear electric motors rather than air cylinders can result in huge cost and emission savings across the board. The recent dramatic increase in energy cost is a big concern for industry, which makes switching to electrical actuators even more attractive. Compressed air is very wasteful of energy and can be eliminated in machines by using linear motors in place of air cylinders. Quin Systems, exclusive UK suppliers of LinMot Linear Motors for over 25 years, can help you calculate the predicted carbon and energy savings achieved by switching from a pneumatic solution to a linear motion solution. LinMot, one of the world’s leading manufacturers of industrial linear motors has released a new component of its LinMot Designer software that can quantify just how energy efficient its solution is, and the sizeable return on investment their motors can provide over pneumatics.

EXAMPLE

cover its higher initial outlay within a very short timeframe, typically less than a year.

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 diameter rodless air cylinder for this task, ultimately reducing annual energy cost by over 10,000 EUR and CO2 emissions by over 26,000 kg.

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. This improves the cost benefits and environmental efficiency of your production line by a significant margin. For more information, please contact Quin Systems, the LinMot distributor for UK & Ireland on 0118 977 1077 or sales@quin.co.uk.

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

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 56

EDITOR’S CHOICE

Premium Electric Actuator for Complex Open/Closed & Dynamic Control Applications GEMÜ offers an extensive range of electric valves for a wide variety of applications. When it comes to high requirements on performance and service life, GEMÜ eSyDrive valves are the ideal choice as they are perfectly suited for variable and complex open/closed and dynamic control applications. Designed on the basis of the hollow shaft principle in conjunction with technology that does not use brushes/sensors, the eSyDrive actuator sets new standards in terms of service life, compactness, actuating speed and energy efficiency. The self-locking actuator also offers a high level of reproducibility for positioning and is therefore ideal for use in control applications. The actuator has an integrated Ethernetbased eSy-web solution and Modbus TCP interface for exchanging process, parameterization and diagnostics data. This “live communication” therefore offers advantages such as remote control, installation and maintenance as well as potential for process optimization thanks to its progressive digitization.

For more information, please click here. Youtube video:Online Setting GEMÜ eSyDrive:

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Issue 56 PECM

EDITOR’S CHOICE

FABULOUS MACH FOR FILTERMIST FILTERMIST

Filtermist has reported a 60% increase in enquiries at this year’s MACH show compared with the 2018 exhibition The UK’s leading provider of LEV extraction systems took the opportunity to showcase some of its latest clean air innovations to the UK’s manufacturing industry following a fouryear hiatus caused by the pandemic. Located on Telford 54 Business Park, the company’s own brand oil mist filters received a significant level of enquiries, as did filters from sister company Absolent AB and Kerstar’s industrial vacuum cleaners which are manufactured at its Shropshire base. Lydia Barber, Director of Group Marketing, commented: “We wanted to display the wide range of solutions that we offer, including some of the products that we manufacture here in the UK and our comprehensive aftermarket services. “Visitors are always interested in Filtermist oil mist filters as they are so well known – in addition to our own stand, our units were also on seven OEM stands around the show which was fabulous to see.” She continued: “The HSE’s recent inspection programme, coupled with an increased awareness of how hazardous particles can travel in the air thanks to Covid-19, has resulted in an increasing

perfect for cleaning up excess swarf and coolant in and around CNC machines.

It’s all about offering a complete turnkey service, which is designed to ensure our customers don’t need to think about COSHH compliance. number of manufacturers realising the importance of using effective mist extraction. “We spoke to lots of machine operatives who commented on the huge difference they experienced when their employer invested in oil mist extraction that works.” Last week’s exhibition was the first time Filtermist has shown the Kerstar brand of industrial vacuum cleaners to UK manufacturers and the products shown were the subject of a huge amount of interest. Visitors were particularly interested in the swarf and coolant vacuums as they are

There was a clear focus on the ATEX and Type H rated units from companies that need to comply with DSEAR regulations and those that work with potentially hazardous dusts, including dusts found in additive manufacturing processes. Finally, the Dustcheck brand was also on the 2022 MACH stand, as well as the aftermarket services the company offers throughout the UK, including servicing and maintenance, LEV testing, air monitoring, critical spares and consumables, and a brand-new 24-hour breakdown cover service. “We have worked with the UK’s manufacturing community for more than 50 years helping them to ensure the air in their production facilities is clean and safe to breathe,” added Lydia. “It’s all about offering a complete turnkey service, which is designed to ensure our customers don’t need to think about COSHH compliance – we can look after all aspects of their internal air quality, meaning they can concentrate on production. “We are really excited by the conversations we had at MACH last week and we’re looking forward to following up in more detail over the coming weeks and months.” She concluded: “The energy levels and enthusiasm from both fellow exhibitors and show visitors was inspiring and we are very confident that the trajectory of the UK’s manufacturing industry will continue to increase following a challenging few years. We are proud to be part of, and to be able to support, this forward-thinking industry.” Find out more about Filtermist by visiting www.filtermist.co.uk, Dustcheck at www.dustcheck.com and Kerstar at www.kerstar.com. Alternatively, please call our sales team on 01952 290550 and they will be happy to discuss your clean air requirements.

For further information, please visit www.filtermist.co.uk | www.dustcheck.com | www.kerstar.com

PECM Issue 56

Designed for ISO 14644 ygienic standards Designed with creativity and obsessive attention to detail, for tomorrow’s ultra-sterile spaces, today. From a team renowned for outstanding service and support.

Visit: teknomek.co.uk/hygienox Call: +44(0)1603 788833

EDITOR’S CHOICE

A WORLD OF OPPORTUNITIES KOLABTREE

The benefits of becoming a freelance engineer According to a report by the Association of Independent Professionals and the Self-Employed (IPSE), there are almost 2.2 million freelancers working in the UK, with over 1.9 million reporting that freelancing is their main source of income. Freelancing provides freedom for individuals to choose projects that align with their interests, while being beneficial for companies that require specialist skills for one-off projects. Here Ashmita Das, CEO of science and engineering freelance platform Kolabtree, highlights the benefits of being a freelance engineer and offers tips for getting started. It’s no secret that engineering businesses are facing a skills shortage, with many companies flagging access to talent as one of the biggest challenges they are facing. According to some estimates, the STEM skills shortage costs UK businesses £1.5 billion a year. With the rise of the gig economy, this once traditional industry is starting to be able to benefit from the work of freelance engineers — meaning one person can solve engineering challenges in several organisations. Freelancing provides a world of opportunity. It offers the freedom to choose what projects you work on, while enabling you to set your own working hours and salary. With remote working now the norm for many businesses, the age of the “digital nomad” is here — you can now apply your skills around the world and earn a living without being tied to a particular institution or organisation. This reduces travel and allows you to work around other commitments, like family.

FLEXIBILITY In traditional employment, you either have a job or you don’t, and your working hours are determined by business needs. With the knowledge and expert economies on the rise, more highly specialised experts are moving into freelancing because of the versatility it offers. In a recent study ‘Understanding the work of independent scientists’, conducted by an international social science research team with the University of North Carolina, University of Michigan, McMaster University and the University of Calgary, over 90 per cent of freelance scientists said that flexibility

There are no limits to the projects that freelance engineering experts could take on. Once the project has been won, the freelancer can discuss the project details, like budget, timeline and conditions, with the client before beginning work.

BUILDING SKILLS

was highly important. Although many projects will have a timeline and involve scheduled meetings with the client, you will generally have the freedom to work when you want during the day.

CHOOSING PROJECTS The types of freelance roles available to engineers is broad: in 2021, top LinkedIn listings for freelance engineer posts in the UK included project, site and electronics engineers. The desire for flexibility also applies to the work itself: the previously mentioned freelancer survey found that 85 per cent of respondents said they choose to freelance because they wanted to select the projects they work on. People also value being able to use their knowledge in a variety of areas — 42 per cent said their independent work was a mix of gigs both inside and outside of their specialization. Again, traditional full-time employment provides little room to manoeuvre here. Freelancers are in the unique position of being able to choose the clients they work with and, consequently, the projects that they take on. As well as this, they can set their own conditions and select clients that share their values and priorities. “I take on a wide range of projects as a freelance expert, but I really like working on projects that focus on relevant problems in society,” explained Dr Hugo Lisboa, one of Kolabtree’s freelancers. “For example, turning polysaccharides extracted from food waste into medical devices was something that greatly appealed to me, since you’re solving a problem whilst simultaneously creating something out of it.”

According to CV Library’s 2020 Candidate Behaviour Barometer survey of 1,700 employees, 35 per cent searched for new roles while at work due to boredom in their current jobs. Improving engagement is key for both boosting productivity and ensuring workplace satisfaction, and one way to do this is by injecting more variety into work schedules. By moving into the world of freelancing, you can take on multiple projects at the same time, each bringing something new and giving you the opportunity to broaden your horizons. Not only can you offer your skills and expertise to those who need it, you can also continue learning and developing on the job — building and refining the skills of everyone involved while meeting the project’s objectives. Being your own boss also means you can innovate and experiment with your skills, applying them in all sorts of ways. Say you are recruited to help with developing a particular product, like an internal combustion engine or fuel cells. You could join the project at the preliminary design phase and then offer your services right through to the beta and release build stage by assisting with technical challenges, providing advice on product development, and helping with the actual assembly. With over two million people in the UK now signed up to the gig economy, there’s never been a better time to join the world of freelancing. In contrast to traditional in-house jobs, freelancing allows you to pick and choose how and when you work, select what projects to take on and continue learning on the job. On Kolabtree, our freelance experts help companies publish research papers, develop products, analyse data and more.

PECM Issue 56

7+( +20( 2) 9,6&286 3803,1* 62/87,216

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

A sample of products we already pump… ᅚHoney ᅚPetroleum Jelly ᅚMascara ᅚSauces ᅚLanolin ᅚLip Gloss ᅚEssences ᅚEye Ointment ᅚMeat Paste ᅚParaffin Wax

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

ᅚFace Scrub ᅚTeething Gel ᅚTomato Puree ᅚMedical Adhesives ᅚVeterinary Creams ᅚFruit Paste ᅚToothpaste ᅚMalt ᅚJam ᅚWax

Hall 4.1 Stand C043

EDITOR’S CHOICE

PRECISE & CONSISTENT AXAIR FANS

Effective Fume & Over Spray Protection for Spray Booths Choosing a fan that can deliver a precise airflow and a consistent pressure in and out of spray booths is critical when removing fumes and overspray, and ensures an adequate change in makeup air in paint booths. Airflow in paint booths must be even and compatible with the desired conditions, therefore selecting the correct impeller or industrial fan will ensure that the fan unit can work within the spray booth to provide the optimal air condition to positively affect productivity. Spray booths are engineered to move air at the appropriate rate while maintaining a clean painting environment. Airflow styles within spray booths vary according to the desired outcome of the spray but typically the most common types are cross-draught, semi-downdraught, and downdraught. Spray booth manufacturers should work with a fan supplier that can select the right impeller to match the system requirements of each of these airflow styles. A fan supplier won’t supply spray booths, prep benches or any finished product but offer an industrial range of impellers and fans that adhere to industry standards, specifications and meet the requirements of both standard and custom manufacturing plants. Paint shops in most manufacturing

We help spray booth manufacturers precisely match the size of the motor and fan performance for each paint booth so that each fan operates at dBa levels within specified levels. plants are the largest consumer of energy, especially in the automotive industry. Therefore, choosing the most effective and efficient ventilation components is the only solution to delivering an energy efficient and greener manufacturing plant. Sourcing fans with motors for spray booth ventilation can make plant assembly a little more cumbersome. This can lead to delays in production as engineers have to find a work around a fan and motor module

to ensure it fits, quite often this can lead to unbalanced impellers and a lack of performance. Choosing to source a correctly sized impeller for a spray booth application based on its own advantageous qualities, is the preferred route for the largest players in the paint booth market and one that smaller independent paint booth manufacturers are looking to replicate. With this method, the manufacturer supplies their own motor that is located outside of the airstream for additional safety. Generally, manufacturers often have their own preferred suppliers for their motors, so this works out as the perfect solution for both parties. When we supply the impeller only, in line with major manufacturer preferences, we advise our clients to use the LRHF range of aluminium impellers along with matching inlet rings from our manufacturing partner, Rosenberg. The LRHF range, also referred to as the R63 range of impellers are manufactured from a lightweight aluminium material ensuring they are much easier to transport and install than steel alternatives. Our industrial team can advise on the motor and shaft size that are suitable for the impeller we chose, ensuring that it meets your operating point of X airflow @ X pressure, so the unit performs accurately. Taper lock bushes are also supplied according to the shaft size. Where ATEX motors are required, the onus is on the manufacturer to determine the zone that the unit will be operating in and take responsibility for the appropriateness of the motor they select. Usually motors are 400V, 3 phase with inverter control. Where required this can be supplied with an inverter drive that is suitable for the chosen motor. We help spray booth manufacturers precisely match the size of the motor and fan performance for each paint booth so that each fan operates at dBa levels within specified levels. Axair continues to work with major spray booth manufacturers in the UK market, providing low noise, low weight, fan and impeller solutions for automotive & aerospace finishing, outdoor paint booths or industrial applications.

www.axair-fans.co.uk | 01782 349 430

PECM Issue 56

Impeller Only Solutions for spraybooth ventilation Axair has supported spray booth manufacturers for over 30 years, providing low noise, low weight, fan and impeller solutions. Trust our team of fan integration experts to select the best fan for your application. Lightweight Aluminium Dynamically Balanced Technical Understanding Increased Safety

Axair Fans UK Limited 01782 349 430 | sales@axair-fans.co.uk | www.axair-fans.co.uk Contact us or talk to our team of integration experts now on our LIVE online chat

EDITOR’S CHOICE

MAXIMUM OIL RECOVERY NORTH RIDGE PUMPS

Low Shear Atex Pumps for Produced Water Improve Oily Water Separator Efficiency Onshore production of Oil and Gas is used for the extraction of Oil and Gas from reserves deep below ground. Responsible for approximately 2% of total UK supply, it is still a vital source of Oil, producing approximately 14000-15000 barrels per day. To achieve maximum recovery of oil from wells, water is injected into underground wells, flooding the area, and as oil is less dense than the water, oil is brought to the surface and recovered using Oily water separators.

PECM Issue 56

The water used to undertake this process is known as produced water, where after recovery it is recycled and reinjected back into wells. Often Saline or Brackish in nature, it can contain dissolved solids, silt and other particles present within a wells environment.

They required a flow ranging from 50 to 200 Litres a minute with a constant pressure of 8 bar. They were unsure of the best technology to handle the emulsion, as viscosity could vary, solids were present and the pumps needed to be certified to ATEX Zone1 where gas was present.

An Oil Extraction company contacted us who were looking for two pumps for their processing facility, to feed an Oily Water Separator, as well as inject produced water into a well.

Initially, when discussing their requirements, they were interested in utilising a high pressure Centrifugal pump, however on review of the project requirements, we felt another solution would not only

achieve their desired flow and pressure requirements but also improve efficiency of their Oily Water Separators.

IMPROVING EFFICIENCY OF OILY WATER SEPARATORS Oily Water Separators separate water and oil firstly by pumping the fluid through filters to capture droplets, but also by using the liquids natural characteristics -its specific gravity to separate oil, with oil rising above the water and sludge settling at the bottom of tanks. As oil and water do not mix, when it is pumped it forms an emulsion. If this mixture is pumped with high amounts of shear - produced by some pump types such as centrifugal, the droplets can split forming multiple smaller droplets making separation more difficult. The efficiency of Oily water separators is improved by utilising progressing cavity pumps, as its design affects oil particles the least due to its low shear movement, meaning separation equipment captures a greater amount of undamaged oil droplets.

Progressing Cavity pumps were rated by the SPE (Society of Petroleum Engineers) in Paper SPE18204 as the preferred pump to use for oil droplets which were found to be disturbed the least during handling against a comparison of lobe, vane and screw technology.

WHAT IS OILY WATER CUT?

Progressing cavity pumps were chosen as the ideal technology for this project as not only do they handle the oil droplets gently but they produce a constant volume of flow at varying pressures, are affected very little by changes in viscosity and can handle solids without issue.

We specified and supplied two Horizontal Progressing Cavity pumps perfect for the low shear transfer of Oil / Water Mix, capable of a flow range of 50-200 L/ min with a performance and hydrostatic test to 18 bar. Due to the presence of solids the Stainless-Steel Rotor was hard chrome plated to protect it from abrasion, prolonging its lifespan.

This is important due to the changing nature of the application. When oil is extracted, initially the produced water content of a well will be kept as low as possible to reduce the amount of oily water treatment required, with volumes increasing as it becomes inevitable due to the lowering level of oil within a well as it is extracted. The amount of water present within a well is often referred to as oily water cut.

Oily water cut is the amount of water produced in a well compared to the amount of oil or solids present which is often expressed as a percentage, with a 30% water cut meaning 30% of the extracted volume contains 30% water

The units were fitted with PT100 Dry run protection sensors, to ensure pumps could not be ran dry, and IP65 ATEX variable speed motors due to the sites exposed location. If you have an ATEX application and are unsure of the correct solution, contact North Ridge Pumps on 01773 302 660 or visit www.northridgepumps.com to see how we can help.

Progressing cavity pumps were chosen as the ideal technology for this project as not only do they handle the oil droplets gently but they produce a constant volume of flow at varying pressures For further information, please visit www.northridgepumps.com Issue 56 PECM

EDITOR’S CHOICE

NON-CONTACT TECHNOLOGY XAAR

Xaar’s guide helps new users explore the possibilities of inkjet

Xaar has launched its guide to help those new to inkjet maximise the potential of this extremely versatile non-contact technology. The ability to apply a wide range of fluids with precision and accuracy across a variety of different substrates and materials, is seeing inkjet grow in importance to today’s manufacturing processes. Increasingly, it is either replacing traditional production methods or delivering new applications. Titled, ‘Your guide to a successful inkjet development project’, the guide will help readers learn more about what to consider when starting their inkjet development journey, including ‘Why digital inkjet?’, ‘What fluid do I use?’ and ‘What system components do I need?’. From the need to use difficult fluids on

a variety of substrates, to the ability to print in multiple orientations, the guide encapsulates Xaar’s 30 years of experience in a single resource, to demonstrate how a wide range of industries can now seize the opportunity of inkjet technology. Graham Tweedale, Chief Operating Officer at Xaar said, “Inkjet is enabling a multitude of new manufacturing applications, yet as a technology it can seem daunting to the uninitiated. “That’s why we’ve created this guide; to help inform our customers’ inkjet development journey and assist in delivering a successful outcome with the shortest possible time to market. Ultimately, it will help businesses take advantage of on-demand and variable data printing, reduce waste, and deliver an improved

Inkjet is enabling a multitude of new manufacturing applications, yet as a technology it can seem daunting to the uninitiated. return on investment – all through exploring the possibilities of inkjet.” Users can download a free copy of the guide from the Xaar website here.

For further information, please visit www.xaar.com

PECM Issue 56

EDITOR’S CHOICE

Above ground flat bottomed storage tanks - a guide to inspection, maintenance and repair

A Practitioner's Handbook for potentially explosive atmospheres

EEMUA Publication 201 Control rooms: A guide to their specification, design, commissioning and operation

Publication 159 Edition 5

Publication 186 Edition 7

Publication 201 Edition 3

Alarm systems

- a guide to design, management and procurement

Management of ageing electrical assets Publication 227 Edition 1 EEMUA Publication 191 Third Edition

Good Practice Guidance for Electrical, Control and Cyber Security in Industrial Engineering • Practical guidance for everyday and irregular situations and tasks

• Readily accessible for all in the industry – wherever they are, whatever time they have

• Verified and developed from contributions by the industry, for the industry

• FREE task and procedure checklists • E-learning for professional development

Management of ageing electrical assets Publication 227 Edition 1

To purchase or for more information, please visit www.eemua.org

Issue 56 PECM

EDITOR’S CHOICE

ENHANCED R&D PORTESCAP

Portescap’s new miniature motor R&D facility increases customisation capability The design and development of miniature motor motion solutions is integral to applications from medical equipment to robotics through to industrial power tools, in settings that demand performance and reliability. Concept design, development and testing not only has to be rigorous and relevant to specific application conditions, but also has to be fast enough to meet the needs of demanding markets. As a result, Portescap, which develops miniature motors for global OEMs, has enhanced its R&D capabilities by creating a new Engineering Lab.

accelerate the development of a miniature motor package for the benefit of our customers. The new lab is integral to this,” explains Dheeraj.

The Covid-19 pandemic meant that fast reaction was needed. A key requirement for the medical care of patients who had contracted the virus was the use of ventilator machines, and with high and urgent demand, new machine designs were needed that could rapidly fill the gap. A ventilator OEM in India turned to Portescap’s Mumbai team for a fast yet reliable motion solution. The company’s new Engineering Lab had recently come on-line at Portescap’s Mumbai facility, which allowed a suitable miniature slotless, brushless DC (BLDC) motor to be designed, tested and then brought into production quickly. “While Portescap has R&D expertise and facilities in Switzerland, the United States and in India, the new Engineering Lab in Mumbai has enhanced the company’s ability to quickly develop new products for production, meaning a faster time to market for our customers,” says Dheeraj Saxena, Portescap’s global head of research & development. The new Engineering Lab has been developed to enhance miniature motor design across worldwide markets. Ideally located in close proximity to the company’s India production facility, the expertise of the Mumbai Engineering Lab team will develop solutions for customers in India selling globally, as well as supporting the company’s international R&D capability which creates products for use worldwide. The facility will develop miniature motors

to standard designs for large-scale markets, where the Mumbai team will assist Portescap’s global R&D capability in bringing new products to market. In addition, a particular focus for the Engineering Lab includes custom OEM projects. “Our DNA is to provide custom motion solutions, and that’s where we work very closely with customers,” says Dheeraj. “The Switzerland and U.S. teams have their own expertise, and the new Mumbai Engineering Lab will support the customisation development for customers worldwide.” In the US, the focus for Portescap is to design and develop slotted BLDC custom motion solutions to maintain its leading position in the surgical motion solutions market. Meanwhile, Portescap’s Switzerland team designs and develops BLDC slotless motion solutions motors manufactured in Mumbai. The new Engineering Lab means that the Mumbai team will now also support BLDC slotted flat motion solutions for the global robotic and surveillance market in addition to its expertise with DC and stepper motion solutions. This covers applications such as surgical robots and surgical tools, ventilators, medical infusion systems, as well as industrial power tools. The facility will also focus on emerging markets, enabling Portescap to utilise its technology to meet new demand, part of the company’s ‘Dream, Develop, Deliver’ concept. “Our approach covers theoretical designs and prototyping through to manufacture. It helps us create the highest performance, most reliable motion solutions for compact applications, and also enables us to

For more information, visit www.portescap.com

PECM Issue 56

Important for standard products but crucial for bespoke development is the proof of concept stage. As part of this, the new Mumbai lab includes in-house 3D printing, enabling the team to rapidly create and test designs. This can involve customising standard parts for fast delivery, utilising existing projects from the company’s customisation portfolio, or creating entirely new designs. “With 3D printing we’ve been able to manufacture parts that would have been difficult to manufacture otherwise, especially at high speed and using new materials, so the ability to achieve this in-house is certainly advantageous for our customers for fast development,” says Dheeraj. “The capabilities of the new lab will also help our global teams receive prototype parts more quickly from our Mumbai factory, speeding up application development around the world.” To validate concepts and prototypes for production, the Mumbai Engineering Lab includes testing across all miniature motor characteristics, such as performance, torque and noise, as well as life testing to ensure long-term reliability of motors for critical applications. Specific to Portescap’s customisation ethos, the new lab is also able to recreate field conditions for dedicated applications. Simulation techniques in virtual and live situations include aspects such as direction of rotation with variable load. Facilities at the new lab include an environment chamber to test a motor against various temperatures and humidity, as well as an autoclave tester for sterilisation applications such as surgical hand tools. The lab also includes an NVH (noise, vibration, harshness) chamber for analysis over varying duty cycles. In addition to the latest test technology, the facilities require subject matter experts to optimise the procedures.

