Unleashing robotic potential with real-time operating
The role of nature's greenest metal in the energy transition
ABB ROBOTICS - 52
ABB Robotics teams with innovative tech start-up to deliver sustainable and affordable housing
CWIEME BERLIN - 24
Editor’s Choice
CLPA
Advancing industrial printing with TSN
FERRARI
The electrochemical research laboratory promoted by Ferrari in Collaboration with the university of Bologna and NXP
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Polymer Succession Planning … without the drama
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Discover your next manufacturing partner at Subcon - The Manufacturing Solutions Show
SM&E WEEK 2024
Smart Manufacturing & Engineering Week 2024: A Hub for Education and Innovation
EXEL COMPOSITES
Small-diameter composite tubes and robotics
CPA LTD
What to consider when choosing a power quality meter
FLEX
How AI and ML are Revolutionizing Electronics Manufacturing
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Your future in the Nuclear Industry
SULZER
Sulzer introduces rental test equipment for agile and cost-effective process development
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In manufacturing — where precision is paramount — the role of robotics in shaping efficient assembly lines, welding processes, and material handling cannot be overstated. The demand for precise synchronization in these operations is key; any deviation can lead to misalignments, defective products, and decreased overall throughput.
Particularly critical in automotive assembly, even the slightest jitter or latency issues can disrupt the seamless integration of components, resulting in quality control complications and increased production costs.
Embedded software addresses these challenges as highperformance, hard real-time operating systems emerge. They are designed for a spectrum of applications from robotic arms to autonomous mobile robots (AMRs) to drones. These systems must address present needs and align with Industry 5.0’s trajectory, which is built upon an even greater collaboration between humans and robots than we see today.
Manufacturing Challenge: The High-Stakes Precision Struggle
The critical demand for precision in production creates formidable challenges, particularly when it comes to high-speed robotic movements. Systems and devices requiring microprocessors with memory management units, such as robot manipulators, land and aerial drones, and automated guided vehicles (AGVs) require
hard real-time operating systems to facilitate seamless kernel execution across multiple cores. This provides the performance needed for safety-critical systems, particularly in advanced robotics and industrial controls.
The issue of jitter, defined by unpredictable timing variations, looms as a substantial threat to the meticulous accuracy required in these operations. This concern is amplified in scenarios where milliseconds wield immense significance, as observed in the intricacies of automotive assembly lines.
The repercussions of heightened jitter extend beyond mere inconveniences: They manifest as misaligned components and the creation of defective products, both of which contribute to a palpable decline in overall operational efficiency.
As industries strive for heightened productivity, the precise calibration of robotic movements emerges as a keystone that necessitates a strategic approach to address the intricacies of timing variations and safeguard the delicate orchestration of highspeed operations.
Maximizing the performance of robotic systems, particularly in the face of high-speed movements, requires a strategic ally in the form of real-time operating systems (RTOS). Precision becomes a guiding compass for unparalleled efficiency.
RTOS optimizes the overall performance of robotic systems by finely tuning task scheduling and execution. This meticulous orchestration ensures that critical operations take precedence, resulting in increased throughput and heightened production rates.
At the core of RTOS lies the ability to minimize processor utilization. By efficiently managing tasks and system resources, RTOS guarantees judicious use of processing power to prevent unnecessary delays and bottlenecks. This not only boosts overall robotic system efficiency but also yields significant cost savings by maximizing available processing power.
Introducing resilient power-safe recovery mechanisms, RTOS enables robotic systems to gracefully handle unexpected events or faults. In case of a failure, the system can recover seamlessly without compromising precision. This minimizes downtime and helps ensure uninterrupted operation. This resilience is crucial to maintain a consistent level of precision in production processes.
The fast boot capabilities of RTOS significantly reduce the start-up time of robotic systems. This is particularly beneficial in scenarios where rapid deployment and initiation of operations are critical. With minimized start-up times, manufacturers can enhance the agility of their production processes to respond promptly to market demands while maintaining the desired level of precision.
RTOS contributes to energy efficiency by managing power consumption intelligently. Through optimized task scheduling and resource allocation, RTOS helps ensure that energy is utilized efficiently, reducing overall power consumption. This both aids in achieving sustainability goals and contributes to cost savings.
