PECM - Issue 65 2023 by MH Media Global

Engineering Process

Control &

MANUFACTURING

PRIME VISION - 40

WMCA - 48

Computer vision keeps track of warehouse operations

In-Comm Training awarded £429,000 funding boost to increase advanced manufacturing skills

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SULZER - 68 Sulzer 55 MW generator winding upgrade improves reliability and reduces unscheduled stoppages

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Engineering Process

Sections

Control &

MANUFACTURING

Inside...

Inside Issue 65

Editor’s Choice

Connectors & Fittings

FORTRESS TECHNOLOGY

PRIME VISION

Fortress upgrades quality control at bulk rice mill

Control & Automation

PORTESCAP

LONTRA

Electrical & Electronics

Gears, Drives & Motors

Health & Safety

Machining & Machinery

Measurement & Monitoring

Packaging

Process Technologies

Pumps

Renishaw to unveil step-change in additive manufacturing productivity at Formnext 2023, Frankfurt

Software & Systems

BURCKHARDT COMPRESSION

Tools

Reviving a steel mill’s compressors to enhance sustainability

Valves & Flow Control

Cover photo: BURKERT

The role of miniature motors in robotic surgery

FANUC

Robot system integration in the plastics sector

AIRLY

Airly air quality monitors receive independent certification

RENISHAW

Computer vision keeps track of warehouse operations Lontra set to blow away the competition as first compressors roll-off ‘smart factory’ production line

GOUGH ENGINEERING

How can ultrasonics benefit my production process?

ABB ROBOTICS

ABB Robotics and Porsche Consulting collaborate to automate the construction industry

SMB BEARINGS

Ceramic bearings allow high speeds, low noise and non-magnetic properties in medical devices

“The centre of excellence for strainer and ﬁltraaon technology”

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Engineering 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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MANUFACTURING

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Issue 65 PECM

EDITOR’S CHOICE

RICE WITH RE-PURPOSE FORTRESS TECHNOLOGY

Fortress upgrades quality control at bulk rice mill One of the largest rice cooperatives in North America has more than 50 Fortress Technology metal contaminant inspection units installed in its processing plants, including 13 ground-breaking incline conveyor metal detectors. Being able to upgrade to the latest, greatest inspection features is why this bulk rice processor has remained loyal to Fortress for close to two decades. The ‘Holy Grail’ of any food machinery investment is to maximise Total Cost of Ownership in a sustainable way, without

compromising performance and consumer safety. Continuing to benefit from Fortress Technology’s contaminant detection ‘Never Obsolete’ pledge, this dry rice manufacturing and packing facility now has in excess of 50 gravity, bulk, lab unit and incline conveyor metal detectors. Processing and packaging more than 100 long and medium-grain rice brands - supplying retailers, restaurants, food service companies and exporting globally - Fortress has supported the farmer-owned rice cooperative by issuing a number of

technology and machine upgrades. Analogue metal detectors more than 10 years old have been converted to digital to improve contaminant detection and add data logging and reporting capabilities. Making them comparable to new Fortress metal detectors. However, in the latest and largest project, Fortress surpassed itself by reconditioning and mounting 13 existing metal detector heads onto new incline conveyor frames robustly designed to transport heavier bags of rice, introducing an innovative bidirectional sweep reject.

One of the largest rice cooperatives in North America has over 50 Fortress metal detector systems installed in their mill processing and packing plants.

PECM Issue 65

Fortress engineered 13 incline metal detector systems each featuring a flighted belt, re-purposed metal detector and bidirectional sweep reject to inspect smaller rice packs weighing up to 9 kg.

From soil to steam Harvesting, milling, grading and packing over 60-million rice bushels annually, the US producer is reliant on robust best-in-class metal detection. Upstream, prior to packing, are a number of Fortress Gravity metal detectors located between product shoots and hoppers. Each rapidly inspects between 40,000 and 75,000 cubic feet of free-falling dried long-grain rice hourly, automatically rejecting metal contaminants from the product flow and keeping rice waste to a minimum.

The ‘Holy Grail’ of any food machinery investment is to maximise Total Cost of Ownership in a sustainable way, without compromising performance and consumer safety.

the plants’ limited floor space. Measuring 4.25 metres in length, packs move up a special flighted conveyor belt at a 45° angle. Designed to handle a fast product rate, a Stealth metal detector with a customised head and aperture ensures performance and detection sensitivity is not forfeited. Having ground level remote access enables staff to safely select the inspection parameters and access data from the metal detector heads if the HMI control panel is beyond reach.

Sustainable and waste reducing Compact offline lab units are then deployed to quickly examine any rejected product and separate the metal contaminants from the rice. This enables the rice producer to filter out and rework all good product, again helping to minimise waste and identify contaminants for further investigation.

a large aperture, a special coil structure, and Vector heavy duty conveyor, this market-leading bulk inspection metal detector can guarantee detection of ferrous and non-ferrous metals as small as 1.5mm, and 2.0mm non-magnetic 316 stainless steel contaminants in the aperture centre.

For bulk bags of rice weighing up to 50kg, large bag metal detectors are, for weight and safety reasons, located at floor level. Featuring

To inspect smaller rice packs weighing up to 9kg, Fortress engineered a special incline conveyor frame to overcome

Many Fortress engineers contributed to the design. Yet, as testament to the level of detail and collaboration that goes into each and every Fortress commission, company founder and President Steve Gidman couldn’t restrain himself from getting involved. Steve reflects: “Because the conveyor was inclined and as the product had to be rejected perpendicular to the flow, rubber grips were not advisable as they Issue 65 PECM

would inhibit reject performance, damage bags and make a mess. Knowing that this would create unnecessary waste, to address this we instead opted for belting with flighted sections. This solution allowed the rice bags to be conveyed uphill at a steep angle, without impacting the lateral rejection.” Due to the high product rate – on average 150ppm - and the flighted belt, deploying a reject device with a return stroke was ruled out. To avoid collisions with the belt features and trailing rice bags, Fortress instead created a bi-directional paddle sweep reject. Rejecting contaminated packs on either side of the conveyor, chutes funnel rejected product safely to ground level, securing it behind lock and key for authorised quality control personnel to remove. For this customer, like many, the

sensitivity of each metal detector combined with the compatibility

machines purchased by this rice producer over 10 years ago.

of components, provides added assurance that investments can be spread out. Knowing that the technology will never be obsolete is especially valued by this customer. Parent company Fortress Inc is currently in the process of upgrading more than 10 Phantom metal detectors to Stealth, on

Because Fortress always sticks to its universal modular design, upgrading to a Stealth Metal Detector is very straightforward.

“Very often, metal detection hardware remains fit for purpose long after the software has evolved. Many fast-growth companies approach us to discuss adding extra features, including sophisticated data logging capabilities,” explains Fortress Europe’s Managing Director Phil Brown. Because Fortress always sticks to its universal modular design, upgrading to a Stealth Metal Detector is very straightforward. Not only does this save customers a lot of money disposing of and replacing assets that remain perfectly functional, it also prevents industrial assets adding to the environmental costs. Being able to offer this upgrade service and additional field support is a huge tick for responsible waste stewardship, reports Phil.

A paddle sweep reject pushes contaminated packs into chutes located on either side of the conveyor, funnelling rejected product safely to ground level.

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

PECM Issue 65

EDITOR’S CHOICE

One Source For All Your Compressed Air Needs HIGH ENERGY SAVING SOLUTIONS

IE4 MOTOR

PERMANENT MAGNET

Introducing the New GEMÜ 652 Pulsation Damper An innovative solution to compensate pressure and volume fluctuations (e.g. water hammer / vapour pressure surge). • Pre-deﬁned compensation volume and deﬁned pressure range. • Tried and tested reliable actuator design. • Self-acting, no need for electric or pneumatic supply.

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• CIP/SIP, autoclave capable and full bore design. • Aseptic (sterilisation temperature max. 150°C) and suitable for corrosive liquid and gaseous media.

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Issue 65 PECM

EDITOR’S CHOICE

MAXIMISING PRECISION PORTESCAP

The role of miniature motors in robotic surgery Robotic-assisted surgery, once a marvel of sci-fi predictions, has come a long way since its introduction in the 1980’s and now plays an instrumental role in operating theatres. The precise and refined movements made possible by robotic arms, combined with imaging technology, signify a marked improvement over conventional surgical methods. However, a predominant consideration in surgical robot manufacture is the need for motors that can deliver both dexterity and power, all while maintaining a compact size. In recent years, surgical robotics has experienced a significant surge, reshaped surgical paradigms and offered a level of flexibility and precision that surpasses human capabilities. With the continuous diversification of surgical methods, from orthopaedics to less invasive common procedures, there is an increasing demand for varied motor solutions to suit the application.

Redefining surgical robotics: the motor challenges Traditional motors typically used in surgical settings often come with design limitations, especially in their size, which can lead to design compromises in robotic arms. Furthermore, they operate with wound iron cores, introducing issues like cogging torque, or the unwanted pulsating force caused by the motor’s magnets’ attraction to the iron-core windings, which can interfere with the smooth operation. In a domain like surgical robotics, where every micromovement counts, even the slightest judder can be detrimental.

PECM Issue 65

Motor selection plays a significant role in surgical robot applications.

Another inherent concern with traditional motors is significant heat generation during operation. Excessive heat is the result of resistive losses in the winding and core losses in the iron, posing potential risks to patient safety. Additionally, it can degrade the longevity and reliability of other integrated sensitive electronic components, all while decreasing the overall efficiency of the robotic system.

Slotless motors in the operating theatre Brushless DC (BLDC) slotless motors are an innovative solution that offers immense power in a compact design, making them particularly suitable for surgical robotics. These motors distinguish themselves by forgoing the traditional restrictive, bulky construction of their traditional counterparts. By eliminating iron-core windings, they have a more streamlined design that

A range of brushless slotless Ultra EC motors

demanding tasks at speeds up to 30,000 rpm and deliver a continuous torque of approximately 133.137nMm. Constructed with sturdy stainless steel combined with a lightweight aluminium flange, they provide essential durability for surgical applications. The integrated Hall sensors offer vital real-time feedback, ensuring unparalleled precision where there’s no margin for error. It’s patented “U-Coil” technology provides up to 30% more torque than similar-sized motors with conventional coils, operating cooler and more efficiently. Highlighting their adaptability for medical settings, while many motors can withstand up to 1,000 autoclave cycles, the Ultra EC range endures over 3,000 ensuring consistent sterility.

The crucial role of engineering partnerships in medical advancements

conserves space, enabling a compact size and agility without sacrificing on power or precision. Another distinct advantage of slotless BLDC is their immunity to cogging. There are no iron-core windings to attract the interior magnets, which translates to better precision, consistent force and a broader dynamic range – qualities that are indispensable for surgical procedures. Slotless BLDC motors also have the advantage of operating more efficiently with minimal heat generation due to the absence of iron-core windings. This ensures that the surgical area remains stable, without disruptive temperature fluctuations, ensuring the patient’s safety during the procedure and minimising heat-related damage of the robot’s components.

Brushless DC (BLDC) slotless motors are an innovative solution that offers immense power in a compact design, making them particularly suitable for surgical robotics.

The dynamic landscape of medical motion solutions, especially in robotic surgeries, necessitates engineer-toengineer collaboration. Partnering with a miniature motor manufacturer with extensive experience in medical motor solutions, like Portescap, not only facilitates optimal outcomes but also ensures the precise customisation required to meet the evolving demands of the medical sector. This collaboration drives innovation, streamlines integration and fosters cooperation, leading to improved patient recovery times and procedural efficiencies.

Ultra EC™ – the evolution in precision and power Portescap’s Ultra EC coreless brushless DC motors, available in compact diameters of either 22 mm or 30 mm, represent a convergence of technological advancements in the realm of robotics surgeries. Precisionengineered for high performance, these BLDC motors handle

Brushless Slotless Ultra EC (22ECS) coil with output

For more information, visit www.portescap.com Issue 65 PECM

EDITOR’S CHOICE

FINDING THE RIGHT SUPPLIER POWERLED

Excellence in LED Technology and Solutions Finding Excellence in LED Technology and Solutions While choice is important, the sheer number of LED Lighting and power supply products available today means finding the right solution can be like looking for a needle in a haystack. The challenge is even greater for engineers and managers in the process and manufacturing industries, who, besides luminosity, need to consider factors like efficiency, reliability, adaptability and longevity. Russell Parr, CEO at PowerLed, explains why finding the right supplier can be the key to finding the right solutions.

PowerLed, with two decades of industry experience, stands as a trusted leader in the LED lighting and power supply industry. both power technology and mass production improves the chances of obtaining innovative products that are not only reliable and efficient but are constantly evolving to meet changing needs.

Customer focused suppliers Rather than finding a supplier of generic products, engineers and managers in processing and manufacturing can benefit considerably from a lighting and power supply partner that takes a strategic, tailored approach. This means working with a supplier that places its clients’ specific needs at its core and ensures that every solution is tailor-made for its particular application. Finding a partner with expertise in

Beyond out-of-the-box products Engineers and managers in the process and manufacturing industries often require applicationspecific solutions, not just products. This makes a client-focused approach to developing tailored solutions, together with firstclass customer service, must-have attributes when seeking a reliable and trusted supplier. Today, many suppliers offer extensive lineups of products but

don’t follow this up with detailed technical information, leaving customers hard-pressed to make informed decisions. What engineers and managers need, however, is a supplier that offers expert advice and tailored technical design support, while offering highquality LED drivers and lighting solutions that cover the spectrum of industrial, commercial and residential applications.

An established leader PowerLed, with two decades of industry experience, stands as a trusted leader in the LED lighting and power supply industry. Its products are equipped with bestof-breed components, innovative technologies and EU-compliant parts; and its client-centric approach and dedicated customer service ensures customers varied needs are catered for. This includes extensive warranties or lifetime values, and cost-free lighting design support. For engineers and managers in the process and manufacturing industries searching for safe, reliable, cost-efficient and tailored lighting solutions, PowerLed is a clear choice.

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

PECM Issue 65

TRUSTED SUPPLIERS OF OVER 10,000 MEAN WELL PRODUCTS

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EDITOR’S CHOICE

EVO 2.0. WILKINSON STAR

Introducing JASIC’s new single phase PFC range of welding inverters and plasma cutters

JASIC EVO is the new standard of UK in welding and is supported with an unparalleled 5 year out of the box warranty.

have been used in some of the most ambitious products in modern history such as the historic Beijing Bird’s Nest Stadium.

JASIC is a forerunner of IGBT inverter welding technology and its products

JASIC is driven by its passion for the worlds welding needs and strives to

deliver reliable and ecological solutions. JASIC’ EVO range offers a redefined industrial design and human machine interface. Solid welding performance and high standards in sustainability, safety and reliability.

For further information please visit jasic.co.uk or contact your local JASIC Welding Distributor.

PECM Issue 65

EDITOR’S CHOICE

GEMÜ introduces the new innovative solution to water hammer or vapourIntroducing the New pressure surge GEMÜ 652 Pulsation D THE REX-SYSTEM

Pressure surges are recurrent problems that occur as a result of turning on pumps, changes in temperatures of enclosed innovative solution to compen liquids or switching the valves too An rapidly. pressure GEMÜ and 652 volume This could damage the plant components Pulsationfluctuations and cause the shut-off valves to accidentally hammer Damper / vapour pressure surge) open for a brief moment. The medium may then get contaminated which leads• toPre-deﬁned product loss or downtime compensation volume a due to necessary repairs. GEMÜ has developed the 652 Pulsation pressure range. Damper to compensate pressure and volume fluctuations. Based on tried and tested diaphragm valve reliable • technology Tried and and tested reliable actuator de actuator design, this new innovative solution is CIP/SIP capable • compensate Self-acting, nopressure need for electric or p and totally drainable. To absorb and the supply. surge, the GEMÜ 652 Pulsation Damper’s main function is to dampen as much volume as possible within a specific operating • CIP/SIP, autoclave capable and full b range. The body is designed without a sealing weir and therefore the actual expansion volume is compensated the moving temperature m • Asepticby (sterilisation diaphragm. This ingenious solution bysuitable GEMÜ will multipleliquid and gas forsolve corrosive problems in many varied applications. Please contact us to speak to one of our local product specialists for further information about this product.

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ENGINEERING TECHNOLOGY

ViSWIR … Bringing Visible & SWIR into Focus Introducing the award-winning Computar ViSWIR-Series

ViSWIR Hyper APO Features: • Capable of fully corrected focus shift in visible and SWIR range (400nm - 1700nm) • Achieves spectral imaging with a single sensor camera by simply syncing the lighting • Floating design adjusts focus for different wavelengths • 8mm, 12mm, 16mm, 25mm, 35mm* and 50mm* (*2023)

ViSWIR Lite Features: • High transmittance at whole wavelength of 400nm - 1700nm by adopting hyper wideband AR coat • Outstanding cost-performance for single-wavelength lighting & narrow-band imaging • Compact design • 5mm, 8mm, 12mm, 16mm, 25mm, 35mm, 50mm

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Issue 65 PECM

EDITOR’S CHOICE

EVOLVING DYNAMICS 3DPRINTUK

3DPRINTUK redefines the AM production landscape to ensure customer success In the rapidly evolving world of 3D printing / additive manufacturing (AM), the burgeoning number of production bureaux that have begun to proliferate today offers a vast spectrum of options for consumers. The surge in 3D printing bureaux asserting their readiness for production applications can be attributed to the industry’s evolving dynamics. As AM technology has matured, it has moved beyond its traditional niche of prototyping and into the realm of full-scale production. This transition is fuelled by advancements in machine capabilities, material properties, and cost efficiencies, making it viable for producing end-use parts. Recognizing this shift and the potential economic advantages, many bureaux are keen to position themselves at the forefront of this transformation, capturing the growing demand from industries seeking agile, customisable, and efficient production solutions.

But how do you tell the good from the bad? Leading UK 3D printing service provider, 3DPRINTUK, maintains that a distinction emerges when one sifts through the sea of providers, and for customers seeking those that truly stand out in delivering production parts of impeccable quality care needs to be taken in supplier selection. Nick Allen, CEO at 3DPRINTUK says, “The capability to handle higher volumes of parts for production is an unmistakable trait of top-tier AM bureaux. Rather than merely having a multitude of machines, these bureaux prioritize both quantity and

PECM Issue 65

3DPRINTUK’s manufacturing capacity is made up of 14 EOS SLS printers and 5 MJF 5210 systems

The capability to handle higher volumes of parts for production is an unmistakable trait of toptier AM bureaux. quality. It’s about harnessing the power of advanced machinery and technologies to undertake largescale projects, ensuring precision and speed are never compromised. Thus, they can weave seamlessly between intricate custom jobs, batch production and extended production runs. However, no matter how advanced a machine is, the wisdom of experience remains irreplaceable. The most revered AM bureaux wear their years of experience like a badge of honour. With each project, they accumulate insights into materials, processes,

and potential challenges. This repository of knowledge doesn’t just aid in flawless execution but also enables them to pre-empt challenges, offering proactive solutions. Moreover, their longstanding presence often means they have robust partnerships with material suppliers and other industry stakeholders, an element that subtly but significantly influences the end products quality.” Beyond the tangible, 3DPRINTUK also maintains that the very soul of a bureau, its core values, play a pivotal role. Best in class AM bureaux radiate values like passion, dedication, and innovation. There’s a palpable zest within their teams, a fervour about realizing the untapped potentials of 3D printing. This often infectious enthusiasm cascades into an unmatched customer service experience, stemming from a genuine commitment to a project’s success.