EDITOR’S CHOICE

You could be entitled to R&D Tax Credits The R&D Tax Relief scheme is basically a form of tax relief that may reduce your company or organisation’s Corporation Tax bill. Tax relief can be claimed on a wide range of R&D projects – even those that ultimately proved unsuccessful. It’s quick and easy to determine if you might be able to make a claim for R&D Tax Relief. But 97% of eligible businesses don’t check or claim – don’t let your business miss out in this way!

www.mcs-corporate.com | charlotte@mcs-corporate.com | +44 (0)1926 512475

Issue 56 PECM

HEATSENSE CABLES HEATSENSE CABLES

Specialist High-Performance thermocouple and signal cable Specialist High-Performance High-Performancethermocouple thermocoupleand andsignal signalcable cable manufacturer continues to broaden its manufacturing capabilities manufacturer capabilities manufacturer continues continuesto tobroaden broadenmanufacturing its manufacturing capabilities

CAPABILITIES Heatsense Cables is the UK’s leading CAPABILITIES CAPABILITIES

specialist high performance Heatsense Cables the UK’s UK’sthermocouple leading Heatsense Cables isis the leading and signal cable manufacturer. The specialist high performance thermocouple specialist high-performance thermocouple company highly customer focussed and and signaliscable cable manufacturer. The and signal manufacturer. Its offers a bespoke technical design and company is highly customer focussed and manufacturing capabilities cover a broad manufacturing service, rapid response offers a technical design andin range ofbespoke specialist cables that operate times, short lead times,rapid low MOQ’s and manufacturing service, response extreme (harsh) environments. The company competitive pricing. The company is times, short lead times, low MOQ’s and is a technology leader in fluoropolymer a technology leaderThe in fluoropolymer competitive pricing. company is extrusion, high-performance taping and extrusion, high performance tapinginclude and a technology leader in fluoropolymer cable wrapping. Related processes cable wrapping. Related processes extrusion, high performance taping and cover sintering, colouring, etching andinclude the cover wrapping. sintering, colouring, etching and the cable Related processes include application of various specialist coatings. application of various specialist cover sintering, colouring, etching and theto The range covers cables that are coatings. resistant The range covers cables thatwhich operate in application of various specialist coatings. flame, oils and chemicals and operate extreme environments; cables resistant The range covers cables that operate in ultra-high vacuum, cryogenic and highin to flame, oils & chemicals cables and which operate extreme environments; resistant to radiation environments. in ultra-high vacuum, cryogenic and high flame, oils & chemicals and which operate radiation environments. in ultra-high vacuum, and high The company offers a cryogenic bespoke advanced radiation environments. technical design and manufacturing service INSULATION & BRAIDING and undertakes development work on new EXPERTS INSULATION &materials. BRAIDING cable designs and Insulation materials include; PFA, FEP, EXPERTS PTFE, ETFE, EFGLAS, SILICONE, PE, Insulation materials include; PFA, FEP,PU, INSULATION & BRAIDING EXPERTS PVC, Taped & Sintered PTFE, Polyimide, PTFE, ETFE, EFGLAS, SILICONE, PE, PU, PFA, FEP, PTFE, ETFE, EFGLAS, SILICONE, Aramid, PTFE yarns and Mica. PVC, Taped & impregnated Sintered PTFE, Polyimide, PE, PU, PVC, Taped & Sintered PTFE, Aramid, PTFE impregnated yarns and Mica. Polyimide & Aramid Yarns, PTFE Braiding materials include glass, quartz, impregnated yarns and Mica. ceramic fibre and other specialist yarns Braiding materials include glass, quartz, and various ceramic fibremetals. and other specialist yarns Braiding materials include glass, quartz & and various metals. ceramic fibres, other specialist yarns and PRODUCTS various metals. The company manufactures a broad range PRODUCTS of cables including; thermocouple cables, The company manufactures a broad range PRODUCTS RTD cables & PRT wires, sensor wires & of cables including; thermocouple cables, The high-performance cable rangequartz, includes recently acquired the Chords & Lacing improvement journey. The company is cables, cryogenic glass, RTD cables & PRT cables, wires, sensor wires & thermocouple cables, RTD cables & PRT business from Carlisle Interconnect currently working on Industry 4.0 technology, Tapes and improve efficiencies. The company ceramiccryogenic fibre and pure nickel cables, cables, cables, glass, quartz, EXPANSION wires, sensor wires & cables, micro-wire & Blackburn. utilising digital processes on individual continues to develop its digital strategy the INTEMP® Range (250°C 1250°C), and improve efficiencies. The company ceramic fibre and pure nickel cables, Heatsense remained extremely active EXPANSION miniature cables, cryogenic cables, heatwires production lines to further improve encompassing shopfloor data capture, radiation resistant cables, continues to develop its digital strategy the INTEMP® Range (250°Cequipment - 1250°C), during the COVID lockdown period. Over Heatsense remained extremely active resistant & wires – the INTEMP™ This will present additional efficiencies, quality andtwelve throughput rates. ERP,acquisition CRM and machine automation. & cables,cables high voltage cables, multicore encompassing shopfloor data capture, radiation resistant cables, equipment wires the course of the last months during the COVID lockdown period. Over range of cables, glass fibre, quartz, ceramic opportunities in the aerospace market. cables, micro wires & cables, micro-coaxial ERP, CRM and machine automation. & cables, high voltage cables, multicore Heatsense acquired & equipment, the course of the last plant twelve months &cables, pure nickel cables, resistant Eincluding XPANSION Heatsense is ISO9001:2015 and high-flex braided cables and cables, micro wires &radiation cables, micro-coaxial 16acquired additional high& speed yarn Heatsense plant equipment, wires cables, equipment wires, UHV & MARKETS ACCREDITATIONS ISO14001:2015 Accredited and PTFE &yarns & threads. support these Heatsense is&ISO9001:2015 andhas F4N cables, high-flex braidedTocables and braiders, 16 a continues PTFE Paste Extrusion Line, Heatsense tohigh addspeed specialist including additional yarn low outgassing cables, high-voltage wires Status (Fit for Nuclear), awarded byF4N activities Heatsense has its own specialist ISO14001:2015 and has PTFE yarns & threads. To support these Markets includeAccredited aerospace, nuclear, a horizontal twin Paste headed taping line, plant &equipment and over the last braiders, a PTFE Extrusion Line,an &thermocouple cables, Heatsense micro-coaxial cables, bespoke the Nuclear Advanced Manufacturing calibration and additional corona etcher and refurbished Status (Fit for Nuclear), awarded by automotive, medical, R&D, Oil & Gas and activities has itsfacilities own specialist twelve months has installed a PTFE a horizontal twin headed taping line, an cables, multicore cables, high flex braided Research Centre. The company is in the cable testing laboratory. and upgraded aline, number of manufacturing general industry. Heatsense is EN9100:2018, the Nuclear Advanced Manufacturing thermocouple calibration facilities and paste extrusion 26 additional highadditional corona etcher and refurbished cables,testing PTFE yarns and PTFE chords & process ofCentre. working towards AS9100D:2016 lines.upgraded The company also of upgraded its ISO9001:2015 and The ISO14001:2015 Research company is in the cable laboratory. speed braiders, horizontal dual headed and aanumber manufacturing lacing tapes. Accreditation and expects to be Markets include, aerospace, nuclear, internal manufacturing systems and ‘went Accredited. The Company has alsoaccredited been process of working towards AS9100D:2016 taping line, an additional corona etcher lines. The company also upgraded its by the end of (Fit thisfor year. automotive,, medical, R&D, oil & gas live’refurbished on manufacturing a new fully awarded F4N Nuclear) Accreditation and expects to Status. be accredited Markets include, aerospace, nuclear, and andintegrated upgraded several internal systemsERP andsystem. ‘went Iand NDUSTRY4.0 general medical, industry. R&D, The company manufacturing lines.integrated The company by the end of this year. automotive,, oil & gas live’ on a new fully ERP has system. offers a range of approvals which T: +44 (0) 1706 767070 The upgraded company continually strives to For further information please visit Heatsense has fully embraced LEANmeet also its internal manufacturing and general industry. The company broaden its manufacturing capabilities W:+44 www.heatsensecables.co.uk internationally recognised specifications. manufacturing and has made www.heatsensecables.co.uk and/or contact systems and went live on astrives new fully offers a range techniques of approvals which T: (0) 1706 767070 meet The company continually to integrateditsERP system. Heatsense has substantial progress on its continuous sales@heatsensecables.co.uk broaden manufacturing capabilities W: www.heatsensecables.co.uk internationally recognised specifications. For further information please visit www.heatsensecables.co.uk and/or contact sales@heatsensecables.co.uk For further please visit www.heatsensecables.co.uk For further information please visit information, www.heatsensecables.co.uk and/or contact sales@heatsensecables.co.uk

PECM Issue 56

SPECIALIST HIGH-PERFORMANCE SOLUTIONS

CABLE INNOVATION INNOVATION CABLE

SPECIALIST HIGH-PERFORMANCE SOLUTIONS SPECIALIST HIGH-PER UTIONS

EDITOR’S CHOICE EDITOR’S CHOICE

SPECIALIST HIGH-PERFORMANCE SOLUTIONS

Thermocouple Cables

RTD Cables & PRT Wires

Sensor Wires & Cables

Micro Wires & Miniature Cables

Heat Resistant Cables & Wires for Extreme Temperatures

Glass Fibre, Quartz, Ceramic & Pure Nickel Cables

INTEMPTM Range of Cables

Radiation Resistant Wires & Cables

Equipment Wires & Cables

UHV & Low Outgassing Wires & Cables

High-Voltage Wires & Cables

Micro-Coaxial Cables

Bespoke Cables

Multicore Cables

High Flex & Braided Cables

PTFE Yarns, Lacing Tapes & Chords

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

EDITOR’S CHOICE

LONG TERM EFFICIENCY BURCKHARDT

Prevention is better than the cure Well-planned maintenance of any equipment is essential for long-term reliability and efficiency. Following the routine servicing carefully detailed in the operator’s manual may seem obvious, but this is crucial to preventing potential downtime caused by avoidable issues. This is especially important for equipment, such as reciprocating compressors, that form a vital part of multi-million dollar marine gas transport vessels and need to operate reliably round-the-clock. Anthony Cornes, Key Account Manager – Marine Service Solutions at Burckhardt Compression looks at the importance of following the correct maintenance procedures. Like most large pieces of equipment, each compressor is specifically designed for a particular application. Using the most appropriate materials and components, which are tailored to the individual application, each build is unique. To reflect this, the installation and operation manuals will often have information that is exclusive to a particular machine.

EXPERT ADVICE Reciprocating compressors are similar in principle to internal combustion engines and share concepts in lubrication, cooling and reciprocating pistons. The precision engineering of the design affords excellent reliability, which is supported by regular inspections and maintenance, as detailed by the OEM. Each aspect of operation is carefully explained with cautionary notes about the consequences of poor maintenance to emphasize the importance of following procedures and using the right materials and components. For the lubrication systems, this is relatively obvious since all the moving parts rely on the correct specification of oil to perform reliably. The associated heaters and filtration systems need to be checked regularly to ensure a long service life. The coolant system for a gas compressor is similar to that of a car or truck, in that it

PECM Issue 56

Corrosion caused to cylinder water chamber due to an incorrect glycol mixture crack if the coolant froze as a consequence of incorrect maintenance.

Like most large pieces of equipment, each compressor is specifically designed for a particular application. requires glycol to be added to the coolant water. This not only increases the boiling point of the coolant, but it also provides anti-corrosive properties to protect the internal galleries of the compressor and the heat exchanger. Glycol is used in marine applications, not because of the probable low ambient temperature, but due to the low suction temperature of the gas, which is related to the type of gas and its composition. In a land-based application, the compressor may be exposed to much lower temperatures and if it is stationary without antifreeze, the cylinder blocks could

MINI CASE STUDY: CHECK-LIST CAUTION As part of the delivery of a new LNG vessel, all the equipment and systems are checked and commissioned prior to hand-over to the customer. This should involve a series of checklists and actions to ensure that everything is ready for the first day of full operation. The consequences of making assumptions or not following this system are highlighted in a recent example. As part of a new build, Burckhardt Compression had delivered two boiloff gas (BOG) compressors to an LNG transport vessel. The design was based on numerous criteria that had been established during the project planning phase. The coolant water specifications were part of this information package provided by the customer because they could affect the materials used in the construction of the compressor. Furthermore, the overall compressor cooling system is separate from the compressors and beyond the scope of Burckhardt Compression. Following on from

After less than one year in service, the vessel reported coolant in the compressor oil system and requested Burckhardt attend to investigate and provide technical support. When Burckhardt’s engineers came on board to carry out this inspection, they found that the coolant galleries around the cylinders were more corroded than they expected. Further investigation showed that the correct, specified mixture of glycol had not been installed by the responsible maintenance team during the commissioning process and preas a result, some corrosion was found in the cooling jacket of the cylinders as well as in the pipework to the compressor. While this was not an immediate problem, left unchecked, the corrosion could cause serious damage. A plan was formulated where the compressors could continue to operate, having installed new coolant with the correct mixture of glycol, and the damaged parts would be replaced during the first dry-dock maintenance period.

ONGOING SUPPORT Thankfully, the Burckhardt Compression service team discovered the issue and established the extent of the damage before it had an impact on the performance of the vessel. However, there is little consolation that this whole situation could have been avoided had the correct maintenance procedures been followed.

Laby®-GI Compressor skid package for marine applications

To resolve the situation, the cylinders and the pipework needed to be replaced. Aside from the time required to complete this work, the overall project cost was considerable. Burckhardt Compression has supported the operator with a comprehensive inspection report and planning for the new components that will be installed to ensure continued, reliable operation of the compressors.

installation, any treatment of the cooling water, such as the addition of biocide, anti-freeze or anti-corrosion additives and maintaining proper mixture is a responsibility that is retained by either the shipyard or the vessel’s owner.

PREDICTIVE MAINTENANCE As with all equipment, manufacturers provide an owner’s manual that offers all the information required to operate and maintain the machinery. In today’s world where modern servicing routines are more proactive, manufacturers such as Burckhardt Compression encourage predictive maintenance practices to optimize performance and minimize downtime. A flexible approach includes both regular maintenance schedules and predictive practices to ensure the continued reliable and efficient operation of the equipment.

Cylinder water chamber after cleaning About Burckhardt Compression

For further information, please visit www.burckhardtcompression.com Issue 56 PECM

EDITOR’S CHOICE

PHOTOCHEMICAL ETCHING PRECISION MICRO

Medical device manufacturer partners with Precision Micro to increase etched component production – fast For manufacturing firms looking to scale their operations quickly and affordably, leaning on the expertise of their supply chain can be highly impactful. It is this approach which has enabled a leading manufacturer of medical components to increase the production of its nebuliser while maintaining the same high standards of quality. Through the process of photochemical etching, Precision Micro has been able to quickly move from prototyping to largescale the production of a critical etched shim, while keeping costs down. Made of stainless steel, which is used widely across the industry thanks to its versatility and durability, this small shim, though simple, is instrumental in the nebuliser’s operation.

CRITICAL DESIGN FEATURES As a stress-free component which is required to be completely flat and clean, the process of photochemical etching delivers shims in which there are no unaltered physical properties – precision crafted to specification. In practice, this ensures its customer can rely on components which are 100% true to specification, without the possibility of burrs or stresses which are common in other types of metal machining.

SUPPORTING GROWTH WITH SCALABLE SUPPLY Now producing more than 100,000 precision-etched shims, Precision Micro’s process of photochemical etching has enabled the company to scale its operations – doing so cost-effectively and without compromising on quality. Combining sheet metal with a CADimage-printed photoresist mask, the required components are then selectively etched with chemical etchants, photochemical etching presents a less

intrusive, more accurate and repeatable option for creating intricate components. Alongside the uncompromising quality of final components, photochemical etching benefits from extremely low tooling and set-up costs which facilitate the turnaround of components in short timescales. Capable of producing parts to the same exacting quality every time, components can be produced at differing volumes and at short notice.

A STRONG CUSTOMER SUPPLIER RELATIONSHIP Despite Brexit, Precision Micro has been able to maintain its commitment to providing the highest levels of service and support to its international customers, which has been critical to supply chains at a point of high growth.

something which would be difficult to replicate with other machining processes where scale and complexity generally results in increased costs. We’re looking forward to continuing our relationship and working closely to bring out even more benefits of photochemical etching in their business.”

Markus Rettig of Precision Micro said: “This example, of components for an innovative nebuliser machine, really demonstrates how working as partners can lead to success. Our process has allowed for consistent, cost-effective scaling as demand has increased –

By working together when the needs of its customer were small, Precision Micro was able to lay the foundations for growth through their specialist machining process. This has resulted in scaled production which consistently and costeffectively delivers quality.

For further information, please visit www.precisionmicro.com

PECM Issue 56

EDITOR’S CHOICE

ifm helps to ensure safe extraction! Full design and manufacturing service for bespoke and standard Pressings, Wireforms, Coil and Gas Springs We understand that no two jobs are the same; often requiring the use of different materials, treatments, variable tolerances or specific heat resistance. Investing in the latest technology and qualified toolmakers ensures that we can design and produce the very best bespoke stampings, springs and wire forms. A custom-tailored manufacturing process and in-house design

PECM Issue 56

service – with CAD/CAM software and systems – means we can help you realise a range of prototype ideas, individually cut using precision lasers for R&D testing or put into full production. Our fully-equipped tool room can design and build any production tooling needed, assuring you of competitive pricing, consistent quality and dependable supply.

www.europeansprings.com

Flow sensors in the new SA series from ifm electronic have been specifically developed to provide accurate and reliable monitoring of exhaust air flow on machines, thereby helping to ensure that potentially harmful dust, gases and vapours are safely removed and do not escape into the factory environment. The sensors incorporate robust stainlesssteel probes, which makes them suitable for use in many applications where corrosive gases and vapours are present. Three versions of ifm’s new SA sensors are available. The SA5020 has a 45 mm long probe and an M18 fitting, while

the SA4120 and SA4320 have 100 mm and 200 mm long probes respectively and are installed via a compression fitting that allows optimal installation in ducts and pipes. All types available in this range have an air velocity measuring range of 0.6 to 30 m/s and all incorporate a temperature sensor. In many applications, this means that one sensor can do the job of two.

https://www.ifm.com/ gb/en/shared/productnews/2020/sps/flowsensor-ensures-safety

EDITOR’S CHOICE

1982 – 2022 Celebrating 40 Years of Premier Coatings Ltd Premier Coatings Ltd are proud to be celebrating 40 years of trading this year. Founded in 1982 and operating from Smarden in Kent, Premier Coatings Ltd specialise in the manufacture and supply of a wide range of corrosion prevention and chemical resistant coatings, linings, and waterproofing systems. The company supplies reliable and cost-effective products to the Oil & Gas sector, Utilities sector, and construction industry. Their Products are supplied to a variety of National, ISO, and commercial standards. The Premseal™ range of waterproofing and gasproofing products are CE and UKCA marked, and the company operates under ISO 9001:2015 and ISO 14001:2015 quality and environmental management systems. In 1997 Premier Coatings Ltd was acquired by anti-corrosion and sealing specialist Winn & Coales International, where it continued to prosper and in 2017 achieved a Queen’s Award for Enterprise: International Trade. Steve Crawley, Managing Director of Premier Coatings Ltd commented, ‘This major milestone of 40 years could not have been achieved without the support of our employees, distributors, clients and the continual development of the company and its products. We are proud of our past and look forward to an exciting and successful future together.’ The 40-year success of Premier Coatings Ltd is a story of technical expertise coupled with high-quality, long-lasting products underpinned by continued investment in new manufacturing methods and technology.

www.premiercoatings.com

SmartZone G5 Security Handle Offers Secure Dual Authentication Panduit has launched the SmartZone™ G5 Security Handle for ITE cabinets, which is designed to meet the most rigorous security challenges, both physical and digital, in today’s data centre environments. The multifunctional smart handle offers multiple configurations with and without a keypad to compliment users’ operational requirements. The integrated keypad version enables dual authentication by allowing for a card swipe and pin-code combination to access the cabinet.

the capability to read both low frequency (125kHz) and high frequency (13.5MHz) cards. The handle has been designed to be current and future compliant with regulations required within this environment and is also GDPR ready, HIPAA ready and PCI-DSS ready to ensure that this design meets data centres and users’ cabinet security needs. It can support 200 authorised users and features an integral humidity sensor allowing humidity sensing to be optimally placed near the centre of the cabinet.

The G5 Security handle seamlessly mates with most data centre cabinets and has

To learn more, visit www.panduit.com.

Issue 56 PECM

EDITOR’S CHOICE

A GREENER FUTURE EXPROMET GROUP

How Expromet Group companies are reducing their environmental impact In the wake of COP26, the need to reduce emissions and find more sustainable means of meeting our energy demands has never been clearer. As a major contributor to pollution, it is incumbent on the global manufacturing industry to take all possible steps to reduce its impact on the environment. Expromet Technologies Group takes this responsibility very seriously and our Group companies, Haworth Castings, Investacast and Metaltech, are working on a variety of initiatives to achieve this goal.

LEAN MANUFACTURING At the simplest level, the Group companies work continuously to ensure their various manufacturing methods minimise the use of energy, materials and time to deliver the best outcomes at the lowest environmental cost. This includes recovering scrap metal, recycling sand and swarf and reusing customer packaging where appropriate.

WASTE-FREE DESIGN The use of state-of-the-art simulation software enables products to be designed right first time, without the trial and error of using metal, tooling or consumables to prove a design concept. Prototypes are produced quickly using methods such as 3D scanning and printing, providing customers with an early opportunity to verify the product prior to committing to full production. Indeed, throughout the design and manufacturing process we push the boundaries of engineering to achieve efficient and sustainable design. Each of our companies strives to deliver lean and green manufacturing processes that benefit both Expromet’s customers and the planet.

INVESTMENT IN GREEN ENERGY As a group, Expromet is investing to reduce its environmental footprint. Major projects include the installation of biomass heating to reduce the use of fossil fuels, and extensive solar panels to provide sustainable energy.

providing products used in applications such as pump & valve and safety critical equipment.

Expromet is committed to providing solutions for the clean energy sector and is participating in schemes to promote green energy Each Group company is also looking at ways to make better use of energy – for example, upgrading a factory roof has improved access to natural light whilst providing better insulation; and installing motion-sensitive LEDs has significantly reduced the demand for electric lighting.

DELIVERING FOR THE RENEWABLE ENERGY SECTOR For many years, Haworth Castings, Investacast and Metaltech have supported multiple customers in the Energy sector,

Expromet is committed to providing solutions for the clean energy sector and is participating in schemes to promote green energy, such as the Offshore Wind Growth Partnership WEST programme, which supports UK companies that have the potential to work in the offshore wind sector by helping them to develop and commercialise their offering to the sector.

EXPROMET LOOKS TO A CLEANER MANUFACTURING FUTURE Expromet Technologies Group has a clear commitment to working towards a sustainable manufacturing future through direct and indirect initiatives, knowing that every little helps. “We are committed to minimising our impact on the environment,” confirms CEO Alistair Schofield. “Expromet aims to play a leading role in the manufacturing supply chain, driving the development of clean and renewable energy solutions, whilst delivering leaner and greener manufacturing processes.”

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

PECM Issue 56

EDITOR’S CHOICE

WIDER PRODUCT OFFERING OEM

Zoedale Ltd has now integrated into OEM Automatic Ltd Zoedale Ltd was founded in 1976 and is a specialist in solenoid valves and valve actuators. Amongst others, Zoedale represents ASCO, Valpes, Omal, Bernard Controls and Peter Paul, which manufacture valves and actuators for various process and industrial applications. OEM Automatic acquired Zoedale in January 2020 and Zoedale has been integrated into OEM Automatic since 1st April 2022. Customers will continue to receive the excellent customer service they’ve come to expect from Zoedale, but in addition, enjoy a wider product offering. “Because of the synergy between both companies’ product offerings, it means we can offer our customers and Zoedale’s customers a much broader range of products. Not only will we be offering more products, but we will also be utilising both companies’ expert technical advice to provide the best solutions for their applications,” commented Peter Evans, Managing Director at OEM Automatic Ltd. The Pressure & Flow department specialises in the specification and supply of a wide range of products and instrumentation designed to measure and control liquids and gases’ pressure, flow, and level in industrial and hygienic markets. Product offering includes process instrumentation, float, flow, pressure and level switches, valves, pumps and pigging systems/valves. OEM Automatic market and sell components for industrial automation and currently represent over 100 leading suppliers, including, Datalogic, Definox, Contaclip, Kubler, Basler, Panasonic, Val.Co, GHM Group, Crouzet, Asco, Auer Signal, Anderson Negele, Ensto, Suco, Doga Motors and Idem safety switches. OEM can supply and advise on a wide range of industrial automation solutions for a vast range of industries, including rail transport, food & beverage production, medical and life sciences, process packaging & machinery, AVG and robotics,

Because of the synergy between both companies’ product offerings, it means we can offer our customers and Zoedale’s customers a much broader range of products

customised and bespoke solutions. The technical workshop added value facility offer services such as pressure switch setting, switch potting & cabling, additional wiring looms, kitting of multiple parts and bagging and labelling to your requirements. OEM Automatic Ltd is a UK subsidiary of OEM International AB of Sweden and has been representing leading manufacturers of industrial automation products in the UK since 1989. You can find more information about OEM Automatic Ltd on www.oem.co.uk or the parent company on www.oem.se.

building automation, security, conveying and lifting, hydrogen and chemical industries to name just a few.

Read zoedale’s new brochure on our website, which also has our pressure and flow brochure too. Read them here: https://www.oem.co.uk/downloadableresources/downloads

OEM Automatic stocks over 8,500 products from their centrally located logistics centre. The OEM Automatic technical workshop facility is also available to their customers, where the technical teams can offer

If you have any further questions, please feel free to contact your Zoedale sales contact or the team here at OEM Automatic – 0116 284 9900.