Conclusion
In the pursuit of precision in production, the choice of a realtime operating system emerges as an imperative. Its ability to elevate system throughput, minimize processor utilization, deploy power-safe recovery, reduce startup time, and optimize energy consumption aligns seamlessly with the demands of high-speed robotic movements. As industries strive for enhanced efficiency,
Introducing resilient power-safe recovery mechanisms, RTOS enables robotic systems to gracefully handle unexpected events or faults.
reduced costs, and impeccable precision, integrating an RTOS into robotic systems becomes a requisite step.
In the intricate balance of precision and efficiency within robotic systems, QNX® Software Development Platform (SDP) 8.0 emerges as the orchestrator of unparalleled solutions. It delivers
enhanced efficiency, costeffectiveness, and unwavering precision.
Its future-ready architecture, perfectly suited for the nuances of high-speed robotic movements, positions it as a key to unlocking the full potential of manufacturing processes.
BlackBerry® QNX® software solutions — including the SDP, RTOS, and Hypervisor — accommodate higher-compute applications. As Industry 5.0 unfolds, the integration of robotics and the human workforce becomes vital. BlackBerry QNX’s robust OS helps provide fault tolerance, failsafe deployment, and the hard real-time performance crucial for manufacturing applications where safety and reliability are paramount.
For further information, please visit www.blackberry.qnx.com/en
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From day one, Learners on the EEMUA MIPC® training build a unique workbook of mechanical integrity know how tailored to each Learner, site and company. Combining live online classes, e-learning, and one-to-one sessions with expert Tutors, enhanced by Mentor support and guidance throughout, EEMUA's Mechanical Integrity Practitioner Certificate course gives professionals the flexibility to learn on-site or on-call.
Registration open now. Learning starts 21October 2024. .
Developed and verified by industry to satisfy industrial engineering’s requirements for primary containment in old and new equipment – including pressure systems.
Keeps practitioner-level engineers on top of industry developments and good practice – so that valuable practitioners are most effective wherever they’re needed on-site. Enterprise-class, blended, live online system for productive learning – on-site or on-call.
Adapts to the engineering needs of each Learner and their company via an Induction of 2 hours prior to the course – to fit work schedules from September 2024
In-depth training to fit work schedules – 4 hours per week for 27 weeks.
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MIPC® shortlisted for the Best E-learning/ Online Education Initiative memcom membership excellence awards 2020 and 2022
Rozone’s bioremediating ROwasher range outperforms every parts washer on the market and beats our previous machine’s running costs by 54.5% and uses 30%-37% less consumables.* The ROwasher is the first innovation in parts washing for decades. It is UK-designed and manufactured, together with the bioremediating filter mat and the ROwash degreaser.
Contaminants such as oils and grease are always present in engineering and workshop environments. Current legislation makes us improve our sustainability, environmentally friendly, and health and safety credentials.
The ROwasher reduces toxic solvent use, cuts any toxic waste, and improves the technicians’ working environment, whilst reducing operating costs.
Discover more about bioremediation at www.rozone.co.uk/ bioremediation
For more information on the ROwasher, visit www.rozone.co.uk/ rowasher
Call Rozone’s ROwasher experts on 0121 514 0607, or email info@rozone.co.uk.
*Based on data from controlled laboratory trials in 2022
The GEMÜ 1441 cPos-X with ATEX / IECEx certification
An intelligent, digital electro-pneumatic positioner in two-wire technology used to control pneumatically operated process valves.
• ATEX / IECEx certified explosion protection for gas environments.
• Two-wire connection technology.
• Bluetooth communication for remote app access and configuration.
• Fast commissioning using well-balanced reconfiguration.
• Economical, almost no air consumption when idle.
• Low maintenance replaceable solenoid / filter cartridge.
www.gemu.co.uk
The key benefits of manufacturing components using this versatile process
Investment casting allows us to create highly intricate and complex components with virtually any alloy. It produces excellent dimensional accuracy, high integrity, and a fine surface finish, capable of meeting the demanding specifications of a wide range of industry sectors.
What is investment casting?