Allen continues, “However, passion without knowledge can be directionless. That’s why the best AM bureaux like 3DPRINTUK are also hubs of technical expertise. Their teams are not just well-versed with current AM technologies, but are continually updating their knowledge reservoir. From understanding the nuances of material science to mastering post-processing techniques and quality assurance protocols, their expertise is comprehensive and current. An often-underestimated factor that separates the leaders from the crowd is an unwavering emphasis on quality control. For leading bureaux like us, quality isn’t a final checkpoint but a journey that begins right from the initial design assessment and meanders through post-production inspections.” A holistic approach to AM for production ensures that every phase, from initial design consultation to final post-processing, is optimized for efficiency, quality, and cost-effectiveness. True vertical integration in this context means that an AM provider manages and controls each step of the production process in-house, offering customers the benefits of

Production automotive parts for Wiesner Design, manufactured in MJF Nylon 12 seamless communication, reduced lead times, consistent quality, and a streamlined experience, eliminating the complexities and inconsistencies that might arise when coordinating with multiple vendors. Allen concludes, “We maintain that while the landscape of AM production bureaux may seem vast, discerning eyes will recognize that merely professing to be production-focused doesn’t equate to excellence. It’s the harmonious blend of scale, experience, core values, and unwavering commitment to quality and innovation that truly sets the

best apart. Our company mission moving towards 2024 is to refresh and change the language that surrounds the use of 3D printing bureaux for production, and to ensure that as a leading bureau we always differentiate itself from less compelling alternatives and draw attention to the capabilities and values that we have that cannot be replicated. We believe in the disruptive power of AM and want ensure that customers avoid disappointment.”

Performance bike parts manufactured by 3DPRINTUK For further information, please visit www.3dprint-uk.co.uk Issue 65 PECM

EDITOR’S CHOICE

SUCCESSFUL PARTNERSHIPS FANUC

Robot system integration in the plastics sector FANUC UK and Hi-Tech Automation, Stand D60, Interplas 2023, 26-28 September, NEC, Birmingham System integrators (SIs) in the plastics sector serve as a valuable link between robot suppliers and automation end-users, providing industry-specific automation advice to help companies improve their efficiency, as well as building standard or bespoke automation systems that allow manufacturers to benefit from the latest robotic technology. Leading robot manufacturer FANUC has worked with Hi-Tech Automation as its plastics SI partner for over 15 years, during which time the skills required to be a successful integrator have evolved. Since the introduction of the IIoT, many of today’s factories are smart and connected, 24/7. Being able to integrate a robot into an existing line therefore requires more than mechanical capabilities; like HiTech, today’s SIs must also possess a high level of programming and other software skills to ensure that factory managers are able to receive a constant flow of data to enhance their manufacturing operation, as well as for transparency and reporting purposes.

what is in effect a mini warehouse management system is nevertheless a crucial skill for an SI. This includes being proficient across multiple programming languages. However, while lots of engineers are software savvy, some lack traditional mechanical skills that are still essential to a successful automation installation, such welding, guarding and fabricating. For this reason, we ensure that any SI we work with not only demonstrates strong programming abilities but is also supported by a network of mechanical engineers.”

Reliability for life The majority of automation system integrators are independent service providers, meaning they can specify robots from a variety of manufacturers. Deciding which automation company to partner

with is an important choice that can make or break a project, as Gary Probert, Director of Hi Tech Automation, explains: “We deliver standard and bespoke automated injection moulding systems for the plastics sector and have been a FANUC system integrator partner for over 15 years, most commonly specifying their ROBOSHOT all-electric injection moulding machine. For us, reliability is key – when dealing with a new customer, it’s important that the first installation goes well as that sets the tone for the rest of the relationship. Using FANUC products means we can be sure that the project will be right first time. Their equipment is built to last. They’re also one of the only robot companies that manufacture every part of the robot themselves –

Programming prowess + mechanical muscle Dan Fisher is the Partner Sales Manager for FANUC UK and has seen this evolution ramp up over the past few years. “Factory managers now expect instant information on a product’s position in the manufacturing lifecycle. FANUC’s robots are known for being simple to install, easy to programme and user-friendly. But being able to integrate a robot into

PECM Issue 65

FANUC treats its SI partners as extensions of its in-house sales teams and provides no-charge training for up to 30 employees from their company throughout the year.

To ensure the customer gets the very best out of their automation solution, it is imperative that the SI understands the full capabilities of any robot, machine or ancillary equipment that they are specifying. FANUC treats its SI partners as extensions of its inhouse sales teams and provides training for up to 30 employees from their company throughout the year. As well as ensuring they are comprehensively trained on FANUC’s entire product portfolio, it also offers specialist courses in ever-evolving areas such as vision, safety (e.g., Dual Check Safety software), and simulation (e.g., FANUC ROBOGUIDE) to keep them up to date with the very latest in automation technology.

Immediate response Leading robot manufacturer FANUC has worked with Hi-Tech Automation as its plastics SI partner for over 15 years, during which time the skills required to be a successful integrator have evolved.

motors, drives, everything. It reflects badly on us if a system breaks down so knowing the base robot is rock solid is a real advantage.” Gary adds: “In addition, as 90% of the systems we sell have something extra on them – for example, integrated vision or auxiliary axes – it helps that we are able to get it all from FANUC. There’s no need for us to go to another supplier, which keeps things simple and reduces the risk to the client.”

Specialist sector knowledge As Gary mentions, for the customer, working with a system integrator is a sure-fire way to derisk an automation installation project. Responsibility lies with one SI, rather a number of external suppliers – and SIs also bring with them sector-specific knowledge and expertise which individual robot suppliers may not possess. This view is echoed by FANUC’s Dan Fisher, who states: “For the customer, working with an SI partner that only operates within your chosen sector – in Hi-Tech’s case, plastics – is a real bonus. They

Factory managers now expect instant information on a product’s position in the manufacturing lifecycle. will understand the challenges you’re looking to overcome, the pitfalls you want to avoid, and the advantages you expect to make from your automation installation. From FANUC’s perspective, while we’re the expert in our own range of products, we may not know everything about each sector in which our robots are employed. To ensure the customer gets the right solution, at the right price, and that it works as intended for their particular application, dealing with an SI like Hi-Tech, who have specialist sector knowledge, is a fasttrack to success.”

Ongoing support This works both ways, however.

FANUC’s support extends beyond training to offer a complete wraparound service. “We have dedicated engineering support and software support teams, and a specialist integrator hotline which puts our SI partners through to FANUC technical experts within seconds,” says Dan Fisher. “While the reliability of our products is obviously important, the real difference to an SI is knowing that technical knowledge and support is there, whenever and wherever they need it. When we work with a system integrator, we’re building a long-term relationship. And just as our partnership with Hi-Tech Automation demonstrates, we want to remain connected in 10 or 20 years’ time.”

Live automation demonstration FANUC UK and Hi-Tech Automation are showcasing the benefits of their combined technological know-how on stand D60 at Interplas 2023, 2628 Sept, NEC, Birmingham. Their live on-stand automated manufacturing cell comprises a FANUC all-electric ROBOSHOT injection moulding machine, a FANUC LR-10iA 6-axis robot arm and ancillary equipment provided by Hi-Tech Automation, highlighting the duo’s end-to-end sustainability credentials from raw material handling to final packaging.

For further information, please visit www.fanuc.eu/uk/en Issue 65 PECM

EDITOR’S CHOICE

Leading manufacturer & charitable trust support local foodbank to fight food poverty Winn & Coales International Ltd. (W.C.I.) and the F.B. Coales No.4 (Family) Trust were delighted to support the Norwood & Brixton Foodbank with a £25,000 donation in 2022. The donation has now funded the hire of an electric delivery vehicle and driver for a 12-month period, increasing food parcel deliveries across the borough. The foodbank, part of the Trussell Trust’s UK foodbank network, is a lifeline for the local community, providing emergency food parcels, advice, and support in times of crisis. Operating since 2011, the foodbank serves all of Lambeth and north Croydon, with a team of dedicated volunteers working to provide much-needed items to families in need. “The sheer scale of the foodbank’s operations is astounding, matched only by the professionalism and kindness of the volunteers working there,” said Sarah Hashmi, an F.B. Coales Trustee. “We’re overjoyed to support

W.C.I.’s Sarah Hashmi (far right) joins volunteers from Norwood & Brixton Foodbank at the unveiling of their new delivery van at St. Margaret the Queen’s Church, Streatham.

the foodbank’s great work to reach more families facing food poverty in Lambeth.” W.C.I. is a leading manufacturer and supplier of corrosion prevention and www.denso.net

PECM Issue 65

sealing technologies based in West Norwood, London. The F.B. Coales No.4 (Family) Trust was set up by company co-founder Frank Coales, and today has three trustees and is a registered charity (no. 1179856).

EDITOR’S CHOICE

PRECISION & EFFICIENCY MARSH BELLOFRAM

Marsh Bellofram Europe releases new I/P regulators

Experience precision and efficiency with the Type 3700 Proportional Pressure Regulator. It features an LED display for easy output pressure monitoring and offers fast response times for optimal performance. With a high flow rate, it ensures seamless operation and maintains output pressure even during power loss. The IP65 class protection ensures durability in various environments. Its compact and lightweight design allows for effortless installation, whether standalone or modular. Say goodbye to complexities in tension control, glue proportioning, spot welding, speed and force control, zero weighing balancing, position control, fl uid coating, and more. Achieve consistent and precise

• Compact and lightweight

With a high flow rate, it ensures seamless operation and maintains output pressure even during power loss. results, enhancing the efficiency and reliability of your processes. Features • LED display for monitoring output pressure • Fast response • High flow rate • Output pressure is maintained in the event of power loss • IP65 class protection

• Suitable for standalone and modular mounting • Straight and right angle cable options available Applications • Tension control applications • Glue proportioning • Spot welding • Control of speed, force, and torque • Zero weighing balancer • Position control • Fluid coating and many more!

Marsh Bellofram Europe Ltd, Unit 9, Castle Park Queens Drive, Nottingham NG2 1AH Tel: +44(0)1159933300 Email: sales@marshbellofram.co.uk

For further information, please visit www.marshbellofram.com Issue 65 PECM

Why blend with Plastrac? We design and manufacture disc-based gravimetric blending equipment as well as material loaders for all plastics processing. Our equipment is engineered to make plastics processing easier and more cost efficient. We put our combined 75 plus years of experience in plastics processing to use in the development of Plastrac’s Auto-Disc™ systems to provide you with versatile and effective machinery that will exceed all of your blending requirements. Plastrac was established in 1995 in order to provide the best, most affordable, most effective, easy-to-operate blending systems available to market. We continually strive to keep our customers online and producing only the best product which fully meets the requirements of their respective customers and consumers. We surround ourselves with outstanding employees who take the utmost care in the assembly of all Plastrac machinery and take pride in their work. Our knowledgeable staff is available to provide assistance should the need arise. Plastrac is here to supply your company with the latest blending technology available and is committed to support it for years to come.

Quick, accurate blending and color changeovers. Plastrac offers a variety of gravimetric material blenders and loader systems that are ideal for a multitude of plastic processing methods. Our plastic processing machines and auxiliary equipment is engineered to make plastics processing easier and more costefficient. Plastrac material blenders

and loading systems synchronize in real-time with plastics molding machines to provide an accurate and consistent material mixture with no mechanical mixing. The Auto-Disc™ material feeder is engineered for quick material changeovers to reduce downtime. Our gravimetric blending systems will handle just about any injection, extrusion, or injection blow molding application. Disc based metering allows our equipment to cost-effectively feed at a wide range of throughputs without compromising consistency. The Auto-Disc™ can be configured into self-contained systems with material feeders and loaders that are all operated from a single controller.

Our newest innovation – ColorStream™ – is a Blending Revolution. ColorStream is not just another cart system. It feeds colors and additives from the plant floor in real-time and transports them to the machine throat to blend with the main resin still being flood-fed out of the central loading system. ColorStream eliminates the need for climbing to the top of process machinery to change canisters or perform maintenance. It increases safety, slashes capital equipment costs, saves time, labor, and energy, and allows even faster color changes. So no more climbing on top of presses to perform maintenance or move blenders! ColorStream can easily be moved from machine to machine, and is nearly 100% maintenance-free. It also works for almost all injection molding, injection blow molding, extrusion, and PET applications.

610-356-3000 • Plastrac.com sales@Plastrac.com

The Blending Revolution is Here!

Increases Safety Slashes Costs of Capital Equipment Quick Color Changes

Reduces Costs on Time/Labor/Energy

On the Plant Floor!! Our patented, modular, virtually maintenance-free system moves dosing and master batch changing to ground level. No more catwalks, scissor lifts, ladders, or climbing to swap out canisters or perform maintenance. And because it is cart-based, ColorStream can move easily between multiple machines.

Join the Blending Revolution. 610-356-3000 • Plastrac.com sales@Plastrac.com

EDITOR’S CHOICE

SPECIALISED FASTENERS STAR FASTENERS

Key Features and Benefits of Huck® Fasteners Huck® Lockbolt’s® and structural blind rivets are specialised highstrength fasteners designed for creating permanent and vibration-resistant joints. They are chosen for these applications due to their exceptional shear and tensile strength and ability to provide reliable and long-lasting connections. The versatility of Huck® fasteners allows them to be used in a diverse array of industries where structural integrity is critical and where a strong, permanent, and tamper-resistant joint is required. Huck® fasteners key characteristics and benefits: • High Strength: Huck® fasteners offer exceptional shear and tensile strength, making them suitable for heavy-duty and structural applications. • Vibration Resistance: They are designed to maintain their integrity even in environments with high levels of vibration, ensuring longterm reliability. • Quick Installation: While specialised tools are required for installation, the process is relatively fast and straightforward, enhancing productivity. • Corrosion Resistance: Huck® fasteners are available in various materials and plating finishes offering added resistance to corrosion in harsh environments. • Tamper Resistance: Once installed, Huck® fasteners are challenging to remove or tamper with, enhancing security in certain applications. They can be removed, if necessary, with the correct tooling.

PECM Issue 65

The versatility of Huck® fasteners allows them to be used in a diverse array of industries where structural integrity is critical and where a strong, permanent, and tamper-resistant joint is required. • Accessibility: The structural blind fastener range are ideal when only one side of the workpiece can be accessed. • Versatility: Lockbolts and structural blind fasteners can be installed in a wide variety of materials, including metals, plastics, and composites. What are Huck® fasteners used for? Here are some common industries and specific applications where Huck® fasteners are frequently used: Construction: Huck® fasteners are commonly used in the construction industry for structural steel connections in buildings, bridges, and other infrastructure projects. From Building a warehouse to installing the door gear, Huck® fasteners have an application. Transportation: Examples include, truck and bus chassis assembly, securing body panels, frames, and interior components. They are also widely used in the

rail industry – track, carriage / locomotive construction and related infastructure. In aerospace applications, Huck® fasteners are used in aircraft assembly and maintenance, where reliability and strength are paramount. Mining and Heavy Machinery: Huck® fasteners are used to secure structural components in mining equipment, power station screens, recycling equipment, conveyors and heavy machinery, where durability and vibration resistance are crucial. Infrastructure: Huck® fasteners play a significant role in infrastructure projects. An example of this is the fastening of highway and road infrastructure components, for example signage and (Armco) vehicle crash barriers. Marine: In shipbuilding and ship repair, Huck® fasteners are used to create strong and corrosionresistant connections for various marine structures and vessels. Manufacturing: In general manufacturing applications, Huck® fasteners are used for machinery and equipment assembly, providing reliable and long-lasting connections – applications are endless! Oil and Gas: for oil rig construction and maintenance, as well as in offshore platforms. Utilities: Huck® fasteners are used for the installation of utility poles and transmission towers. They are also employed in water treatment and distribution infrastructure projects.

Lockbolt® installation sequence (BobTail®) 1

The pin is inserted into

The installation tool is

At a predetermined

When swaging of the

the prepared hole, and

applied to the annular

force, the anvil begins to

collar into pin

the collar is spun onto

pull grooves. When the

swage the collar into the

lockgrooves is complete,

the pin.

tool is activated, a puller

pin’s lockgrooves.

the tool ejects the

in the nose assembly

Continued swaging

fastener and releases the

draws the pin into the

elongates the collar and

puller to complete the

tool, causing the

pin, developing precis precise clamp. * clamp.

sequence.

swaging anvil to press on the collar, drawing up any sheet gap.

Renewable Energy: In the renewable energy sector, Huck® fasteners are used in wind turbine assembly and maintenance, ensuring the structural integrity of these tall and exposed structures. They are also used in the mounting systems of solar panels. Agriculture: They find use in the assembly of agricultural heavy equipment, including tractors, farming machinery and silos. Military and Defence: Huck® fasteners are employed in the defence industry for military vehicle assembly, maintenance, and equipment manufacturing. What are Lockbolt’s and how are they installed? Lockbolt’s, also known as Huckbolts®, consist of a headed pin

Based on a typical installation of 5/8" grade 8 fastener

and a collar that when installed, is swaged into the locking grooves of the pin. The tip of the pin is made up of a series of annular pull grooves. The installation tool (driven by pneudraulic, or battery power), when activated, grips the grooves. The puller in the tools nose assembly draws the pin into the tool. The anvil in the nose assembly is forced down over the collar. Continued swaging elongates the collar and pin, progressively cold forming (swaging) the collar into the grooves of the harder pin developing precise clamp. The combined pin and swaged collar form the installed fastener providing a permanent and vibration resistant joint. Lockbolts are renowned for their strength, durability, ease

of installation, and resistance to vibration. They are a preferred choice in industries where secure and long-lasting connections are essential, offering superior performance compared to many conventional fastening systems or welded joints. Lockbolts are a cost-effective fastening solution for industries and applications where reducing labour and installation costs is essential. A combination of quick, straight forward installation and long-term reliability make them a preferred choice for many professionals looking to optimise both time and budget resources. Huck® LockBolt brand names include, BobTail®, Magna-Grip®, C6L®, C50L®, C120L® and Hucktainer®; each differing in design, diameter, grip range material, plating and purpose. Issue 65 PECM

Huck® structural blind fastener installation sequence (HuckLok®) 1

Insert the fastener into the

Press the trigger to initiate

Continued pulling on the

A solid circle lock between

hole and slip the

pulling action. As the tool

pintail draws the hollow pin

the pin and sleeve is

installation tool over the

pulls on the pintail, the pin

head inside sleeve. The pin

formed just prior to the pin

pintail.

(mandrel) expands the

extrudes itself inside the

breaking ﬂush with the

sleeve and begins drawing

sleeve and the work pieces

sleeve head, completing the

the work pieces together.

completely expand the

installation.

sleeve to match the hole of

What are Huck® structural blind rivets and how are they installed? A blind rivet is a single-piece fastener made of two components; the body (referred to as the sleeve) and a pin (referred to as a mandrel). When pulling pressure is applied to the pin, the pin-head applies pressure on the sleeve increasing its diameter on the blind side of the application fastening it in place. A simple yet effective mechanism. A Huck® structural blind rivet retains the pin in the rivet body (sleeve) post-installation for extra strength. Structural blind rivets are available in sizes ranging from 4.8 mm (3/16’’) up to 19.1 mm (3/4’’). The primary benefit of blind rivets is that access is only required on one side of the application, meaning typically only one person is needed to install it. The process is fast, clean, and safe, delivering consistent results across the board without requiring skilled personnel. Huck® structural blind fastener brand names include, Auto-Bulb®, BOM®, FloorTight®, HuckLok®, Magna-Bulb®, Magna-Lok®, Magna-Tite®, and PentaLok™

the work pieces. Huck® Lockbolts and structural blind fasteners are available in a wide range of sizes, head styles, materials and plating’s, offering versatility to accommodate a wide range of applications. Their diversity allows users to choose the most suitable Huck® fastener for their specific needs.

tooling, as well as offering advice on correct fastener installation and process optimisation. Working closely with our customers, we can suggest new products that may not have initially been considered for an application.