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

PECM Issue 56

EDITOR’S CHOICE

EFFICIENT PROCESSES OEM

Industrial process equipment suitable for your production line Industrial process equipment is used in many sectors including mobile hydraulics, water treatment, chemical industry, pneumatics, cooling systems and medical gas systems. For an efficient and effective process, industrial equipment should be robust, longlasting and use material fit for the application in order to monitor the flow, level and pressure of elements like air, gas, water, oil and steam. These components must be able to with-stand harsh conditions and all types of media. Good quality industrial products comply with industrial regulations and approvals such as ATEX, IECEX, DNV, HAT, SIL, PED and MID. Let’s turn to some of the equipment that is essential for the smooth running of an industrial production line. FLOW SENSOR A flow sensor records the measurement of flow velocity, temperature, and volume of liquid media. Reasons why we recommend the Honsberg OMNIPLUS thermal flow sensor 1. Three measurement variables in a single device It’s an all-in-one solution that includes a flow sensor, volume meter and thermometer. 2. Reliability with the wear-free measuring principle This is a low maintenance device so, system downtime is at a minimum. It allows you to monitor cooling and lubrication circuits whilst managing pump protection. This ensures proper functioning of the system and avoids the chances of damage. 3. Fast response times The OMNIPLUS is one of the fastest calorimetric flow sensors on the market because of its special sensor arrangement and software, it’s ideally suited for minimum quantity monitoring. 4. IO-Link The IO-Link interface reduces wiring costs, and it enables digital transfer of measurements and sensor data, including

the complete parameterisation of the sensor. 5. Easy-to-read display A large and high-resolution display shows the measurement variables. You can even use the OMNIPLUS in low light environments. 6. Configurable for every purpose The OMNIPLUS can be flexibly assigned to analogue or digital outputs. It’s easy to change the settings directly on the device by using the multifunction ring, and there is 100% connection compatibility with existing OMNI devices. FLOW SWITCHES Flow switches increase system safety and protection and are used in applications like industrial washing machines, self-service car washes, refrigeration, and hydraulic applications. They can be used on water, oil and aggressive media such as corrosive and abrasive flows. Depending on your application, you may require a specific type of flow switch like paddle or piston. Flow switches are available in various materials, including stainless steel, brass, and nickel-plated brass, to suit your application. FLOW METERS Flow meters measure flow velocity and volume flow. A number of different ones are available so there will be a flow meter to suit your requirements. When you require an accurate volume calculation, the right flow meter can provide accurate measurements. Perhaps you may require a flow sensor with no moving parts or a flow sensor for

large pipe dimensions. Or you may need a compact flow sensor in other materials which suit different types of media. INDUSTRIAL DIN CONNECTORS Industrial cable connectors, otherwise known as DIN connectors, are used to provide an electrical connection to your flow monitor, solenoid valves, pressure monitors and sensors. Ensure the connector protects against dust and water ingress. Choose connectors depending on the cable material and length appropriate for the application. INDUSTRIAL VALVES A wide range and variety of industrial valves can be used on your production line. They control the critical flow of air, gas, water, oil and steam and are key components of a production line. Valves used in the industrial sector must be able to handle the most challenging conditions. For example, you may use angle seat and motorised valves for automotive and wastewater management, or you may require solenoid valves that are explosionproof in hazardous environments. If you are interested in learning more about any of these components and discussing your requirements, do contact pressureandflow@oem.co.uk. We’re always happy to advise you on the best solution to ensuring a successful production line that’s safe, reliable and efficient.

For further information, please visit www.oem.co.uk Issue 56 PECM

EDITOR’S CHOICE

CHANGING PERCEPTIONS PP C&A

PP C&A boss urges UK manufacturers to make the most of a ‘once in a generation’ reshoring boom PP C&A boss urges UK manufacturers to make the most of a ‘once in a generation’ reshoring boom De-risking supply chains, mitigating long lead times and ensuring security of supply are driving a major reshoring trend back to the UK according to a leading manufacturing boss. Tony Hague, CEO of PP Control & Automation (PP C&A), believes that cost and availability of freight, combined with huge economic and political uncertainty, is changing perceptions when it comes to the ‘total cost of acquisition’ and this translates into a ‘once in a generation’ opportunity for domestic manufacturers. His own business is already reaping

PECM Issue 56

dividends, picking up new contract manufacturing orders with OEMs involved in transport, energy and power and warehousing and logistics. These clients had previously worked with partners in China, Eastern Europe and India, but have recently turned their attention closer to home to achieve higher added value and shorter lead times. “Reshoring is happening and the opportunity for the wider UK economy will only increase in my opinion,” commented Tony, who was named in LDC’s top 50 most ambitious business leaders last year. “The political and economic landscape is volatile, and this is driving questions relating to risks and costs around ‘extended’

Reshoring is happening and the opportunity for the wider UK economy will only increase in my opinion.

and distant supply chains. There is also growing environmental concerns, as well as corporate and social responsibility of partners that reside in the supply chain.”

He continued: “All of this means we are now more competitive than ever, and this is encouraging companies to return to the UK or increase local content.” PP Control & Automation, which employs 230 people at its world class factory in Cheslyn Hay, is on course to post £28m sales for the last twelve months, with a future order pipeline suggesting further growth is on the horizon. The strategic manufacturing outsourcing specialist has seen demand for its services rise by 25% on the previous year and bosses at the firm believe this is due to a combination of reshoring and an increasing number of high technology businesses bringing new innovations to market. Member of the Manufacturing Assembly Network (MAN), the firm has recently widened its engineering and manufacturing capabilities to include a more comprehensive mechanical/ pneumatic offer and a dedicated Electrostatic Discharge (ESD) area to support electronics integration. “The opportunity is there, but UK manufacturers need to be bold and brave to ensure they take advantage of it,” added Tony.

“We need to invest in people, process and automation in order to create manufacturing models that are agile and flexible. Focus and spend in areas where you have really strong core competences and ensure you partner with experts in their respective fields.” He concluded: “Companies do not need to get bogged down with high levels of

vertical integration, it just causes higher overheads and can lead to lack of flexibility when capacity and demand cycles changes. “Get this balance right and there’s no reason why UK manufacturers can’t overcome international rivals by delivering design for manufacturing support, security of supply and more added value.”

For further information, please visit www.ppcanda.com or follow @ppcanda on twitter Issue 56 PECM

EDITOR’S CHOICE

REAL TIME MONITORING BENDER

COMTRAXX® CP9i delivers touch screen condition monitoring for industrial applications

The increased communication functionality also allows the end-users to receive remote information when site access is not always possible, reducing the time taken to identify and rectify developing power systems issues.

New touchscreens from Bender offer intelligent condition monitoring and an overview of connected electrical systems to deliver real-time monitoring, fault diagnosis and alarm in industrial settings. With an integrated touch display, customised visualisation of connected systems and intuitive operation, the new displays help engineers and maintenance teams manage the performance, availability, and uptime of high-value assets. Available in 7- and 15.6-inch display sizes, the CP9…-I series features a condition monitor with web interface, a display with integrated BMS and BCOM interfaces as well as Modbus RTU/TCP, for connecting to Bender and third-party devices. Measured values, parameters and other data are available via the web interface or display. The 7-inch version is suitable to be mounted in a control cabinet door so that information is highly visible.

Robust construction and solid Bender design mean there are few limits to potential industrial applications, with remote access via LAN, WAN or Internet allowing for diagnosis and maintenance. Typical applications include data centres, wind farm, manufacturing, process, and plant. The flexible display format provides an overview of connected system parameters, with active visual and acoustic notifications in the event of alarms, with the option of displaying the source and corrective action for any faults that occur. The COMTRAXX® CP9...-I has antireflective IP54 rated glass and a screwless front plate that is easy to clean. The screen offers high-resolution representation with excellent contrast and wide viewing angle, with the option for incorporating associated building plans.

Lee Slater of Bender UK said: “The CP9…-I allows greater visibility of electrical power system health at a glance. The increased communication functionality also allows the end-users to receive remote information when site access is not always possible, reducing the time taken to identify and rectify developing power systems issues. The CP9…-I is suited to both those with and without an existing building management system”. Continuous hardware and software development means these products are future proof with updates provided free of charge. And as with all COMTRAXX® devices, comprehensive analysis and evaluation functions are available and include the opportunity to investigate abnormal conditions using memory and data loggers. Contact Bender UK Industrial sales team for information industrialsales@bender-uk.com.

For further information, please visit www.bender-uk.com

PECM Issue 56

NEW Bender CP9i Condition Monitor

Improve engineering efficiency in industrial applications

Continuously monitor installations with one holistic overview

Simple and easy to operate via an intuitive, touch-sensitive display console

Integration and visualisation of all Bender and third-party devices

Flexible to suit a range of industrial and commercial settings

Future-proof technology due to software development

Available in a 7” or 15.6” display with tempered, non-reflective glass

www.bender-uk.com

EDITOR’S CHOICE

EST. 1850

Thorite showcases energy efficiency and training expertise at Air-Tech The Bradford based company will demonstrate how its innovative technology, unique design-and-build pneumatic systems service, and tailored aftermarket support can save companies significant sums and help them reduce their carbon footprint.

Mark Yates, Head of Sales and Marketing at Thorite, said: “We place a huge focus on energy efficiency, not just in terms of the systems we supply, but as part of a comprehensive support service that ensures long term operational efficiency and cost savings for our customers. “Our market-leading training courses in Pneumatics and Hydraulics cover everything from Foundation, Intermediate and Advanced Engineering, through to Troubleshooting and Maintenance. Our intent is to ensure that inhouse teams have a better understanding of the assets they maintain and thus save on the cost of engaging external help”. “We believe that this tailored, end-toend service is what sets us apart from our competitors and we’re excited to be showcasing it at Air-Tech.” www.thorite.co.uk

PECM Issue 56

SCAN NOW

Looking to Develop Your Existing Skillsets

Leading independent air and fluid power specialist Thorite will showcase its 360° energy efficiency service at the Air-Tech exhibition in Birmingham on April 5th to 7th.

Thorite’s bespoke training offer will also be a focus at Air-Tech, the UK’s largest exhibition for compressed air, vacuum and generator innovation.

/thorite-academy

Pneumatics, Hydraulics, Troubleshooting & Maintenance Courses

Why Choose Thorite Academy?

We believe that this tailored, end-to-end service is what sets us apart from our competitors and we’re excited to be showcasing it at Air-Tech.

Programmes that Reﬂect Modern Industry Personalised and Practical Approach to Learning In House & Distance / eLearning Options Available Industry Recognised Training for Beginner & Advanced Delegates

0800 034 5850

www.thorite.co.uk *T&Cs apply

EDITOR’S CHOICE

Standard Flow Measurement Solutions INTRODUCING THE UK’S FLOW METER DISTRIBUTOR – MARSTON FLOW

Marston Flow aims to deliver standard flow meter solutions with quick delivery times and lower costs.

Following the successful website launch in April, Marston Flow (forming part of Litre Meter) brings a range of standard flow meter solutions direct to businesses within the UK.

With a range of flow meters from Litre Meter, KEM, Sierra, TRICOR Coriolis and AW Lake, you can be sure to find your standard flow solution with Marston Flow.

www.marstonflow.co.uk

we make ideas come to life

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

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

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

Issue 56 PECM

EDITOR’S CHOICE

A PLETHORA OF POSSIBILITIES 3D PRINT UK

3D printing for unique automotive applications

Nick Allen, Managing Director, 3DPRINTUK The uses of 3D printing today are well established across industry, and it is routinely used as a prototype and production technology. As more and more companies become aware of the design freedom that 3D printing stimulates, and the versatility of the technology when it comes to creating innovative parts and components, its adoption by a whole host of designers and manufacturers is burgeoning.

PECM Issue 56

Occasionally, however, the use of 3D printing has the ability to stop you in your tracks, and such is the case when looking at the work undertaken by Jonny Ambrose (www.jonnyambrose.com). Ambrose makes hugely imaginative and tactile automotive sculptures, and for the last five years or so, 3D printed parts have been at the heart of his work (@ jonnyambrose.autoart). Ambrose says, “What makes my automotive sculptures work is the

juxtaposition of traditional techniques such as steam bending of wood alongside the use of ultra-up-to-date manufacturing processes such as CAD solid modelling and 3D printing. Whereas previously I would use milling when trying to create lattice structures, for example, today I use 3D printing which is able to build strong, lightweight structures with geometries impossible to achieve using traditional manufacturing methods.”

material that brings new elements to my works that I cannot achieve via alternate means.”

What makes my automotive sculptures work is the juxtaposition of traditional techniques such as steam bending of wood alongside the use of ultra-up-to-date manufacturing processes such as CAD solid modelling and 3D printing.

Ambrose came into contact with 3DPRINTUK at a trade show when he was researching the state of the 3D printing sector and whether the technology was something that he could incorporate into his work. Initial projects tinkered around

with the technology often building simple solid parts that could have been milled, but which through the use of 3D printing and Autodesk’s Fusion 360 software facilitated a relatively simple and seamless workflow. Over time, Ambrose has used both the SLS and MJF processes through 3DPRINTUK, and also an array of postprocessing technologies as he creates more and more intricate parts.

Ambrose has been working with 3DRPINTUK for a number of years since recognising the ways in which 3D printing could be incorporated into his work. Lattices are an ideal example of how 3D printing opens up design possibilities. What makes lattices unique is how they lay out materials into design elements to form an ideal structure that are made up of micro-architectures with a network of nodes and beams or struts. This format dramatically reduces weight while retaining structural integrity and giving a larger degree of control over certain characteristics. These interlinking portions can enhance various areas of performance and use less material without weakening the object or compromising its integrity. The largest one-piece lattice that Ambrose has produced was 40 cm long, and this demanded that the team at 3DPRINTUK used all their know-how and understanding of 3D printing to accommodate the piece in the build chamber, and ensure its integrity once built. This was all about orienting the part correctly to get the best print definition, and making sure that there were no peripheral distortions at the extremities of the part. For Ambrose, 3D printing has opened up a plethora of possibilities for using lattices in his work, but that is not all that the technology allows. He says, “Beyond the creation of lattices per se, I use 3D printing because I like the aesthetic of some of the polished finishes. Also, it allows me to create more intricate shapes and features which would not be feasible for me to do by hand. I find the aesthetics of parts produced via selective laser sintering (SLS) or via Multi-Jet Fusion (MJF) extremely attractive, and it complements the woods, metals, or carbon fibre I use in many of my works. For me, 3D printed parts are just another material, but a Issue 56 PECM

“I use polishing to add the required aesthetic to some parts. I find that polishing gives the parts produced a nice patina-like effect especially on the black parts but to an extent on white parts as well. While on occasion I use unpolished parts where I require the almost ‘sugar lump’ aesthetic, where you can see the grain, it is more often than not nice to have control over the smoothness of parts, and I especially like the almost slate like appearance that can be achieved on polished black MJF parts,” Ambrose comments. Ambrose has been working with 3DPRINTUK since before the company introduced its upload portal and ordering interface, which has more recently transformed the way that he uses the technology. Ambrose continues, “I have to say that I love the ordering interface and file upload portal at 3DPRINTUK. Above all, its, easyto-use. You simply drag and drop files, and you have the ability to track everything and see how an order is progressing. Also, I can get into the system and edit part details if needed. It just works, and is very well thought out. It makes the customer’s

It just works, and is very well thought out. It makes the customer’s life easier, and is obviously designed with the ultimate customer experience in mind. life easier, and is obviously designed with the ultimate customer experience in mind. I love being in control of my projects and getting all the cost and timeof-build feedback automatically without the intervention of sales people. With the 3DPRINTUK system, I can tweak things and assess the effect on cost and build time, and select what I want rather than what I am being sold.” One of Jonny’s recent projects is the Monster 917, a stunning half-sized sculpture inspired by the iconic Porsche 917k, which

is a maze of tubular aluminium and carbon fibre connected by his own 3D printed joints. Ambrose concludes, “The Monster 917 has taken a lot of work, and the use of 3D printing to produce the joints that hold all the tubes together exemplifies a perfect use of the technology. Creating a sculpture like this is a learning curve. Some of the first 3D printed parts used in the chassis were grey undyed MJF parts as they suited the aluminium tubes. I then used black polished joints when joining the carbon fibre. I knew 3DPRINTUK had the process versatility and post-processing technologies I needed to accommodate these requirements. Each of the male lugs that hold the tubes were initially un-flanged, but as the design went on, I designed them to have a spring-like tension which gripped the tube more firmly. Design tweaks and innovative possibilities that could only really be realised through 3D printing.” “The combination of capability and expertise at 3DPRINTUK is what works for me. While the automated system is so good, it is re-assuring to know that behind the scenes is a team of experts that are always on hand to advise and optimise outcomes.”

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

PECM Issue 56

EDITOR’S CHOICE

HUCK MAGNA-LOK MX STAR FASTENERS

The new Huck® Magna-Lok MX has been specially designed to replace M10 bolting, enabling reduced assembly times and production costs Many hours are spent engineering, designing and finally turning raw materials into finished parts, but the next manufacturing step is often assembling and fastening these parts together. While welding, bolting and solid rivets have long been utilized in demanding, loadbearing or high-vibration applications, today’s manufacturers have several strong reasons to consider a proven alternative to these traditional methods. Huck structural fasteners are proven to hold up over years of service in demanding high-stress, high-vibration environments. Whilst ensuring a secure joint, 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. The Magna-Lok MX has been designed to accommodate standard produced holes traditionally suitable for M10 bolts (the recommended holes size for this is 10.8/11.2mm). For applications where only one side of the joint material is accessible, performance-engineered Huck structural

blind fasteners can often meet design requirements. The Huck Magna-Lok MX (MCHFR) delivers repeatable and consistent joint performance, with washer-free waterresistance (fastener should be application tested to ensure suitability) as well as excellent shear, tensile and fatigue performance. Once installed Magna-Lok MX will consistently perform over time, even when exposed to changing loads (vibration / expanding or contracting), eliminating the need for regular maintenance. Magna-Lok MX is installed quickly and easily in a matter of seconds, the installation only requires access to one side of the assembly, meaning only a single labourer is needed. This ensures the assembly is completed both quickly and cost-effectively

Magna-Lok MX Installed

Huck Magna-Lok Cross-Section Cross-Installed Section

PECM Issue 56

Magna-Lok MX

FASTENING WITH HUCK STRUCTURAL FASTENERS DELIVERS FIVE KEY BENEFITS: Safety - The heat generated by welding can often reduce the strength of the metals being joined, and damage critical surface coatings. In addition, welding dissimilar metals or pieces of varying sizes can be a challenge. Welding also often requires an on-going process of inspection, with many of these procedures being both costly and time consuming

Magna-Lok MX

With excellent shear, tensile and fatigue performance, the permanent nature of the joint ensures reduced maintenance costs; the joint does not need to be regularly checked or re-torqued, eliminating ongoing costs over the product lifetime.

Magna-Lok MX Installed Cross- Section

The Huck Magna-Lok is a versatile, hole filling fastener that can be installed with conventional and battery-operated installation tools. It has a unique circlelock design creates an internal lock during installation that virtually eliminates pin pushout by mechanically locking the pin to the sleeve.

Simplicity – Huck fasteners are easy to install and require a minimal amount of training. The Huck system only requires a single trigger press to deliver high, consistent preload. No operator discretion or adjustment required.

Magna-Lok MX Installed Magna-Lok MX Installed

Huck Magna-Lok MX Installed

Huck Magna-Lok MX Revolutionising Silo Assembly

The Huck Magna-Lok is a versatile, hole filling fastener that can be installed with conventional and batteryoperated installation tools.

Speed – As the MX is a blind fastener it just takes one operative to install it. Just the time needed to put the fastener into the pre-prepared hole, to apply the tool to the pin and initiate the installation cycle (approx. 3-4 seconds). Cost Saving – A quick visual inspection is all it takes to ensure a solid joint. Once installed, there are no ongoing maintenance costs.

Huck Magna-Lok MX

Magna-Lok MX

Structural Integrity - creating semipermanent joints that will perform in extreme conditions for years to come without the issues of weld fatigue. Huck structural blind fasteners are not designed to replace all welds. These fasteners can leave a protrusion, which may not be acceptable for some applications. However, there are many applications, where M10 bolts have been traditionally employed, in which these fasteners are a viable alternative. As a well-established leader in the global Huck fastener distribution network Star Fasteners are committed to supplying customers with the most innovative fastening solutions on the market. Working with a diverse range of end users and distributors from across a number of industries including general engineering, rail, solar, wind power automotive, marine and construction markets. In fact, they are widely used in any industry where a quality, strong and dependable fastener is a required… application possibilities are endless!

Battery Powered installation Tool BV-17 Magna-Lok MX Installed Cross- Section

Battery Powered installation Tool For more information on our products and services, potential applications, tips, ideas and product news, follow along on

Batte

Magna-Lok MX Installed

our social media platforms Facebook: Huck Magna-Lok MX Revolu @starfastenersuk and @starfasteners LinkedIn, Twitter, Instagram.

Battery Powered installation Tool

Tel: +44 (0)115 9324939 | email: sales@starfasteners.co.uk | starfasteners.co.uk Issue 56 PECM

BOILERS & MAINTENANCE

New Lanemark process gas burner installations bring clear gains to dumper truck manufacturing The latest process gas burner technology from Lanemark Combustion Engineering Ltd. is now helping one of the country’s leading manufacturers of construction equipment to benefit from optimised energy usage and minimised emissions. Warwickshire-based Thwaites Ltd., who provide a wide range of dumper truck designs particularly to the construction industry, have replaced two well-proven existing Lanemark FD5EP-3 burner installations with the company’s latest force-draught gas and air FD5GAP-3 models. The result is a combination of excellent heat control and an anticipated, significant saving in gas usage. “The two new burners have been fixed to two separate drying ovens, both of which receive products via an overhead conveyor – one for an epoxy primer preheat facility and the other for a polyurethane top coat drying installation,” says Jeff Foster, Lanemark’s Sale Director who says up to 60 different components for 1 - 10 tonne machines are handled each day. “In both cases the burners, which here operate with a Propane gas source, fire through the wall of the oven into a combustion chamber with a recirculating fan then distributing the heat evenly around the oven chamber,” he adds.

The replacement of the two existing Lanemark burners – both hi/lo units which have delivered reliable performance since 1998 – have allowed Thwaites to gain from the latest designs and technology. Lanemark’s FDGA burners utilise the latest ‘air pressure lead’ mono-bloc gas valve technology which is central to ensuring safe and efficient gas/air ratios are always maintained even under variable plant operating conditions. These offer significant benefits compared with alternative fixed gas/air valve linkage control arrangements while the absence of mechanical linkages between the gas and combustion air control valve and dampers means the need for adjustment or the risk of sticking are avoided. “We have ensured that the mounting flanges have remained unchanged over the period so the removal of the old and the connection of the new burners proved to be a very straightforward exercise,” adds Jeff Foster. He points out that the work was completed in just two days during a shutdown maintenance period. Thwaites’ Paintshop Supervisor highlights the importance of the new installations – “Temperature control and stability are vital for the paint adherence process to be optimised

and this is fulfilled by the Lanemark burners,” he says. “Typically, we set the oven temperature to 90°C but the burners can operate at up to 110°C – a useful factor during winter months when ambient temperature can, of course, be somewhat lower.” Thwaites decision to install the two new Lanemark burners was partly based on the company’s long term association with the burner manufacturer. Apart from the burners that were replaced meeting operational requirements for more than 20 years, Thwaites had also, more recently, benefited from a further FDGA unit installed on a new standalone oven. “The performance here meant we had no hesitation in opting for the two additional Lanemark burners for the paint drying facility,” adds the Paintshop Supervisor. With the ongoing support of the Lanemark BurnerCare service package – which offers a range of benefits from installation, commissioning and service plans to spare parts supply and rapid engineer call-out, if needed – the new installations at Thwaites are set to deliver reliable, long term process heating efficiency for many years to come. Central to such an important element of the production process, this translates into significant, ongoing peace of mind for the dumper truck manufacturer.

www.lanemark.com

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

• • • • FD-C high turndown oven/

FD-E low cost high turndown

dryer air heating burners.

oven/dryer air heating burners.

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

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

• • • •

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

• • •

Midco HMA high efficiency,

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

TX high efficiency small diameter immersion tube tank heating systems.

Lanemark Combustion Engineering Limited Lanemark House, Whitacre Road, Nuneaton, Warwickshire CV11 6BW United Kingdom Tel: +44 (0) 24 7635 2000 Fax: +44 (0) 24 7634 1166 E-mail: info@lanemark.com www.lanemark.com X4620PECM Lanemark Ad SDAW.indd 48 Issue 56 1

•

COMBUSTION ENGINEERING

31/08/2016 09:04

11th & 12th May 2022 The NEC, Birmingham, UK PRE-REGISTER FOR FREE ENTRY!

CHEMUK2022 The Supply Chain Expo for the UK’s Chemical, Pharma & Process Industries

FREE ENTRY

WHEN ERED PRE-REGIST

2 Packed Days 300+ Leading Exhibitors Panel Sessions Plant & Process Intensification Control & Instrumentation CHEMICAL 4.0 – Automation / Digitisation Asset Management & Maintenance Plant Management Flow & Thermal Solutions... plus more!