Investment casting derives its name from the process used to form the moulds. A series of wax patterns is assembled together and dipped (‘invested’) in tanks of liquid slurry alternated with ceramic stucco. This builds up layers that dry to form a ceramic mould.
The wax is melted away, then molten metal is carefully poured into the mould. After cooling under controlled conditions, the ceramic shell can be removed, and the cast metal parts finished to requirements.
The key benefits of investment casting
• Versatility of design
Investment casting offers exceptional design flexibility. Complex components can be cast to near net shape, including internal shaping, undercuts and slots, and complex passageways. Thinner walls may be cast than is possible in other processes such as sand casting, leading to lower overall weight and improved efficiency.
• Versatility of materials
Most alloy bases, such as ferrous, aluminium, nickel, copper and cobalt, are well-suited to investment casting. At Investacast, we are expert in air investment casting nickel-base
superalloys. These alloys can be difficult to machine from solid, or to machine post-casting, and expensive to forge. Investment casting is the more economical manufacturing process of choice for components in these materials.
• Range of sizes and applications
At Investacast we have cast components weighing from 10g to 30Kg, for applications from turbine blades to camera housings, for a wide range of industries.
Tight tolerances
Investment castings can be held to much tighter tolerances than sand castings or forgings: close dimensional tolerances down to +/ - 0.15mm/25mm can be achieved.
• Exceptional surface finish
Investment casting gives a very smooth finish thanks to the ceramic mould, typically offering 1.6 Ra to 3.2 Ra surface finish as cast. This can significantly reduce the amount of secondary machining, and therefore time, required compared to other manufacturing processes.
• Rapid prototyping
Investacast’s rapid prototyping service allows companies to turn ideas
into products quickly and efficiently. We offer casting simulation and rapid production of prototypes to mitigate any risks when transitioning to production tooling.
• Low tooling costs
The investment casting process has much lower tooling set-up costs than gravity die or high pressure die casting, which require permanent casts to be manufactured. This makes it suitable for pre-production runs for high-volume pressure die cast products.
• Repeatability
The quality of investment castings is maintained, providing a very reliable product and low-cost repeat runs.
• Sustainability
Investment castings are created to near net shape, and we recycle our wax, so production waste is minimal. Advice from the investment casting experts
Our expert team can advise on DfM and whether investment casting is the right manufacturing method for your components. Call+44 (0) 1271 866200 or email info@investacast.com
Developers of printing machines are facing particularly fast-paced and dynamic market conditions.
Harnessing the true potential of smart, automated industrial operations is crucial to meeting ever more ambitious customers’ needs and staying ahead of the competition. As fractions of a second can make a significant difference within advanced printing machines, cutting-edge motion control becomes paramount.
Tom Burke, Global Strategic Advisor at the CC-Link Partner Association (CLPA), looks at how Time-Sensitive Networking (TSN) can help achieve seamless synchronization, accuracy, and precision within complex, autonomous printing systems.
In many sectors, from publishing to pharmaceutical manufacturing, printing and stamping operations rely on machines that can quickly and reliably add high-quality designs and text with excellent resolution. To this end, the equipment must effectively offer precise positioning capabilities, correctly handle products and have all its axes moving in sync.
State-of-the-art motion control is therefore at the core of such units and their activities. Even more, as printing applications demand higher speed, greater resolutions and accuracies as well as lower tolerances, the need for next-level motion control solutions is evident.
Besides, as Industry 4.0 frameworks become a must to remain competitive, printing machine users are asking for solutions that can communicate with other machines
on the shop floor as well as higher enterprise-level systems to support smarter operations. Ultimately, to meet these demands, OEMs need to create highly interoperable setups that are equipped to offer this level of convergence. In this
regard, the selected industrial automation components must be able to leverage a high-performance network technology.
Addressing the needs of competitive industrial printing
Traditionally, standard Ethernet has had limitations in meeting the stringent requirements of motion control, necessitating the setup of isolated networks to reduce latency, avoiding jitter and delay. The advent of Time Sensitive Networking (TSN) is providing a breakthrough solution. This technology, defined by IEEE 802.1 standards, is capable of establishing accurate, distributed time synchronization across multiple axes and network nodes.