Technical support that will add value to your project Star Fasteners engineering support services enhances customers experience – we can assist with design, development and testing right through to choosing installation

RangeForce® Huck® Battery Installation Tool BV17 / BV13 Huck® Battery Tool

For further information please visit starfasteners.co.uk or call +44(0)1159324939

PECM Issue 65

UK's largest distributor

AUTHORISED HUCK TOOLING SALES, HIRE & REPAIR RIVETS,THREADED INSERTS

MAGNA-LOK® BOBTAIL®

PENTALOK

HUCKTAINER® C5OL®

MAGNA-GRIP® BOM®

·�· ·�· -

Traditionally Traditionally Innovative Innovative

EDITOR’S CHOICE

REPAIR THE AIR AIRLY

Airly air quality monitors receive independent certification The instrumentation company Airly has announced the award of an MCERTS certificate for its ‘Airly Air Quality Sensor PM+Gas’ systems. This means that the Airly particulate matter (PM2.5 and PM10) sensors have been independently verified for qualitative and quantitative measurements, and comply with the Environment Agency’s MCERTS Performance Standards for Indicative Ambient Particulate Monitors. Explaining the value of MCERTS accreditation, Airly CEO Wiktor Warchalowski says: “Air quality data is used to inform extremely important decisions, so it is vitally important that measurements are accurate and reliable. Third-party verification through schemes such as MCERTS, therefore allows local authorities, consultants and

researchers to choose technology with independently proven levels of performance. “We already have thousands of sensors operating in the field, but the award of this MCERTS certificate is particularly important because it adds a further layer of credibility to Airly’s products and services.” In order to achieve the MCERT requirements, Airly’s sensors were tested in a laboratory and in the field. Assessors also visited Airly’s manufacturing facility to verify the robustness of the company’s quality management systems. The field tests were conducted over a 3-month period with two candidate Airly PM+Gas sensor systems, collocated with a reference PM monitor in Birmingham. Additional testing was undertaken using two Airly Air Quality PM sensor systems and two Airly Air Quality PM+Gas sensor systems. The two variants were found to agree well, with R2 = 0.998 and slopes close to 1 for both PM2.5 and PM10. The test data report was submitted by Bureau Veritas to CSA Group, the MCERTS certification body. Commenting on the results of the tests, Warchalowski says: “Our sensors have been tested extensively before, but these evaluations, coupled with the MCERTS award, provide Airly customers with the

The world is beginning to recognise the enormous air quality opportunity presented by small sensors, and new players are entering the market with increasing frequency. confidence that they are using one of the best performing small sensors in the world. “It was interesting to note, for example, that the results from the Airly sensors in the Birmingham evaluation did not require any correction factors. Airly customers will also be pleased to learn that the MCERTS certificate applies to both PM2.5 and PM10 over an extremely wide range, 0-1,000 µg/m3. This is important, because it means that the sensors can be used at low levels for assessment against hourly, daily and yearly limit values, as well as for monitoring dust levels near development projects, waste management facilities, materials handling sites, industrial processes etc. “The world is beginning to recognise the enormous air quality opportunity presented by small sensors, and new players are entering the market with increasing frequency, we therefore urge customers to include MCERTS in their specifications to ensure they achieve the levels of performance that companies like Airly are able to deliver.”

For further information, please visit www.airly.org/en/

PECM Issue 65

EDITOR’S CHOICE

Specialist Training for the Storage Tank Industry Live online, classroom, blended, e-learning or in-house • • • •

Gain or renew your 5-year Certificates of Competence* Courses based on EEMUA 159 English, Dutch, German and French language options Select from courses each year, including:

TankAssessor courses*

TankInspector courses*

6-9 November 2023 – in German – 19-21 February 2024 – in English live online – live online 13-16 November 2023 – in English 4-6 March 2024 – in Dutch – near Manchester, UK – live online 26-29 February 2024 – in Dutch – TankBasics courses live online 5 February - 15 March 2024 – in English – blended learning (combines live 18-21 March 2024 – in French – classroom – Près de Lyon, FR online, e-learning, and more)

Storage Tanks e-learning

In-house courses

On-demand – in English or Dutch

By arrangement to match your: time, language, location, or live online

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

Publication 159 Edition5

Also... **Storage Tanks Seminar – 30 November 2023 – Rotterdam, NL** * Current research * Robotic Tank Cleaning * Professional networking * Statistical analysis for tank floor inspection * Mothballing * More

More choices, information and registration at www.eemua.org and events@eemua.org

–

Custom Inline Disc Filters

TankBasics courses

25 September - 3 November 2023 – in English – live online

You design, we create Helapet knows that no single filter can be suitable for the varied filtration applications that are used across industries. Our new online design tool provides customers with a simple-to-use design wizard, combined with enhanced information to guide customers through the 100’s of available filter combinations.

Try out our filter design tool for yourself today! Visit filterdevices.com Issue 65 PECM

EDITOR’S CHOICE

REDUCING BUILD TIME RENISHAW

Renishaw to unveil step-change in additive manufacturing productivity at Formnext 2023, Frankfurt Global engineering technologies company Renishaw will unveil previously unseen metal additive manufacturing (AM) technology at Formnext 2023, being held in Frankfurt, Germany. The upgrade to the bestselling RenAM 500 series of metal additive manufacturing systems will reduce build time by up to half, without any loss of part quality. By lowering cost per part, these innovations will help drive wider industry adoption of AM. From November 7th to 10th, Renishaw will be running daily demonstrations of its new technology at stand C11 in Hall 11.0. “This launch demonstrates Renishaw’s commitment to putting the best possible AM tools in the hands of the user,” said Louise Callanan, Director of Additive Manufacturing at Renishaw. “To bring AM to the mainstream, Renishaw is addressing what has historically been a huge barrier to AM adoption: productivity. The RenAM 500 metal AM series, already the most productive system on the market, can now build up to twice as fast as before. This dramatic change of pace drives down cost per part and broadens the range of viable applications.” “As well as supercharging productivity, we want to empower our users with the best possible quality management toolkit,” added Callanan. “By equipping users with data, giving them more control and providing in-process visibility, Renishaw is helping operators gain the confidence needed to move forward. Our new products will

As well as supercharging productivity, we want to empower our users with the best possible quality management toolkit. help users ensure a solid process foundation and optimal machine performance to consistently produce high quality parts.” Alongside its new products, the stand will feature Renishaw’s flagship four-laser system, the RenAM 500Q as well the RenAM 500 Flex, which is optimised for R&D work. These will feature alongside an array of real production parts

from Renishaw’s global customer base. Fans of mountain biking will also be excited to see Atherton Bikes’ AM.200M, the ‘fastest bike in the world’; produced using a RenAM 500Q system and ridden to gold medal success by UCI Mountain Bike World Champion Charlie Hatton. Formnext is one of the world’s leading trade shows for AM and modern manufacturing technology, with over 800 exhibitors, attracting more than 30,000 visitors each year. The show offers a unique insight into the state-of-the-art, focussing on innovations, applications and critical topics affecting the industry such as sustainability, skills and supply chains. To see a live demo of the new technologies, visit stand C11 in Hall 11.0 at Formnext 2023.

For further information, visit www.renishaw.com/metal-3d-printing.

PECM Issue 65

EDITOR’S CHOICE

EXCLUSIVE DISTRIBUTION SEELEY INTERNATIONAL

CPA Engineered Solutions appointed as UK national distributor for Breezair evaporative coolers Seeley International are pleased to announce that they have signed an agreement with CPA Engineered Solutions for the exclusive national distribution of Breezair evaporative coolers in the United Kingdom, effective from 15th October. Breezair is world leading in evaporative cooling, the ideal solution to cool commercial and industrial spaces at a fraction of the cost compared to conventional A/C systems. Fully manufactured in Australia, Breezair is the most reliable and durable brand available in the market, with premium features that guarantee cool temperatures and improved Indoor Air Quality. “This key appointment will expand Seeley International’s presence in the country, ensure improved support to the UK market and timely supply of products and spare parts.” Says Fabio Marioni, UK and Ireland Sales Manager at Seeley International. “CPA is a solid, long-standing company, with a capable and trained technical and sales team, covering the entire country”. CPA Engineered Solutions, based in Central Scotland, will ensure total customer service to the current customer base. They will oversee site surveys, installation, and maintenance for any new and proposed projects. “UK is a key market for Seeley International and it is critical that we have the right distribution arrangements in place,” said Sam Peli, Seeley International General Manager Sales EMENA.

This key appointment will expand Seeley International’s presence in the country. “This is a significant step in Seeley International’s global growth plans and represents a new level of commitment to the local market. Our objective is to realise the significant growth potential we see for Breezair evaporative cooling products in UK in the years ahead, which will benefit us all”. “This prestigious brand fits seamlessly into our Controlled Air Division, a dedicated business unit committed to offering products that enhance indoor air quality

and energy efficiency. We are fully equipped to manage the national distribution and look forward to a long and successful partnership and their loyal customers” states Alan Collin, CEO of CPA Group. “CPA have been our customers for many years” continues Fabio Marioni “we are confident that this is another step towards an even more tight partnership with them.” More information on the appointment here: https://www. seeleyinternational.com/uk/news/ appointment-of-new-uk-distributor/ If you are a contractor, end-user, consultant, or in general you wish to get more information on Breezair evaporative cooling, you can contact CPA Engineered Solutions at: T: +44 (0) 1501 825024 sales@cpa-group.com

For further information, please visit www.cpa-group.com Issue 65 PECM

EDITOR’S CHOICE

A SAFER WORKSPACE AXAIR FANS

The Ultimate Guide to Fan Selection in Fume Extraction Systems With laboratory set up, operational maintenance and the intricacies of daily running, ensuring worker safety, regulatory compliance, and operational efficiency in labs is paramount. Containment of chemical substances is one of the key activities in laboratories and process systems, and at the core of these systems, when maintaining the required pressure and airflow to extract fumes effectively, the responsibility rests with the industrial fan. This makes correct fan selection one of the most important system specifications. Enter our comprehensive specifier white paper: “The Ultimate Guide to Fan Selection in Fume Extraction Systems.” ¬¬ Free to download from the Axair Fans website by scanning the QR code shown, this comprehensive resource, written by the experts in fume fans and air movement for chemical applications, is your roadmap to mastering the process of fan selection in complicated fume extraction systems, ensuring a healthier, safer, and more productive workspace. Navigating the array of fan options can be overwhelming, especially when faced with the challenging task of managing hazardous fumes and airborne contaminants. That’s where our guide comes in. With over 30 years of fan selection expertise, we’ve condensed the complexities of fan selection into an accessible and easy to understand document, that equips you with the knowledge you need to make informed decisions. Whether from supplier choice, to understanding the questions you’re

in potentially explosive atmospheres” and how products must be constructed in compliance with directives to ensure fan components do not act as a source of ignition.

With over 30 years of fan selection expertise, we’ve condensed the complexities of fan selection into an accessible and easy to understand document. asked to ensure system compliance, understanding airflow requirements and system compatibility to deciphering the nuances of corrosion resistance and material durability, offering a practical toolkit to guide you through the selection process. Where static discharge can be a concern in certain environments such as chemical laboratories, we’ll explore the role of carbon loaded ATEX fans that effectively dissipate accumulated static discharge and gain a deeper understanding of the relationship between fan specifications, ductwork design, and effective fume extraction. We’ll explain the importance of EN14986 known as “The design of fans working

By the time you’ve gone through the pages in the guide, you’ll be in a stronger position to write specifications to pass to future stakeholders, to talk to suppliers confidently or to troubleshoot poor system performance, armed with the information you need for fast and efficient decisions.

Who are Axair Fans? Axair Fans are industrial air movement and fan integration specialists established in 1985 with a singular goal – to help to build better systems, systems that make our customers more successful. Working with specifiers, consultants, OEM’s and contractors at all stages of the specification and buying process in a wide range of chemical applications including laboratory, containment, process, environmental and industrial sectors. Visit www.axair-fans.co.uk/industrialapplications-industrial-fans/theultimate-guideto-specifier-fanselection-in-fumeextraction-systems/ to download your free copy now.

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

PECM Issue 65

GET THE KNOW-HOW IN FUME FAN SPECIFICATIONS Containment of chemicals is one of the key activities in fume extraction processes, and at the core of these systems, when maintaining the required pressure and airflow to extract fumes effectively, the responsibility rests with the industrial fan. This makes correct fan selection one of the most important system specifications. Enter our comprehensive specifier white paper:

The Ultimate Guide to Fan Selection in Fume Extraction Systems.

Learn more at: www.axair-fans.co.uk

FREE Whitepaper

DOWNLOAD

EDITOR’S CHOICE

Good Practice Guidance for Electrical Instrumentation, Control and Cyber Security in Industrial Engineering – Improving efficiency and safety • ‘By Industry, For Industry’, practical guidance for everyday and irregular situations and tasks • Readily accessible for all in the industry – wherever they are, whatever time they have • FREE task and procedure checklists

Management of ageing Management ofassets ageing electrical electrical assets Publication 227

Edition 1

Publication 227 Edition 1

• E-learning for continuing professional development • Webinars and seminars for knowledge sharing and professional networking • This selection of specialist publications and many more resources

A Practitionerʼs Handbook for potentially explosive atmospheres

Alarm systems: Guide to design, management, and procurement

Control rooms: Guide to specification, design, commissioning and operation

Publication 186 Edition 7

Publication 191 Edition 3

Publication 201 Edition 1

To make EEMUA’s guidance, training, events and other practical resources work best for you and your team – ask@eemua.org or visit www.eemua.org

PECM Issue 65

In the simplest terms, a heat exchanger is like a

CHOOSING THE RIGHT HEAT EXCHANGER

radiator, designed to heat (or cool) one material from another. However, over the last 150 years or so, a wide variety of types and designs have emerged, meaning that finding the most suitable type of heat exchanger for your application is not always simple.

For the most challenging applications scraped surface heat exchangers (such as the rotating HRS R Series) are recommended

All but the most basic heat exchangers are created to a bespoke brief, designed to take into account the material/s being heated or cooled, the heating or cooling medium, the amount of product being processed, product velocity, risk of fouling and a host of other factors. However, over the years some standard design types have emerged (as well as more specific types) and understanding the differences between these can make the specification process less of a mystery. In this article, we guide you through the main types of heat exchangers produced by HRS Heat Exchangers and what applications and product types each is best suited to. KEY CONSIDERATIONS When specifying a heat exchanger, the first consideration is whether your application requires complete stainlesssteel construction for hygiene reasons; for example, in the food and beverage industry. Next, you should consider the nature of the material being processed, in

particular its viscosity and whether it contains particles. The simpler and less viscous the material being processed, the simpler the heat exchanger can be. As materials become thicker, or contain suspended particles or large solids, then heat exchange becomes more difficult, and more sophisticated designs are required to guarantee the necessary performance. Starting with simple multi tube designs, the range moves through double tubes – where viscosity is higher or solids are present – and annular space designs for highly viscous products, to the most challenging materials (such as food stuffs containing pieces or very thick products like honey) requiring the use of scraped surface heat exchangers. Another consideration is what happens in the event of a leak. In certain circumstances, particularly where the service fluid is not water, a leak can be business critical. In such cases, double tubeplate multitube heat exchangers should be specified, as these provide leak detection in order to avoid cross contamination between the service and product fluids.

MAIN HEAT EXCHANGER TYPES Most heat transfer applications will require the use of corrugated tube heat exchangers. These offer a number of benefits over smooth tube designs – in particular, heat transfer and energy efficiency are increased (making them better for high-capacity heating or cooling). Fouling is also minimised meaning that units can be more compact and economical, and cleaning and servicing requirements are reduced. For the most challenging applications (such as materials with high fouling potential, or where certain product characteristics are required), scraped surface heat exchangers are recommended. Depending on whether the product needs gentle handling or increased mixing, HRS offers rotating and reciprocating designs. Whatever food or drink product you need to process, whether warming dairy products ahead of processing, or pasteurising juices, thick pastes or meat slurries, HRS have the ideal heat exchanger for you, and the expert staff to help you find it.

For more information contact +44 1923 545 625, info@uk.hrs-he.com or visit www.hrs-heatexchangers.com

EDITOR’S CHOICE

COMPRESSION SOLUTIONS BURCKHARDT COMPRESSION

Burckhardt Compression revives steel mill’s compressors to enhance sustainability Burckhardt Compression, a pioneer in compression solutions, recently partnered with one of Europe’s leading steelmaking mills undergoing a significant transformation. The mill aimed to convert one of its plants into a sustainable facility in compliance with stringent environmental guidelines. The project’s critical aspect involved reviving four non-Burckhardt compressors that had been inactive for a decade. Acknowledging the crucial role of these compressors in steel production, the mill sought the expertise of Burckhardt Compression. Addressing the challenges posed by the steel mill’s transformation, Burckhardt Compression offered a comprehensive range of services, from major inspection and revamping to supplying necessary spare parts. Its efforts didn’t stop at the compressors. The expert team from Burckhardt Compression also revamped auxiliary equipment such as motors and coolers. Its commitment to delivering a turnkey solution within a tight schedule and budget demonstrates its leadership in the realm of compressor technology. The task at hand required expert knowledge and precise execution within a tight schedule and budget. Alongside the overhaul of the compressors, auxiliary equipment such as motors and coolers also needed an upgrade. A fullservice solution was required, and Burckhardt Compression was wellpositioned to deliver. The company’s expert team dived into the project, conducting a

The expertise and commitment to quality demonstrated by Burckhardt Compression continue to be a vital asset to its customers. major inspection, revamp, and upgrade of all four compressors. It inspected the electrical motors and refurbished the lube oil coolers. The team also updated the instrumentation, performed calculations for increasing discharge pressure, and supplied necessary spare parts. The project’s success was due to the broad expertise of Burckhardt Compression’s team and the company’s ability to provide comprehensive, customized solutions. Despite the challenging nature

of the project, Burckhardt Compression maintained its commitment to quality and safety. The result was a set of revitalized compressors optimized for improved performance, ensuring their reliable operation. The client acknowledged Burckhardt Compression’s technical acumen, quick response to challenges, and commitment to safety. A spokesperson for the steel manufacturing facility stated, “Burckhardt Compression has been a crucial partner in our journey towards sustainable steelmaking. Its dedication and skill ensured our compressors were not only revived but also optimized for enhanced performance.” The expertise and commitment to quality demonstrated by Burckhardt Compression continue to be a vital asset to its customers. As the steel mill transitions to greener operations, the company’s revived and optimized compressors are set to play an integral role in its sustainable journey.