Supporting Partner

Supporting Partners include:

11TH & 12TH MAY 2022 REGISTER FREE AT WWW.CHEMICALUKEXPO.COM

CHEMUK SHOW PREVIEW

THE CHEMUK 2022 EXPO CHEMUK 2022

CHEMUK2022 CHEMICAL SUPPLY CHAIN

●

CHEMICAL ENGINEERING

CHEMUK 2022 presents ‘the chemical, process & plant engineering show’ & ‘the chemical industries supply chain show’ The CHEMUK 2022 EXPO returns on the 11th & 12th May 2022 at the NEC in Birmingham. The event, now established as the UK’s only major expo for the UK chemical industries, will showcase 300+ specialist exhibitors and 100+ expert speakers across two co-locating shows; ‘The Chemical, Process & Plant Engineering Show’, and ‘The Chemical Industries Supply Chain Show’.

Separating into two complimentary yet contrasting exhibition shows can only help to get attendees locked into discussions with their primary targets quicker, as well as providing an easy ‘under one giant roof’ experience to take in the broader trends of the sector”

Show organiser, Ian Stone, comments: “CHEMUK is deliberately set out to be a total industry meeting point, creating a fusion of cross-sector energies, inputs and connectivity, however we also recognise the contrasting needs of attending ‘engineering & plant technical management’ and the wider ‘industry supply chain’ focused attendees, on themes such as supply chain chemicals & ingredients, logistics & outsourcing, HSE, regulatory compliance, R&D management and more….

The Chemical, Process & Plant Engineering Show will showcase latest technology and specialist services to attending UK plant, process, control & engineering professionals across the chemical and wider process industries embracing:

PECM Issue 56

THE CHEMICAL, PROCESS & PLANT ENGINEERING SHOW

• Process Plant / Chemical Unit Equipment / Process Ancillaries & Consumables • CHEMICAL 4.0 / Digital / Automation • Plant Energy Management • Catalysis & Reaction Engineering • Heat Exchanger technology / Thermal transfer innovation • Control Valves & Actuators / Digital &

• • • • • • • • • • • • •

Automation Pipes, Hoses, Tubing & Fittings Flow Technologies Filtration & Separation Mixing, Agitation & Dispersion Metering & Dosing Chemical Processing Tanks / Storage Tanks Conveying/Feeding / Materials Handling Industrial dryers Bio-Chemical Process Engineering Process Design / Modelling, Scale-up & Pilot Plant Predictive Maintenance / Condition monitoring / Asset management Plant Safety Systems Process QA / QC …and more

Current Exhibitors already booked into the show include; FESTO, Schenk Process, Endress+Hauser, Applied Scientific Technologies, GEMU Valves, Moody Direct, Gericke, APEX Pumps, Atlas Copco, AVT Pump, Carbis Filtration, CDR Pumps, Elaflex, Falck Fire Services, HRS Heat Exchangers, VEGA Controls… and many others

Partners supporting the show include GAMBICA, BPMA - British Pump Manufacturers’ Association, BVAA – The British Valve & Actuator Association, Process Intensification Network, NEPIC, Chemicals Northwest and the Tank Storage Association... to name a few

SHOW FEATURE: CHEMICAL 4.0 STAGE – THE DIGITAL OPPORTUNITY Reflecting the tectonic shift towards digitized operations, CHEMUK 2022 will present a dedicated speaker programme covering Digital Adoption Strategies, Process Automation & Robotics, Big Data & Process Data Management, AI & Deep Learning, IIoT/VR, Digital-driven sustainability, and lots more.

Also new for 2022 will be the ‘Bio-Based Chemicals & Processing INNOVATION ZONE’, showcasing breaking innovation start-ups, university spinouts etc, with exciting concepts.

THE CHEMICAL INDUSTRIES SUPPLY CHAIN SHOW

SHOW FEATURE: ‘CHEMLAB’ PROGRAMME

The Chemical Industries Supply Chain Show will showcase specialist exhibitors to attending Product Development, R&D, Supply Chain, Operational and Logistics teams from across the chemicals, chemical products & chemicalsdependent industries, covering: • Chemicals, Raw Materials & Ingredients • Chemical Logistics & Transportation • HSE Management & Regulatory Compliance • Specialist Chemical Labelling • Toll / Contract / Outsourcing/ White & Private Label Services • R&D/Laboratory, Analytical & Testing • Skills, Training & Recruitment • Business & Operational Support

Partners supporting the show include the CBA – Chemical Business Association, BCMPA – The Association for Contract Manufacturing, Packing, Fulfilment & Logistics, BIOVALE, Chemicals Northwest, NEPIC, CATCH, Royal Society of Chemistry… to name a few

Major names already booked into the show include: BTC Europe, Brenntag, Surfachem, Robinson Brothers, Kimia UK. Cod Beck Blenders, Airedale Group, Briar Chemicals, Libra Specialty Chemicals, NCEC, AirSea Containers, Knoell, RAS Risk & Hazard Management, Lakeland Laboratories, Rutpen… and many others.

New for 2022 is the dedicated ‘Sustainability Stage’, hosting panel sessions and feature presentations embracing critical themes such as chemical recycling & sustainable chemical processing, together with ‘green chemistry’ innovation and transition to bio-based products.

EXPANDED SUSTAINABILITY & CIRCULAR ECONOMY AGENDA AT CHEMUK 2022:

CHEMLAB will showcase specialist exhibitors providing Laboratory solutions & services, embracing Research & Development, Testing & Analysis, Process Design & Optimisation through to QC/QA Laboratory testing, serving the industrial chemicals & chemical products industries. HERE’S WHAT THEY SAID AFTER CHEMUK 2021... Excellent exhibition, including all aspects of the chemical industry in the UK. Product Group Leader, Caldic UK Ltd

DATES FOR THE DIARY CHEMUK 2022 takes place on Wed 11th & Thu 12th May 2022 Venue: NEC - National Exhibition Centre, Birmingham, B40 1NT Opening Times: Day 1: 9.30am – 5.00pm Day 2: 9.30am – 4.00pm

CHEMUK PREVIEW

COMMITTED TO LONGEVITY DRALLIM

Obsolescence review and reverse engineering services Obsolescence issues beat on the door of any organisation that operates complex engineering equipment. Specialist equipment manufacturers such as Drallim already seek to ensure that their products provide a very long life, but this is now being driven even harder by end users aiming for greater sustainability and “green” credentials. In truth it just makes great economic sense to the user and creates real customer loyalty, while minimising global resource consumption. Drallim has been committed to longevity of its products throughout their 60+ years of trading. Indeed, examples of their Rotary Selector Valves, Compressor Desiccators and Cargo Hooks are regularly returned for service and repair with some having seen over 40 years continuous service. Obsolescence issues are inevitable over this sort of period, but careful management and planning have allowed them to provide

Increasingly Drallim Industries are seeing demand from new customers for obsolescence review and reverse engineering services to produce vital spare parts with a failed supply chain. these very long product support periods. Electronic equipment provides the most significant challenges and even over relatively short periods of just a few

years component availability can dry up suddenly, as has happened for many users during the Covid crisis. Establishing long term support contracts with key customers allows planning ahead to mitigate problems arising by using smart procurement techniques, stocking of components and or redesign exercises. Increasingly Drallim Industries are seeing demand from new customers for obsolescence review and reverse engineering services to produce vital spare parts with a failed supply chain. Projects have included special manufacture of obsolete metals, redesign, and qualification of electronic assemblies through to reconstruction of specialist fabric assemblies and redesign of cast or forged components for low volume supply. Contact sales@drallim.com for help and information.

Examples of Obsolescence & Reverse Engineering Projects

For further information, please visit www.drallim.com

PECM Issue 56

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CONTROL & AUTOMATION

THE PLACE FOR

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Issue 56 PECM

CONTROL & AUTOMATION

PICKED UP AND PUT OFF IDS IMAGING DEVELOPMENT SYSTEMS

Autonomously driving robotic assistance system for the automated placement of coil creels Due to the industry standard 4.0, digitalisation, automation and networking of systems and facilities are becoming the predominant topics in production and thus also in logistics. Industry 4.0 pursues the increasing optimisation of processes and workflows in favour of productivity and flexibility and thus the saving of time and costs. Robotic systems have become the driving force for automating processes. Through the Internet of Things (IoT), robots are becoming increasingly sensitive, autonomous, mobile and easier to operate. More and more they are becoming an everyday helper in factories and warehouses. Intelligent imaging techniques are playing an increasingly important role in this. To meet the growing demands in scaling and changing production environments towards fully automated and intelligently networked production, the company ONTEC Automation GmbH from Naila in Bavaria has developed an autonomously driving robotic assistance system. The “Smart Robot Assistant” uses the synergies of mobility and automation: it consists of a powerful and efficient intralogistics platform, a flexible robot arm and a robust 3D stereo camera system from the Ensenso N series by IDS Imaging Development Systems GmbH. The solution is versatile and takes over monotonous, weighty set-up and placement tasks, for example. The autonomous transport system is suitable for floor-level lifting of Euro pallets up to container or industrial format as well as mesh pallets in various sizes with a maximum load of up to 1,200 kilograms. For a customer in the textile industry, the AGV (Automated Guided Vehicle) is used for the automated loading of coil creels. For this purpose, it picks up pallets with yarn spools, transports them to the designated creel and loads it for further processing. Using a specially developed gripper system, up to 1000 yarn packages per 8-hour shift are picked up and pushed onto a mandrel of the creel. The sizing scheme and the position of the coils are captured by an Ensenso 3D camera (N45 series) installed on the gripper arm.

PECM Issue 56

Further development of the system is planned, among other things, in terms of navigation of the autonomous vehicle.

APPLICATION

Pallets loaded with industrial yarn spools are picked up from the floor of a predefined storage place and transported to the creel location. There, the gripper positions itself vertically above the pallet. An image trigger is sent to the Ensenso 3D camera from the N45 series, triggered by the in-house software ONTEC SPSComm. It networks with the vehicle’s PLC and can thus read out and pass on data. In the application, SPSComm controls the communication between the software parts of the vehicle, gripper and camera. This way, the camera knows when the vehicle and the grabber are in position to take a picture. This takes an image and passes on a point cloud to a software solution from ONTEC based on the standard HALCON software, which reports the coordinates of the coils on the pallet to the robot. The robot can then accurately pick up the coils and process them further. As soon as the gripper has cleared a layer of the yarn spools, the Ensenso camera takes a picture of the packaging material lying between the yarn spools and provides point clouds of this as well. These point clouds are processed similarly to provide the robot with the information with which a needle gripper removes the intermediate layers. “This approach means that the number of layers and finishing patterns of the pallets do not have to be defined in advance and even

incomplete pallets can be processed without any problems,” explains Tim Böckel, software developer at ONTEC. “The gripper does not have to be converted for the use of the needle gripper. For this application, it has a normal gripping component for the coils and a needle gripping component for the intermediate layers.” For this task, the mobile use for 3D acquisition of moving and static objects on the robot arm, the Ensenso 3D camera is suitable due to its compact design. The Ensenso N 45’s 3D stereo electronics are completely decoupled from the housing, allowing the use of a lightweight plastic composite as the housing material. The low weight facilitates the use on robot arms such as the Smart Robotic Assistant. The camera can also cope with demanding environmental conditions. “Challenges with this application can be found primarily in the different lighting conditions that are evident in different rooms of the hall and at different times of the day,” Tim Böckel describes the situation. Even in difficult lighting conditions, the integrated projector projects a highcontrast texture onto the object to be imaged by means of a pattern mask with a random dot pattern, thus supplementing the structures on featureless homogenous surfaces. This means that the integrated camera meets the requirements exactly. “By pre-configuring within NxView, the task was solved well.” This sample programme with source code demonstrates the main functions of the NxLib library, which can be used to open one or more stereo and colour cameras whose image and depth

data are visualised. Parameters such as exposure time, binning, AOI and depth measuring range can - as in this case - be adjusted live for the matching method used. The matching process empowers the Ensenso 3D camera to recognise a very high number of pixels, including their position change, by means of the auxiliary structures projected onto the surface and to create complete, homogeneous depth information of the scene from this. This in turn ensures the necessary precision with which the Smart Robot Assistant proceeds. Other selection criteria for the camera were, among others, the standard vision interface Gigabit Ethernet and the global shutter 1.3 MP sensor. “The camera only takes one image pair of the entire pallet in favour of a faster throughput time, but it has to provide the coordinates from a relatively large distance with an accuracy in the millimetre range to enable the robot arm to grip precisely,” explains Matthias Hofmann, IT specialist for application development at ONTEC. “We therefore need the high resolution of the camera to be able to safely record the edges of the coils with the 3D camera.” The localisation of the edges is important in order to be able to pass on as accurate as possible the position from the centre of the spool to the gripper. Furthermore, the camera is specially designed for use in harsh environmental conditions. It has a screwable GPIO connector for trigger and flash and is IP65/67 protected against dirt, dust, splash water or cleaning agents.

SOFTWARE

The Ensenso SDK enables hand-eye calibration of the camera to the robot arm, allowing easy translation or displacement of coordinates using the robot pose. In addition, by using the internal camera settings, a “FileCam” of the current situation is recorded at each pass, i.e. at each image trigger. This makes it possible to easily adjust any edge cases later on, in this application for example unexpected lighting conditions, obstacles in the image or also an unexpected positioning of the coils in the image. The Ensenso SDK also allows the internal camera LOG files to be stored and archived for possible evaluation. ONTEC also uses these “FileCams” to automatically check test cases and thus ensure the correct functioning of all arrangements when making adjustments to the vision software. In addition, various vehicles can be coordinated and logistical bottlenecks minimised on the basis of the control system specially developed by ONTEC. Different assistants can be navigated and act simultaneously in a very confined space. By using the industrial interface tool ONTEC SPSComm, even standard industrial robots can be safely integrated into the overall application and data can be exchanged between the different systems.

OUTLOOK

Further development of the system is planned, among other things, in terms of

navigation of the autonomous vehicle. “With regard to vehicle navigation for our AGV, the use of IDS cameras is very interesting. We are currently evaluating the use of the new Ensenso S series to enable the vehicle to react even more flexibly to obstacles, for example, classify them and possibly even drive around them,” says Tim Böckel, software developer at ONTEC, outlining the next development step. ONTEC’s own interface configuration already enables the system to be integrated into a wide variety of Industry 4.0 applications, while the modular structure of the autonomously moving robot solution leaves room for adaptation to a wide variety of tasks. In this way, it not only serves to increase efficiency and flexibility in production and logistics, but in many places also literally contributes to relieving the workload of employees.

CLIENT

ONTEC Automation GmbH is a system provider for integrated and innovative automation systems, plants and special machines for industrial production. The business units consist of Technical Textile Solutions, Automation Solutions, Smart Robotic Solutions and Electric Switchboard Solutions. The company’s expertise with 25 years of experience is reflected in innovative, customer-oriented solutions along the entire value chain and includes robotics, industrial image processing, software development, electrical engineering and mechanics.

For further information, please visit www.en.ids-imaging.com Issue 56 PECM

CONTROL & AUTOMATION

INNOVATIVE DIGITISATION SAB BROCKSKES

High Flexible Industrial Ethernet Cables Flexibility, efficiency and digitisation. This is industry 4.0 – the current subject of German manufacturing industry. Due to the complete linking and communication on all levels of the production process considerable amelioration with regard to productivity and flexibility may result. Today it is not quite clear how industry 4.0 in fully automated production will look like. Nevertheless, it is sure that a reliable transmission of increasing data volumes due to the steadily growing linking and communication of machine parts even under the most difficult conditions have to be ensured. As a consequence cables especially for machine construction, robotics or railway techniques are subject to extreme torsional stress and very high temperatures. These cables get in contact with different chemicals, oils or detergents. Also the subject of longevity with respect to industry 4.0 in industrial sectors are of basic importance. 70 years after its foundation, SAB Bröckskes presents itself highly innovative as answer to the mega trends of digitisation and industry 4.0 . The company presents a range of new industrial Ethernet cables 6, 6A, 7 and 7A that are not only extremely robust but also ensure a quick and efficient data transmission. SAB is not only a cable manufacturer but also offers support in automation technique for example in the range of new communication systems for drive technology. Herewith, the individual requirements of the customer and the longterm experience of SAB as manufacturer of highly flexible cables are combined in new products . The quick and flexible production of sample lengths is no problem at all. The cable manufacturer focus on two Industrial Gigabit Ethernet cables that have been especially developed for the increasing data transfer in automation technique. Besides the world innovation CATLine CAT 7A RT, a CAT 7 A cable for robot application, SAB Bröckskes is also going to present a cable chain cable with UL/ CSA approval – the CATLine CAT 7 A S.

INDUSTRIAL ETHERNET CABLES AND WIRES CATEGORY 6A AND 7A: CATLINE CAT 7 A RT – for robot application Gigabit Ethernet cable with UL/ CSA The cable CATLine CT 7 A RT for robot application is suitable for rough industrial conditions in automation technique for example at high temperatures, pollution by oil and aggressive chemicals. CATLINE CAT 7A S – FOR CABLE CHAIN APPLICATION GIGABIT ETHERNET CABLE WITH UL/ CSA

The cable chain cable CATLine CAT 7A S is suitable for rough industrial conditions in cable chains for example at high temperatures, pollution by oil and aggressive chemicals.

CATLINE CAT 6A HT – TEMPERATURE RESISTANT The temperature resistant cable CATLine CAT 6A HT is suitable for rough industrial conditions at temperatures up to fixed: -90°C/+ 180°C flexible: -55°C/ + 180°C.

CATLINE CAT 7A DR REELING CAT 7A GIGABIT ETHERNET CABLE

Our reeling CATLine CAT 7A cables have been developed for different applications whenever a considerable data volume must be transferred safely. They are for example used in stage technique of theaters, signal transmission and mobile trash rake cleaning or in high rack storage technique.

CATLINE CAT 7A R - RAIL CAT 7A

CATLine CAT 7A R acc. to DIN EN 45545-2, is especially appropriate for rail applications. The cable fulfills the requirements on no flame propagation of DIN EN 60332-3-25 + DIN EN 50305 section 9.1.1 + 9.1.2 and is flame retardant and self-extinguishing acc. to DIN EN 60332-1-2

SPECIAL SOLUTIONS FOR SPECIAL APPLICATIONS The production possibilities of SAB range from basic types and standard dimensions to special cables according to the individual requirements of our customers. New productions are already possible for small quantities – especially interesting for small and pilot productions. Cable manufacturer – SAB Bröckskes is a worldwide leading manufacturer of cables and wires, cable harnessing and temperature measuring technique. More than 60 years of experience in cable manufacturing as well as in temperature measuring technique have made out of a one man business a company with almost 500 staff members. The strength of SAB Bröckskes is not only the manufacturing of standard cables but also the construction of special items. Every year SAB manufactures more than 1500 special cables on customer´s request.

For further information, please visit www.sab-cable.com

PECM Issue 56

CONTROL & AUTOMATION

SCALING UP PRODUCTION, FAST EMS LTD

How manufacturers can increase productivity to meet growing demand The IHS Markit/CIPS Manufacturing Purchasing Managers’ Index (PMI) value for May 2021 demonstrated that UK manufacturing is growing at its fastest rate in almost 30 years. Manufacturers must increase production to capitalise on the record growth in new orders. However, scaling up production quickly without additional floor space and workers can be challenging. Here Dave Walsha, sales manager at precision drive system supplier EMS, explores how expanding automation holds the answer. In the PMI, any reading above 50 indicates growth. The value announced for May 2021 was 65.6 — the highest reading since the survey began in 1992. The easing of lockdown has unleashed pent-up demand, causing a steep increase in production volumes. The plentiful market provides hope for manufacturers to bounce back after the pandemic by using the high demand to make up for lost profit. To make the most of this opportunity, manufacturers must quickly ensure their facilities are ready to accommodate the influx of new orders.

ACCELERATE AUTOMATION Scaling up production requires investment in high quality equipment. The benefits of automation are widely known, and most manufacturers aim to incorporate it into production to some degree. However, many of these targets have so far only resulted in plans, pilots or small scale automation projects. In fact, research conducted earlier this year by supply chain specialist Balloon One found that the UK lags behind ten other nations with similar levels of manufacturing, including Sweden, USA and Italy, for robot density. The investigation also found that the UK falls behind in productivity levels, which is arguably due to lower levels of automation. Investing in automated equipment is an efficient way to increase production, as it doesn’t require the company to hire a

large number of extra workers. In addition, it’s possible to increase manufacturing productivity in the same floor space.

SELECT RELIABLE COMPONENTS In order for UK manufacturers to profit from growing demand, they must widely rollout automation across the supply chain. However, not all automated machines are built equal, and the components engineered into their systems play a large role in their overall performance. Manufacturers must remember that automation is an investment, that must be thought through with care.

Automated equipment should be designed with dependable motors, such as the DMN range of brushed motors, which are renowned for their high quality and long life, while remaining a cost effective solution. The motors have an optimised brush design that allows intermittent operation over one million cycles, and a continuous operating life of 3,000 hours. This long life cycle is achieved while still delivering a high output due to the range’s enhanced heat dissipation and resistance.

When scaling up production, it’s important that manufacturers and design engineers don’t look for quick fixes. The new machines implemented should be not only able to accommodate the recent rise in orders, but also continue to benefit production in the long run.

UK motor supplier EMS has a selection of sample stock of the DMN brushed motor range available for express delivery to accelerate development of automated equipment. EMS also has a selection of complementary gear heads, reduction ratios and encoders available to suit a variety of manufacturing applications.

Therefore, it’s important that automated machinery components, particularly their powering motors, are selected for reliability. An unreliable motor can ultimately lead to failure, but it’s important to note that, before it even reaches that point, a motor can cause inefficiency. In fact, an inefficient motor can result in electricity running costs that account for 97 per cent of its lifetime costing.

After the challenges of the pandemic, the UK manufacturing sector is now seeing a sharp rise in demand. Manufacturers must prepare their factories to accommodate the increased volume of orders. Facility managers who widely implement automated equipment designed with reliable and cost effective components can quickly scale up production to meet rising demand.

For further information, please visit www.ems-limited.co.uk/blog

PECM Issue 56

CONTROL & AUTOMATION

THE RISE OF THE MACHINES JC AUTOMATION LTD

Industrial Automation in Post-Covid World The early 20s will be remembered for the COVID-19 pandemic, but folded into that simple statement are all sorts of lessnoticed, world-changing consequences. Not least of these was that a recordbreaking number of assembly line robots were purchased in 2021. According to the official resources, orders were up 37% compared to the same period the year before, an increase of almost 30,000 units worth $1.48 billion. Lockdown, originally industry’s greatest fear, has become its greatest opportunity. Online sales have driven up demand, but human workers have been in short supply. The result is that all industries are now racing to automate. 2022, Enter the JAKA Zu Cobot range. See www.JAKA.com for the full product range. Collaborative robot 2.0 is here! With the Zu model, JAKA is at the forefront of the latest major innovations in Cobots, making them safer and easier to teach. EASE OF PROGRAMMING. Until now, a major bottleneck for manufacturing has been the teaching stage, usually requiring time and highlevel programming experience. JAKA seeks to change that with the JAKA Zu Cobot. JAKA Zu programming is done on a Tablet / pad or laptop readily available in the UK with a Zu app installed. No in depth knowledge of programming is required as the App is using a drag and drop programming method. None of this will compromise performance. The JAKA Zu Cobots has a jointed-arm with 6 degrees of freedom, high accuracy and maximum 18kg load.

A typical camera for 2D sensing the Cobot whenever contact made with humans. Additional sensing and camera systems can also be added to enhance this further. 8 CRUCIAL FACTS ABOUT JAKA ZU • Ease of programming on detachable tablet / lap top computer with Zu App. • High flexibility / accuracy and load capacity. • Large number of add on end effectors to suit any application. • Force sensors as a state-of-the-art safety feature. • Integrated camera systems for part location / recognition. • Service support in the UK and 24/7 direct support from manufacturer. • Online training available in easily understood video files. • CE certified.

Lockdown, originally industry’s greatest fear, has become its greatest opportunity.

The JAKA Zu7 with controller

SAFETY FIRST JAKA has always been especially proud of its state-of-the-art safety features which protect the workers essential to global supply chains. On the JAKA Zu models, force sensors can automatically stop Email: jaka@jc-automation.com | Web: www.JAKA.com Issue 56 PECM

CONTROL & AUTOMATION

QUALITY ROBOTICS ACTIVE ROBOTS

Specialists in the smarter application of robotics technologies, industrial automation and system integration solutions A repetitive dexterous task, such as grabbing, lifting, picking or positioning is considered simple and easy for an ablebodied human but is often too complicated and involved for a robot to achieve by itself. Active8 Robots has considerable expertise in designing and developing solutions to overcome such challenges. With an industry-renowned rapid prototyping capability that can go from paper to prototype in 24 hours, Active8 Robots has provided countless iterations for bespoke end-of-arm tooling and adaptations to existing industrial robots and cobots. Having worked with CREAT3D, independent Additive Manufacturing solutions provider, over the past five years, Active8 Robots have developed a dedicated innovation centre, whereby Additive Manufacturing has become an integral part of Active8’s portfolio. A particular focus has been delivering bespoke 3D printed end-use components for highly intricate tasks. These 3D printed parts have enhanced functionality, are more lightweight, have lower costs and are designed, developed, tested and produced faster than traditionally manufactured parts.