TSN also enables the prioritization of urgent, time-sensitive traffic, while reserving cycle time for regular control data packets. This ensures deterministic performance even with large volumes of non-transient traffic, eliminating the need for specialized communication infrastructures for motion control. As a result, TSN can support the seamless integration of various message types from both the information technology (IT) and operational technology (OT) domains, in line with smart manufacturing strategies.
A leading network solution that embraces this technology is CC-Link
IE TSN, the first open industrial Ethernet with TSN functions and gigabit bandwidth. It offers a cycle time of 31.25μs and can synchronize up to 256 axes with accuracies in the order of ±1μs, therefore helping machine builders and end users with ambitious motion control systems for printing applications.
A leading OEM of industrial printing and stamping machines wanted to develop an innovative, highly competitive solution to address its customers’ needs for increased speed, accuracy and repeatable quality. To deliver a such machine, the company invested in industrial automation technologies compatible with CCLink IE TSN, namely PLCs and servo drives.
In particular, the resulting machine could combine high-precision screen printing and hot stamping operations by being able to accommodate 90 axes. Through CC-Link IE TSN, these could all be synchronized with limited tolerances to deliver the high level of accuracy that customers would require. As a result, the setup offers a highly integrated and versatile solution that maximizes productivity, cost-effectiveness, flexibility, print quality as well as scalability.
Extremely happy with the capabilities of CC-Link IE TSN compatible devices, the OEM is now using them to upgrade its printing machine portfolio, driving its customers as well as its own competitiveness.
For further information, please visit www.cc-link.org/en/clpa/members/index.html
RMIG is the world’s largest manufacturer and supplier of perforated metal and its related products.
We know our customers’ requirements for price and quality and meet their demands with uncompromising service.
Not only do we offer standard and bespoke perforated metal sheets, we are able to offer you a range of secondary operations as detailed below.
Complete solutions
Cutting
We can cut and shape perforated sheet to meet the needs of your nal application.
Levelling
For some applications a high degree of atness is required, we have processes in place to ensure our perforated coils and sheets meet with your most demanding requirements.
Rolling and forming
We can roll, bend and form perforated sheets to match your design.
,
• Gain or renew your 5-year Certificates of Competence*
• Courses based on EEMUA 159
• English, Dutch, German and French language options
• Select from courses throughout year, including: TankInspector courses*
20-23 May 2024 – in English –classroom – London, UK
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27-30 May 2024 – in English –live online – for MEA – GMT+3
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TankBasics courses 16 September - 25 October 2024
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28-30 October 2024 – in English – classroom – London, UK Storage Tanks e-learning
On-demand – in E English or D Dutch In-house courses
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EEMUA Seminar – Engineering the Energy Transition 6 June 2024 – London, UK
Above ground flat bottomed storage tanks A guide to inspection, maintenance and repair Publication 159 Edition5 TankAssessor courses*
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As the industrial filtration, bulk handling and process industries face the constant challenge of explosion hazards, MacClancy and Sons Ltd emerges as a reliable partner in workplace safety. Their range of integrated Fire and Explosion Mitigation solutions includes top-ofthe-line fire & explosion protection systems.
In this article, we explore the critical role of these systems in mitigating risks and maintaining a safe and secure working environment for your personnel, plant and property.
Explosions in industrial settings can, sadly, have catastrophic consequences, posing threats to human life, property, and operations. Investing in reliable explosion protection systems is a simple proactive approach to safeguarding your facility against potential disasters and it could cost less than you think.
Early Detection: Raptor Spark detection systems feature advanced
A safe work environment fosters trust which is known to increase productivity.
infra-red sensors capable of detecting even the slightest presence of sparks, embers or even glowing dust particles. Early detection enables swift responses to potential ignition sources in multiple protected zones which can prevent a full deluge scenario across your plant.
Rapid Isolation & Venting: In the event of an explosion, VigilEX products simultaneously close isolation valves and release overpressure via sacrificial explosion vents in milliseconds, preventing any escalation beyond your filter, minimizing collateral damage and maximising safe working areas.
MacClancy and Sons understand that each industrial facility has unique explosion risks. Therefore, systems
are customizable and adaptable to specific needs, whilst providing optimal protection.