For further information, please visit www.burckhardtcompression.com

PECM Issue 65

EDITOR’S CHOICE

Save Energy with Hot Air Recycling Leister’s new Chinook side channel blower is the perfect complement to the LHS 210 or LHS 410 series air heaters, saving users both energy and costs. Named after the warm fall Chinook winds which can produce a remarkable temperature increase, this innovative blower has been specifically designed to feed process air at inlet temperatures of up to 350°C (662°F) back into industrial processes at high pressure. Working in nearly all hot air processes that allow for hot air recirculation, and in which energy recovery is reasonable and possible, the CHINOOK blower can help to save up to 50% energy and costs and reduce CO2 footprint. The Leister CHINOOK highpressure blower is highly durable and designed to perform reliably for a long time despite high thermal

loads, thanks to its compact insulation, solid construction, and high-quality components. The low maintenance CHINOOK boasts of being the quietest Leister side channel blower with a mere 58 dB(A) operating sound level. Capable of delivering air flow (20°C) of 1,640 l/min at 50Hz with a static pressure of 14.6kPa, the CHINOOK delivers optimum and effortless performance in ambient temperatures up to 60°C and is also the first Leister air blower to operate at both 230V & 400V (50Hz) or 275V & 480V (60Hz) from a single unit. For further information and technical advice for equipment in this field, please contact Welwyn Tool Group on 01707 331111, email them on info@welwyntoolgroup.com, or visit their website www.welwyntoolgroup.com

HIGH PRESSURE HOT AIR RECIRCULATION

Save energy Save money Integrate the LHS 210/410 series air heaters with Leister’s new CHINOOK blower.

Speciﬁcally designed to feed process air at inlet temperatures of up to 350°C Quiet operating sound level of 58dB(A) Capable of delivering air ﬂow of 1,640 l/min at 50Hz with a static pressure of 14.6kPa

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

HELPING YOUR FACILITY ON THE ROAD TO NET ZERO Our class-leading range of fuel-fired and electric steam boilers and portfolio of aftercare solutions can help with your decarbonisation strategy and put your company on the Road to Net Zero. As a complete solutions provider, Fulton can provide your food processing facility with: · fuel-fired and electric steam boilers · off-grid and point-of-use solutions · ancillary plant / engineered systems · steam surveys · project management · water treatment contracts · accredited / certified training · installation / commissioning / upgrades · repair / service / maintenance programmes

For further information scan the QR code, visit www.fulton.co.uk, email sales@fulton.co.uk or call the office on +44 (0)117 972 3322. FBW253 - Net Zero Advertisement - PECM.indd 1

22/09/2023 10:35

Issue 65 PECM

EDITOR’S CHOICE

SUSTAINABLE PRODUCTION QUIN SYSTEMS

Gardena is moving into the future of water with LinMot GARDENA has always proven to be a particularly sustainable innovator. Thanks to a partner, the basic requirements for future-oriented and sustainable production have been met: With the latest linear rotary and linear technology from the drive specialist LinMot, GARDENA has succeeded in redefining the precision, speed and sustainability of its production systems. The Micro-Drip System (MDS) is a resource-efficient irrigation solution that delivers water drop by drop to where plants need it: to the roots thus greatly reducing water consumption. The new generation of production should offer more process reliability, increased precision in force control and process parameters as well as sustainability and energy efficiency, which led GARDENA to choose LinMot.

Thanks to the precision of the LinMot PR02 motors, GARDENA have found their systems are 3 to 4 times faster than their older process.

PR02 – Linear /Rotary modules.

Total Flexibility

Implementing industrial systems for precise and dynamic locking, screwing or assembly is an extremely complex challenge with conventional servo solutions.

Parameters and contours can change fundamentally and quickly on both the product and the machine side, so that the re-teaching of the individual positions must be done quickly, easily and precisely. Thanks to their flexibility, the LinMot motors adapt to all adjustments to the production machines at lightning speed and all changes can be made very quickly.

The LinMot PR02 provides both the rotary and linear servo motion combined in one compact motor avoiding the need for more complex and heavy servo motors and guides.

DM01 / SM01 – Linear modules The modularity of the LinMot linear modules such as the DM01 and SM01 also impressed the GARDENA engineers. This provides a way for X and Y pick and place units to be quickly and easily assembled.

Sustainability or efficiency? The question of having sustainability and efficiency working together has been well and truly answered as the collaboration between GARDENA and LinMot proves.

Precision with Feedback Force and Torque sensors are available as options for the LinMot PR02 which enable real-time monitoring and evaluation of process parameters with an accuracy of equal or better than 1% of the demanded value. For further information, please visit www.quin.co.uk/linmot

PECM Issue 65

Linear motors for

Dynamics & Precision ..clean room & wash down applicaons

www.quin.co.uk/linmot - Linmot distributor for the UK & Ireland Issue 65 PECM 39

www.quin.co.uk/linmot - Linmot distributor for the UK & Ireland

EDITOR’S CHOICE

A SECOND PAIR OF EYES PRIME VISION

Computer vision keeps track of warehouse operations The human eye is a marvel of nature, but nowadays it is often complemented by the vision of cameras and machines. In warehouse logistics, this technology is allowing operators to validate the logistics process reducing human errors, tracking parcels and providing real-time feedback for improvements. This is giving businesses the opportunity to see the bigger picture. Mathijs Baron, International Sales & Business Development at Prime Vision and Lorenzo D’Arsiè, Computer Vision Product Manager at Prime Vision, explore how image-based tracking can positively affect warehouse operations.

Setting the scene Smart scene understanding is the ability to visualise the exact location of an item within a warehouse at any time. To achieve this, cameras must capture all goods passing through the facility. Reading labels on inbound goods ready for sorting can be achieved with optical character recognition (OCR) for recording stock keeping units (SKUs), purchase order (PO) numbers, best before dates and more. Similar technology can be used at picking stations to validate a successful sorting process, imaging barcodes to check order completeness. Cameras installed on the ceiling or areas where actions take place provide complete coverage of items in the warehouse. These cameras are smart enough to offer mapping and overlap, enabling the tracking of objects between them. All imagery can then be stored in a central location and combined

PECM Issue 65

Prime Vision’s ‘Proof of Pick & Pack’ technology leverages a combination of cameras and voice recognition systems to ensure the accuracy of the picking and packing process.

with other parcel data for total traceability. All this can be done safe and secure and compliant to GDPR and privacy rules. With this set up, operators can get a complete picture of every single item or order journeying through the warehouse. The benefits of this monitoring are manifold.

Picturing benefits Image-based tracking reduces manual actions and reasoning in processes like data input or sorting, with the overall aim of minimising human error. However, another important benefit is that it can provide proof of sorting. This level of validation allows operators to identify where problems have occurred during the process. A centrally stored database of images, such as that provided by Prime Vision’s Smart Store solution, means every action is documented,

so records can be accessed to spot mistakes. Operators can identify sorting errors or where an item has become damaged. This can help reduce the number of customer claims by verifying the authenticity of complaints with video evidence. However, a system shouldn’t just be reactive, it needs to provide realtime feedback to prevent sorting mistakes before an item leaves the warehouse. If an error occurs, an alert should be quickly delivered via a flashing light, alarm or notification to an operator. Staff can then double-check the current location of the item against where the vision system knows it should be. In this way, mistakes are resolved quickly, well before an order is loaded onto the wrong conveyor or delivery truck, saving time and cost.

Getting a better view The function and technological capabilities of an image-based

tracking system are highly flexible depending on the application’s requirements. A recent project for an Italian fulfilment company illustrates this. Prime Vision was asked to improve a process where products are selected from storage, verified, and prepared for shipment. Historically, this step had been prone to human errors, resulting in mispacked items or incorrect quantities. This translated to delays, additional costs and customer dissatisfaction. However, Prime Vision had cutting-edge technology ready to transform this process by carrying out a double check. Prime Vision’s ‘Proof of Pick & Pack’ is a game-changing warehouse technology that leverages a combination of cameras and voice recognition systems to ensure the accuracy of the picking and packing process. In this system, forklift trucks or pickers are equipped with cameras that capture images and videos of the selected products during the picking phase. These images and videos are then crossreferenced with a comprehensive reference database containing tens of thousands of product records. The Proof of Pick & Pack system was a gamechanger for warehouse operations at the Italian fulfilment company. By combining cuttingedge camera technology with a vast reference database and a Pick-byVoice system, it offered an efficient and error-free solution to the ageold problem of mispacked items and incorrect quantities. As the logistics industry continues to evolve, embracing innovative technologies like Proof of Pick & Pack is essential for staying ahead of the curve and delivering exceptional service to customers. More than that, the flexibility of imagetracking systems brings benefits to warehouse employees too.

Staff perceive the advantages Contrary to the story of automation taking jobs, computer vision is proving highly beneficial for

warehouse workers, making tasks easier and more attractive. This is especially important for a sector facing a chronic labour shortage. Monitoring warehouse activities lets businesses identify best practices and new efficiencies. Personal innovations like better sorting routines can be shared with the rest of the team, making work easier for everyone. Additionally, data from image-based tracking can greatly simplify sorting. Devices such as Prime Vision’s Flow Projector eliminate boring, timeconsuming label reading by imaging the label, determining the correct destination and projecting a number onto the item that corresponds to it. Therefore, it is much faster for workers to move parcels to the right place, improving job satisfaction and efficiency. Intuitive systems that simplify processes expedite training too. Prime Vision engineers have witnessed this first-hand. A new starter at a customer’s site was able to begin work immediately with a Flow Projector as it was quick and easy to provide adequate training. As well as getting up to speed almost instantaneously, staff enjoy collaborating with exciting technology that adds game-like elements to the most mundane tasks. This helps to attract and retain workers, helping warehouses overcome the challenges of the labour shortage.

Seeing into the future Computer vision and machine learning technology is developing rapidly, and Prime Vision works with academia to harness the

Smart scene understanding allows to visualise the exact location of an item within a warehouse at any time.

By collaborating with the wider computer vision community, the business develops state-of-the-art, customisable systems to benefit any operation. latest research and deliver new, innovative image-tracking solutions. By collaborating with the wider computer vision community, the business develops state-of-the-art, customisable systems to benefit any operation. Validation is critical in any logistics process, but modern image-based tracking goes a step further, enabling operators to take a more proactive approach to enhancing warehouse efficiency and profitability. As well as minimising errors, the technology is allowing humans to excel, augmenting operations with a third person perspective for a deeper understanding of the mise-en-scène.

For more information, visit https://primevision.com/ Issue 65 PECM

EDITOR’S CHOICE

Fulton introduces two new larger outputs to expand its VSRT range and open new markets Fulton is expanding its award-winning VSRT steam boilers range and introducing two new re-designed models with outputs of 1565 and 1956 kg/h. Fulton’s Carl Knight says: “These new models are groundbreaking for their output range. There are no truly-efficient tubeless vertical steam boilers with similar outputs, the VSRT is the only tubeless boiler available with the capability of efficiently producing nearly two tonnes per hour of steam.”. The new VSRT models maintain exceptionally high operating efficiencies (>86% gross thermal efficiency compared to approximately 80% from typical boiler designs), resulting in lower operating and lifecycle costs and improved return on investment. The latest models also achieve ultra-low NOx emissions of less than 20ppm and 10:1 turndown capability. The water volume of these latest VSRT models is far greater than equivalent horizontal shell and tube boilers and steam generators, combined with an impressive steam chest volume giving it the ability to react quickly to changes in steam demand. The VSRT still boasts a start-up time of approximately 20 minutes and achieves a 99.75% steam quality, a detail most manufacturers are unwilling to publish.

Compared to equivalent vertical tubeless steam boilers, the VSRT is a more durable, and in many cases, compact boiler that is energy-efficient, produces an increased volume of higher quality steam, is easy to maintain. They also come with the assurance of a 10-year “unparalleled” warranty on the pressure vessel, double that of the industry standard.

For further information on the VSRT, call Fulton on 0117 972 3322, email sales@fulton.co.uk or visit www.fulton.co.uk.

Rotaflow swivel joints for all sectors of engineering

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Flexibility

flows through a single unit, enabling the pipework to rotate 360 degrees whilst carrying fluids (including hydraulic and pneumatic) of different pressures without cross-contamination or leakage. With 40 years of experience, Rotaflow, are specialists in taking your bespoke requirements and being able to design a solution that can fit your budget, dimensions, materials, FAT/witness testing; hygienic and pressurised environments. We regularly

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requirements for Hygienic, Nuclear, Oxygen duty, Submerged, Marine and many other applications. The photo attached shows two 4” SK Series swivels, with bespoke requirements fulfilled, for use in energy production. 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

PECM Issue 65

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EDITOR’S CHOICE

LP2 BLADE BLOWER LONTRA

Lontra set to blow away the competition as first compressors roll-off ‘smart factory’ production line

The first reinvention of air compressor technology in more than 85 years has rolled off the production line of a £17m new smart factory in Doncaster. Lontra, an engineering technology company led by innovator Steve Lindsey, is committed to answering increasing demand by quadrupling the production of their innovative LP2 Blade Blower year-on-year until 2025. This ambitious plan is designed to meet growing industry requirements and provides the market with a new, environmentally

PECM Issue 65

sustainable solution for air delivery in industrial settings all over the world. Backed by the design and product lifecycle management capability of PTC’s Creo and Windchill platforms, the company has integrated its unique, patented and proven Blade Compressor® positive displacement technology within the custom engineered LP2 Blade Blowers. This delivers a world-class performance, reduced noise and, importantly electricity savings of up to 34% compared with traditional products.

Demand is already coming from the US, which accounts for nearly 25% of the global market, and a further recruitment push is expected to increase a workforce that has already doubled in the last year. “Seeing the first LP2 Blower come off the production line was a real milestone moment for the business,” explained Steve Lindsey, who formed the company in 2004. “This is the first commercial innovation seen in the air compressor market in 85 years and it can’t come soon enough. Heavy industry uses these products to

deliver power to manufacturing lines, to drive furnaces, convey material and blow away granules in cement factories and crumbs in biscuit factories.”

“The power of the software ensures that everybody is working off the most up-to-date data. In the future, we know the company is planning to provide certain suppliers with access to this too.” The digital thread is at the heart of the next exciting stages of Lontra’s expansion, bringing to life all the benefits of the connectivity built into the LP2 Blower’s design, with its 25-plus internal smart sensors.

He went on to add: “All that blowing comes at a heavy cost to the environment. Compressors account for a staggering 10% of Europe’s industrial electricity use, which equates to more than 10TWh (Terawatt-hours) of power per year and some 4.3million tonnes of CO2 emissions. “We have an innovation that has been designed and now manufactured in the UK, with the investment in our Smart Manufacturing Centre giving us the capability to scale up quickly to meet what we expect to be huge demand.” Inneo Solutions introduced Lontra to PTC’s cloud-based 3D CAD Design software Creo and this platform has been critical in achieving the complex geometry that makes the LP2 Blade Blower so different to its predecessors. This includes add-ons covering finite element analysis (FEA) and behaviour modelling, which were used by up to 10 designers to achieve the necessary stillness and distortion requirements that deliver the environmentally sustainable performance. “Where simultaneous optimisation of mechanical and thermodynamic performance is required, data from PTC Creo feeds directly into BladeSim, a software suite built in-house at Lontra for the virtual prototyping of positive displacement compressors, vacuum pumps, and their ancillaries,” pointed out Daryl Koch of Inneo Solutions. “As well as improvements to compression, internal leakage and heat transfer, these tools tune silencers, and ancillaries for optimisation of the complete system.”

Steve Lindsey

As well as improvements to compression, internal leakage and heat transfer, these tools tune silencers, and ancillaries for optimisation of the complete system. Another key element of the portfolio is Windchill, PTC’s product lifecycle management (PLM) suite, which makes a big difference in Lontra’s efficiency and sustainability, by saving not only time but also waste. Windchill ensures that the record of materials and components used in its products are kept up to date, helping it capture learning from the design and development process, as well as reducing errors, scrap, and waste on the factory floor. Elliot Clarke, UKi Director at PTC, added his support: “Both of Lontra’s sites have access to Windchill, as does the firm’s teams who work remotely – designers, purchasing, manufacturing engineers, CNC, assembly, and quality.

This work will be overseen by Lontra Digital, a new arm of the business responsible for the design and development of a proprietary state-of-the-art cloud-based technology stack (LontraEDGE) and its next-generation UI platform (LontraLENS) that powers HMIs, tablets and mobile apps. This will enable the company and its customers to remotely monitor the health and efficiency of the units once they’re installed onsite in manufacturing and water treatment facilities. “Almost every factory will have a maintenance person or team, whose job it is to keep machines running. They spend their days in and around those machines and, regardless of whether an alarm has been triggered or not, they can tell when something doesn’t sound right or is running hot, signalling that there may be a potential problem,” added Steve. “That kind of experience is in short supply and dwindling fast as older members of the workforce retire. Now, thanks to data collection and machine learning, instead of that expert walking around just one factory, they can be maintaining 30 factories all around the world from one centralised location.” He concluded: “In this way, Lontra Digital will help to increase reliability and efficiency, and reduce downtime for customers.” For further information, please visit www.lontra.co.uk.

More details on PTC can be found at www.ptc.com or by following @ptc on twitter Issue 65 PECM

EDITOR’S CHOICE

ULTRASONIC VIBRATIONS GOUGH ENGINEERING

How can ultrasonics benefit my production process? Adding ultrasonic capabilities to your industrial sieving processes can improve separation accuracy and offer a more efficient material flow, especially when handling powders. Here, Stephen Harding, managing director at the materials handling specialist Gough Engineering, looks at what you need to know about combining sieving with ultrasonics to benefit your production process. Adding ultrasonics to your industrial sieving process adds an extra level of vibration to materials handling. Ultrasonic vibrations, made up of inaudible soundwaves, are created by a special generator and converter that are connected to the edge of the mesh frame of the sieve. The high frequency waves then vibrate the screen to provide additional stimulation in the production process. This is especially effective when handling fine powders or delicate ingredients.

What are the benefits of using ultrasonics? While a Gough Engineering sieve will effectively and efficiently break up any agglomerates or clumped material at its point of input into the production process, adding ultrasonics to this process takes the level of separation one step further. The mesh within the sieve will be tailored to the customer’s inputs. However, the addition of the Gough Engineering Ultrasonics package means that the high frequency sound waves break up blockages and increase throughput and material flow. This keeps screens very easy to clean, and further minimises any downtime.

An ultrasonic screening system, shown here attached to a Gough GV550 Batch Sieve, comprises a generator, a converter and a matched screen resonator with screen frame.

Adding ultrasonics to your industrial sieving process adds an extra level of vibration to materials handling. Can I add ultrasonics to my existing equipment? Ultrasonics can be used in combination with screens sized between 50 and 200 microns. This makes Gough Engineering’s Ultrasonics Package ideal for fine powder applications. Ultrasonics are an integral part of the sieving process in the chemical or pharmaceutical industries and, for companies looking to improve sieving processes in either of these areas, the Gough Engineering

Ultrasonics Package is an essential upgrade. You should expect to see: • A higher sieving throughput • No pegging or blockages of the apertures in the screen mesh • Superior separation accuracy of the sieved product • A reduction in system downtime • More efficient material flow If you’re currently considering adding to, or upgrading, your existing sieving processes, then Gough Engineering’s Ultrasonics Package is an easy addition to any of our circular and linear screens, sieves and separators. Whatever your requirements, you can be sure that our experienced team at Gough Engineering will expertly tailor any system to your exact production needs. Do you have an existing Gough Engineering sieve, and would like to discuss adding an Ultrasonics Package? Then contact Gough Engineering today on 01782 567770, or visit its website to send an email with details of your existing equipment.