THE APPLICATIONS Clients approach Active8 Robots with a wide variety of needs and objectives for adopting new or adapting existing robotic technologies. The solution will often be uniquely tailored to carry out a particular task, so Active8 needs tools that can deliver on these aspects. Producing more lightweight end effectors increases the productivity of the robot, which in turn increases efficiency and reduces costs, while ensuring the parts are capable of withstanding harsh environments. Active8 Robots has a dedicated

PECM Issue 56

We can prototype quicker, design better, produce a more refined end product and we can achieve continuous improvement. Additive Manufacturing innovation centre, with over 12 3D printers in total, including a range of FFF, SLA, and three CFF Markforged Industrial and Desktop Composite 3D printers, provided and supported by CREAT3D (fully certified provider for all Markforged’s composite desktop, industrial and metal 3D printers).

“Our 3D printers are indispensable to us. They form a fundamental part of our process,” explains Alan Quinn, Engineering Manager from Activ8 Robots. The SLA and FFF machines are used for early-stage prototype and design development, whilst the Markforged 3D printers are also used to produce tooling and end-use components to customers — from conveyor guides to sensor mounts and tooling.

THE RESULTS Alan Quinn: “We can prototype quicker, design better, produce a more refined end product and we can achieve continuous improvement.” Faster Turnaround Additive presents a phenomenal time saving, reducing lead times to a matter of hours versus 3-4 weeks for external CNC machining. Using 3D printers in-house means that Active8 Robots can provide its clients with a superfast turnaround on idea and product development. Designs, from initial concept, to end components, are done in-house, overnight. Testing is carried out faster, and any design changes that need to be made are adopted immediately, re-printed and retested, reducing risk. There is no need for additional purchase orders, supplier selection or supplier management. Custom solution – manipulating sandwiches The development of a bread lifting tool was achieved through the use of Markforged Composite 3D printers - producing accurate prototypes for fit and test assessments, before producing the final product in stainless steel. Using Additive resulted in: • Reduction of 88.6% in lead time. From outsourced supply of 4-6 weeks to internal 3D print time of < 24 hours

Lightweight = enhanced part performance Often the geometry of end of arm tooling can be difficult to machine. With 3D printing, the design can be adapted to better fit the task, and it is made lighter. Using Onyx (nylon with micro carbon fibres), Active8 Robots are able to print end-of-arm tooling that is hollow, yet strong. 3D printing end effectors also enables the storing of a digital file only, enabling manufacturing on demand, avoiding stockholding, reducing warehousing space and storage costs.

The main body of this gripper is a 3D printed one-piece hollowed part, something hard to achieve through traditional fabrication methods. Alan Quinn: “Cobots have limitations on pay loads, generally somewhere between 2 - 6kg. The benefit of 3D printed endof-arm tooling is that those 3D printed components are extremely lightweight, which means the productivity of a robot can be substantially increased.” • Benefits of 3D printing:

End-of-arm tooling – foam gripper

• Reduction of weight by 50%

Active8 Robots’ Foam Gripper is a highly versatile tool, able to pick up multiple objects up to a weight of 10kg, thanks to a vacuum generator and solenoid built inside.

• Reduction of development time from 1 week to 3 days • Reduction of costs from £70 to £10 in materials

3D printing as a trusted tool in every solution 3D printing is used in some context on all physical projects by Active8 Robots, whether in early concept stages, design development, product testing, end solutions or end-use component and continuous development. Simon Chandler, Managing Director of CREAT3D: “Its great to support manufacturing companies in adopting Additive in order to unlock the large gains which this technology makes possible. Not only are Active8 benefitting from flexible on-demand production, but also their customers are receiving market leading performance from their advanced automation and robotic solutions.”

For further information, please visit www.active-robots.com Issue 56 PECM

Complete surface finishing solution The The OnRobot OnRobot Sander Sander comes comes with with everything everything you you need need to to get get started started right right away: away: plug-and-play plug-and-play sanding sanding tool, tool, aa variety variety of of standard standard sanding sanding and and polishing polishing discs, discs, easy-to-use easy-to-use software, software, and and optional optional automated automated Grit Grit Changer Changer and and force force torque torque sensor. sensor. What What you you don’t don’t need need is is aa noisy noisy and and expensive expensive air air compressor compressor for for this this economical economical electric electric sander. sander. Use Use this this flexible flexible tool tool for for aa wide wide range range of of part part gegeometries ometries and and materials materials to to get get greater greater consistency, consistency, higher higher finish finish quality, quality, and and lower lower scrap scrap rate. rate. You’ll You’ll reduce reduce workplace workplace dust dust due due to to the the use use of of standard standard 3M 3M clean clean sandpaper sandpaper discs discs and and reduce reduce the the risk risk of of worker worker injury injury from from the the vibration vibration of of manual manual sanders. sanders. Programming Programming for for simple simple surface surface treatments treatments can can be be completed completed with with basic basic robot robot knowledge—no knowledge—no addiadditional tional training training required. required. The The sanding sanding tool’s tool’s softsoftware ware is is automatically automatically integrated integrated into into the the robot’s robot’s teach teach pendant, pendant, but but aa manual manual “save “save position” position” button button on on the the tool tool allows allows for for even even easier easier waypoint waypoint setsettings, tings, without without using using the the teach teach pendant. pendant. The The Sander Sander software software comes comes with with different different path path planning planning opoptions tions -- path path from from handguide, handguide, shape shape and and points, points, and and allows allows users users to to adjust adjust rotation rotation speed, speed, optimizing optimizing cycle cycle time time and and consistency. consistency.

Complete Complete surface surface finishing finishing solution solution with with fast fast and and easy easy setup setup reduces reduces complexity complexity associate associate with with material material removal removal applications. applications.

POWER UP PRODUCTION Powerful Powerful and and durable durable electric electric sander sander requires requires no no compressed compressed air, air, significantly significantly reducing reducing running running and and maintenance maintenance costs costs Cost-effective Cost-effective Grit Grit Changer Changer allows allows automatic automatic switching switching bebetween tween sanding sanding grits grits without without opoperator erator intervention intervention for for increased increased efficiency efficiency Flexible Flexible tool tool can can be be used used on on aa wide wide range range of of part part geometries geometries and and materials materials Sensing Sensing capabilities capabilities ensure ensure precise precise adaptation adaptation to to surface surface variations variations or or part part misalignment, misalignment, improves improves product product quality quality and and consistency consistency while while reducing reducing scrap scrap Eliminates Eliminates operator operator fatigue fatigue and and

All All of of the the advanced advanced features features of of the the OnRobot OnRobot SandSander er are are supported supported on on Universal Universal Robots Robots arms, arms, but but the the tool tool is is easily easily integrated integrated with with any any major major robot robot brand. brand.

OnRobot Sander

The World’s Leading One Stop Shop for Collaborative Applications

ONE SYSTEM, ZERO COMPLEXITY www.onrobot.com

Contact Contact OnRobot OnRobot to to find find out out more more about about our our palletizing palletizing solutions. solutions. north-europe@onrobot.com north-europe@onrobot.com Or Or visit visit our our Learningsite Learningsite on on Collaborative Collaborative applications applications know-how know-how to to all all learn.onrobot.com/en learn.onrobot.com/en

CONTROL & AUTOMATION

The World’s Leading One Stop Shop for Collaborative Applications 2FG7 is a complete, low cost, easy to use, outof-the-box, cleanroom-ready parallel gripper. Designed to enable companies of all sizes to set up gripping applications at low cost, the 2FG7 can be deployed within minutes and is specially designed to handle demanding payloads

–even in tight spaces. The new 2FG7 gripper is ideal for low-volume, high-mix production and enables fast ROI for many different applications, including machine tending, material handling and assembly.

2FG7

For more information visit our site at www.onrobot.com Or contact us at: north-europe@onrobot.com

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

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

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

www.tfautomation.co.uk Issue 56 PECM

CONTROL & AUTOMATION

THE NEW PS216 SWITCH SCHMERSAL

Compact and extremely versatile The Schmersal Group launches a new pull-wire switch that can be used as a signal generator to start machines, open electrically operated guard doors and gates and as a light switch in lift shafts. Key benefits of the new PS216 switch are its compact dimensions and extreme versatility, enabled thanks to high degrees of protection under EN 60529 and suitable for use in a wide range of temperatures. Thanks to IP66 degree of protection, the PS216 pull-wire switch is protected against dust and strong water jets and thanks to IP67 degree of protection, is also protected against temporary submersion in water. The switch can be used in ambient temperatures ranging from -30°C to +80°C. Another practical benefit is that the PS216 operates according to the ‘start/ stop principle’ in that it remains switched on after initial actuation and subsequent release. Only when the switch is actuated and released a second time is the latch released and the switch switched off. The PS216 pull-wire switch comes in two versions – the Q200 has a holding force of 45 N and is suitable for wire lengths of up to 50 m, while the Q210 has a holding force of 70 N and can be used with wires stretching up to 100 m. Pulling on the pull wire actuates the switch function in the pullwire switch. Other distinctive features of the PS216 include cable entry via M20 or M12 connector and six different NC/NO contact variants.

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

PECM Issue 56

ELECTRICAL & ELECTRONICS

Leaders in temperature measurement

Thermocouple Cables

In Stock For Immediate Worldwide Despatch Heading 3

IEC or ANSI Colour Codes PVC, PFA, PTFE, Glasﬁbre & Silicon Rubber types available XE-2440-025

Flat pair or twin twisted pair in various calibration types

XE-2800-050

10m, 25, 50, 100m & 200m lengths from stock XE-2801-010

www.labfacility.com Bognor Regis tel: +44 (0)1243 871280

We carry out many seminars with consultants and specialist training organisations as well as attending exhibitions and conferences both in the UK and overseas, where our knowledge

PECM Issue 56

PRT

XE-2757-025

sales@labfacility.com Shefﬁeld tel: +44 (0)1909 569446

Lightning & Surge Protection Solutions SPD Ltd and our partners have been solving problems in Lightning & Surge Protection for over 50 years. Our devices are European designed and manufactured, state of the art products, which exceed the requirements of the latest standards. With over 3000 products in our range, we are the markets Surge Protection specialists, with a device to suit every installation.

XE-2275-050

XE-2363-100

is renowned. We also hold regular contractor training sessions online, some of which are live webinar sessions, where you can ask our Technical Director any questions, and some are on-demand, so can be accessed at a time to suit yourself. If you have any questions at all please give us a call on 01484 851 747 or email info@surgedevices.co.uk.

ELECTRICAL & ELECTRONICS

Lascar Electronics PanelPilot B: Ruggedized Power Supply for undercover surveillance Active in the government security market since 1984, MIB Electronic is a well-known manufacturer and supplier of specialised undercover surveillance equipment. Providing and serving government, defence, and law enforcement agencies across the world from their offices in South Germany and South West England. MIB Electronic pride themselves on their ability to design, develop and manufacture a wide range of high-quality equipment. This equipment includes undercover surveillance smartphones, mini pan, tilt and zoom camera systems, laser, and IR audio surveillance devices, alarm system sensors, and much more. Thanks to their extensive manufacturing capabilities, MIB Electronic also offer customisation services, enabling them to meet their customers’ particular design needs.

THE CHALLENGE

One of MIB Electronics’ projects involved building Ruggedized Power Supply units for outdoor surveillance applications. The brief was very specific: the units needed to be weatherproof, hard-wearing, suitable for outdoor power supplies and able to withstand harsh environments.

The need for a display was also important, a display that provided valuable visual feedback by showing the voltage and status of the battery was essential.

THE SOLUTION

After several attempts at finding a product that suited both the application and their client’s needs, MIB Electronic discovered the SGD 21-B from Lascar Electronics. A low-cost, ultralow-power, sunlight-readable, single-channel voltmeter with a sleek, monochrome 2.1” e-paper dot matrix display. “The SGD 21-B has an ultra-low power consumption along with a sun-readable

display, both very important points for this application. “ “The SGD 21-B also provides a quick and easy visual feedback, informing the user about the status of the battery pack.” With the use of Lascar’s SGD 21-B, MIB Electronics successfully created the battery pack with the capacity to manage multiple output options to power surveillance equipment in a range of demanding situations including bad weather conditions. Lascar Electronics sales@lascar.co.uk | 01794884567

www.lascarelectronics.com

Issue 56 PECM

ELECTRICAL & ELECTRONICS

A TRUE WARRANTY WILKINSON STAR

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

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

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

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

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

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

BE VIGILANT WHEN PURCHASING EQUIPMENT WITH EXTENDED WARRANTY

UNPARALLELED AFTER SALES SUPPORT

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

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

WITH JASIC 5 MEANS 5

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

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

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

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

PECM Issue 56

Importer and specialist distributor of E-MECH products

4M ST ELECTRONICS AUTOMATION E-Stop Switches XW Series

XW Illuminated

HW Series

Smart Cable Management Split Cable Entry System

Brush Plates

Strain Relief Plates

IMAS Connect

Digital Design Tools

From Concept to CAD in minutes! Our 3D conﬁgurators feature an intui�ve graphical user interface, dynamic CAD genera�on and full integra�on into website without addi�onal so�ware installa�on.

Varistar Cabinet Conﬁgurator

T: +44 (0)1371 811 171 E: sales@4most.co.uk

www.4most.co.uk

Novastar Cabinet Conﬁgurator

Pla�num Distributor

ELECTRICAL & ELECTRONICS / FACILITIES MANAGEMENT

D ANLERS

Assured control

New Smart ISI range

look for the sign of quality

View the Range

new website

krausnaimer.com 100% confidence that you’re making the right choice with the help of our skilled technical team if needed. Next Day Delivery on most products.

♦ Ideal for energy-saving automatic lighting control ♦ PIR occupancy switches with built-in photocells ♦ Free-to-download DANLERS iOS and Android app ♦ Easy-to-use; quick set-up ♦ Versions for switching & for DALI & 0-10V dimming ♦ Programmable setback light levels and fade rates ♦ Upgradeable via over-the-air updates for extra features such as group control and asset tracking

DANLERS Lighting Controls T: 01635 26 26 26

e: sales-uk@krausnaimer.com

T: +44 (0)1249 443377 E: sales@danlers.co.uk www.danlers.co.uk

THE LOW COST AND ENERGY EFFICIENT ALTERNATIVE TO AIR CONDITIONING

EcoCooling Evaporative Cooling – Cool a 250m2 area for the same cost as boiling a kettle Refrigerant free cooling and ventilation As part of a balanced ventilation system, evaporative cooling is achieved through the natural process of direct evaporation of water into supply air, which is extremely effective in temperate climates like the UK. Air supply temperatures off the coolers do not exceed 25C, without the need to utilise any refrigerant technology. The most energy efficient cooling system for large spaces Even on the hottest days, a standard unit covering a 250m2 area or spot cooling a 15m diameter zone can operate at a cost less than 13p in electricity and 1p in water per hour, based on service costs of £0.12/ kWhr and £1.20/cum respectively (2021 figures). This gives an energy saving of 90% on an equivalent refrigeration-based system with a 35kW cooling load. EcoCooling are based in Suffolk, UK.

www.ecocooling.co.uk

PECM Issue 56

Save up to 90% on your operational costs and reduce your capital spend by 40%. Proven, versatile solutions to suit your requirements. 100% fresh air solution, no refrigeration.

data centres

factory

gym

printing

retail

Book your free site visit. www.ecocooling.co.uk +44 (0)1284 810 586

sales@ecocooling.co.uk

telecom

warehouse

FLUID HANDLING

Bespoke Swivel Joint Replacement

Fluid Carrying

Seanic Ocean Systems needed a replacement swivel for an existing unit, which was made by another company - they contacted us. The existing unit had worn out and needed to be replaced and the competitor lead time was simply too long to be practical for Seanic Ocean Systems. At Rotaflow we have our design, manufacturing and testing departments within the same building so save significant time and costs. We can take a project from design to shipping with significantly reduced external reliance – this saves a lot of time and money. Our engineers discussed the merits of our designs compared to that of the current unit with Seanic. It was deemed that we would be able to design a more effective and efficient alternative on a much shorter lead time, which was welcomed by the Seanic team – in industry time literally is money, so the sooner we could deliver the swivel joint the better.

Flexibility Articulated Torsion Pipework In Hoses

The Rotaflow designed swivel was used on a hose reel. It was required to withstand very high pressure and high temperature, including oil 206 bar (~3000 psi) /121 deg C. It is a dual flow unit, allowing two separate flows through the same swivel joint. 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

Rotating Cylinders

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

Tel:

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

+44(0)1663 735003

E-mail:

New C-PVC pressure pipe range BESPOKE CONVEYOR SYSTEMS FOR: Food Beverage Medical and Pharmaceutical Packaging Industries

01753 548801 WWW.UPMCONVEYORS.COM SALES@UPM.CO.UK

PECM Issue 56

epco Pipe Systems are specialists in supplying comprehensive pressure pipe systems for both Industrial and Commercial applications, available from our UK stockholding in Leeds. We are proud to announce the arrival of our new C-PVC range including Pipe, Fittings, Valves and Accessories. Thanks to its high temperature resistance, reaching up to 80°C, C-PVC has excellent chemical resistance and is suitable in applications such as metal surface treatment, chemical processing, pulp and

paper production and the food and drinks sector. Manufactured in Europe to DIN 8079/80 & DIN 8063 under the ISO 9001:2015 Quality Management system, C-PVC enhances our current range of ABS & U-PVC, offering an ideal and more cost-effective alternative for legacy materials such as steel. sales@epco-plastics.com Tel: 0113 249 1155 www.epco-plastics.com

Custom Solutions for Electric Motors Around the Clock, Against the Clock!

Whenever existing mechanical and electrical interfaces are key coupled with fast delivery Motors up to 15 MW and 13.8 kV • • • • •

Low voltage slip-ring and squirrel cage motors up to 3,000 kW Medium voltage slip-ring and squirrel cage motors up to 15,000 kW Direct current motors up to 2,000 kW Frequency converter-proof drives In-house load test facility up to 13.800 V, 2.300 kVA, 120 Hz

More than 20.000 motors available from stock!

Customized special designs • • • •

Custom designs for special applications and operating conditions Optimized motor design for higher efficiency Mechanically and electrically interchangeable motors Commissioning worldwide

24/7 emergency service

Certified Management System

info@menzel-motors.com www.menzel-motors.com

Member

GEARS, DRIVES & MOTORS

Herga Technology’s 6256 heavy-duty industrial footswitch has AC15 utilisation category rating Herga Technology’s 6256 series heavyduty footswitch range is especially suited to switching the inductive loads typically required for low-voltage industrial motors and other electromechanical control apparatus. Its AC-15 utilisation category covers electromagnetic loads from 250 VAC at 6 A to 500 VAC at 1 A, and with CE/UL and CSA C22 60947-1 & 60947-5-1 standards approval, safe and long reliable working life is ensured. The IP67 waterproof-rated 6256 footswitch is manufactured in injection moulded, highimpact ABS with a choice of open or safetyguarded models offering extreme levels of toughness and durability for switching tasks on industrial machinery. A comprehensive choice of accessories allow individually configured footswitches to perform as singlepedals or assembled as multi-pedal switching groups thanks to a modular and aesthetic interlocking design. A broad selection of electrical ratings, potentiometer options and switch operations ensure maximum working flexibility. The flexibility for electrical switching on the 6256 series includes slow break & make and snap action options to AC-15 6A 250V / DC-12 6A 24V (UL) as well as a high-power model for 25A 125/250V AC. 1HP 125/250V AC (with

Herga Technology’s 6256 in 4- footswitch configuration with safety guards on two footswitches. double pole change over contacts over two switches). 5 kΩ and 10 kΩ potentiometer versions with double pole change over contacts are also available. The series has a rated insulation voltage of 500 VAC 600 VDC (300V UL Rating), and further protection via a short circuit current rating to 1 kA and a shortcircuit protective device 10 A aM fuse. The footswitch has a specified mechanical working life of 2 million cycles and an electrical life of 10 million cycles. For additional safety in especially hazardous environments the 6256 is available with a pressure point actuated cut-off feature where

the switching contact is broken and the footswitch locks, preventing an unintended restart. This option is also available configured with a mechanical resistance that adds tactile feedback where the operator can sense the pressure change. A manual release can also be included after the footswitch locks. Other safety related options include emergency stop equipped models with a conventional emergency stop switch either assembled on the footswitch housing – available on both the guarded and unguarded versions - or attached to an extended pole. Other accessories include extended base plates for securing the footswitch directly to machine or floor surface as well as pole & handle attachments for increased portability and ease of operation. Displaying the heavy-duty characteristics of 6256 footswitch, which has a specified drop weight stability of 20 kg at 1 metre for the guarded model, a demonstration video on Herga’s website compares its drop test performance against several competitive lines - some with all-steel construction. For comprehensive information on the 6256 series and application specific assistance, visit www.herga.com, email sales@herga.com or call +44 (0)1284 701422.

For further information, please visit www.herga.com

Pump motor with special flange for chemical plant Menzel Elektromotoren has realized an unusual motor configuration to help out a customer: Currenta, Headquartered in Leverkusen, needed a replacement for a failed pump motor in one of its chemical plants but found it difficult, at first, to find a suitable machine to able to accommodate an existing oversized pump flange dimension. Only the family-run company Menzel offered a size 400 motor which could match the required profile, whilst maintaining a lightweight design. The Berlin-based manufacturer converted a stock, IM B3 type motor (foot mounting) to type IM V1 (vertical flange mounting). For this purpose, the application-side bearing seat was converted to install a thrust bearing. Menzel also manufactured the special flange in-house, adapting the shaft, which could only protrude 120 mm from the flange. Menzel prepared the motor for quick installation at the customer’s site, shifting the main terminal box to the most accessible position whilst mounting a cable entry that could be readily adapted to the existing cable diameter on site. By installing both the heater and PT100 connections in one auxiliary terminal box, Menzel was able to save one terminal box.

The motor, which is now successfully in operation in the customer’s plant, has a rated output of 315 kW and a nominal voltage of 5000 V. It features the cooling type IC 411, IP55 protection rating and weighs 4900 kg.

More information about squirrel-cage motors with cooling type IC 411 is available at the website below.

www.menzel-motors.com/squirrel-cage-motor/ic411-ic416/

PECM Issue 56

DRIVES, GEARS & MOTORS

Cross+Morse Power Transmission Manufacturing Specialists ◊ ◊ ◊ ◊ ◊ ◊ ◊ ◊ ◊ ◊ ◊

Since 1984

Manufacturing up to 1450mm diameter Turning - CNC lathes, Vertical Machining Centre Gear Cutting - Hobbing, Planing, Shaping Gears Bevel Gears, Helical, External & Internal cut Gears Rack Shaping, Broaching, Keywaying Vertical Boring, Centreless & Rotary Grinding Bore Honing ◊ Induction Hardening ◊ Blacking Drilling & Tapping ◊ Marking Large stocks of Transmission Drive components CAD - CAM Design & Development ISO 9001 : 2015

Yes we can make it.

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

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 wash-down 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 56 PECM

HEALTH & SAFETY

STRATEGIC PARTNERSHIP TEPEE ELECTRICAL

Teepee harnesses electrification dreams for fire and rescue appliance specialist Teepee Electrical has signed an extension with one of the UK’s leading emergency appliance manufacturers that will see it support a concerted roll-out of its new electric vehicles. The Black Country-based company will supply complex harnesses and wiring looms to Emergency One’s latest electric fire engines, which are increasingly destined for use across the UK and the rest of the world. It marks what has become a 15-year strategic partnership for both firms and a relationship that has developed from a few harness sets per month to providing eighteen different configured sets for six different vehicles every month. The move to electrification has involved the development of a different type of harness, with alternative specifications of cables and connectors catering for high and lower

PECM Issue 56

voltage circuits, integrating with on-vehicle systems and full harness sets. This was a challenge that Teepee relished. Systems and processes have been developed so the firm can use Emergency One’s design software outputs and import them into harness and manufacturing software. Dedicated production cells and comprehensive testing facilities have subsequently been set-up to ensure the necessary capacity required by the Scottish manufacturer is in place. “Emergency One has grown massively in the 15 years we have been supplying it and expect production to be more than 250 fire fighting vehicles this year,” commented Steve Clarke, Managing Director of Teepee Electrical. “Electrification isn’t purely for passenger

cars; all sectors are looking at cleaner engines and more sustainable means of transport. It became the first in the world to develop an all-electric model in 2020 and continue to be ahead of its rivals in terms of delivering a vehicle that offers similar if not better performance and range than its traditional counterparts. “We have been with them from the start of this journey and our agility and desire to be involved in the early-stage development work has paid dividends with the harness architecture proving ideal for what the Emergency One engineers were looking to achieve.” He continued: “This new deal extends the partnership and will see us continue to supply traditional sets for the Volvo, MAN and Eurocargo chassis, as well as building in new capacity so we can meet the expected demand for electric fire engines going forward.”