By integrating VigilEX explosion protection & Raptor Spark detection systems into your workplace, you are demonstrating your strong commitment to the safety and well-being of your employees. A safe work environment fosters trust which is known to increase productivity. A well protected and safe workplace also reduces downtime due to better housekeeping, reduced safety related incidents or accidents and helps enhance your company’s reputation as an employer who leads the way in safety and safe working practices.
These explosion protection & detection systems are a crucial part of a comprehensive safety strategy for industrial filtration, bulk handling and process industries. With their cutting-edge technology, customization options, and expert guidance, they can empower your facility to stay ahead of any potential explosion risks and protect your assets.
The Huck® 316 (A4) Stainless Steel Magna-Lok® Structural Blind Fastener
Engineered for superior corrosion resistance and retaining all the features of the standard (steel, aluminium and A2 stainless steel) version of the Huck® Magna-Lok®, the 316 A4 stainless steel MagnaLok® offers corrosion resistance beyond anything else in the Huck® blind fastener range.
The Huck® structural blind MagnaLok® retains the pin in the rivet body (sleeve) post-installation for extra tensile and shear strength. This 360° internal locking technology enables the pin to be mechanically locked to the sleeve as it expands during installation, giving excellent joint tightness and high-quality resistance to liquid penetration. The Huck® 316 (A4) stainless steel MagnaLok® is available in 6.4mm (1/4’’) diameter, with a wide grip range to accommodate variations in joint thickness (2.03mm -15.88mm).
Key Advantages of 316 Marine Grade, Non-Magnetic Huck® Fasteners:
metals and composites, expanding their applicability across industries.
Non-magnetic properties: Non-magnetic fasteners are essential in environments where magnetic fields can disrupt sensitive electronic components or equipment
Strength and durability: Huck® fasteners provide strong and reliable joints, often with loadcarrying capabilities comparable to or even exceeding traditional fasteners. 316 stainless steel offers high tensile strength and durability, allowing fasteners to withstand significant loads and stresses.
Ease of installation: Huck® MagnaLok® structural blind fasteners are relatively easy to install, requiring minimal access to only one side of the of the joint.
Vibration resistance: Huck® fasteners offer excellent resistance to vibration, making them suitable for applications where the joint might experience movement or mechanical stress.
Corrosion resistance: The primary advantage of using 316 stainless steel fasteners is their exceptional resistance to corrosion.
Aesthetic appeal: The smooth and polished appearance of stainless steel 316 gives a visually appealing finish to the fasteners, making them suitable for applications where aesthetics matter.
Low maintenance: Thanks to their corrosion resistance, Huck® fasteners generally require minimal maintenance over their lifespan.
Versatility: They can be used to join different materials, including
Replaces welding: In some cases, 316 Magna-Lok’s can replace the need for welding. 316 stainless steel is susceptible to weld decay; the welded area can be more vulnerable to corrosion, weakening the bond of the weld. Weld decay primarily affects the microstructure of the material around the weld joint. When 316 stainless steel is heated to certain temperatures (typically in the range of 800 to 1600°F or 425 to 870°C) during welding, carbon in the steel combines with chromium to form chromium carbides. This process depletes the chromium content in the immediate vicinity of the weld joint, leading to a reduced ability to form a protective chromium oxide layer that provides the stainless steel’s corrosion resistance.
Mechanical advantages: these include, excellent gap closure capability, a flush pin break and outstanding hole filling on the blind side and is capable of filling irregular, slotted, oversized, or misaligned holes, whilst providing strong, vibration resistant joints.
Where is the Huck® A4 MagnaLok® Fastener Used
The A4 stainless steel Magna-Lok® is widely used in industries and applications where a combination of corrosion resistance, strength, durability, and aesthetic appeal is required. It finds applications in construction, architecture, automotive, aerospace, food processing, medical devices, household appliances, and many other areas where resistance to corrosion and staining is essential.
Stainless Steel: A2 vs A4
– a simple guide
Chemical Composition
A2: Often referred to as 304 or 18/8 stainless.
18/8 refers to the amount of chromium and nickel in the alloy – 18% chromium and 8% nickel, the chromium provides a corrosion and oxidation resistance, however it can be prone to tarnishing.
A4: often referred to as 316, 18/10 and marine grade stainless.