For further information, please visit www.goughengineering.com

PECM Issue 65

EDITOR’S CHOICE

CUTTING-EDGE TECHNOLOGY SEEPEX

SEEPEX 4.0 Technology at Anglian Water’s Pump Station Anglian Water has revolutionised its Brockley pump station operations by integrating SEEPEX Pump Monitoring and Connected Services. This cuttingedge technology enables remote monitoring, providing Anglian Water with numerous benefits. It helps with compliance and consent flows, avoids pipework rupture caused by excessive pressure, and will support Anglian Water to efficiently implement planned maintenance work.

placed a significant burden on resources. The need to spend a considerable amount of maintenance time on the older pumps prompted Anglian Water to explore the latest maintain-in-place technologies. As they sought a solution to replace both the macerators and pumps, Anglian Water turned to SEEPEX, their trusted framework partner.

Simplified Pump Maintenance

First-time Fix Using Digital Monitoring and Cloud Services

The Brockley sewage pump station was using SEEPEX macerators alongside obsolete pumps from a different supplier resulting in frequent engineer attendance to address performance, which

SEEPEX provided Anglian Water with new replacement macerators and progressive cavity (PC) pumps fitted with Smart Conveying Technology (SCT) and Pump Monitoring with advanced analytics.

SCT enables the adjustment of the pumping elements, restoring pump efficiency and extending the life of wearing parts. Additionally, it allows for easy dismantling, changing of parts, and reassembly without the need to remove suction or discharge pipework, reducing on-site maintenance time. Anglian Water can remotely monitor Brockley through SEEPEX Pump Monitoring, gaining insight into operating conditions and performance before visiting the station. By implementing planned maintenance and spare parts availability, Anglian Water achieves a ‘first-time’ fix approach, sending the right person with the right skills at the right time, resulting in improved efficiency and reduced downtime. Newly optimised pump station’s key benefits • Total remote monitoring with advanced analytics of pump station assets • Flow verification ensures compliance • Forward planned maintenance • First-time fix with issue detection before arrival for skill-based attendance • Preventive maintenance to avoid pump station outage • Reduced maintenance costs with SCT pumps SEEPEX Smart Pump Stations Minimise Risk

Empowering Anglian Water’s Asset Management with SEEPEX Digital Solutions.

Are you experiencing issues with aged or obsolete pump stations? Would you like to reduce costs and improve efficiencies, contact SEEPEX to discuss upgrading.

For further information, please visit www.seepex.com Issue 65 PECM

EDITOR’S CHOICE

SKILLS BOOST WMCA

In-Comm Training awarded £429,000 funding boost to increase advanced manufacturing skills One of the UK’s leading independent training providers has secured a £429,000 boost for delivering advanced engineering and manufacturing skills. In-Comm Training, which already supports 865 apprentices and over 2500 learners, has been awarded ‘Higher Level Skills’ funding by the West Midlands Combined Authority (WMCA) in a bid to help industry bridge the skills and competency gaps. Accessed via the Training & Manufacturing Group (TMG), up to 126 learners in the WMCA area will be able to tap into modularised units for the first time, giving existing workers the most flexible opportunity yet to upskill. These bespoke courses will be delivered at state-of-the-art technical academies in Aldridge and Telford and gives individuals the opportunity to study specific modules of the Level 3-5 Engineering & Management programmes tailored to ensure job progression and sustainable employment. This includes project management, maintenance, electrical and fluid power and, thanks to In-Comm’s tie-up with Brandauer, learners can also complete a 20-week Level 4 Toolmaking apprenticeship at the UK’s first Precision Tooling Academy. “This is the flexible type of training we have been looking to deliver for some time and the WMCA funding has now made it possible for skilled engineers to upskill even further,”

PECM Issue 65

explained Gareth Jones, Managing Director of In-Comm Training.

time, you are getting back a higher skilled employee. It’s a real win-win.”

“By adopting a modularised approach for the first time, individuals can train on specific elements of the course rather than the entire qualification. This means they focus on the skills they need most at the time, whilst alleviating workload and time pressures.

The Higher Level Skills funding is available for any existing workers that live in the West Midlands Combined Authority area and looking to embark on Level 3 or higher training in engineering and manufacturing.

“In our latest In-Comm Training Barometer released this summer, 59% of companies cited releasing staff as the biggest barrier to investing in training. We heard this message loud and clear and developed a modularised offer that WMCA recognised and agreed to fund.” He continued: ““From a business perspective, you are not losing a valuable member of staff for extended periods but, at the same

There are also opportunities to participate in a modularised and full ILM Level 5 Diploma in Leadership & Management, essential for developing the next industry leaders in a bid to ease the brain drain we’re seeing from ageing workers retiring. Gareth went on to add: “We can be creative with how we deploy the funding and, whilst it is learner focused, there are opportunities for us to design bespoke programmes for companies.

“For example, there is a Level 3 Machinist and Fitters course we’re putting together that will help get new entries into the sector. “Created in partnership with a large aerospace company, the Department for Work and Pensions and WMCA, this will fast track competences to access vital high-value jobs for the benefit of the sector and people in our region.” The In-Comm-backed Training & Manufacturing Group is a collection of 100 like-minded businesses bound together by a commitment to achieve world class best practices and futureproof training to boost UK industry. It harnesses twelve technical partnerships, with the likes of Engineering Technology Group, Hexagon Metrology and IMI Norgren, to give SMEs access to the latest technology and equipment.

This is the flexible type of training we have been looking to deliver for some time and the WMCA funding has now made it possible for skilled engineers to upskill even further. Andy Street, Mayor of the West Midlands, and Chair of the WMCA, said: “One of our region’s top priorities is to equip local people with the skills they need to succeed. Partners like In-Comm training are central to enabling us to do exactly that. “In-Comm has a proven track record of providing high quality training in

the West Midlands - improving the lives of residents and the prospects of the companies they work for. “The modern world demands we deliver training in a flexible and business friendly way. This latest WMCA funding illustrates our ability to adjust accordingly.” Clare Hatton, Interim director for Employment, Skills, Health and Communities at the WMCA, concluded: “We’re delighted to have In-Comm Training onboard to deliver higher level skills training in engineering and manufacturing to our residents and employers. “Through our Plan for Growth, we have highlighted Advanced Manufacturing as a cluster set to see accelerated growth over the next ten years and this modularised approach will play an important part of the skills response to support this growth.”

For further information, please visit https://in-comm.co.uk/modularised-training/ Issue 65 PECM

EDITOR’S CHOICE

PROMOTING INNOVATION ABB ROBOTICS

ABB’s Amina Hamidi wins Industry Personality of the Year in Instrumentation Excellence Awards Amina Hamidi, Managing Director of ABB’s Instrumentation Business Line within the Measurement & Analytics Division, was named Industry Personality of the Year at this year’s Instrumentation Excellence Awards. The award was presented at a ceremony in London organized by Instrumentation Monthly publisher Datateam Business Media. Through her work, Hamidi has taken ABB’s instrumentation business closer to customers while building an inclusive, innovationdriven work environment. Together with the team, she is focused on making some of the toughest and fundamental measurement challenges easy, providing customers with quantifiable benefits in terms of process control, resource efficiency, safety, and sustainability. Her engineering and science background has encouraged her to keep technology close to her heart and promote innovation in instrumentation at every step. “With sustainability and innovation at the core of what we do in ABB, I often ask myself what is best for our business and people,” said Hamidi. “Are we running our business in a way that is right for our people, the environment, our customers, the industry and ultimately, the wider society? Reflecting on this helps me make better informed decisions. I thank the team at the Instrumentation Excellence Awards for this recognition, and I am most grateful to my talented colleagues for all their hard work and dedication that helps us make a

industry for years to come.”

Through her work, Hamidi has taken ABB’s instrumentation business closer to customers while building an inclusive, innovation-driven work environment. difference to the industries we serve – and the world around us.” “I could not be more pleased to learn that Amina has won this award,” said Jacques Mulbert, President, ABB Measurement & Analytics. “Her example to young women and men planning STEM careers should keep a pipeline of young talent joining ABB and the instrumentation

Hamidi has held multiple roles since joining ABB in 1998, including 15 years in Research & Development and 10 years in business development. Hamidi holds a Ph.D. in Electrical Engineering at Institute National Polytechnique de Lorraine in France. Having started her career in a traditionally male-dominated industry, Hamidi is passionate about gender equality and has driven ABB’s “Stars in STEM” campaign to inspire ABB’s own workforce and attract new female talent. ABB’s Instrumentation Business Line offers measurement technology such as smart sensing devices and digital solutions across the chemical, oil & gas, water, power, hydrogen, and battery industries, and many more.

For further information, please visit www. go.abb/robotics | www.abb.com

PECM Issue 65

www.trfastenings.com The go-to place for Engineers, Designers and Specifiers

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CONTROL & AUTOMATION

DRIVING AUTOMATION ABB ROBOTICS

ABB Robotics and Porsche Consulting collaborate to automate the construction industry ABB Robotics and Porsche Consulting have announced their collaboration to drive automation in the construction industry with a pilot project to develop innovative new practices in modular housing manufacture. The collaboration will help to meet the need for more affordable and sustainable buildings and reduce the environmental impact of construction, amidst widespread labor and skills shortages. “The construction industry is facing numerous challenges. Highly automated factories for buildings can deliver higher quality and more affordable housing. In combining ABB’s leading robotic solutions and Porsche Consulting’s knowledge in planning and running state-ofthe-art factories, we want to help

PECM Issue 65

transform this important industry” said Eberhard Weiblen, Chairman of the Executive Board, Porsche Consulting. “We think there is a clear opportunity to transform this sector and the way homes are built by automating the process of manufacturing modular components,” added Marc Segura, President of the ABB Robotics Division. “Greater, more intelligent automation is the answer to widespread labor shortages and this collaboration will boost productivity, allow greater customization and enable more sustainable and efficient construction practices.” Construction-related occupations typically dominate the list of labor shortages , a contributing factor to

the shortage of housing in many countries. In the United States, labor shortages are contributing to a housing shortfall of nearly four million homes , while Germany is forecast to have housing supply shortages in 35 of its cities by 2030 . The traditional construction sector is struggling to meet the demand for new homes, while the environmental performance and efficiency of buildings needs to improve, along with the adoption of more sustainable construction methods. These include reducing the transportation of raw materials to construction sites and eliminating the corresponding costs and impact of removing unwanted materials and waste. This is estimated to account for up to 25 percent of the material transported to a building site .

Modular construction will yield efficiencies through the reduction in material wastage and the number of days lost to adverse weather conditions. Factories also provide a safer and more hospitable working environment, as construction workers account for around 30 percent of workplace injuries and are four times more likely to be involved in a fatal accident versus other sectors. Construction lags behind other industries in adoption of automation and robotics. In a global sur-vey commissioned by ABB of 1,900 large and small construction businesses in Europe, the US and China, only 55 percent of construction companies say they use robots, compared with

robotics and automation in the next decade.

We think there is a clear opportunity to transform this sector and the way homes are built by automating the process of manufacturing modular components. 84 percent in automotive and 79 percent in manufacturing. The survey also shows 81 percent of construction businesses plan to introduce or increase the use of

“We understand the importance of sustainable housing and believe the transfer of technology and expertise to the construction sector will deliver the positive impact we have seen in other industries,” added Porsche Consulting’s Eberhard Weiblen. “We will bring our blueprint to life and demonstrate how robotic modular construction can help support the changes our society is demanding. The joint approach will take modular construction to a new level in terms of quality, efficiency, design, and sustainability,” concluded ABB’s Marc Segura.

For further information, please visit www. go.abb/robotics | www.porsche-consulting.com Issue 65 PECM

CONTROL & AUTOMATION

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CONTROL & AUTOMATION

MEDICAL ROBOTS SMB BEARINGS

Ceramic bearings allow high speeds, low noise and non-magnetic properties in medical devices Robots are on the rise in medical environments, and are being increasingly relied-upon to carry out more complex procedures. Although martensitic stainless steels have been favoured for bearings in robot applications, their performance is falling short against rising standards to prevent contamination in medical environments. Here, Chris Johnson, managing director at specialist ceramic bearings supplier SMB Bearings, explains why ceramic highprecision bearings hold the answer.

Analyst GlobalData predicts the medical robotics market will rise from $4.7 billion in 2020 to $14.5 billion in 2030, and those robots will “be cast more as companions providing emotional support, rather than seen as tools.” The quote refers to artificial intelligence (AI) becoming more advanced, allowing robots to offer increasingly therapeutic support to patients in ways we can’t imagine today, and counter staff shortages.

From surgical assistance robots that help perform minimally invasive surgeries, to AI-equipped therapeutic robots used in rehabilitation for injuries and paralysis, medical robots have come a long way since simple robotic arm technologies were first introduced in the 1980s. Although surgical robots are becoming cheaper, modern medical applications are also demanding higher precision and speed capabilities from these robots.

It’s predicted that future medical robots will be cast more as companions providing emotional support, rather than seen as tools.

PECM Issue 65

Traditionally, in medical instruments, bearings — that optimise the rotation of axes like robot arms by limiting or avoiding friction and jolts — have been made from high purity metals such as martensitic stainless steel. Examples include medical robots that help undertake keyhole surgery where the utmost precision is required. Surgical robot bearings must deliver the highest possible rotational accuracy, while also being small enough to fit into these often compact and portable hospital devices. However, steel bearings have limitations including contamination. While steel bearings are tough and capable of withstanding highly-corrosive environments, they are susceptible to particulate contamination due to the very high contact pressures against the steel within the bearing while it moves. If left unchecked, this contamination can cause denting and wear. Of course, contamination in general is unacceptable in health and safety environments. As robots become more prevalent in medical applications, regulations are getting stricter in order to prevent contamination.

Replacing steel The need to avoid contamination accompanies other design requirements such as high speeds, low noise and non-magnetic properties. For instance, because Magnetic Resonance Imaging (MRI) scanners use a strong magnetic field to generate two- or threedimensional images of any living subject, steel bearings cannot be used due to their magnetic properties. All of these factors influence the choice of material for bearings in medical environments — but what material can replace steel? The medical equipment sector is increasingly choosing bearings made exclusively of zirconia (ZrO2), or other exotic ceramic compounds. According to the Institute of

Ceramic bearings hold a number of advantages for medical environments.

Although surgical robots are becoming cheaper, modern medical applications are also demanding higher precision and speed capabilities from these robots. Materials, Minerals and Mining, “ceramic bearings made from ZrO2 are tough with similar expansion properties to chrome steel and 440 stainless steel, although they are 30 per cent lighter.” Indeed, full ceramic precision bearings are harder than steel, with superior corrosion and heat resistance, higher dimensional stability and lower density. However, ceramic bearings are expensive. This is a big issue for health institutes that operate within tight budgets, so the decision to invest in them must be well-considered. Fortunately, ceramic bearings hold a number of advantages for medical environments. One is that the bearings don’t react to chemicals. That means they don’t

corrode or weaken when subjected to harsh chemicals used for sterilisation in hospitals. Ceramics don’t require lubrication that would otherwise draw contaminants like dust, water or humidity and this also eliminates the need for maintenance processes like relubrication. They are also waterresistant, so can be washed-down regularly.

High-value applications So, is investing in ceramic bearings for medical environments worth it? There are still certain applications where the speed and precision of steel are crucial, like in surgical robots for example. However, there are other instances where using the wrong components in such medical or laboratory equipment can contaminate study conditions, or cause the study to cease altogether. Instead, the extra investment in ceramic bearings can help ensure that medical robots run with effectiveness and longevity — especially as they are “cast more as companions providing emotional support, rather than seen as tools.” For more information on how specialist precision bearings can support longer service life in medical devices, visits SMB Bearings’ website or email sales@smbbearings.com.

For further information, please visit www.smbbearings.com Issue 65 PECM

ELECTRICAL & ELECTRONICS

THE HV 1000 C SERIES SAB BRÖCKSKES

Highly robust single and multi-core high-voltage cables for construction and special vehicles With the HV 1000 C series, SAB Bröckskes, one of the world’s leading manufacturers of special cables, has developed new highly robust single-core (SC) and multi-core (MC) cables for highvoltage wiring in construction, agricultural, and special vehicles. The HV single-core, available in eight standard dimensions with nominal cross-sections from 6 mm2 to 95 mm2, meets the special requirements for safety and reliability in electrically or hybrid-driven utility vehicles. The multi-core version is available in dimensions from 2 x 2.50 mm² to 5 x 6.00 mm². Due to its high mechanical strength and resistance to environmental influences as well as its very good oil and temperature resistance, the HV single core solution designed for nominal voltages of up to 1,000 V AC/DC is suitable, for example, for the electrical connection of inverters and electric motors. The HV multi-core cable is used, for example, as a connecting cable to the cabin heater, the e-compressor or the HV heat pump in electric and hybrid vehicles. The double EMC-shielded high-voltage cables with bare copper stranding and orange-colored TPE-U sheathing have a low-temperature resistance down to -50°C according to DIN EN 60811-506 and withstand temperatures of up to +125°C

for a operating time of up to 2,000 hours. The extremely tensile, abrasion and shear resistant outer sheath allows tight bending radii and, in many cases, eliminates the need for installation with additional protective tubing. Other quality and safety features include flame-retardant and self-extinguishing material properties in accordance with IEC 60332-1-2 as well as standardized high resistance to mud, UV, ozone, and salt water. All materials are free of harmful substances and meet RoHS criteria. In addition to the standard designs, SAB Bröckskes also offers intermediate cross-sections of e.g. 8 mm2 as well as sheaths in other color variants on request.

The extremely tensile, abrasion and shear resistant outer sheath allows tight bending radii and, in many cases, eliminates the need for installation with additional protective tubing.

Robust, process-safe high-voltage cable for connecting electric motors in mobile machinery, agricultural and special vehicles.

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PECM Issue 65

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ELECTRICAL & ELECTRONICS

VALUABLE NEW RESOURCE PEMD

Body of Knowledge launches to drive £12bn Power Electronics, Machines and Drives opportunity A landmark initiative that aims to unlock the universal language of electrification was launched yesterday at a major event in London. Over 100 industry experts were present at the Museum of London to take a first look at The Power Electronics, Machines and Drives Body of Knowledge (PEMDBoK). This valuable new resource is set to redefine industry standards and align understanding of the essential skills and capabilities required by the sector. Hosted on the Electric Revolution Skills (ERS) Hub, individuals, employers, course providers, recruiters, and companies are urged to sign up and access the wealth of information on skills, competencies and training needed to work in PEMD now and in the future. The shared framework, developed through a collaboration of industry and academic experts led by Coventry University, is being hailed as a game-changing moment for a sector expected to generate more than £12bn of domestic revenue by 2025 and create over 169,000 jobs. A special panel discussion Chaired by Deepak Farmah (ERS Hub Commercial Director) and featuring Rowan Crozier (Brandauer), Louise Phipps (West Midlands Combined Authority), Jason Cole (Jonathan Lee Recruitment) and Elizabeth Bonfield (Skills 4) discussed current industry challenges and heralded the difference the Body of Knowledge could make.

PECM Issue 65

PEMD Bok Launch: From left, Deepak Farmah, James Shuttleworth, Bruna Pinto, Wissam Jamal and Petar Igic (all ERS Hub)

This valuable new resource is set to redefine industry standards and align understanding of the essential skills and capabilities required by the sector. Petar Igic, Academic Director of the ERS Hub, commented: “PEMD requires a broad and evolving set of skills and competencies that traditionally have been challenging to navigate for individuals and organisations, a problem exacerbated by differences in language used by employers, course providers and learners.