Emergency One, which was established in 1989 in the Scottish town of Cumnock, is emerging from the shackles of the pandemic with a growing order book for its fire and rescue service appliances. Two production facilities spread over an eight-acre campus are home to 240 staff, with the firm expecting sales to hit £40m for the first time by the end of this financial year. This will be boosted by a growing export market that includes clients in Malta, New Zealand and the US. Ali Bell, Director at Emergency One, added his support: “Harnesses are a critical part of the build and often the first piece of architecture we add to the chassis. Traditionally, trying to find a supplier with this expertise was challenging, that was until we were introduced to Teepee in 2007.

mark as more customers tap into its ability to supply low, medium and high volumes.

Electrification isn’t purely for passenger cars; all sectors are looking at cleaner engines and more sustainable means of transport.

Following the purchase of £100,000 worth of automatic crimp presses, ancillary tooling and a cable cutting and process machine, the Bloxwich-based company has started supplying volume cable assemblies to a second tier UK automotive supplier with plans in place to be involved in new vehicle platforms by Spring 2022. This complements recent wins with a major rail customer for an ongoing fleet upgrade project and the development of a wiring harness for a niche EV client.

“Steve and his team got to know our business and what was required and there was an immediate eagerness to deliver solutions, often in a matter of weeks which is pretty much unheard of in our sector.” He went on to add: “The partnership has continued to get stronger, and we now see Teepee as a Category 1 supplier to our business, meaning they are critical to our current and future production schedules.” Teepee Electrical, which also supports clients in the automotive, rail and electrification sectors, is looking to grow 20% in 2022, taking turnover past the £3m For further information, please visit www.teepeeelectrical.co.uk or www.e1group.co.uk Issue 56 PECM

HEALTH & SAFETY

VIRTUAL ENGINEERING REMBE

Achieving the right installation torque with a virtual calculation Determining the required installation torque for a tight flange system is a daily challenge for industrial valve manufacturers and plant operators alike. All of the components in the flange system have their own individual installation requirements. Environmental requirements, such as evidence according to TA Luft, add further difficulty to the project. The collaboration between manufacturers of individual components and the plant operator for a holistic approach is crucial to bring everything into harmony. The German rupture disc manufacturer REMBE already recognised this task at an early stage and has long been committed to complying with its customers’ installation requirements. What exactly this challenge entails and what possible solutions are available are described in this article. There are generally different approaches when it comes to selecting the required installation torque. Alongside manufacturer information for individual components, there are calculation standards such as DIN EN 1591-1 or the AD 2000 set of rules, with which conventional flange systems can

The collaboration between manufacturers of individual components and the plant operator for a holistic approach is crucial to bring everything into harmony. be calculated analytically. A conventional flange system (see figure 1, left) according to the stated calculation standards is defined as a flange inlet (flange I), flange outlet (flange O), gasket and connecting elements (e.g. bolts). In practice, a flange system is often expanded by additional components (cf. figure 1, right). This can be a pressure protection mechanism, such as a rupture disc. A rupture disc is usually installed with a mounting unit (hereinafter called a holder), consisting of a holder inlet

(holder I) and holder outlet (holder O). A second gasket (gasket I) is also required. In this case, four additional components must be taken into account at once. The conventional/stated calculation standards become invalid for these expanded flange systems as the equations underlying these standards do not take any additional components into account. All of the required calculations stated above for configuring the installation torque cannot currently be performed with sufficient precision using analytical calculation principles. In order to take into account, the complexity and the ever greater challenges on the configuration of the installation torque, REMBE makes use of virtual engineering with the finite elements method. This makes it possible to depict the flange system including all (additional) components as a digital twin and thus simulate its mechanical behaviour before manufacture and commissioning. With this digital twin, the mutual influences of all of the components are thus taken into account in advance before being brought together in reality.

Fig. 1: Comparison of conventional flange system (left) and flange system with rupture disc and holder (right)

For further information, please visit www.rembe.de

PECM Issue 56

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

30 YEARS OF BUSINESS GreCon

30th Anniversary celebrations for GreCon Limited GreCon Limited is celebrating a significant milestone, with 30 years of business and commitment to the UK & Ireland market. Established in April 1992, GreCon is located just outside of Newcastle upon Tyne and is a member of the Fagus-GreCon Group. With a wealth of experience as a global market leader, GreCon demonstrates a strong understanding of customer needs and provides turnkey solutions for multiple industries, including the wood-based panel industry, manufacturing, recycling, biomass, pharmaceutical, food, hygiene and more. GreCon’s fire prevention technology protects industrial premises, processes and people, detecting and extinguishing ignition sources, making workplaces safer and enabling uninterrupted production. In addition, GreCon’s measuring technology solutions help customers improve product quality in their production processes, using proven German engineering to reduce material and energy costs, ultimately maximising operational efficiency. During these 30 years, the company has focused on developing sustainable relationships with its customers and adopting the role of a strategic partner. Founding GreCon Limited in 1992 enabled a more local connection and enhanced response times. As a result, customers across the UK & Ireland depend on GreCon for consultative and problem-solving sales engagement and first-class customer service. In addition, fast deliveries of parts and systems are possible due to comprehensive local stock-holding and local manufacturing of Water Pressurisation Systems, which provide a dedicated water supply for our fire prevention systems. Due to a solid track record of performance and growth, it has been possible for GreCon Limited to include customer requirements in the technology roadmap and contribute to developing innovative new products. A recent example of this development is the launch of the GreCon IEM, the Intelligent Extinguishing Module. The GreCon IEM launched this month as a

fit for the future addition to the intelligent fire prevention solutions portfolio. The GreCon team is keen to discuss this newest product’s features and benefits, how it can form part of a compelling fire prevention solution, and how it can take the intelligence and reliability of existing spark extinguishing systems to the next level. Critical benefits include more rapid extinguishing of sparks and harmful ignition sources. In addition, integrated intelligent extinguishing technology (IET®) enables highly precise extinguishing process monitoring and predictive maintenance control. The company is also undertaking recruitment for roles in a new Service & Operations department, streamlining the former structure. A Head of Service & Operations and Service Coordinator are amongst the roles sought. This recruitment will ensure additional skills and expertise address current and future needs and ensure customer expectations remain in focus.

service to our customers, who rely on GreCon to add vital protection and to help them optimise their manufacturing process. Today we celebrate our 30th Birthday and pause to celebrate the contribution of the whole team and the loyalty of our customers. We also reflect on our business success and our tremendous opportunity to make people and places safer and factories smarter.” Uwe Kahmann, joint Group Managing Director, commented, “This significant business milestone and 30th anniversary reaffirms our commitment to the UK & Ireland market. We fully support GreCon Limited and are committed to our role as a strategic partner to our customers. We thank the team for delivering a vital contribution in looking after our customers even during difficult times such as the current pandemic. We will continue to invest in innovative products and equip our organisation to continue delivering the best in class customer service our customers expect.”

Jonathan Hamill, Managing Director of GreCon Limited, said, “We have a solid track record of providing a first-class

Email: sales@grecon.co.uk | T: 0191 414 7200 | www.grecon.co.uk

PECM Issue 56

HEALTH & SAFETY

MANUFACTURING EXCELLENCE TELEDYNE GAS AND FLAME DETECTION

In-house manufacturing excellence drives quality at Teledyne Gas and Flame Detection Industry-certified processes, stringent quality control, dedicated workforce skills and the latest production technologies underpin manufacturing excellence at Teledyne Gas & Flame Detection. Comprising the Teledyne Oldham Simtronics, Teledyne Gas Measurement Instruments and Teledyne Detcon brands, the company’s meticulously designed and controlled production operations help impart its core product attribute: safety. Robust and quality-centric manufacturing processes ensure that products perform their designated function, be it site protection, area monitoring or personal protection, in a failsafe manner. At three highly-specified manufacturing sites in France, the UK and the US, Teledyne produces a market-wide range of gas and flame detection solutions to meet the requirements of customers across all industry sectors. Product quality and reliability equate to customer trust. But delivering these attributes relies on robust manufacturing processes. At Teledyne Gas and Flame Detection, production operations leverage the experience of a history in manufacturing that dates back more than a century. Of course, locations and facilities have changed over the years, but production capacity today is a global concern that embraces Teledyne Oldham Simtronics (Arras, France), Teledyne Gas Measurement Instruments (Renfrew, UK) and Teledyne Detcon (Cypress, US), with each facility supported by expert staff and a commitment to customer satisfaction.

MADE IN ARRAS The Arras headquarters and manufacturing plant of Teledyne Oldham Simtronics is located in the Hauts-de-France region. Market leader in France for gas detection, the brand is also strong across Europe, CIS (Commonwealth of Independent States) countries, Africa and Asia. Covering an area of 5,552 m2, the Teledyne Oldham Simtronics’ plant includes 3,379 m2 of workshop and warehouse space. Manufacturing class-leading products since 1948, the factory’s track record of production

excellence centres on its accreditations, which include ISO9001 for quality, ISO14001 for environmental management and ISO45001 for health and safety. The plant benefits from an advanced in-house manufacturing engineering team that creates the software, tools and machines required by production. With over 100 highly capable employees on site, some 75,000 gas and flame detectors and controllers are ‘Made in Arras’ every year. Each one provides customers with highly capable and dependable performance to ensure complete protection.

UK MANUFACTURER Teledyne Gas Measurement Instruments is the number one supplier of gas leak detectors to the UK natural gas distributor sector, and a key player in the industrial portable gas detection market with over 300,000 high-quality instruments delivered. Ideal for use in challenging industries such as gas utilities, chemical, shipping, brewing, construction, defence, nuclear, petrochemical, papermaking, refining and telecoms Teledyne Gas Measurement Instruments is also prominent across Europe and North America. Producing trustworthy, proficient products is key to building further on the brand’s established reputation for providing customers with assured protection. The company’s production facility is located in Renfrew, near Glasgow, where its portable gas detection and measurement devices have been manufactured in the UK since 1947. Spanning 2,230 m2, the site boasts ISO9001, ISO14001 and ISO45001 accreditations. Additionally, Teledyne Gas Measurement Instruments is an active member of many global gas associations, including the Institution of Gas Engineers & Managers (UK), the American Gas Association (USA) and the Canadian Gas Association. The company was also a founding member of the Council for Gas Detection and Environmental Monitoring (CoGDEM) in Europe. There are around 80 knowledgeable employees at Renfrew including 35 fully cross-trained assembly operators. In particular, the site is notable for its high-end production technologies.

US MANUFACTURER Teledyne Detcon has its 2,929 m2 headquarters in Cypress, near Houston, from where it manufactures over 15,000 industryleading fixed gas detectors, control systems and analysers every year. The advanced site is ISO9001-certified and carries accreditations to IECEx and Intertek. Extremely proud of its ‘manufactured in the US’ heritage, which extends back to 1983, the brand is well known in North America, the Middle East, CIS countries and Asia. With 32 expert employees, Teledyne Detcon also has extensive experience in cell manufacturing and wireless technology.

PROVEN DESIGN (AND MANUFACTURING Each Teledyne Gas and Flame Detection manufacturing site houses its own customer service, technical support, engineering and R&D functions, all staffed by personnel with considerable industry experience and long service within the business. These employees nurture established professional relationships with customers, adding value with their knowhow and market awareness. Furthermore, throughout the Teledyne Gas and Flame Detection business, inherent flexibility means the team can react accordingly to customer requirements as they evolve. Offering one of the most extensive gas and flame detection portfolio on the market, Teledyne has in-country approvals and certifications for most products. A proven range of accomplished and convincing measurement, detection and wireless technologies, alongside the unrivalled skills and innovation of employees, ensures Teledyne Gas and Flame Detection can meet the safety and protection requirements of all applications. The company’s rugged yet reliable and precise gas and flame detection products offer fast response times, durability and intrinsically safe instrumentation. With excellence in manufacturing at the heart of its customer offer, Teledyne Gas and Flame Detection will continue providing products that support and protect workforces, assets, operations and the environment.

For more information, visit www.TeledyneGFD.com or contact gasandflamedetection@teledyne.com

PECM Issue 56

In-house manufacturing excellence drives quality at Teledyne Gas and Flame Detection

Te l e d y n e D e t c o n h a s i t s 2,929m2 headquarters in Cypress, near Houston, from where it manufactures over 15,000 industry leading fixed gas detectors, control systems and analysers every year.

Covering an area of 5,552m2, the Teledyne Oldham Simtronics’ plant includes 3,379m 2 of workshop and warehouse space.

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

Teledyne Gas Measurement Instruments is the number one supplier of gas leak detectors to the UK natural gas distributor sector with over 300,000 high-quality instruments delivered.

gasandflamedetection@teledyne.com

HEALTH & SAFETY

PLANNING FOR THE UNPLANNED HOUGHTON INTERNATIONAL

The importance of a planned preventative maintenance strategy National Grid operates a Liquid Natural Gas (LNG) terminal at the Isle of Grain in Kent, the largest LNG facility in Europe with a throughput capacity of 15 million tonnes per year. Given the critical nature of operations at the facility, stringent safety controls must be followed and a planned preventative maintenance strategy is crucial to the functioning of the terminal. To ensure the strategy was implemented in an effective way, electro mechanical specialist Houghton International was called to assist. The LNG facility operates a series of 6.6kV blower motors. Since the plant provides essential services, it is crucial to minimise unplanned downtime for all assets and carry out maintenance during planned intervals. Houghton International was contracted by National Grid to carry out periodic testing on a number of motors at the facility. The condition monitoring regime assessed the quality of the HV insulation and the dielectric properties of the motor windings.

THE IMPORTANCE OF TESTING Houghton International’s site services team managed the whole process of testing, decommissioning, removal, transportation, overhaul or rewind, reinstallation and recommissioning at Grain LNG, making operations simpler and smoother for National Grid. During periodic site visits, engineers from Houghton International carried out tests on the high voltage motors to monitor and log the condition of the electrical insulation of each asset. The engineers used the data as a trending measure to identify motors showing high levels of Partial Discharge (PD) or other signs of insulation material deterioration or aging. The test regime consisted of PD testing and a range of high voltage Baker tests, such as the low resistance and impedance testing, Insulation Resistance (IR), HiPot test and the surge interturn test. Collectively, these tests can identify a range of insulation and winding issues, both turn-to-turn and phaseto-phase, providing a thorough assessment of the motor’s condition.

A well-planned preventative maintenance strategy is key to the dependable, longlife operation of electric motors. Reports conducted by Houghton International gave National Grid a clear pass or fail indicator for each test. Further analysis of each motor highlighted recommendations for ongoing monitoring and suggestions for when the motor should be tested again, allowing LNG to establish a clear testing and maintenance schedule. Where results showed signs of insulation aging or deterioration, the reports included recommendations for overhaul. These overhauls, which ranged from minor maintenance to full rewinds, were carried out in Houghton International’s 120,000 square foot facility in Newcastle-upon-Tyne. Rewinds were completed using Houghton International’s HiFLEX coils, which are manufactured in-house by Houghton International. This gives the company full confidence that it can deliver a quality

product within the lead time specified. Houghton’s coils also offer better windability, more protection from moisture and contaminants, and reduced Partial Discharge. In one recent rewind, the motor’s Partial Discharge reading was independently verified, demonstrating a reduction in PD from 5041pC to 220pC (Pico Coulombs).

THE RESULT By carrying out regular testing, Houghton International could identify which motors were deteriorating, allowing LNG to carry out any necessary repairs before this led to an unanticipated failure. “At Houghton International we believe a periodic testing regime is important for all industries but especially those that perform critical operations,” commented Chris Measor, Winding Assistant Manager of Houghton International. “A well-planned preventative maintenance strategy is key to the dependable, long-life operation of electric motors. This is why we continuously invest in the latest equipment to provide a comprehensive range of testing, repair and maintenance services for our customers.” “Without the testing regime implemented by Houghton International, several of our critical motors could have failed in service, leading to large commercial costs for the terminal,” explained Ashley Smith, LNG Terminal electrical engineer.

To find out more about Houghton International and our services, go to www.houghton-international.com.

PECM Issue 56

HEALTH & SAFETY

DSEAR 3 DAY - Risk Assessment Training Course (14th - 16th June) Our “Three Day” DSEAR course is aimed at those who responsible for conducting DSEAR assessments, but are not necessarily fully confident with the process. They may work in a flammable environment, inaddition to being responsible for managing the area, day to day.

Advanced technology With over 20 years’ experience in preventing workplace health and safety issues, Reactec introduce R-Link, our latest workplace wearable with expanded functionality. With the R-Link watch, fully integrated eco-system, and the powerful Reactec Analytics, you have an unprecedented view of your employees’ environment to deliver effective risk prevention and open new avenues to improve operational efficiency: • Keep workers safe from proximity to dangerous

equipment or vehicles • Gain real insight of exposure to vibration and readily show compliance • Create exclusion zones, based on workers’ credentials, to restrict access • Send alerts and track lone workers • Track employee movements and activity levels The R-link eco-system and cloud-based analytics are easy to deploy, and simple to use. Info@reactec.com www.reactec.com

The course content: • Legal foundations • How sources of danger arise. • What is the difference between flashpoint, fire point, boiling point and Auto Ignition? • The fundamentals on the origin of Explosions, Deflagrations and Fires • Risks resulting from improper storage or handling of these substances • The meaning of the danger triangle and pentagon. An overview of the regulations, understanding solvents and their physical properties, explosive dusts, ATEX classifications, gas groups, temperature ratings and BS 60079-10 Ex Zone determination, all giving

a greater understanding of how ATEX fits into the DSEAR equation when establishing hazardous zones. Reference is made to the theoretical understanding of flammable vapours with examples of how the L.E.L can be converted into a meaningful quantity of chemical per cubic metre. Supported by a full and detailed 200-page, training manual to assist with their learning.

sales@dsc-ltd.co.uk www.dsc-ltd.co.uk

Issue 56 PECM

HYDRAULICS & PNEUMATICS

AN ESTEEMED REPUTATION TOM PARKER

Leading Independent Fluid Power Distributor Celebrate 50th Anniversary The entire team at Tom Parker Ltd, including the Preston Northwest HQ, those based in the Basingstoke branch and the network of Area Sales Managers covering the UK, are immensely proud to be celebrating their 50th anniversary.

A ONE STOP FLUID POWER SHOP

Tom Parker Ltd have worked hard over the last five decades to build a thriving business that now has 80+ employees and to earn their esteemed reputation in the industry of being one of the leading fluid power distribution companies in the UK, whilst remaining an independent family business.

Their recently launched 2-year product catalogue contains 36,000 product lines with more than 80 brands spanning the pneumatics, hydraulics, industrial and process markets.

Whilst there have been many changes throughout the company’s history many of their core values remain the same. Their focus remains firmly on supplying high quality connection solutions, whilst prioritising their customers’ needs and providing high levels of technical advice and support.

CONNECTION SPECIALISTS Mr Tom Parker first established the business back in 1972, distributing Swedish connection specialist Cejn’s innovative quick connect couplings to the UK pneumatic and hydraulic market. The company went from strength to strength, soon acquiring the UK distribution rights for products from American

Tom Parker Ltd consider their expert technical knowledge, high quality products, after sales service and close working relationships with suppliers and customers to be their major ongoing strengths.

connection specialists CPC – Colder Products Company; both of whom the company are proud to work closely with to this day alongside a portfolio of other leading brands. In 1999 Tom Parker Ltd started to produce product catalogues aimed at distribution, OEM and end users: building up a comprehensive resale network of companies who distribute fluid power products alongside their own ranges and specialist services throughout the UK.

Services also provided from their on-site facility is a BFPA certified and approved hydraulic and pneumatic hose assembly, in-house pressure testing, and a 24-hour bespoke pneumatic cylinder build service. UK Sales Manager and BFPDA Board Member, Seb Cole comments: “We have built up a strong team here at Tom Parker Ltd with a wealth of experience. Our people, as well as our on-site vast stock levels and a passion for putting our customers’ needs first are the main reasons behind our ongoing success. …We pride ourselves on our ability to source complete turnkey product solutions to the most challenging of fluid power projects. We particularly relish a challenge so why not put us to the test?”

For further information, please visit www.tom-parker.co.uk

PECM Issue 56

Your One Stop Fluid Power Source NEW

2022-23

CATALOGUE

36,000 Fluid Power Products Vast Stocks - Next Day Delivery Pneumatic & Hydraulic Hose Assembly & On-site Testing 24 Hour Bespoke Pneumatic Cylinder Build An Expert Fluid Power Focused Friendly Team

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email: catalogue@tom-parker.co.uk

sales@tom-parker.co.uk

tom-parker.co.uk

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 56

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

OUR PROVEN PROCESS UNISIG

How UNISIG leverages experience and expertise to solve customer challenges For over 40 years, we’ve helped our customers achieve success in deep hole drilling, providing them with the machines, automation and support they need to be competitive and profitable. We have found that the initial energy we and our customers spend at the beginning of a quoting process pays off throughout the entire project, from inception to installation. We take a systemized approach not only during this critical phase but also throughout the entire sales process. This ensures there are no surprises and that our customers know exactly what they can expect when starting discussions with UNISIG about their gundrilling and deep hole drilling needs. This is our approach at UNISIG: We listen to our customers, ask questions and understand what they need. This may seem obvious, but often the temptation is there to just skip to a quote because we think we know what is needed after a brief discussion. Sometimes that is true, when the application is straightforward and familiar, or it is something we have a packaged solution for. We always try to make the quoting process quick and efficient, but there are times when the application deserves a more in-depth conversation. Our salespeople and engineers listen very carefully and often pick up on small details – a specific tolerance, material condition, process requirement or a future need for flexibility – that may change our recommendations. When it makes sense, our experienced sales team or engineers will visit a customer to see what is needed firsthand. Whether a site visit or just a virtual meeting, this initial investment of time to clarify the need saves the customer money and provides them a truly valuable solution. We first identify a standard solution from our product line that can be applied at the lowest cost and shortest delivery possible. At UNISIG, our product development

confident moving forward with a UNISIG mindset is to systemize solutions from our custom machine is that they know we will experience in many different industries, stand behind it and that we have substantial make them automation ready and embed capabilities to ensure it always exceeds application flexibility whenever possible. Increase your mold manufacturing versatility their production expectations. We approach We invest millions of dollars annually in using therelated power gundrilling withprojects the with the mindset that these special our product line and spareof parts, a custom machine will be used for decades giving us a strong starting point for new leaders in deep hole drilling, UNISIG. Oﬀering in production, which is why we provide applications. Our standard product line the same documentation encompasses much more than machines, complete solutions for everything from and long-term technical support for all our machines including standard automation, workholding, simple to complex mold whether standard orUNISIG custom. accessories and tooling that we can offer as components, part of the solution. machines help moldmakers improve If a commodity solution is readily available, eﬃciency, andweprecision with recommend that rather than upsell a Once we have identifiedthroughput a standard machine machine the customer doesn’t need. as a starting point, our engineers seek out outstanding part-processing versatility at an smart, practical ways to meet the customer’s application needs. The goal is to innovate We build machines that can gundrill or BTA exceptional value. within the machining operation planning, drill deep holes that are impossible to drill work holding or automation, as opposed to on machining centers. Even if it may be engineering a completely special solution possible to drill some deep holes on a CNC YOURopportunities MOLDMAKING OPERATIONS without TAKE first exhausting to machining center, our machines have the solve problems with standard products. power, speed, dimensional accuracy, spindle FURTHER WITH UNISIG TODAY. density, coolant systems and process control that will improve productivity, tool life and For our customers, this approach provides reliability. Typically, though, when a customer them a reliable, standard machine that comes to UNISIG with a specific part need, can be used for many years and that has at that point they’ve most likely already the built-in flexibility easy re-tooling Find outformore at www.UNISIG.com struggled with a conventional machine and to adapt to future needs. For us, initially realized that a deep hole drilling machine is working within the boundaries of our catalog obviously the way to go. cultivates new ideas that can then be applied to improve our standard products as well as help us direct future research and However, our team knows how to identify development budgets. whether or not an application would truly benefit from a UNISIG solution. When it wouldn’t, we will suggest viable alternatives. If a standard solution isn’t available, we It’s not that we don’t want to sell a machine. consider a customized solution and we But the fact is that our experience has shown stand behind it. that at some point the alternative-solution direction becomes obvious, and we want to UNISIG is very good at building customized make that apparent early on in the process machines, and we do so often. Once we and so as to avoid wasting a lot of our customer’s our customers agree that a special solution time. is needed, we move forward with a great deal of confidence and experience. We start Our customers expect the best from us, and by evaluating how we might approach the we believe that our proven process ensures design using standard modules or proven we never disappoint. Our goal is to leverage concepts, thus eliminating long debug our core values to serve our customers as cycles and/or high costs. Then we use best we can and build strong, productive our mechanical and electrical engineering relationships for years to come. disciplines to virtually test the new machine before we build it. Please contact us to discuss your application. One of the key reasons our customers are

More information and the complete UNISIG machine program at www.unisig.com

PECM Issue 56

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.