“This situation is holding the sector back and preventing new talent from entering at exactly the time companies need them – if we don’t try to reverse this trend, then the UK could quite easily find itself falling behind in the electrification race.” He continued: “We had to do something about this and by bringing together more than 100 different industry and academic experts, we have come up with The Power Electronics, Machines and Drives Body of Knowledge. “This ground-breaking initiative has captured the full scope of topic specialist areas and the skills required to do jobs ranging from Lead Power Electronics Engineer, Thermal Management Design, PCB and Sub Systems Integration to Power Converters and Instrumentation and Compliance

and has already enjoyed 87,000 engagements. The digital platform is helping hundreds of businesses attract new individuals to work in electrification and support growth in this vital industry by making 838 training courses – including electrical engineering, laminations, motors, automation, and 3D printing - easy to find through a comprehensive catalogue.

Testing all in one place and, importantly, in a unified language that everyone can understand.” The PEMDBoK is now live and can be accessed through the ERS Hub website, with thousands of new users expected over the next twelve months. Job specifications, courses, skills breakdowns, and career paths will be readily available, whilst machine-readable specification allows services for industry, recruiters, and course providers to specify underlying data accurately and ensure consistency and interoperability. The aim is to start bridging the skills gap by establishing a shared framework of technology, skills, and proficiencies, emphasising continuous learning and evolution as the landmark initiative develops and the electrification ecosystem matures.

“ERS Hub and BoK aim to support at both ends of the spectrum. By creating a common language, we allow recruiters and employers to easily create ‘standardised’ job profiles that can be understood whilst also helping education and course providers design their courses/training to better meet those demands.” PEMD Body of Knowledge is at the heart of the ERS Hub, which was successfully launched in Birmingham earlier this year

There is also the industry’s first jobs board purely for electrification, providing a constantly updated 390-strong list of available positions, the skills required for those roles and average remuneration. The final element of the offering is for academia, with the ERS Hub forging strong links with more than 200 partners, including schools, colleges, universities and businesses. Deepak Farmah, Commercial Director at the ERS Hub, concluded: “There was a fantastic response to the official PEMDBoK launch yesterday and we want to take this level of interest and leverage it to ensure everyone knows and interacts with the Body of Knowledge. “The universal language of electrification is now live – it is time for the sector to embrace it to ensure the UK leads the way to a greener future.”

“The issue is that there aren’t enough people to fill those 169,000+ jobs. While there are multiple engineers with experience and recent graduates, only a few decide to enter the PEMD field,” added Petar. “There are multiple reasons from both a recruiter and workforce perspective. Employers would rather hire experienced engineers than train people, unappealing job offers, unclear requirements/ skills for roles, or a language gap in industry and education. For further information, please visit www.ershub.co.uk/body-of-knowledge Issue 65 PECM

ELECTRICAL & ELECTRONICS

Whippendell Whippendell specialises in providing electrical solutions for harsh environments such as the Rail, Naval and Commercial Marine Industrial Sectors. This includes design, manufacture, in-service support and maintenance. For example, the company has been supporting the Royal Navy since the 1930s, with equipment on all current surface ships and submarines. We offer a range of electrical panels, motor starters, control systems, power

PECM Issue 65

conversion equipment and aircraft ground power support systems.

Many of our solutions arise from a reverse engineering task to replace obsolete systems with modern alternatives. Typical applications include high pressure air control systems, pumps, steering gear, stabilisers, lifts, winches, mechanical handling equipment and HVAC systems. Solutions can be designed around Whippendell components or to customer preferred requirements and components – use of COTS and PLC technology is standard. www.whippendell-marine.co.uk

ELECTRICAL & ELECTRONICS

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Issue 65 PECM

GEARS, DRIVES & MOTORS

NEW MENZEL HEADQUARTERS MENZEL

Larger plant for larger motors At the new motor plant of Menzel Elektromotoren, which is currently being built in Hennigsdorf, near Berlin, Germany, the interior construction has now been completed on schedule. Moving to the new site with a total area of 24,000 m², the electric motor manufacturer will increase its floor space and capacities, optimize the factory layout for an efficient production flow and is planning to create additional jobs. The crane capacities will be increased to 80 tons and the entire shop floor will be accessible via two crane levels, which will bring significant logistical advantages. In recent years, MENZEL has seen a growing demand for larger, more complex drive systems with a variety of auxiliary equipment such as transformers, converters, controllers and starters. The new test facilities are tailored to this need. For example, the area for load testing of large machines and generators has been significantly enhanced to cater for the largest frame sizes and loadings. A two-floor construction inside the load test field will house the control room, offices for the test field technicians and a separate lounge from which customers can observe ongoing tests. The soundproofing measures have been completed, and heavy-duty racks for shelf loads of 6,000 kg have been procured, which will accommodate part of the large MENZEL motor inventory and thus further shorten delivery times.

The crane capacities will be increased to 80 tons and the entire shop floor will be accessible via two crane levels, which will bring significant logistical advantages.

continue without interruption. The commissioning of the new company headquarters is scheduled for early 2024. MENZEL designs and manufactures its own efficient series of slip ring motors and squirrel-cage motors and also specializes in custommade products, even with unusual specifications. Photo construction diary for the new plant: www.menzel-motors.com/ article/photo-report-new-electricmotor-plant/

In the next few months, the gradual relocation from the existing headquarters in Berlin will commence. The production and shipping of industrial motors in the high output range will For further information, please visit www.menzel-motors.com

PECM Issue 65

NEW ELECTRIC MOTOR PLANT FROM JANUARY 2024

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AROUND THE CLOCK, AGAINST THE CLOCK!

HEALTH & SAFETY

Revolutionising Food Industry Displays: Display Technology-Harford Control Collaboration In the challenging realm of food manufacturing, the need for resilient touch monitors in harsh processing environments is evident. These monitors must withstand water, chemicals, and extreme temperatures to prevent screen damage from contaminating production. Partnering with Harford Control, renowned for its effective stainless steel touch terminals, Display Technology embarked on a close collaboration to formulate a solution. Harford Control’s terminals are tailored to meet the demands of the food industry by streamlining workflows, enhancing data

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capture, in tandem with dependable touch input from Zytronic’s sensor, minimized human errors during data entry, ensuring precise information recording. Conclusion: The collaboration involving Display Technology, Harford Control, and Zytronic yielded a groundbreaking touch screen solution. This innovation bolsters operational efficiency, reduces contamination hazards, and guarantees a safer food production process. It serves as a prime example of expertise’s transformative role in reshaping safety and reliability standards within the food industry.

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PECM Issue 65

MACHINING & MACHINERY

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Issue 65 PECM

MACHINING & MACHINERY

GENERATOR RELIABILITY SULZER

Sulzer 55 MW generator winding upgrade improves reliability and reduces unscheduled stoppages Large-scale manufacturing facilities in remote areas often rely on independent power generation sources to deliver the vast amounts of energy needed for operations. Turbo generators are often the cornerstones of these power sources. However, if they suffer unforeseen downtime, this reliance can result in a 100% loss of production. This was the situation faced by an Indonesian cement producer, which turned to Sulzer to resolve the failure quickly and upgrade its generator to protect uptime.

Ground to an unscheduled stoppage The breakdown of the 55 MW generator was caused by strand-tostrand faults that eventuated into a stator connection phase ground fault. Due to the excessive amount of winding oil contamination from a leaking bearing labyrinth seal, the ground fault flash resulted in a stator fire. As this was the only power source for the facility, production was immediately halted, risking the delivery of orders to customers. Any order obligations would need to be met by other facilities, placing stress on the cement producer’s regional operations. To resolve this, root cause analysis and a rapid temporary repair was requested by the cement plant management, followed by a full stator rewind at a more convenient time to suit their production commitments. A thorough investigative inspection by Sulzer’s experts revealed that the failure was attributed to the stator winding design having parallel stranding, which caused

PECM Issue 65

Sulzer was awarded the repair and upgrade project by direct appointment for the scope of winding and incorporating a 360° Roebel bar.

high circulating currents. The tracking across the surface of the stranding resulted in excessive winding temperature, eventually instigating the ground connection phase fault.

Rapidly responding to an urgent repair Due to a proven track record supporting the customer’s various production facilities, Sulzer was awarded the repair and upgrade project by direct appointment for the scope of winding and incorporating a 360° Roebel bar. A leading independent service provider for rotating equipment, Sulzer is a global expert in generator repairs and upgrades for

steam and gas turbines with a local presence in Indonesia. The technical proposal of utilizing 360° Roebel bars presented by Sulzer’s global technical team convinced the cement plant management that it was the most optimal solution, along with timeline assurance. Furthermore, the customer was aware of Sulzer’s robust global supply chain, which would expedite the project and support the generator long into the future. Compounding these advantages, Sulzer could offer a lead time of 10 weeks, while other vendors were still offering parallel strand conductors and completion schedules of several months.

To get the plant temporarily operational as soon as possible, Sulzer quickly completed a partial repair to the failed stator windings. This allowed the cement producer to work through their material stockpile and meet existing orders – which helped to reduce any loss of revenue caused by the generator failure. Illustrating its global engineering flexibility, Sulzer was the only vendor which could offer this partial repair - a testament to the company’s customer centricity.

When critical equipment suffers a breakdown, operations and production are always at risk. in-house by Sulzer’s experienced engineering and design team.

A generator upgrade uncoiled

A question of half-bar engineering and manufacturing Meanwhile, Sulzer worked on redesigning the new stator windings. The 360° Roebel bars would eliminate future circulating current problems compared to the original designed parallel conductors. However, this required overcoming numerous engineering challenges due to the short length of the stator core First of all, fitting the Roebel bars into the short stator core was going to take exceptional technical expertise. The OEM did not offer Roebel bars for this generator model, so Sulzer would be breaking new ground. Precision reverse engineering was required to ensure that the new top and bottom bars with a 360° Roebel would fit. Finally, the replacement bars would have to be engineered and manufactured specially for this generator. Thankfully, all these requirements were accomplished

Leveraging its global network, Sulzer Indonesia connected with the Birmingham Service Center in the UK, one of the numerous facilities within Sulzer which has the engineering and manufacturing facilities for high voltage stator coils and half bar production, backed by a comprehensive database and automated design capabilities. This overseas collaboration is common practice at Sulzer, with each facility in its network offering seamless access to the full global capabilities of the company. Using data collected from the stator and existing top and bottom bars, the Birmingham Service Center reverse engineered the winding to incorporate a 360° Roebel. With this complete, engineers precision manufactured a half stator section to confirm the correct fit of winding pitch to expedite installation onsite. Sulzer produced 48 top bars and 48 bottom bars in 10 weeks – a

lead time much shorter than the several months quoted by other service providers. To ensure a continuous workflow and minimize the duration of the winding process, the bottom bars were shipped first, followed by the top bars. This phased delivery allowed the Sulzer Indonesia team to complete the generator rewind sooner, as waiting for a single shipment would’ve increased the project timeline by several days. Furthermore, this scheduling ensured that the project could be completed within a planned shutdown period of 10-12 weeks, reducing disturbance to their production operations.

A concrete foundation for reliability The benefits of switching to Roebel bars were quickly apparent. Winding temperatures were greatly reduced, allowing the generator to be run more efficiently, providing energy cost savings to the cement plant. In terms of reliability, electrical circulating currents were all but eliminated, greatly reducing the risk of any future premature failures. Reduced winding temperatures also meant less thermal stresses on the winding insultation, improving service life. With the generator up and running, the pressure on the customer’s other facilities was alleviated too, with the plant now operating at full capacity. When critical equipment suffers a breakdown, operations and production are always at risk. However, by trusting in the global expertise of Sulzer, this cement producer was able to avoid the worst-case scenario. The customer centric approach of Sulzer prioritized the needs of the cement producer, minimizing any impact to operations or business reputation. Beyond providing a stop-gap repair to keep production running, Sulzer employed its coil manufacturing and reverse engineering skills to build a new foundation for future generator reliability.

For more information, visit www.sulzer.com Issue 65 PECM

MACHINING & MACHINERY

SPECIALISTS IN TOOLS & GAUGES WISEMAN THREADING TOOLS LTD

WISEMAN THREADING TOOLS LTD Specialists in Tools & Gauges for Screw Threads We We have have been been supplying supplying threading threading tools tools and and gauges gauges since since 1987. 1987. Together Together with with supplying supplying plain plain plug plug and and ring ring gauges gauges this this is is all all that that we we do, do, we we therefore therefore consider consider ourselves ourselves to to be be specialists specialists in in this this field. field. We We supply supply worldwide. worldwide. We We hold hold extensive extensive ready ready stocks stocks that that include include all all of of the the standard standard stuff stuff that that others others offer, offer, but but also also includes includes taps, taps, dies, dies, die die nuts, nuts, die die head head chasers, chasers, thread thread rolls rolls and and gauging gauging for for threads threads not not normally normally available available 'off 'off the the shelf shelf '.'. Our Our real real time time stocks stocks can can be be checked checked and and purchased purchased online online at at www.threadtools. www.threadtools. com com Just Just enter enter the the thread thread details details into into the the search search box box on on the the home home page. page. You You will will be be directed directed to to the the item, item, ifif stocked, stocked, or or to to our our specials, specials, (custom (custom manufacture), manufacture), sales sales team. team. who who will will quote quote to to supply supply at at competitive competitive rates, rates, in in good good time. time. As As an an account account holder holder you you can can also also order order online online from from our our listed listed in in stock stock items, items, at at your your normal normal terms. terms. We We realise realise that that you you need need the the right right item item at at the the right right price price and and quality, quality, and and in in aa reasonable reasonable time time frame. frame. We We are are geared geared to to provide provide that. that. We We can can ship ship stocked stocked items items same same day. day. Our Our experienced experienced sales sales staff staff can can assist assist and and advise advise you you on on any any technical technical issues. issues. We We welcome welcome enquiries enquiries from from resellers resellers and and can can offer offer terms terms to to suit. suit. WISEMAN WISEMAN THREADING THREADING TOOLS TOOLS LTD LTD 11 11 Padgets Padgets Lane Lane South South Moons Moons Moat Moat Redditch Redditch B98 B98 0RA 0RA UK UK +44(0)1527 +44(0)1527 520 520 580 580 sales@threadtools.com sales@threadtools.com www.threadtools.com www.threadtools.com

For For further further information, information, please please visit visit www.threadtools.com www.threadtools.com

88 PECM Issue Issue 64 64 70 PECM 65

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

DELIVERY WITH SYSTEM KASTO

The potential for growth Numerous items, small batch sizes – this demands flexible and speedy handling. To offer customers these advantages, the steel distributor Hagelauer Dewald relies on an automated high-bay storage system from KASTO. Equipped with the KASTOcenter varioplus 2 sawing centre, the company can handle processing stages for their customers, opening up the potential for growth in response to the growing trend. Stepping into the offices of Hagelauer Dewald GmbH in Pleidelsheim, you would never imagine what the buildings next to and behind it hold. Ever since the merger of Hagelauer and

Dewald under the umbrella of the Lotter Group, their warehouses and production halls have been bulging at the seams. Due to the overcrowding, the management board decided to construct a new building to make use of every available metre, both horizontally and vertically, within the limited space. Now a 20-metre-high building towers between the administration facilities and the new production halls, accommodating a high-bay warehouse and sawing centre. “Although demolition and the construction of the new building took place basically amid ongoing operations, we could maintain production throughout the entire

building phase,” explains Jörg Bayer proudly. As one of two managing directors at Hagelauer Dewald, he helped shape the “Growth” project and offered assistance throughout the project. The newly constructed halls have an impressive appearance due to their extensive extension in all directions, landscaping, and the installation of photovoltaic cells on the roofs. Underneath the concrete foundation for the high-bay storage system lies a sustainable concept: in addition to the ground slab, posts were driven into the ground. Not only do these posts carry heavy loads, but they also harness geothermal energy

The UNICOMPACT 3.5 honeycomb storage system is the core component of the new building at the steel distributor Hagelauer Dewald. It has a total storage capacity of nearly 14,000 tonnes.

PECM Issue 65

Photos: KASTO Maschinenbau GmbH & Co. KG

One of the unique features is that the UNICOMPACT storage system can supply the adjacent sawing centre with material via special saw cassettes and automatically longitudinal moving carriages.

The KASTO sawing centre is ideal because it fits perfectly with our itemdriven business from the ground. “We use this energy for heating and cooling our office building,” Jörg Bayer explains while adding: “We are committed to sustainability.”

weights,” Jörg Bayer explains. In the 1990s, KASTO demonstrated their expertise by providing the first machines for Hagelauer. Later, a storage system and several KASTOvariospeed C15 circular saws were added to the mix, which still perform well today. The UNICOMPACT 3.5 honeycomb storage system is the core component of the new building. It has a total storage capacity of nearly 14,000 tonnes; after its completion, it can accommodate 4,000 cassettes, each with a storage capacity of 3.5

tonnes. “We use this high-bay storage system to stock material and supply the surrounding stations,” explains Jörg Bayer. There, employees pick the orders and handle the processing by cutting the pieces to length. The fully automatic, operator-free operation of the UNICOMPACT storage system in Pleidelsheim is one of its unique features, enabling it to supply the adjacent fully automated KASTOcenter varioplus 2 sawing centre with material via special saw cassettes and automatically longitudinal moving carriages. “Not only was KASTO our first choice for storage systems, but from the very beginning, it was also our frontrunner when selecting new saws”, the managing director emphasises. This enabled KASTO to automate the process from raw material storage to initial processing to the structured supply of the processed material in loading carriers in one comprehensive solution.

Sawing centre for fully automatic pre-cut parts The KASTOcenter and the two fully automated sawing machines enable the steel distributor to automatically cut the materials flexibly and quickly. The KASTOsort robot removes the cut pieces from the circular saw, a KASTOvariospeed SC 18, and feeds them into a deburring unit as needed. It then sorts them onto the pallets. The pallet rotation unit provides the robot with a load carrier that precisely fits the

High-bay storage system as the core component A vital component for ensuring the growth of the steel distributor is the “furnishings and equipment” in the halls: To achieve this, Hagelauer Dewald turned to KASTO Maschinenbau GmbH und Co KG, a specialist in storage and sawing technology. The familyowned company located in Achern had already been involved in the preliminary planning stages in 2019. It provided the structural calculations for the roof and wall substructure and the structural calculation of the floor loads for the construction of the foundation onsite. “KASTO knows exactly what and how to build to establish the required stability for the massive

Since the 1990s, KASTO circular saws have been used by Hagelauer which still perform well today, for instance, the KASTOvariospeed C15 Issue 65 PECM

Jörg Bayer, Managing Director, views the investment in the KASTOcenter as a win for both parties: “The customer no longer needs to store material and our specialised personnel no longer has to spend time on storage and sawing tasks. As a result, all parties involved can focus on their core competencies.”

The UNICOMPACT storage system can automatically supply the sawing centre with material via a moving carriage and special cassettes. This makes work noticeably easier for warehouse personnel.

material to be sorted. In addition, the system continuously feeds and unloads full and empty containers in the loading and unloading zone. An added feature: the robot automatically attaches a barcode to the cut pieces. This ensures that all data is then available digitally. The production control documents are even available on the pallets. Hagelauer Dewald uses the second machine, a KASTOtec SC 4 band saw, for large dimensions of up to 260 millimetres in diameter. An apron conveyor positions the cut pieces and pushes them to the desired deposit position, either on a closed table surface or pallets.

Customers demand flexibility and speed “The KASTO sawing centre is ideal because it fits perfectly with our item-driven business,” explains Jörg Bayer. The steel distributor requires maximum flexibility and speed with 100,000 items and 2.5 million saw cuts per year. He assures there is no doubt that investing in the KASTOcenter varioplus 2 has paid off: “We can now provide our customers the exact materials they need. This saves storage space, and their well-paid specialised personnel no longer has to spend time on storage and sawing tasks,” Bayer summarises.

Hagelauer Dewald uses the KASTOtec SC 4 band saw machine for large dimensions of up to 260 millimetres in diameter.

The managing director jokes, “Our customers want steel in bags”. In fact, machine manufacturers and other steel fabricators order primarily small quantities from Hagelauer Dewald. “Over 60 per cent of all items leave our hall on a single pallet or plastic crate,” he adds. The new fully automated sawing centre can easily process many different items without any changeover or dwell times. In summary, Jörg Bayer explains: “This quick availability is a major advancement for us. Anything the customer orders today will be delivered tomorrow – regardless of how small the quantities may be.”

Many customers order small quantities. This is why over 60 per cent of all items leave the hall at Hagelauer Dewald on a single pallet or plastic crate.

For more information, see: www.kasto.com

PECM Issue 65

MACHINING & MACHINERY

PRECISION, PERFECTED WDS COMPONENTS

The unseen power of WDS Components’ new milling machine satisfaction and delivering excellence. Our continued investment into our manufacturing process demonstrates the ongoing support and long-term vision for British Manufacturing. WDS Components is committed to producing what the customer needs, when they need it.

As a key part to its ongoing commitment to grow its production capabilities and continue providing its customers with unmatched service, WDS Components has integrated a new 4-axis milling machine into its workshop. This isn’t just a step; it’s a leap towards ensuring the faster, more precise production of standard and bespoke components.

By integrating this advanced milling machine into its operations, WDS Components are not only enhancing its in-house capabilities but are also setting a new standard for quality and efficiency.

The new milling machine has already made a significant impact in the workshop at WDS Components. Its robust construction allows for the precision milling of materials such aluminium, steel, stainless steel and cast iron, in sizes up to 1100 mm by 610 mm and up to a weight of 1,500 kg. This ensures that each component is not only precise but also has a smooth finish, reducing the need for subsequent finishing processes.

This underscores our unwavering dedication to meeting customer needs, both in terms of the extensive range of products available and the speed at which they can be produced.

Fully programmable via its industry standard CNC unit, the machine operates autonomously with unparalleled accuracy, eliminating the need for constant operator intervention. This has enabled WDS Components to optimise its workshop team’s tasks and further enhance production efficiency. Key facts: • Spindle speeds ranging from 5 to 10,000 rpm, allowing for optimisation of the milling process for various materials, ensuring a clean cut while also maximising tool life. • Rapid feed rates up to 24 m/min, contributing to reduced lead times and more competitive prices for its customers.

CY • A 30-station arm-type tool changer with a tool change time of just 2 seconds, minimising downtime CMY and maximising productivity. K

The ± 5 micron positional accuracy and ± 2 micron repeatability ensure that every part for every customer will be dimensionally accurate. In manufacturing, time is of the essence. The features of this new milling machine safeguards that WDS Components can produce parts at a pace that allows it to offer reduced lead times. This is more than just an investment; it’s a testament to WDS Components’ commitment to customer For further information, please visit www.wdscomponents.com Issue 65 PECM

Increase your mold manufacturing versatility using the power of gundrilling with the leaders in deep hole drilling, UNISIG. Oﬀering complete solutions for everything from simple to complex mold components, UNISIG machines help moldmakers improve eﬃciency, throughput and precision with outstanding part-processing versatility at an exceptional value. TAKE YOUR MOLDMAKING OPERATIONS FURTHER WITH UNISIG TODAY.

Find out more at www.UNISIG.com

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 AND MACHINERY

THE BACKBONE OF MACHINERY DONGHUA LIMITED

Keeping the wheels of industry turning Roller Chain plays a pivotal role in countless applications across a wide range of industry sectors. They are the backbone of conveyors, manufacturing equipment, packaging machinery and agricultural machinery. At the forefront of Roller Chain development is the Hangzhou Donghua Chain Group which is one of the world’s biggest chain manufacturers producing over 30 million metres of chain per year.

STANDARD RANGE

SOLUTION RANGE

pitch roller chain; heavy duty roller chain; oil field roller chain and short pitch roller chain.

Donghua’s Roller Chain Range Donghua Ltd categorised their extensive Roller Chain products into three ranges to help UK customers identify the right chain solution quickly and easily. The Standard Range features a variety of standard Roller Chain manufactured with precision to suit simple drives with large diameter sprockets or complex drives with multiple sprockets and high load bearings. Chains within this range include: standard and stainless steel hollow pin bush roller chain; works norm roller chain; cottered type short pitch roller chain; driving chain; double

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. Chains within this range include: chromized pin (CP) chain, heavy duty chain, self-lubricated roller chain and EXL chain. 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 aftermarket, EXL Chain is designed,

Wear Life

PREMIUM RANGE

manufactured and tested for unbeatable accuracy and performance in arduous conditions, offering enhanced wear and fatigue resistance and greater precision. 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. The Premium Range offers 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. Their 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, shotblasted plate shape, calibrated pin and bushing holes, special heat-treated and surface coated pins, seamless rollers and bushings and high performance pre-lubrication.

To read more about Donghua’s Roller Chain, visit https://www.donghua.co.uk/roller-chain/

PECM Issue 65

A PREMIUM CHAIN SOLUTION FOR HIGH DEMAND DRIVES

3 4 5

Optimised plate shape

Calibrated pin and bushing holes

High press fit to guarantee maximum fatigue strength

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

Seamless bushings & rollers throughout

High performance 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 Limited Sidings Close Wednesfield Way Wolverhampton West Midlands WV11 3DR

Tube

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

SENSE MONITOR TRIGGER ACT SEMOTA is a

hardware and software solution with a web-based application that enables the remote monitoring of any load cell, force, torque or pressure sensor using our Wi-Fi enabled hardware

Three years data storage Three years rolling data retention

Live dashboards

Create real-time dashboards to analyze data and control devices

Events engine

Keep operators on-the-ball and informed

Synthetic Variables

Transform raw data into insights

User management 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

Build applications to best ﬁt the operator’s needs

Interface Force Measurements Ltd

Ground Floor, Unit 19, Duke’s Ride, Wellington Business Park Crowthorne, Berkshire RG45 6LS Tel: +44 (0)1344 776666 | Email: info@interface.uk.com | www.interface.uk.com

Fiber Optic Temperature Monitoring for Semiconductor Production Processes Advanced Energy is a specialist in semiconductor manufacturing solutions, offering highly accurate power delivery, frequency tuning, and multi-level pulsing solutions for advanced plasma control in critical etching, deposition, inspection, implantation, and annealing processes. Optimizing yield and throughput requires highly accurate temperature measurement and control. Fiber optic based FOT technologies are becoming increasingly important. AE’s Luxtron range of fiber optic thermography technologies that have

been designed to support precise process control for customer innovations. Leveraging fiber optic probes with phosphor sensor technology, Luxtron FOT sensing systems combine highperformance converters with an advanced light source, a proprietary software algorithm, and low-noise amplification circuitry. The new Luxtron® M-1100 is the latest FOT converter platform offering fiber optic temperature sensing for semiconductor manufacturing etch and deposition applications. This instrument provides temperature measurements from -200 °C (the start of the cryogenic range), to ‘hot chuck’ temperatures of 450 °C with industryleading accuracy of +/- 0.1 °C and stability of +/- 0.05 °C. Integration of five channels facilitates connection to multiple probes using a single converter, while flexible communication outputs simplify digital monitoring, status monitoring and system integration. In addition, the Luxtron www.advancedenergy.com | info@aei.com

PECM Issue 65

M-1100 is the first model to offer both analog and EtherCAT communication interfaces. The new converter simplifies implementation by enabling wallmounting on the side of the system being monitored. User experience is further enhanced with support from Advanced Energy’s global engineering and applications teams, which collaborate with OEMs to develop custom probes for leading edge applications.

MEASUREMENTS & MONITORING

Issue 65 PECM

Save Money, Save Energy: How Tinytag Data Loggers Contribute to Cost Savings and Energy Efficiency Before-and-after power/energy usage analysis is vital in energy audits and for organisations to validate energy-saving measures, especially for high consumers of electricity. The Tinytag Energy Logger is a portable data logger which can be used to monitor electricity consumption in individual pieces of equipment to help identify where potential energy usage savings can be made, improving energy performance and cost savings. For a small initial investment, the Tinytag Energy Logger provides businesses with information about significant areas of energy usage, informing energy savings and leading to reduced costs. Recording data before energy-saving implementation can inform your strategy by revealing areas of high power consumption that could feasibly be reduced, as well as the peak times for energy usage in your facility. Data recorded after energy-saving plans are executed verify the energy savings of the methods in place, providing useful historical data to refer back to and report on.

Energy data logger in electrical monitoring to show its customers how using its products results in energy savings. Before-and-after monitoring using the Tinytag Energy Logger demonstrates how Interflon’s lubricants can significantly lower friction levels in electrically-driven machinery, in turn lowering energy consumption.

Specialist industrial lubricants manufacturer Interflon uses the Tinytag

Gemini Data Loggers designs and manufactures comprehensive building

monitoring equipment, including temperature and relative humidity data loggers for assessing occupant comfort, data loggers for monitoring energy usage and efficiency, and carbon dioxide data loggers for monitoring indoor air quality. The Tinytag Connect system – comprising Radio and LAN data loggers and Tinytag Explorer Connect software – allows wireless, automatic environmental monitoring, ideal for large sites and applications.

Browse Tinytag data loggers at www.tinytag.info

Tinytag Data Loggers:

Tinytag Plus 2

Energy Logger

Rugged outdoor/industrial temperature/RH logger From £110 +VAT

Non-invasive single & three phase power monitoring Full kit £995 +VAT

Radio and LAN loggers

Tinytag Ultra 2

Robust Environmental Monitoring Solutions Data loggers for indoor, outdoor and industrial/process applications • Rugged and compact • Easy to use • Dust, splash or waterproof

Manufactured in the UK

• Data downloaded to PC • Cost-effective Accompanying probes are available for monitoring extremes of temperature, and for awkward to reach areas such as pipework. Automatic data collection Bundles – 3 loggers/receiver/ software from £1,100 +VAT

For sites requiring remote data access, Tinytag Radio and LAN loggers gather data automatically for viewing on a PC, across a LAN, or remotely across the internet. temperature

humidity

Gemini Data Loggers (UK) Ltd Scientific House, Terminus Road, Chichester, West Sussex, PO19 8UJ, England

PECM Issue 65

power usage

Telephone: +44 (0)1243 813000 email: info@tinytag.info www.geminidataloggers.com www.tinytag.info

co2

count

Indoor temperature & RH From £80 +VAT

voltage

current

Sepura 25 Years TECHNOLOGIES Half Page Ad 132x180L.qxp_Layout 1 07/08/2023 17:04 Page 1 PROCESS

A milestone in quality, manufacturing and innovation

Years of excellence For the last 25 years Bowman Stor have been leading the development and refinement of condensate filtration products and technology.

From our industry leading filtration media to our in house development lab and prototyping facilities we are, and always have been, at the forefront of the Oil-Water Filtration industry. • OEM SEPURA™ Separators & service kits • Design and Development facilities • ISO9001 & 14001 Accreditations • Own brand options available • Filter bags to fit all systems • Free Product Finder App to download • All manufactured on site in the UK SEPURA™ is part of the Bowman Group

www.sepura-technologies.com

t: e:

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

The UK’s Laboratory Equipment Experts

THINK YOU KNOW LABTEX? THINK AGAIN. Labtex scale-up equipment, sourced from European and US manufacturers, is amongst the highest quality available.

Aerospace Bio-manufacturing Pharmaceutical Automotive Defence Chemical manufacturing

• Filtration • Fluid transfer • Process automation • Reaction vessel systems • Vacuum pumps and networks • Temperature Control -125oC to +425oC

For innovative process and control equipment, contact Labtex!

01484 600 200 84

PECM Issue 65

info@labtex.co.uk

labtex.co.uk

PROCESS TECHNOLOGIES

PEAK POWER FRANKFURT LASER COMPANY

High Power Picosecond Pulse Laser

The picosecond pulse laser series FPYL-Q-PS is offered with peak power up to 100W at a repetition rate of 1MHz and a pulse width of <10ps. Available wavelengths are 266nm (1-8W), 355nm (1-50W), 532nm (1-80W) and 1064nm (1100W). The repetition frequency range is between 400kHz and 2MHz. The power stability is <3% (<1% optional). The pulse-to-pulse stability is <2%. Both are measured in rms and over 4 hours. The output beam is transverse mode TEM00 and has high beam quality of M2<1,2. With a beam diameter of ~3mm and a divergence <1mrad the output beam is very well collimated.

The laser will be delivered with an appropriate power supply for the voltage range 100-240V as well as a water chiller. Due to the high power with pulse widths <10ps these lasers are excellent suited formicro material processing. Typical applications are:

The laser will be delivered with an appropriate power supply for the voltage range 100-240V as well as a water chiller.

Applications: • Flexible Materials Processing • Brittle Materials Processing • OLEDs Processing • Glass & Ceramic Cutting and Drilling • Semiconductor Industry

www.frlaserco.com | sales@frlaserco.com Issue 65 PECM

PUMPS

ALTERNATIVE FUEL HANDLING NORTHRIDGE PUMPS

In our latest project, we were asked to help a turbine manufacturer who were looking to test operation when fueled with methanol Methanol – known as a future fuel can help to reduce carbon emissions by 65% to 95% depending on the feedstock and conversion process used. That’s one of the highest potential reductions of any fuel currently being developed to replace petrol, diesel, coal and methane. It is a multi-purpose fuel that can be used on its own, blended with other fuels or for producing fuel additives which improve engine performance. It can also be used in fuel cells, which convert energy to electricity.

Rotary vane pumps can bring significant benefits in applications where high performance and reliability are required with minimal loss of downtime.

Rotary Vane Pump Benefits Rotary vane pumps can bring significant benefits in applications where high performance and reliability are required with minimal loss of downtime. They are easy to maintain, and provide consistent flow across varying viscosities at different pressures.

Supplying a methanol turbine feed pump North Ridge were contacted by a gas turbine manufacturer who was looking for a proven methanol feed pump to pump liquid methanol at range of temperatures from -20°C to - 40°C.

Our range of NR-BAL rotary vane pumps for instance, are positive displacement volumetric pumps with a maximum working viscosity of 10,000 cSt. This means they can easily handle the vast majority of low to medium viscosity fluids without loss of performance.

The flow rate would be around 30L/min at pressures of up to 3 bar and was being used to test a newly developed turbines performance. They would vary the pump flow utilising both 50hz and 60hz frequencies to increase flow but required the same consistent pressure to ensure that turbine performance was maintained. For this particular project, we supplied our heavy duty vane pump the NRBAL2R which was longcoupled in cast iron and mounted on a baseplate connected to an ATEX 0.75Kw motor. The NRBAL2R series of vane pumps is a high performance model commonly used in applications

service life without affecting the units overall size. Safe fluid handling is also ensured through the use of the integrated relief valve mounted on the pump head preventing the pump being damaged from excess pressure. This model is also equipped with a double set of bearings ensuring rotational loads are evenly distributed. The pump was operated by a geared motor running at only 470rpm further ensuring any wear was kept to a minimum.

where pumps are ran continuously such as in tank farms, refineries or oil processors pumping a variety of liquids which can be corrosive, flammable and low lubricating. Consequently this design of pump is built with double mechanical seals to ensure almost zero chance of leakage of volatile fluids, as well as longer

Thanks to their efficiency, reliability and heavy-duty design our rotary sliding vane pumps are perfect for volatile, flammable liquids used across industry. They are also perfect for use with alternative or future fuels as discussed. If you’re looking for proven pumps for methanol transfer or any kind of alternative fuel handling in a variety of applications, speak to North Ridge Pumps to see how we can help.

For further information, please visit www.northridgepumps.com

PECM Issue 65

Ready to take your process to the next level? Kit Out Your Process All in One pump kits for fluid transfer without the hassle of sourcing components individually and assembly on-site Would you like a fully tested leak-free solution for handling aggressive chemicals, flammable liquids or are you simply looking to automate fluid transfer?

Here are some kits we have supplied previously: ELIMINATING MANUAL HANDLING & IMPROVING SAFETY

EDIBLE OIL TRANSFER PUMP KIT

Transferring Olive and Rapeseed Oil from a low risk area into a high risk process area with automated remote operation, eliminating manual lifting and forklift movements in hygienic areas.

A pump kit handling High Temperature Viscous Toffee Sauce & Creams eliminating manual handling, & risk from a process.

ATEX RATED MOBILE PUMP KIT FOR METHANOL, LIQUOR & GIN TRANSFER

Mobile pump kit for handling highly flammable bulk alcohols for transfer into IBC’s.

SUMP EMPTYING PUMP KIT

A robust rugged mobile kit Handling High volumes of Waste Water with solid particles from sumps. Plug and Play installation without risk of pump damage and with little training.

BARREL PUMP KIT FOR DISPENSING SOLVENT FROM 25 LITRE JERRY CANS AND IBCS

Decanting solvent from IBC’s and 25L Jerry cans conveniently for a fragrance producer.

+44 (0) 1773 302 660 | sales@northridgepumps.com | www.northridgepumps.com

PUMPS

EMBRACING INNOVATION SEEPEX

Tennent’s Brewery Partners with SEEPEX Tennent’s Wellpark Brewery is Scotland’s oldest brewery, tracing its roots back to the 1500s. Since its establishment in 1885, it has consistently produced awardwinning brews. The brewery’s fascinating story revolves around Hugh Tennent, who defied skeptics in 1885 to create Tennent’s Lager, initially dubbed a ‘madman’s dream’ by newspapers. Today, Tennent’s Lager dominates the Scottish market, accounting for every second pint of lager consumed in the country.

Upgrading Brewery Operations for Enhanced Efficiency As part of their process, spent grain is transferred from two mash filters that drain the spent grain to 24%DS. Originally, the spent grain fell from the mash filters into an expeller unit from where it was conveyed over 64m with a 20m elevation to the silo. With the expeller, the grain transfer took ~90 minutes after each brew and used 1,125Nm³ of air.

Tennent’s Brewery achieves 56% air savings with SEEPEX’s SAI technology.

PECM Issue 65

Tennent’s Lager, part of leading drinks manufacturer and distributor C&C Group, is committed to a robust sustainability strategy, exemplified by ambitious carbon reduction targets. These targets aim to achieve a 35% reduction in scope 1 & 2 emissions by 2030 and have been validated by the Science Based Target initiative. In recent years Tennent’s has made significant investments in various carbon reduction projects, including carbon capture and anaerobic digestion plants.

Tennent’s commitment to innovation, efficiency, and sustainability shines through its partnership with SEEPEX. Additionally, Tennent’s has partnered with SEEPEX to improve energy efficiency in its spent grain transfer process, which is the most air intensive process on site.

Improved Efficiency, Productivity, and Energy Savings Together with SEEPEX, Tennent’s explored the benefits of SEEPEX’s cutting-edge Smart Air Injection (SAI) technology. This groundbreaking solution combines an open hopper progressive cavity pump and pneumatic dense-phase conveying to efficiently transfer 15-40%DS spent grains, draff, and hops in plugs. Controlled air pulses enable seamless conveying over long distances. SEEPEX established the optimum operation point with minimum air consumption to reduce the original air consumption and carbon footprint, and also assessed the energy efficiency in comparison with the initial system. SEEPEX was able to calculate all the consumptions eliminating the need to carry out a trial.