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

MACHINING & MACHINERY

Starrag Heckert’s DBF integrated facing head delivers one-hit savings With a multi-tasking DBF radial (U-axis) facing head, Starrag’s Heckert DBF horizontal machining centres are unrivalled for single set-up, multiface, multi-faceting machining – including conical and contour turning – slashing processing times on, for example, oil & gas sector valves and fluid ends, in one case from 20 hours to just 4.5 and achieving 95% reductions in overall processing times and 77% cuts in cycle times. Compared to machines that may offer, say, facing head tooling via a toolchanger, the universal DBF spindle with face plate has an integrated 45 kW, 3,500 revs/min and 1,700 Nm torque spindle, and accommodates HSK 100 and Capto toolholders. The result is that with DBF, the tool tip is much closer to the workpiece – 200 mm-275 mm rather than the conventional 335 mm-410 mm – and this leads to much more stable and therefore highly accurate machining. KOSO KentIntrol is one of Starrag UK’s customers who realise the benefits of DBF machining, not least because the machine has eliminated the need for two separate machines, and all the associated re-setting and queuing times, to produce finished valve bodies. “The elimination of multiple set-ups on a lathe, plus the lack of queuing and set-up times for drilling, has produced dramatic time savings,” says the company. The Heckert DBF was purchased to increase capacity of the machining of valve and globe bodies in the 1-6 inches range (flange outlet bore size) and from a variety of materials, from carbon steels through to super duplex and Inconel. It enables the production of complete body machining in one or two operations, depending on casting type and size.

The DBF strategy – for angle bodies in one-hit and for globe bodies in two operations of set-up for machining the plug-way (including drilling) then set-up and machine the flanges (including drilling) - has replaced a comparatively longer and laborious process of: • Load to lathe • Set-up and machine first flange • Set-up and machine second flange • Set-up and machine the plug-way • Move body to drilling cell • Set-up and drill.

www.starrag.com

Engineering precisely what you value — Heckert

For those who aim for more.

35%

shorter machining time due to milling, turning and drilling operations in one clamping position

www.starrag.com

PECM Issue 56

Tel: 0191 410 5886 Units 11 & 13 First Avenue, Drum Industrial Estate, Birtley, Co Durham DH2 1AG

MACHINERY Your quality used ENGINEERING, SHEET METAL FABRICATION & WOODWORKING machine supplier; established in 1984 our experience and expertise in high quality machinery is second to none

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MACHINING & MACHINERY

ROLLER CHAIN RANGE DONGHUA

Roller Chain Solutions Just Got Better A new Roller Chain is making waves in the UK thanks to Donghua Limited who launched their new X3 Premium Chain earlier this year. The Chain is manufactured on its own purpose-built production line which encompasses new production techniques and new surface treatments. Designed with a unique pin coating, optimised plate geometry and high precision stamping, X3 offers a new deluxe chain solution and is designed for sectors that use high demand drives such as Timber, Waste & Recycling and Mining & Quarrying.

DONGHUA’S NEW ROLLER CHAIN RANGE Donghua Limited, the UK arm of one of the world’s biggest chain manufacturers, has introduced three Drive Chain ranges: Standard, Solution and Premium. Our extensive Roller Chain products have been categorised into these new ranges to help customers identify the right chain solution quickly and easily. The Standard Range features a variety of standard chain manufactured with precision to suit simple drives with large diameter sprockets or complex drives with multiple sprockets and high load bearings. The Solution Range offers customers a genuine solution to problems with chain wear, chain fatigue, high speed, lubrication, chain length accuracy and chain strength offering optimum performance in extreme conditions. Our new EXL Chain sits within the Premium range together with our Chromized Pin (CP) Chain, Heavy Duty Chain and Self-Lubricated Chain. The EXL Chain offers significant benefits over standard Roller Chain. It utilises different materials, material treatments and layer technologies, to offer the best possible quality/price ratio for all applications. Aimed specifically for the after-market, EXL Chain is designed, manufactured and tested for unbeatable accuracy and performance

in arduous conditions, offering enhanced wear and fatigue resistance and greater precision. The chain is designed with a new hardened, shot-peened wide-waist plate for increased fatigue strength and a seamless cold forged solid bush and roller to give full contact between the pin, bushing and roller for higher durability.

Our new X3 Chain is supplied pre-loaded and pre-lubricated as standard and is available in British Standard 06B to 24B in simplex and duplex, ex-stock from our 25,000 sq ft warehouse in the West Midlands. To download our X3 catalogue visit: https://www.donghua.co.uk/X3-chain

The EXL Chain has optimised cylindrical parts which improve sliding contacts to help increase service life. It also incorporates Donghua’s unique ‘Easy Break Technology’ which enables the EXL Chain to be cut in the field using Donghua’s Plate Extractor tools. To watch our video showing how to cut the EXL Chain using our Plate Extractor tools, visit: https://youtu.be/UD6rtBEJrkM The Premium Range offers our customers a deluxe solution to problems with chain wear, chain fatigue, corrosion, high speed, lubrication, chain length accuracy and chain strength with specific build features designed to enhance durability and withstand a range of arduous environments. The new X3 Chain is exceptional and delivers three times the performance for wear resistance, fatigue resistance and high speed performance for comparable Roller Chain. Its superior quality, durability and outstanding wear and fatigue resistance are realised by the new hardened, shot-blasted plate shape, calibrated pin and bushing holes, special heat-treated and surface coated pins, seamless rollers and bushings and high performance pre-lubrication.

HELP SELECTING THE RIGHT CHAIN To help our customers select the correct chain solution, we have developed a simple reference guide – the Donghua Chain Selection Chart. The chart provides a visual 1 - 5 star rating highlighting our recommendations for each chain product for wear resistance, fatigue resistance, strength, shock load, corrosion resistance, self-lubrication, easy break, FDA approved and so on. It’s a must-have reference document in an engineer’s toolkit. To download your copy of the Chain Selection Chart visit: https://www.donghua. co.uk/roller-chain or for a laminated hard copy call 01902 866 200.

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

PECM Issue 56

A PREMIUM CHAIN SOLUTION FOR HIGH DEMAND DRIVES

33 44 55

1 1

Optimised Optimised plate plate shape shape

2 2

Calibrated Calibrated pin pin and and bushing bushing holes holes

3 3

High High press press fit fit to to guarantee guarantee maximum maximum fatigue fatigue strength strength

4 4

Special Special heat heat treatment treatment and and surface-coated surface-coated pins pins give give exceptional exceptional wear wear life life

5 5

Seamless Seamless bushings bushings & & rollers rollers throughout throughout

6 6

High High performance performance pre-lubrication pre-lubrication

A new Chain for the UK market offering a premium solution with three times the performance for wear resistance, fatigue resistance and high speed performance of comparable Roller Chain. Designed with unique pin coating, optimised plate geometry and high precision stamping, the X³ Roller Chain delivers significantly reduced maintenance downtime and longer service life.

Available from Approved Product Partners and Stockists.

Tel: 01902 866200

DOWNLOAD THE NEW X³ CATALOGUE

donghua.co.uk/X3-chain

Donghua Donghua Limited Limited Sidings Sidings Close Close Wednesfield Wednesfield Way Way Wolverhampton Wolverhampton West West Midlands Midlands WV11 WV11 3DR 3DR

Tube Tube

MACHINING & MACHINERY

STREAMLINED PRODUCTION FILTERFINDER

Automation investment for Micro-Mesh and FilterFinder

Jaden Nicholson, Micro-Mesh’s graduate mechanical engineer, with the new robotic arm. FilterFinder parent company Micro-Mesh Engineering has unveiled the latest innovation at its Nottingham-based factory; a robotic arm to introduce automation to part of its filter production process. This purchase kicks off a round of investment that the company is making in 2022. Representing a £50,000 investment, the robotic arm helps speed up the laser engraving process of filter manufacturing by placing the caps onto an automated conveyor system where they are engraved having never needed to be touched by human hands. When done manually, the task was taking Micro-Mesh staff 16 hours every week, which equates to almost 35 days annually that have now become freed up for operators to do other tasks making the entire production process even more streamlined and efficient. The new equipment was made possible thanks to funding from an Aerospace

Unlocking Potential (Aerospace UP) programme, a collaboration between the University of Nottingham and the Midlands Aerospace Alliance. Launched in 2020 and backed by the European Regional Development Fund, Aerospace UP has more than £5m of funding to provide to SMEs in the aerospace sector who are looking to unlock their innovation potential. Elliott Underwood, head of online sales at FilterFinder, said: “When we looked at potentially automating part of our manufacturing process, this task was an obvious one as it represented one of our operators spending hours a day doing a job no-one wanted to do. They have now been freed up to do other tasks and improve efficiency elsewhere.” Jaden Nicholson, Micro-Mesh’s graduate mechanical engineer, has been busy working on the programming for the robot

arm, which features a built-in ‘machine vision’ camera, which identifies the part it is picking and passes the information onto machines further down the production line, further streamlining the production process. Finally, four sensors are built into its motors which can detect any external forces being applied, causing it to stop and require resetting. This health and safety feature will help maintain and safe working environment for Micro-Mesh operators. Founded in 1968, Micro-Mesh, is the UK’s leading filter manufacturer, providing high quality hydraulic and air filtration solutions to a wide variety of industries. In December 2020 it launched FilterFinder, an online cross-reference database with a catalogue of more than 600,000 part numbers from over 1000 different manufacturers. Together, the two businesses are committed to innovating, evolving and advancing their offerings.

For further information, please visit www.filterfinder.co.uk | www.micro-mesh.co.uk

PECM Issue 56

MACHINING & MACHINERY

01202 875657 sales@laserprofiles.co.uk

Laser Cutting (Flat Profiles)

Sheet & Plate – Up to 25mm thick

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Laser Profiles (Fast-Track) Lead Time 3 hours 6 days

Offering one of the fastest turnarounds in the UK for laser cutting and low volume fabricated components, this fast-track service has previously been sold to the F1 Automotive industry only; we are now able to offer it to all industries.

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CNC deburring and polishing

P09 XEBEC BrushTM Surface End Type

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Cutter mark removal and flat surface polishing.

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

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

P18 XEBEC StoneTM Flexible Shaft

P11 XEBEC BrushTM Crosshole

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Hole deburring.

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

Deburring after drilling.

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

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

Issue 56 PECM

M&E WEEK SHOW PREVIEW

AN UNRIVALLED LINE-UP M&E WEEK

Celebrating the best in UK manufacturing and engineering excellence and innovation With the Government’s plan to help UK manufacturers double exports, the release of the first roadmap to net zero for the sector and ongoing skills shortages, Manufacturing and Engineering Week (M&E Week) comes at a crucial time to bring the community together to debate and discuss the current challenges. M&E Week covers the entire product lifecycle from design, engineering, manufacturing and maintenance and seeks to celebrate the sector sharing successes and future insight, raising critical discussion and is a destination for professionals to source products and services in order to keep them competitive. The week hosts a series of digital sessions plus 4 Live co-located events on the 8-9 June 2022 at the NEC in Birmingham Design Engineering Expo, Engineering Expo, Manufacturing Expo and Maintec. Together the events showcase end-to-end manufacturing and engineering solutions, to encourage business and knowledge sharing across a range of sectors.

of the most cutting edge products allowing visitors to see solutions in action, including AI race car and biplane quadcopter.

CPD ACCREDITED EDUCATIONAL CONTENT

The Award Winning Cyber Demonstrator will deliver live scenarios on how to prepare for cyber threats, explore unknown areas of vulnerability and survive in the new age of information warfare targeted at the manufacturing sector.

An unrivalled line up of inspiring leaders and innovators will debate current issues and challenge thinking with a particular focus on SME’s and OEM’s strategy. Workshops will also feature supplier case study led presentations delivering practical solutions aimed at improving process and efficiencies.

The Great Egg Race is an exciting live challenge taking place over both days of the show where engineers will compete to build gadgets to propel eggs into a tractor trailer. A compare will host the challenge with winners presented with prizes onsite.

MARKET LEADING SUPPLIERS

INDUSTRY SUPPORT

M&E Week will showcase Britain’s best products and services from design services, additive manufacturing, AI, cyber security, robotics & automation, enterprise resource planning (ERP) and instrumentation through to testing and measurement and maintenance, visitors will be able to meet the suppliers who can deliver the latest tech and innovations to drive the sector forward.

LIVE DEMONSTRATIONS

A dedicated innovation zone, sponsored by Arrow, will feature live demonstrations

M&E Week has the support of many leading bodies including the Make UK, Institute of Engineering Designers, Department for Business, Energy and Industrial Strategy, Women’s Engineering Society, Institution of Mechanical Engineers, The Manufacturing Technology Centre and High Value Manufacturing Catapult and guidance of an incredible line up of experts on the Advisory Council. We are also collaborating with other event organisers running related events at the

NEC the same week. Rapid New Group’s TCT 3Sixty and Med-Tech Innovation Expo are taking place in adjacent halls on the same days and visitor passes provide access across all shows.

M&E WEEK IS A NET ZERO EVENT With the UK’s commitment to reach net zero emissions by 2050 the importance of sustainability for the industry is higher than ever before. Manufacturing & Engineering Week will be contributing by running a Net Zero event on the 8-9 June at the NEC in Birmingham. Total emissions of 136.8 tons of CO2 have been calculated to be generated during the running of the event which includes venue usage, materials and exhibitor and staff transport and accommodation. To offset this, the M&E Week team, in association with their Sustainability Partner, have organised the planting of 5472 trees in a dedicated M&E forest to make the event Net Zero. The team will also plant a further tree for every visitor that attends. To find out more about M&E Week visit www.mandeweek.co.uk. Visitor passes are free of charge – register now at https://mandeweek.reg.buzz/pecm

To find out more about M&E Week visit www.mandeweek.co.uk

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Propelling the future of design excellence and innovation. engineering

Celebrating the best in UK manufacturing and 5472 trees planted to make M&E a Net Zero Carbon Event

Incorporating 4 live co-located events

••

Hear Hear inspiring inspiring keynotes, keynotes, exclusive exclusive interviews interviews and and debates debates

••

Attend Attend CPD CPD accredited accredited workshops workshops

••

Source Source products products and and services services from from Britain’s Britain’s

“There “There has has never never been been aa more more important important time time for for our our sector sector to to pull pull together, together, to to create create aa shared shared agenda agenda and and Manufacturing Manufacturing and and Engineering Engineering Week Week will will do do exactly exactly that. that. II am am delighted delighted to to be be part part of of the the M&E M&E Week Week Advisory Advisory Board Board and and that that MAKE MAKE UK UK are are aa partner partner for for this this groundbreaking groundbreaking event.” event.”

best best suppliers suppliers

Stephen Stephen Phipson Phipson CBE, CBE, Chief Chief Executive, Executive, MAKE MAKE UK UK and and Chair Chair of of M&E M&E Week Week Advisory Advisory Council Council

Premier Premier Partners Partners

What’s on during M&E Week

Innovation Innovation Zone Zone Sponsor Sponsor

Theatre Theatre Sponsors Sponsors

Audit, Audit, Tax Tax && Advisory Advisory Partner Partner

7 June - Digital Events Preview 8-9 June - Live Events Programme 10 June - Digital Events Review

Find out more at www.mandeweek.co.uk

MEASUREMENT & MONITORING

ALLOY WHEEL COATING PHOENIX TM

See what truly happens in the powder coating oven process Ever wondered what exactly happens to your product inside your paint oven during normal production? That is exactly what the PhoenixTM new Optic system for Paint Process monitoring allows you to do. The system can monitor the product temperature profile and simultaneously record video of your product travelling through the cure oven at temperature. The PhoenixTM VIS-64 Optic system was recently used to validate the operation of the Ri Wheel Systems Ltd alloy wheel refurbishment line installed at the Dick Lovett Group. To our knowledge, this is the first time that a combined optical and temperature profile of a powder coating line has been performed. 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. During the same run a temperature

PhoenixTM Optic System still video image of the video captured thru-process showing detail of the oven condition and wheel transfer.

profile of either the oven temperature and or product temperature can be performed using the PTM1200 data logger.

From the optical profile run, video of the alloy wheels journey through the oven was obtained showing smooth unhindered travel. The excellent field of view allowed a comprehensive inspection of the inside of the oven and operation of the chain on edge conveyor system. Amazingly, from the optical profile even detail powder coating process transitions were detected. It is possible to see the powder coating transitions from virgin powder through the melt, flow, and final cure stages. Consider combined temperature and optical profiling of your continuous paint cure process and open your eyes to the hidden mysteries of what happens inside that black box that is your paint cure oven. Whether temperature or optical monitoring, PhoenixTM your finishing oven to find, fix and forget those coating cure problems!

PhoenixTM VIS-64 Optic System used on the Ri Wheel Systems Ltd alloy wheel refurbishment line at the Dick Lovett Group.

For more information: Contact Dr Steve Offley - Product Marketing Manager. PhoenixTM Ltd UK; tel: +44(0)1353223100; e-mail: Steve.Offley@phoenixtm.com;

For further information, please visit www.phoenixtm.com

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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

VEGAPULS 6X VEGA

VEGA ushers in a new era in level sensing with the radar sensor VEGAPULS6X With VEGAPULS 6X, VEGA radar “thinks” in a new way. The result: A new level radar sensor that can measure in virtually every conceivable application. The time when users had to choose their level instrument from a multitude of different types are now history. Traditionally, the search for a suitable level sensor begins by thinking about things like: what solution would be best for my application, how can I ensure I choose the correct and most reliable device for a successful outcome for my project? Of course radar offers great answers for these questions. The customer already knows their own process, the details of product properties and processing to be controlled, the temperature ranges involved, the standard needed to be met and installation fittings that are available. But, until now, choosing a radar-based level instrument was a laborious task, matching these process details to myriad radar frequencies, part numbers and options on offer. Now the process is being completely transformed by VEGA with its new VEGAPULS 6X. One device for all and a new selection and ordering method that is customerapplication focused. It enables complete, correct configuration and even pre-calibration of the specific sensor required - for any application, whether for liquids or bulk solids. “Ultimately, it’s not the sensor that counts, but what the users can achieve with it in their individual processes,” says Florian Burgert, who, as a product manager, has been closely involved in product development from the very beginning. “Just knowing that they’ve chosen the best possible measurement solution and that they’ll reach their goal faster with it, makes a big difference in their everyday operations.” Over 1 million instruments in use worldwide. The success story of today’s world market leader in radar level measurement began 30 years ago. In the meantime, VEGA’s sensors have optimized millions of industrial processes. The story includes milestones such as the world’s first two-wire radar instrument and the first 80-GHz radar sensor for liquids on the market, which revolutionised radar level sensor performance for customers. Behind this success are the many people who share a common passion: “At VEGA we don’t do a hundred different things, we concentrate on what we do best: Radar.”, says product manager Jürgen Skowaisa, speaking for all of them.

ALL-ROUND PROTECTION The new VEGAPULS 6X offers the best that is technically feasible today: a self-diagnosis system that immediately detects damage or interference, that ensures significantly high availability and safety, it also has new radar-chip technology, with expanded application possibilities and simpler operation.

The new radar level sensor VEGAPULS 6X is the result of 30 years of experience and over 1 million sensors in use worldwide.

The radar features SIL certification, and the matter of cybersecurity has also been fully taken into account: Compliance with security standard IEC 62443-4-2, which specifies the strictest requirements for secure communication and access control. The value lies in making it easier for users to select their device and monitor their industrial processes. The ultimate purpose of VEGAPULS 6X is just that - through maximum simplification. It is one sensor that can handle virtually any application. In the future, the customer will no longer have to worry about the technology, frequency or instrument version. Even setup and commissioning has been reduced to a minimum, requiring now just a few clicks and basic application parameters. In many cases, all application-specific settings can be made in VEGAPULS 6X before it leaves the factory, so it’s just left for the user to install, connect, done: It doesn’t get any simpler.

For further information, please visit www.vega.com/radar

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BORN, WHERE VALUES ARE VALUED. THE 6X®. AVAILABLE NOW! Technology is only as good as the people who make it. That’s why the new VEGAPULS 6X is the result – made by over 1,800 valuable employees, 60 years of valued measurement experience and every value that is intrinsic to VEGA.

VEGA. HOME OF VALUES. www.vega.com/radar

MEASUREMENT & MONITORING Advanced Engineering Products and Services for the Manufacturing Industry Experts in Press Protection, Quality Assurance and Productivity • Load Monitoring and Automation Systems for manufacturing equipment • Process monitoring and control for assembly machines • Manufacturing Execution Systems including downtime analysis

The Visulex K55 fixed lens cameras from Lumiglas® Visilume present our latest process surveillance & observation technology with the Visulex K55 fixed lens cameras from Lumiglas®. Available in both non-ex and ATEX approved specifications, the K55 is a PoE unit, meaning it is easy to install and start operating and can be viewed on a laptop or pc. This avoids a complex installation and less set up difficulty. Available in HD and 4K versions, it has a 2 MP camera unit and automatically adjusts

its aperture settings to maintain optimum view settings. Multiple picture viewing software is also available for systems comprising of 2 or more camera’s, with optional connectivity to mobile viewing via Apple or Android devices. Save time and money on regular process inspections and view real-time pictures with this easy to install technology. Email: sales@visilume.com Phone: +44 (0) 1457 865700 Web: www.visilume.com

The new acoustic camera SONASREEN Leaks in compressed air and vacuum systems cause significant costs. Therefore, their fast detection and repair saves time and money, while also reducing CO2 emissions. SONOTEC provides the brandnew SONASCREEN acoustic camera that helps you to meet your energy efficiency targets. The SONASCREEN is also used to detect and distinguish typical forms of electrical partial discharges. This new acoustic camera is suitable for high and medium voltage applications, to inspectall air insulated electrical assets like transformers,

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insulators or transmission lines. More features: • 72 sealed microphones for use in industrial areas • Real-time acoustic results at 100 fps for real time results • Wide frequency range: 10 Hz to 100 kHz • Integrated data acquisition and analysis software • Handheld device with IP54 protection • Low weight and small size +44 (0)333 366 1100 sales@vpinstrumentsuk.co.uk www.vpinstruments.com

• Production recording systems • Bespoke control systems • Calibration services • Repair/Maintenance

Decade Monitoring Solutions Ltd Unit 3, Octagon Business Centre, Miller St, Birmingham, B6 4NH Telephone: +44(0)121 359 3978 E-mail: sales@decade.co.uk www.decade.co.uk

The Xi 410 combines a robust, compact pyrometer and an advanced IR camera with a resolution of 384 x 240 pixels. The autonomous operation with automatic spot finder function as well as the direct analog output and affordable price make it a perfect match for all safety-relevant applications in the fields of preventive fire safety and machine and equipment condition monitoring.

IR Cameras. Pyrometers. Accessories. Software. We measure temperature non-contact from –50 °C to +3000 °C. Visit: www.optris.global Our affordable and fixed installed longwave and shortwave IR cameras with analog/digital outputs are ideal for industrial and R&D applications.

The compact imager optris Xi 410 with auto hotspot finder, Ethernet and autonomous operation

On target.

MEASUREMENT & MONITORING

If the network connection is disrupted or there is a problem with the connected PC, the camera takes over and ensures a reliable alarm if a problem is detected.

The autonomous operation with automatic spot finder function as well as the direct analog output and affordable price make it a perfect match for all safety-relevant applications in the fields of preventive fire safety and machine and equipment condition monitoring.

when temperature matters www.optris.global Issue 56 PECM

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MEASUREMENT & MONITORING

Advanced Energy’s Expanded Modular Pyrometer Series Simplifies and Speeds Non-Contact Measurement in Industrial Applications Impac Series 600 – pyrometer with 4 sensor heads (optional)

Interchangeable sensor heads minimize downtime by allowing a single system to be re-configured for a variety of measurement criteria Advanced Energy expand the Impac® Series 600 of pyrometers with new modular sensor heads. Supporting a wide range of wavelengths and temperature ranges, the new IS 600, IGA 600, IGA 600/23 and IN 600/5 sensors complement AE’s leading non-contact temperature measurement portfolio for steel and glass manufacturing applications. Thanks to its modular nature, the Series 600 simplifies the design, installation, and maintenance of industrial manufacturing. By providing highly accurate, multipoint temperature monitoring and control, the Series 600 equips customers with real-time data analysis, improved control and repeatability. Single and multi-box architectures are available with up to eight individually customizable pyrometer heads in one system, eliminating the need to set up multiple systems saving cost and effort. Alternatively, customers can choose between three converter boxes as well as Profinet interface. The converter boxes provide an optional display for temperature measurement and parameters directly in the instrument, eliminating the need to connect to a computer to change the settings. Different sensor heads cover temperature ranges between -40 to 2500°C and operate in spectral ranges between 0.7 to 14 μm for different applications. The IS 600, IGA 600, and IGA 600/23 short wavelength digital pyrometers are well-suited for the measurements of metals, ceramics, or graphite while the IN 600/5 is specifically designed for the measurement of glass surfaces.

Thanks to its modular nature, the Series 600 simplifies the design, installation, and maintenance of industrial manufacturing.

Modular system-architecture allowing up to 8 different measurement spots

info@aei.com | www.advancedenergy.com

Heat-processing with constant and precise control Advanced Energy's SCR power controllers, optical temperature pyrometers, and thermal imagers set the standard for thermal processing precision, repeatability, and reliability.

advancedenergy.com

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MEASUREMENT & MONITORING

Sonophone ultrasound devices from CBM Partners Reduce Energy Costs and Improve Machine Reliability using Ultrasound. At CBM Partners, we offer the SONOTEC SONAPHONE and SONASCREEN range of products on a “Try Before you Buy”, Rental or Sale basis. As users of the whole range of products ourselves we provide unrivalled support and training too! Sonotec’s range of Ultrasound devices have unique and powerful options including SONAPHONE DataSuite enabling route-based bearing inspection and LeakExpert for easy leak detection, energy consumption calculation and reporting! The SONASCREEN ACOUSTIC CAMERA locates sound sources in real time and displays the results on the screen. You are able to view multiple leaks in one image and leak detection audits are easily recorded, with loss estimation reports. The SONAPHONE may be used in conjunction with the SONASCREEN ACOUSTIC CAMERA to detect partial electrical discharges at the earliest stages and help to ensure plant reliability and safety. Ultrasound allows you to “hear” any arcing without the need to open access doors, allowing you to isolate the unit before opening to look for signs of damage, overheating, melted insulation or similar in the safest way possible.

Contact us today for more information on our flexible, Try Me, Rental and Purchase options for SONOTEC Preventative Maintenance Equipment.

+44 (0)1908 229 641 | info@cbmpartners.com

Issue 56 PECM

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PACKAGING INNOVATIONS SHOW PREVIEW

CUTTING-EDGE DESIGN PACKAGING INNOVATIONS & EMPACK

Packaging Innovations and Empack returns to Birmingham’s NEC Packaging Innovations and Empack 2022 will bring together the industry when it returns to Birmingham’s NEC on 25 and 26 May. Leading exhibitors from across the entire packaging spectrum will display their cutting-edge designs and products, with guests able to get hands-on with a broad range of technologies and systems designed to help assist their packaging requirements.

NEW INNOVATION The event will feature a sold-out exhibition floor, with many exhibitors launching their latest innovations live at the event. The Label Makers will display its range of sustainable label solutions, including those for recyclable bottles. The bespoke service is aimed at delivering the strongest on-pack message, to ensure maximum shelf standout. Expac will promote its wide range of bottles, tubes, jars, and glassware, designed for use in the personal care and household sectors. The company has invested in its sustainability credentials, by developing a range of bag-in-box refill products which house a variety of common food products, such as oils, emulsions, and liquids. Epson’s Colorworks range of desktop label printers will also be featured at the show. The printers can be used for several procedures, including food and drink labelling, pharmaceutical and shelf labels, chemical, horticultural, and badge labelling. The C6000 series offers up to 4-inch print widths, with the C6500 offering up to eight inches. The C7500 model can produce a wide range of media, including continuous tickets, fabric labels, and synthetic die-cut labels, with a matte or gloss finish. Also present will be Excel’s EX-FILL-S semiautomatic volumetric filling machine. The technology is suited to a busy production environment, where flexibility, accuracy, and rapid changeovers are required. Volume and flow rate is electronically controlled, with a fill accuracy of +/- 0.5%. The machine

There is so much to look forward to this year, and we can’t wait for the doors to open in May! is fully upgradable, with automation options including conveyors, capping, rotatory tables, and labelling machines.

EVENT FEATURES The Packaging Innovations and Empack 2022 seminar programme will run across three stages, demonstrating the event’s commitment to address the plethora of issues currently affecting the industry. The Empack Technology stage will feature content specifically for manufacturing, processing, and logistics professionals, whilst the Innovation and Design stage and the Ecopack stage will focus on the latest developments in packaging technology, with a specific focus on sustainability.

Further to this and in association with OPRL, the Ecopack Challenge will make its longanticipated return, with innovators pitching their cutting-edge solutions to a panel of judges including Ocado and Pret A Manger. Also, The Big Debate will tackle the latest challenges in packaging regulations and assess whether these guidelines will have a positive impact on reducing waste and improving recyclability. Easyfairs’ Divisional Director, Renan Joel, notes: “The range of exhibitors coming to this year’s show is greater than ever before. Packaging Innovations and Empack caters for every part of the packaging supply chain, no matter how niche. Our visitors will no doubt enjoy getting hands-on with the latest industry tech, designs, and innovations, and will be able to take away some invaluable advice from our expert-led seminar programme. There is so much to look forward to this year, and we can’t wait for the doors to open in May!” To register to attend Packaging Innovations and Empack NEC 2022, please visit the registration page. For any further information, please visit the Packaging Innovations and Empack NEC 2022 website or contact the show team on +44 (0)20 196 4300 or PackagingUK@easyfairs.com.

For further information, please visit www.packagingbirmingham.com

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Packaging Innovations & Empack

25 & 26 May 2022 | NEC, Birmingham

The future of packaging technology! Empack is the UK’s premier show that, alongside Packaging Innovations and the special feature Contract Pack & Fulfilment, covers the entire packaging value chain. • • • • • •

Meet over 280 innovative suppliers Network with and learn from packaging experts on the dedicated Empack stage Discover 100s of NEW technology and packaging solutions See the latest innovations within • Smart Packaging • Industry 4.0 • Industrial Robots & Automation • E-commerce fulfilment

www.packagingbirmingham.com

The show is the perfect place to see and meet with everyone in the industry – you can’t beat it. Sasha Nelhams-Fielding, Sales & Marketing Manager, FMP Ltd

Everything we needed all under one roof, great to be able to take your product ideas with you and look at the filling capacity , bottles, pack of and shipping logistics all in one day saving hours of trying to find the right companies online. Ellie Dunmore, General Manager, Penny Price Aromatherapy Ltd

PACKAGING

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

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

www.storopack.co.uk

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

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

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PECM Issue 56

www.storopack.co.uk

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

100% recycled content and 100% recyclable

PACKAGING

PAPER WRAPPER KHS

Simple retrofits on existing KHS packaging machines As opposed to the former machine segment, this now also has a gluing station that sticks the paper together beneath the pack. The packers also require a paper folding and gluing module – either as an addition or a replacement of the shrink tunnel – where the packs are closed.

Simple conversion for great flexibility: the new packaging alternative from KHS, that wraps beverage cans in paper instead of film, can also be retrofitted to existing Innopack machines manufactured by the Dortmund systems supplier. Customers can either opt for more flexibility by switching between film and paper packaging as required or permanently switch to paper. Since 2020 KHS has provided a facility on its packaging machines for wrapping beverage cans in paper. In order to give customers maximum flexibility, the new function has been integrated into a combined machine: whether wrap-around packs, packs on trays or pads with or without film or paper wrappers, the new system solution can process a broad range of secondary packaging. Paper may be a relatively new packaging material on the beverage market; especially as an alternative to plastic, however, this material is increasingly capturing beverage fillers’ interest. The paper wrapper meets consumer demand for alternative, environmentally-friendly packaging material. As not every beverage producer wishes to install a completely new machine, however, the paper wrapping unit is now also available as a conversion option. This means that bottling companies can quickly and easily react to marketing trends and consumer demands using existing Innopack packaging machines.

REPLACEMENT OR ADDITION KHS provides two retrofit options. If paper wrappers are to permanently replace shrink film as a secondary packaging, all that needs to be done is to substitute two modules; the machine layout can stay practically the same. Here, the former film wrapping module is replaced by the newly developed module that can process paper. The shrink tunnel is also substituted by a module that folds and glues the paper. Beverage producers who do not wish to compromise on flexibility when it comes to secondary packaging can retrofit the new

KHS packaging system as an additional option on their existing machine. In this case, the paper wrapping unit is adapted and the paper folding and gluing module is installed on the machine as an extra.

SIMPLE SWITCH Once the modules have been fitted, switching materials calls for no other conversion except the standard format changeovers. As soon as the packaging materials have been changed over and the hot melt devices are ready for operation, production can begin. “Conversion is a simple matter on all machine types in the Advanced series,” claims Uwe Bartholemy, head of Technical Support for Packaging at the KHS Service Division. This is chiefly facilitated by the modular design of KHS’ Innopack machinery. Then a quantum leap for the industry on its launch in 2000, this plant engineering has long established itself as a standard. “Generally speaking, we can also convert older machines in this way. Here, we carefully examine each individual case to check whether the control unit needs an update or not, for example.”

TECHNICALLY STRAIGHTFORWARD From a technical viewpoint, on KHS Innopack packaging machines with a shrink tunnel only the existing film wrapping module has to be replaced by the further developed module for paper wrapping. This can then process both materials. Packers without a film wrapping module have the new module installed as an extension.

Costs for conversion are much lower than those for investment in a new machine. Moreover, only partial commissioning of the current formats is required as these have already been configured for the existing machine modules. New formats can also be set up with less effort than that required for the existing ones. Incidentally, when asked which of the two variants – replacement or addition – will be more in demand in the future, Bartholemy has a clear answer. “Paper wrappers are still a relatively new form of secondary packaging. With a view to future market development, lots of bottlers want to keep all their options open. I thus assume that the flexible combined machine will prove an extremely attractive proposition for our customers.” At a glance: the paper wrapper conversion

AREAS OF APPLICATION

• Beverage and food cans (all sizes) • Beverage cartons • Other cylindrical and quadratic packaging styles • Pre-packed products

TWO VARIANTS • Machine conversion to switch from film to paper wrappers as the secondary packaging: replacement of the film packaging modules and shrink tunnel by the paper wrapping and paper folding and gluing modules • Conversion to create a combined machine for flexible film and paper processing: replacement of the wrapping module and addition of the paper folding and gluing module

ADVANTAGES • Low cost of investment • Only partial commissioning of existing formats • Faster resumption of production

For more information go to: www.khs.com/en/media

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PROCESS TECHNOLOGIES

Optimum oil-free vacuum technology Clean processes, efficiency and sustainability are important criteria for vacuum technology to meet in the 21st century. To meet these demands, Vacuubrand have created a range of powerful and pure vacuum technology solutions. For fine vacuum applications, the VACUU-PURE 10C screw pump offers an oil-free and chemically resistant solution that saves time and minimises operating costs. Specifically designed for processes in the vacuum range down to 10-3 mbar, it can be used across the entire pressure range. Aggressive gases and vapours can be pumped without worry due to the unit’s high chemical resistance, and the use of a cold trap is no longer necessary for most applications. For rough vacuum, VARIO Select units offer a selection of vacuum ranges and pumping speeds, while the integrated and intuitive VACUU-SELECT controller allows for easy control of vacuum and process steps. Additional features include an inlet separator, which retains particles and droplets, and an exhaust emissions condenser, which enables solvent recovery of nearly 100%. Contact Labtex on 01484 600200 to discover more about Vacuubrand vacuum technology solutions.

www.labtex.co.uk

High performance fluoroplastic procucts from Labtex Labtex offer a vast range of finished and semi-finished products in technical and fluoroplastics. A variety of materials, such as PTFE, FEP, PFA, PEEK, enable the development of innovative products for stirring and mixing, temperature measurement, distillation and filtration, with excellent chemical resistance and thermal resistance. Screw joints and ground joint components, tubing and connectors allow an infinite number of combinations to create sophisticated systems of sampling and feed using standard laboratory bottles and containers. For distillation of strong acids or alkaline products, BOLA manufactures reaction vessels up to 6 litre capacity in PTFE or PFA. All parts exposed to the medium are made completely of PTFE or PFA. The BOLA catalogue also includes a wealth of technical information on the materials used including physical properties and chemical resistance and the safe use and care of fluoroplastic labware. For more information about fluoroplastic products, call Labtex on 01484 600200.

www.labtex.co.uk

PROCESS TECHNOLOGIES

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

PROCESS TECHNOLOGIES

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PROCESS TECHNOLOGIES

New SEPURA™ app makes product selection even easier Global filtration specialist Bowman Stor, has announced the launch of a new SEPURA Technologies app for its extensive oil/water separator range. With a growing number of customers wanting genuine SEPURA™-branded units, the UKbased company has developed a unique mobile application. The new app allows users to access a handy OEM Comparison Tool to find the most suitable product for their needs - all by simply searching for their current manufacturer. Available on both Android and Apple platforms, the application also includes an easy-to-use oil/water calculator which helps establish the right size of filtration unit for the customer’s compressor system. Bowman Stor’s Managing Director, Richard Potts said: “The free SEPURA™ app makes life even easier for distributors, resellers and endusers in every industry. We believe this is the first app of its kind in the filtration industry and users can now source the best separator products for their needs from any location.” Only genuine SEPURA-branded products contain the groundbreaking SILEXA™ media - a revolutionary patented media developed through years of research in Bowman Stor’s

own laboratories. The SILEXA material has major environmental benefits, achieving outlet quality discharges as low as 5ppm. With SEPURA’s comprehensive range of oil/ water separator units and third party service kits covering low, medium and high capacity requirements for multiple industries, the app is the perfect way to find the ideal product for each specific use and send enquiries direct to the distributor.

To download the app Go to your App Store and search “Sepura Technologies”. 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 App Advert 132x180L.qxp 15/03/2022 14:25 www.sepura-technologies.com Page 1

scan the code to go to the download page

Make life easier

Get the free App We have developed a mobile App that will make it easy to identify the right SEPURA™ product to fit your current oil/water filtration system. Not only that, we have also built in a calculator so you will know straight away which product from our comprehensive range is the correct one for you.

Our unique SILEXA™ filtration media is made from recycled materials and is more effective than any other filtration media currently available. Many users are now switching to our products over their existing OEM suppliers to meet their environmental commitments. SEPURA™ is part of the Bowman Group

www.sepura-technologies.com

t: e:

+44 (0)1543 379212 sales@sepura-technologies.com

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PUMPS / SOFTWARE & SYSTEMS

FLOW OPTIMIZATION SECOND TO NONE

THE NEW BLUELINE NOVA ROTARY LOBE PUMP The BLUEline Nova sets new standards in pump technology. With or completely without casing protection – the BLUEline Nova achieves unrivaled volumetric efficiencies. Made for one another – the newly developed DIUS rotors in combination with the flow-optimized pump chamber ensure perfectly smooth running at pressures of up to 12 bar.

EXCELLENCE – MADE TO LAST

BLUEline

NOVA www.newblueline.com

Börger UK Limited • East Wing • Watling St. Gailey • Staffordshire • +44 1902 798977 • uk@boerger.com • www.boerger.com 220318 ANZ UK NOVA 180 x132 mm_RZ.indd 1

18.03.2022 08:02:17

Find us on stand 19-627 in the Measurement & Inspection Zone at MACH 2022

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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 AND MEET US AT SUBCON, NEC, BIRMINGHAM: 7-9 JUNE 2022 Issue 56 PECM

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SUBCON SHOW PREVIEW

SUBCON IS BACK FOR 2022! SUBCON

Three days of innovation, partnerships and excellence Sponsored by Inenco, Omnidex and Qimtek Subcon returns on the 7- 9 June 2022 to the NEC, Birmingham. Now in its 45th year, it remains the UK’s premier event dedicated to subcontract manufacturing buyers, enabling them to source suppliers, benchmark capabilities, and form new manufacturing partnerships. At Subcon, find everything from product design, prototyping and development, contract and subcontract products and services through to machine tools, systems and equipment. This June, Subcon will once again be collocated with The Engineer Expo and Manufacturing Management Show, bringing together even more of the best suppliers, latest innovations and practical advice.

WORLD-CLASS SOLUTION PROVIDERS: THE EXHIBITION Across the three show days the exhibition will deliver the contacts, connections and content that engineering and manufacturing businesses in the UK need to succeed. Visitors will be able to harness new innovations from over 200 world class suppliers to help increase capacity, optimise productivity and improve flexibility, whilst also driving down costs to stay competitive in a global market. Subcon exhibitors span a massive range of manufacturing and engineering businesses, including assembly work, CNC machining, metal fabrication, 3D printing and many more. As this diversity of exhibitors shows, there will be huge opportunities to forge strategic partnerships and improve existing processes.

experts discussing the key issues and trends that are driving innovation and shaping the UK’s industrial landscape in 2022: from the latest developments in key technology areas such as hydrogen mobility, electrification, and nuclear fusion to keynote insights on automation, finance and engineering skills. Speakers confirmed this year include: Dave Short - Technology Director, BAE Systems: Innovation in the defence sector Richard Whiting – Commercial Director, UK Battery Industrialisation Centre: Scaling up UK electric vehicle battery manufacture Tony Langtry – Head of Mechanical Engineering, Tokamak Energy: The engineering challenges of nuclear of fusion

Exhibitors include European Springs & Pressings, DP Engineering, DVR Ltd, Flexible Machining Systems Ltd, Goodman Metal Works, IMSM, JKN Oil Tools, Oldham Engineering, Omnidex, and many more.

Hugo Spowers – Founder, Riversimple: Transforming mobility with hydrogen

SHAPING THE FUTURE: FREE CONFERENCE SESSIONS

Professor Chris Tuck – University of Nottingham: Insight from the cutting edge of the UK additive manufacturing research community.

Visitors can also enjoy over 30 hours of free conference sessions lead by industry

Professor Ric Allot – Director of Business Development, STFC: Industrial applications of Big Science.

Nick Hawker, CEO and co-founder, First Light Fusion on the commercial application of nuclear fusion Martin Little, commercial director, Rail Alliance on the overlooked opportunities within rail Jason Dante, event director for Subcon, points out that this wide range of opportunity and the chance to see so many diverse companies is no accident: “We have crammed as much value into the event as we can. This year, alongside the Engineer Expo and Manufacturing Management Show theatre, we also have a brand new supply chain theatre that will bring together an expert line-up of speakers to talk about the biggest challenges and opportunities for the sector. We also once again have ensured there will be ample networking opportunities available at the show, including the VIP buyers lounge, sponsored by Qimtek. Plus, there will even be a couple of extra surprises in celebration of the Jubilee! We are incredibly excited to include so much new material and look forward to opening the doors at the NEC.”

For further information, please visit www.packagingbirmingham.com

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R TE IS G OW RE N

7-9 JUNE 2022

NEC, BIRMINGHAM 25 25

NOW IN ITS 45TH YEAR 30 30

50 50

BACK THIS JUNE! THE UK'S LARGEST SUBCONTRACT MANUFACTURING SUPPLY CHAIN SHOW 70 70

90 90

CO-LOCATED WITH

SH W Over 200 world-class exhibitors 3 days of cutting-edge conference sessions from industry thought-leaders Countless networking opportunities

AND SO MUCH MORE!

INTERESTED IN EXHIBITING?

Make sure you’re at the must-attend event for subcontract manufacturing buyers across all industry sectors! Get in touch with Jason.dante@markallengroup.com for more information.

2022 SPONSORS

WWW.SUBCONSHOW.CO.UK JOIN THE CONVERSATION

@SubconShow #SubconShow

SWITCHES & SENSORS

SENZTX

PROCESS SENSING TECHNOLOGIES

Compact O2 transmitter for reliable measurement of oxygen concentration Engineers are constantly looking for new and innovative ways to improve the efficiency of their processes. In many cases, this involves finding a product that can be easily integrated and provides flexibility. When it comes to oxygen transmitters, the SenzTx from Process Sensing Technologies (PST) is designed to meet the challenges of demanding industrial applications. Simple to install and easy to maintain, the SenzTx Oxygen Transmitter is suitable for direct insertion or remote installations and can be used in numerous applications including oxygen and nitrogen gas generation, glove box purge and leak detection, industrial gas purity applications, and measurement solutions for medical gases. The SenzTx utilizes proven sensor technology to provide accurate oxygen concentration measurement. With a choice of zirconia or electrochemical sensor technology, the SenzTx offers reliability, accuracy, and flexibility with a broad measurement capability with transmitters covering the ranges of measurement from 0...10ppm up to 100% oxygen.

ZIRCONIA SENSOR TECHNOLOGY The zirconia oxygen sensor is a nondepleting zirconia solid electrolyte sensor. It offers fast response time from ambient oxygen levels with virtually no drift, has

ELECTROCHEMICAL SENSOR TECHNOLOGY

Simple to install and easy to maintain, the SenzTx Oxygen Transmitter is suitable for direct insertion or remote installations and can be used in numerous applications long calibration intervals, and an expected operational life of three to five years with very little user intervention. While not able to perform measurements in a hard vacuum or a pressurized gas environment, the construction of the zirconia sensor will not be damaged if exposed to these conditions. The zirconia sensor also has low crosssensitivity to other gases and is not position or orientation sensitive. This rugged measurement technology enables a wide range of measurement applications in many industries.

The electrochemical sensor performs measurements at ambient temperatures enabling oxygen measurements in combustible gases such as Hydrogen or a process gas containing hydrocarbons. The low power requirement of the electrochemical sensor enables low power and loop-powered instrumentation to be used making for easier integration in to control systems. In the absence of oxygen there is no output from the electrochemical sensor, meaning only one calibration is required.

EASE OF INTEGRATION AND LOW MAINTENANCE The choice of KF-40 flange or flow through block for the process connection enables easy mechanical integration either at the point of measurement. The flow through block can also be specified with an orifice in the inlet port to ensure the correct pressure and flow over the sensor. The SenzTx is a self-contained calibrated transmitter. The transmitter offers a choice of analog and digital outputs through a single electrical connector and no additional signal processing is required to achieve an accurate measurement. The compact size of the transmitter further enhances the ease of integration and installation.

For more information, www.processSensing.com/SenzTx

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TOOLS

Snap-on’s Level 5 tool management system guards against FOD For engineers and technicians working in many industrial sectors FOD will always be a real and present danger. Keeping track of every tool and piece of equipment, especially when several storage cabinets are in simultaneous use, can be challenging. Snap-on Industrial’s Level 5™ automated total asset management system minimises the risk of FOD by constantly tracking every tool, detecting which tools have been removed or returned.

Powerful software enables users to review activity at all boxes in their location from one central computer, avoiding the need to inspect each box.

It also enables engineers and technicians to quickly find every tool they need, when they need it, saving time and easing stress. Engineered to track individual tools by user, without bar codes, scanners, RFID tags or other add-ons, the system works at the speed its users demand.

Major benefits of the system include:

Level 5™ boxes are network ready, using either Ethernet or wireless connection.

• • • •

No individual tool scanning required; No RFID tags to install or replace; Intuitive interface, via touch screen; Audible voice confirmation of tool removal and replacement; • Automatic locking for maximum security; • Errors announced and displayed to indicate incorrect tool position or advise when a drawer is not closed;

• Keyless access control for easy access by authorised users. Says Richard Packham, Director UK & Europe for Snap-on Industrial: “Snap-on’s automated system takes tool management to an entirely new level, giving workshop managers and other authorised users easy access to the tools they need, while protecting against foreign object damage. “The ability to monitor several boxes from one central computer offers managers a huge time saving advantage.”

For technical details visit: snapon-industrial.co.uk; call (01536) 413904 or e-mail: ukindustrialmarketing@snapon.com

Sensors and more

Sensors and more Sensors and more www.sensorcentre.com

Sensors and more

info@sensorcentre.com Sensors and more Tel: 01844 201607

BAR CODE READERS Colour and Measurement Sensors

BAR CODE READERS

Detect, Measure, Identify, Protect

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www.sensorcentre.com

Colour and Measurement Sensors

VALVES & FLOW CONTROL

Myron L Company 900 Series™ Monitor/Controllers The innovative 900 Series Monitor/ Controllers include everything you need to simplify water quality management and chemical dosing in industrial operations in one compact userintuitive instrument. Monitor 7 critical water quality parameters simultaneously from easily configured inputs: 2 Conductivity/Resistivity/TDS/Salinity; 1 pre-amplified pH/ORP; 1 BNC pH/ORP; 1 0/4-20 mA; 1 RTD Temperature; and 1 Flow/Pulse. % Rejection is available as a derived value. Outputs include up to 3 relays; 2 remote alarms; 1 0/4-20 mA; 1 0-10 VDC; and 1 RS-485 ASCII Serial Output. Flow Switch input can disable all relay outputs when triggered by loss of flow. Relays output to any user-supplied control equipment requiring up to 250V each and can trigger on any input parameter.

www.myronl.com

Premium Electric Actuator for Complex Open/Closed & Dynamic Control Applications GEMÜ offers an extensive range of electric valves for a wide variety of applications. When it comes to high requirements on performance and service life, GEMÜ eSyDrive valves are the ideal choice as they are perfectly suited for variable and complex open/closed and dynamic control applications. Designed on the basis of the hollow shaft principle in conjunction with technology that does not use brushes/sensors, the eSyDrive actuator sets new standards in terms of service life, compactness, actuating speed and energy efficiency. The self-locking actuator also offers a high level of reproducibility for positioning and is therefore ideal for use in control applications. The actuator has an integrated Ethernet-based eSy-web solution and Modbus TCP interface for exchanging process, parameterization and diagnostics data. This “live communication” therefore offers advantages such as remote control, installation and maintenance as well as potential for process optimization thanks to its progressive digitization. Tel: 01925 824044 Email: enquiries@gemu.co.uk

Web: www.gemu.co.uk

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 • Operational Savings ARI-Ad-UK-ENCOsys-182-129.indd 1

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:

www.ari-armaturen.com 23.06.2021 14:21:36

Issue 56 PECM

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Portable Fume Extraction, Ventilation and Cooling Solutions Where fumes, smells or dust occur, our Miniveyor Air VAF series 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. VAF-COOL evaporative coolers offer an alternative solution to conventional refrigeration systems or air conditioners. The coolers are portable so provide a highly flexible solution, and their low energy consumption means they are economical to use, kinder to the planet, and unlike air conditioners, they don’t rely on a closed environment, so can be used in more open spaces, such as warehouses, factories, event spaces, agriculture building, and sports arenas.

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