A Path to Sustainability: Scottish Industrial Energy Transformation Fund The demonstrated energy efficiency from SEEPEX Smart Air Injection (SAI) enabled Tennent’s to access the Scottish Industrial Energy Transformation Fund (SIETF), designed to support the development and deployment of technologies that enable businesses with high energy use to transition to a low carbon future. Through this, the government funded 30% of the project.

Tennent’s Brewery embraces innovation with SEEPEX’s Smart Air Injection, revolutionising spent grain transfer efficiency.

Decreased Air Use and Transfer Times Air consumption has decreased by an impressive 56%, dropping from ~1,125Nm³ to 500-700Nm³ per brew. Furthermore, there is a decrease in spent grain transfer time associated with the SAI system. The reduction in air use contributes to Tennent’s carbon reduction plan by reducing electricity use within the site.

potential issues, enabling planned proactive maintenance for increased uptime and lower total cost of ownership.

Seamless Maintenance and Uninterrupted Operation

Tennent’s commitment to innovation, efficiency, and sustainability shines through its partnership with SEEPEX. With enhanced efficiency, substantial energy savings, and a focus on seamless maintenance, Tennent’s continues to set the benchmark for excellence in the brewing industry.

As Tennent’s embraces the future of brewing, it benefits from SEEPEX’s plannedCARE package. This comprehensive service ensures proactive, on-time planned pump maintenance, guaranteeing uninterrupted operation. This includes diagnostics to identify

Join Tennent’s in improving your efficiency and success story. Contact SEEPEX today to explore our innovative pump solutions for the brewing industry and distilleries, addressing your unique pumping challenges.

For further information, please visit www.seepex.com Issue 65 PECM

PUMPS

FLOW OPTIMIZATION SECOND TO NONE

EXCELLENCE – MADE TO LAST

THE NEW BLUELINE NOVA ROTARY LOBE PUMP

BLUEline

NOVA

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.

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

Bespoke Engineered Pump Packages YOU DEFINE. WE DESIGN. At Cat Pumps we can provide engineered pump packages that are bespoke to customer requirements. We have over 50 years’ experience of providing Cat Pumps pump packages to a variety of industries and can provide skid systems with the following options: Electric Motors There are number of options available. Drive Systems Our pumps can be connected to a motor in a variety of ways. Base or Frame Configuration We can mount the pump package simply on a base plate or on a frame designed specifically to meet your installation needs and space envelope. Motor Controls To control the pump package, we can supply DOL or VSD controls configured to meet your exacting requirements. Pump Package Accessories To compliment the Cat Pumps pump package, we can supply a multitude of pump accessories.

PECM Issue 65

SOFTWARE & SYSTEMS

4-wire to 2-wire RS485 conversion and custom data conversion The KD485-ADE-4XX-4XX from KK Systems is a DIN rail mounted interface converter with two serial ports which both support 2-wire or 4-wire RS485. A common application is attaching new 2-wire RS485 devices to an existing 4-wire RS485 bus. The KD485 is protocol transparent and RS485 driver control is performed transparently. Other port types available are RS232 and 20mA TTY.

User programmable versions also support data/protocol conversion. The KD485 is powered from 7-35V DC and its 3-way isolation makes it ideal for industrial applications which require a robust unit with the full RS485 drive capability. Custom products are also available, including C user-programmable versions. www.kksystems.com

Issue 65 PECM

SOFTWARE & SYSTEMS

BUILD OR BUY? HARFORD CONTROL

5 Reasons to Partner with an Established MIS/MES Provider turnovers create extra challenges for in-house developers. Opting for dedicated solution providers, like Harford, ensures 24/7 local support across 6 continents. Expert engineers offer rapid responses and on-site help if needed.

During the first half of 2023, 56 food and drink companies went into administration, constituting 9% of the total UK administrations for this year according to Food Manufacture. The manufacturing sector has been under significant cost pressure due to Brexit, the pandemic and the war in Ukraine. To boost productivity and save costs, businesses increasingly develop in-house software. Yet, for true cost savings, in-house development has proven ineffective and costly. Here’s why:

1. Managing Uncertain Risks and Costs Developing an in-house system presents great risks of exceeding the project’s scope, budget, and timelines, which could even threaten to put the business into administration. McKinsey reveals that IT projects exceed budgets by 45%, timelines by 7%, and deliver only 56% of expected value. Opting for customisable offthe-shelf MIS/MES solutions smartly saves time, resources and risk.

2. Balancing Integration and Scalability Complex factory operations require diverse improvement areas. Building homegrown systems diverts time and capital. However, comprehensive

5. Focusing on Continuous Improvement

Opting for a reliable solution provider is more cost-effective and offers scalable benefits. MIS/MES solutions like Harford’s deliver real-time insights across the factory, enhancing production with quality, performance, labour, wastage and energy data available in one system. In-house system development has proven time and again to be the most costly solution.

3. Amplifying Real-Time Data Analytics Can internal dashboards prompt action? Does a 65% to 40% OEE drop matter? In-house software often lacks root cause analysis for data-driven decisions. In contrast, Harford’s MIS/ MES system tracks production endto-end, offering granular insights for swift root cause identification. Both managers and operators leverage real-time data for instant actionable responses, ensuring lasting solutions, rather than short lived ‘quick fixes’.

4. Ensuring Reliable Maintenance and Support All systems demand training, but staff

In-house advancement demands ongoing research and development, but what if the system developer has left the company? Engaging solution suppliers reallocates internal resources for innovation. Harford invests in MIS/MES systems annually, continually adapting to customer needs and market trends.

Customer Success Stories: Tangible Savings Don’t just take our word; hear from our client: “One year after implementation and Harford has supported us in reducing our bottling losses to less than 0.1% and has taken our overall end to end liquid losses down by more than 50%. This alone has delivered sufficient savings back to the business to pay for Harford.” --Tony Brewerton, Plant Director, Loch Lomond Distillers

Embrace Cost-Effective Transformation Opting for a reliable solution provider is more cost-effective and offers scalable benefits: risk and cost monitoring, advanced functionality, real-time insights and continuous improvement. Meet us on Stand B46 at the PPMA event to explore how we can drive your continuous improvement and competitive edge.

For further information, please visit www.harfordcontrol.com

PECM Issue 65

PRECISION INJECTION MOULDING & TOOLMAKING SERVICES YOU CAN TRUST

For reliable, cost-effective UK manufacturing solutions, with over six decades of industry experience, AC Plastics is the right partner for all your injection moulding needs. We manufacture a comprehensive array of high quality, precision moulded components for a wide variety of industries and sectors. Including automotive, construction, medical, water filtration and electronics, as well as many others. We offer complete project management on all new enquiries or transfer of existing tooling. From component design, tool manufacture, injection moulding of components through to warehousing and despatch we can guide you through every stage to deliver on time and on cost. Technically capable and customer driven, we can accommodate transfer of existing tooling or fully project manage new enquiries from the ground up.

Talk to our team today to see how AC Plastics can help you. 0151 489 8409

info@acplasticsltd.co.uk

www.acplasticsltd.co.uk

VALVES & FLOW CONTROL

REVOLUTIONSIING NUTRITION BURKERT

Industry-scale production of cultivated meat and the importance of valve control Grown from animal cells, cultivated meat has the potential to provide a more environmentally friendly alternative, that is also free from animal harm. Currently, production is laboratory-scale, and expanding to industrial levels could enable this new food to reach our supermarkets. To achieve this, the accurate environmental control of the bioreaction process is essential, meaning that gas flow and temperature regulation with optimised valve systems will be a vital requirement. Kieran Bennett, Industry Account Manager for Food & Beverage applications at Bürkert, discusses the importance of bioreactor controls for scaling-up cultivated meat production. Cultivated meat, produced by growing animal muscle cells, has the potential to revolutionise global nutrition. This ‘new food’ could remove primary ethical concerns surrounding animal care, and help reduce global warming, as well as minimise wider environmental challenges as a result of intensive farming. Producing cultivated meat is achieved through cellular agriculture. A sample of cells is obtained from a donor animal by a physically harmless biopsy. Myocyte cells, the most common cells used to produce cultivated meat, are then separated and placed into a medium, such as a microalgae base, which is rich in the nutrients essential to cell reproduction. For the cells to achieve sufficient yield through further growth,

PECM Issue 65

Growing cultivated meat remains at laboratory scale, and before this new food can reach the supermarket, the cost of production needs to decrease further still. (Copyright (c) 2019 tilialucida/Shutterstock)

Control valves are integral to both the initial cell filtration and separation phase, as well as fermentation, and precision is essential throughout. maintaining the precise environmental conditions within the bioreaction process is also crucial.

Scaling-up production One major challenge the new food industry faces is the need to scale-up production. Although the current price of a cultivated meat burger is, theoretically, around €9(1), this value has decreased significantly since production of the first lab-grown patty in 2013, which

reportedly cost nearly €300,000(2). Growing cultivated meat remains at laboratory scale, and before this new food can reach the supermarket, the cost of production needs to decrease further still. Companies like Zeta are developing systems for meat and fish cell cultivation that have the potential to increase the scale of production over time. Large-scale bioreactors and fermenters that can efficiently create higher yields are required, and to ensure precise environmental control within these cell cultivation vessels, precision process control is vital. A crucial factor to ensure that the initial cells multiply is temperature control. If the cells are not incubated at a precise temperature, they will die. Temperature control remains vital throughout the cultivation process to optimise yield, as well as quality. Within the bioreactor, precise gas control is also essential,

cultivated meat production. These devices control temperature and gas with accuracy down to +/-0.3%, and a deviation in repeatability of just +/-0.1%. Combined with possible flow control volumes as low as 0.005 litres per minute, this assures the accuracy required for large-scale cell production. While a digital valve system helps to optimise this level of accuracy, it also increases control efficiency, important for scaling-up production while minimising cost. Typically, an industry-scale bioreactor features three or more mass flow controllers. Bürkert’s system maintains a central control unit that serves as a master over compliant devices, reducing cost and resources in installation and management. The mass flow controllers communicate via Bürkert’s EDIP digital network, which is based on CANopen, the predominant protocol in the automotive sector, chosen for its reliability.

Making the vision a reality

Zeta, as well as development by the University of Queensland, has used Bürkert’s mass flow controllers to regulate cultivated meat production.

ensuring the correct inlet of gases such as oxygen, as well as the dissipation of carbon dioxide, and the maintenance of the necessary pH level. A sterile environment is also a prerequisite. Quality, quantity, and safety of production depend on hygiene - and future regulation will hinge on this too.

Valve control Central to gas and temperature control in cultivated meat production is the valve system. Zeta has developed a cultivated meat system in conjunction with Bürkert’s flow control technology that optimises fermentation gas dosing. While companies like Zeta are

pioneers in this new field, in many respects, the control technology is already well-established. The exact parameters of temperature and gas modulation to optimise cell yield are still in development. However, cultivated meat production is set to involve industrial-scale bioreactors, controlled by systems like those supplied today by Bürkert to the pharmaceutical sector. Control valves are integral to both the initial cell filtration and separation phase, as well as fermentation, and precision is essential throughout. Zeta, as well as development by the University of Queensland, has used Bürkert’s mass flow controllers to regulate

To ensure CIP protocols, material selection and design is fundamental. For hygienic applications, stainless steel is the benchmark, hence its prevalence in the pharmaceutical sector. While this is crucial for gas control, it’s equally important for temperature control, where steam is usually used to regulate a bioreactor. Painted carbon steel valves are sometimes offered as lower cost alternatives, but stainless steel is the de facto selection, thanks to its higher resistance to corrosion, smoother surface finish, and greater temperature tolerance. The cultivated meat sector is on the brink of a distinct production increase, and this depends on the ability to transition from lab-scale to industrial-scale development. Valve modulation is integral, and while the precise control parameters are in development, the required technology base exists. Meanwhile, flow control manufacturers like Bürkert continue to fine-tune the process with innovators in this revolutionary new field.

For further information, please visit www.burkert.co.uk/en Issue 65 PECM

SPECIALIST SOLUTIONS DRALLIM

Providing engineering skills & custom-built systems We take pride in overseeing the entire manufacturing process, from design, prototyping and manufacture to delivery, installation, full product certification and after-sales service . Drallim is an innovative technology driven British engineering company with global presence. With experience in providing comprehensive turnkey assembly & test solutions covering electronic, electromechanical, engineering, and mechanical products. We offer our customers a total contract manufacturing service, offering design, and manufacturing solutions, providing engineering skills, manufactured equipment & custom-built systems for the Aerospace, Industrial and Utility Markets. Product Realisation Prototyping and New Product Introductions; From the initial enquiry, our Business Development Team analyses the specifications and requirements of a product or project and issues a comprehensive and detailed quotation. When an order is received, a project plan is then developed; our team uses detailed documentation, engineering change and reporting control to ensure continued information integrity. An experienced project manager acts as the interface between Drallim and our customers although, at the same time, we actively encourage engineer-toengineer communication. We have had customers engineers based at our headquarters signing off drawings as they are produced to meet urgent deadlines for manufacture. The designated project manager ensures that resources are allocated appropriately and that all tasks

are tracked and recorded. The result is a controlled transition into the manufacturing process. Design Support When it comes to product manufacturing, a substantial proportion of the end product’s total cost is determined at the design stage. As a result, this part of the manufacturing process presents the perfect opportunity to identify improvements that will lead to cost reductions. A thorough understanding of each element will enable the product to be designed and optimised for procurement, manufacturing and test. We provide an extensive Design for Manufacture service to help our customers achieve substantial improvements, including: • Improved manufacturing productivity • Enhanced product quality and reliability • Minimal/simplified maintenance • Lower Cost • Reduced time to market • Increased customer satisfaction • Manufacturing • Precision assembly We regularly produce complex assemblies that demand high levels of skill, precision, accuracy and consistency. The engineering and manufacturing

teams at Drallim are highly skilled in this type of work, with awareness of critical engineering tolerances when producing assemblies of this complexity. Our skills-base extends to include testing of electrical, electronic, mechanical, hydraulic and pneumatic assemblies. Following rigorous approval processes Drallim’s supply chain partners for custom parts, such as plastics, machined and fabricated metalwork etc, are monitored closely for quality and delivery performance. Tight control of the material supply chain ensures the availability of high quality mechanical parts is maintained for timely production. Electrical assembly Many of the assemblies produced require wire and cable interconnection between boards and sub-assemblies. This can be via cable forms or point to point wiring. As part of our electromechanical assembly service we are often called on to produce products that require critical cable routing. We also undertake electrical wiring of switch and instrument panels plus sophisticated control cabinets. We have highly trained engineering and assembly teams to assist with design and the assembly and support for all your cable and loom requirements. • Electro-mechanical Assembly • Pneumatic & Hydraulic Assembly • Racks & Cabinets • Box-Build Assembly • PCB Assembly • Prototype Wiring • Cable Assembly • Testing

For further information, please visit www.drallim.com

PECM Issue 65

So, if you are interested in British Manufacturing and looking for a Contract Manufacturer, we are sure Drallim can meet your needs.

VALVES & FLOW CONTROL

SUBSEA VALVE SOLUTIONS OLIVER VALVES

Oliver Valvetek Double Gate Valves on the Norwegian Continental Shelf Oliver Valvetek has manufactured a number of 1” Double Block Subsea Gate Valves with manual and hydraulic actuation destined for the Norwegian Continental Shelf (NCS). This dual functioning valve consists of a 1” hydraulic gate valve and a 1” multi-turn manual Gate valve both positioned on a single unitary forged valve block for dual redundancy and functionality. This unique and customised design brings additional benefits to subsea tree engineers in that it now provides flexibility to be used as stand-alone and fully functioning valves on other applications of the tree due to its standardised valve footprint. To date, Oliver Valvetek has manufactured more than 150 double gate valves with the hydraulic gate valve being a coil spring design as specified by the end-user. Interestingly, a continental shelf is a shallow and relatively flat stretch of seabed that extends from the shoreline to water depths of around 200 metres, before dropping off to deeper waters in what’s called the continental slope. The importance of the continental shelf to Norway is that it holds huge natural resources such as oil and gas, but also fishing. The bestknown fishing areas are found on the Shelf and at the edges where it meets the deep sea. Under international law, coastal states are entitled to their continental shelf up to 200 nautical miles from their

shores with some exceptions made to lengthen this, with NCS being one. For information on how Oliver Valvetek can provide subsea valve solutions for your project, telephone +44(0)1565 632 636 or visit our website at www.valves.co.uk

To date, Oliver Valvetek has manufactured more than 150 double gate valves.

For further information, please visit www.valves.co.uk Issue 65 PECM

UPS HIRE RENTAL SYSTEMS POWER CONTINUITY LTD

Any Where - Any Event - Any Time Containerised UPS systems provide emergency backup power on a temporary basis. Power Continuity UPS containers available for various scenarios. From 100kVA to 3000 kVA temporary Uninterruptible Power systems for ‘must have’ critical contingency to prevent power loss during planned site works. ensuring reliable power supply to sensitive electronics, servers, and site operations.

UPS HIRE CONTAINERS FOR TEMPORARY POWER UPS hire containers offer installation, maintenance, and support services, ensuring you can rely on an uninterrupted power supply throughout the temporary deployment. All our containers are ‘walk inside’. Weather protected. Resilient Air Conditioning and remote monitoring.

UPS HIRE SYSTEMS - FLEXIBILITY UPS hire temporary systems offer multiple advantages, including:

EMEGENCY POWER: UPS failure can happen anytime. Deployment can be arranged to position our UPS container on your site, complete with 25 metres of cabling to allow us to temporarily install our UPS system to support your site load. BESPOKE CONTAINER: UPS hire systems can be customised to meet the specific power requirements of power requirement. Plan in advance to ensure we provide the right level of resilient UPS power for your critical site.

INSTALLATION: Whether temporary or long term hire,

Power Continuity offer professional installation services, working day or out or hours.

REMOTE MONITORING: Power Continuity remote monitoring support with maintenance services, ensuring that businesses have uninterrupted power supply throughout the temporary hire installation. UPS Hire Systems- combined with our Emergency Generator Power Continuity UPS hire systems combined with our emergency generators:Healthcare: Hospitals and other healthcare facilities just don’t have enough power to ensure uninterrupted power supplies to their energy consuming medical equipment. UPS rental containers bridge that power gap. Especially with generator back up. Emergency Generator: UPS rental containers have battery autonomy for up to 20 minutes but for extra resilience we recommend installing our temporary diesel generators to allow running for up to 72 hours. Back up power to the Back up UPS container. Manufacturing: We can install short term UPS rental systems to increase your output capacity, without worrying about power spikes or brown outs. Football Stadiums: UEFA televised matches must have UPS power protection. UPS hire systems to protect from power disruptions during high value ticket international events.

www.powercontinuity.co.uk

PECM Issue 65

Data centres: UPS Failure happens. UPS hire systems can be deployed to site, ensuring uninterrupted power supply to data centres, with emergency generators, before power loss damages the reputation of your brand. Call Power Continuity when you need resilience immediately today. Rotary Fly Wheel UPS systems Rotary Flywheel UPS hire systems for motor drives and heavy loads. Only Power Continuity has long term hire Rotary Flywheel UPS systems available Power Continuity has containerised UPS resilient system from 30KVA N+1 up to 2 Megawatts all available, to be delivered to site, installed on a temporary basis. Your Reputation requires reliable UPS temporary when you need it most--which can only mean – Power Continuity Ltd. – There when you need us 24-7. For more information call us on 0845 055 8455.