18/10 refers to the chromium and nickel content- 18% chromium and 10% nickel, and 2-3% molybdenum. The molybdenum increases the corrosion resistance to withstand attack from many solvents, for example, sulfuric acid, chlorides, de-icing salts and industrial chemicals. It is considerably more resistant to solutions of bromides, iodides and fatty acids at high temperature.
A2 (304): Offers good corrosion resistance in most environments, but not as resistant as A4 in corrosive environments like marine or chloride-rich settings.
A4 (316): Provides excellent corrosion resistance, particularly in chloride environments like marine settings or industrial areas with exposure to chemicals.
Strength and Durability
A2 (304): Offers good strength and toughness suitable for many general-purpose applications.
A4 (316): offers the same strength characteristics as A2 but it is more corrosion resistant in demanding environments.
Both A2 and A4 grades are classed as Austenitic stainless steel (sometimes called the 300 series). This means that they have high chemical resistance but cannot be hardened by heat treatment. They can be hardened by cold working.
Molybdenum Content
A2 (304): Does not contain molybdenum.
Huck Magna-Lok Cross SectionUninstalled and Installed
A4 (316): Contains molybdenum which enhances its corrosion resistance.
Stainless steel may also contain other alloying elements such as nickel, titanium, copper and manganese, among others, to enhance specific properties like strength, corrosion resistance, and durability. Non-metal additions are also made, the main ones being Carbon and Nitrogen. The exact composition and properties of stainless steel can vary depending on the specific grade or type.
While A2 (304) and A4 (316) stainless steels share common properties, their differences in composition, particularly the addition of molybdenum in A4 (316), result in variations in corrosion resistance and mechanical properties. As a result, the selection between A2 and A4 stainless steel depends on the specific application requirements, particularly the level of corrosion resistance needed.
In summary, while both A2 (304) and A4 (316) stainless steels offer corrosion resistance and are widely used, the choice between them depends on the specific application requirements. A4 (316) is generally preferred for applications where superior corrosion resistance, particularly in harsh environments is essential.
Star Fasteners have been a Huck® fastener distributor for over thirty years and are the UK’s largest stockists - we have a wealth of knowledge and experience gained from working in a wide variety of industries. An extensive stock ensures that customers never have a break in supply; this together with a hire tool fleet, an in-house tool maintenance repair department, and in-house powder coating facility, ensures an allencompassing service can be relied upon.
A key strength of Star Fasteners is our ability to work with customers on projects and to find solutions that will help optimise the application whilst also improving the overall efficiency. We work globally with a diverse range of end users and distributors from across a number of industries, offering technical application knowledge and customer support. Huck® fasteners guarantee performance and help maximise your return on investment; get the right fastener for your project and achieve your business goals.
Based on data 90% of large, and more than two thirds of smallmedium enterprises are facing skills shortages in engineering. In our industry the problem is far more specific; it’s an in-depth knowledge and application of physics to understand pressure development, air movement behaviour, the infinity fan laws around power, pressure and volume, and a basic awareness of chemical properties, these are the common things that our customers in particular struggle with. In education, this type of knowledge is typically taught only in theory, yet the application of that theory used to problem solve and apply, is a skill that is more difficult to ascertain. As a child I was born with what the industry calls “the knack”, a natural ability to understand and apply concepts quickly and easily, but my formal education was in no way suited to the skill set I had.
This brings me on to qualifications and skills being different. These transferable skills are so specific that companies simply cannot get that experience from looking at employee’s formal qualifications, or by making hires based on statements on paper. Especially, as with my experience, people sometimes don’t find their feet until later due to a lack of direction. As the technical director of a fan business, I’m pleased that we have a forward-thinking approach, removing the barriers that can obstruct people from entering the profession, allowing them to reach their potential and rise to the top.
We hire on ability, through having conversations and interpreting their understanding and approach to problem solving, we quickly determine if the knack is there. Out in the field there are striking gender differences, especially on more technical roles, I’m proud that we have an equal balance of male and female employees. Comparably, our team are getting younger, going against the grain on the issue of an aging workforce in the field. Today’s industry employment reports show that 19.5% of engineers working in the UK will retire by 2026, exacerbating the skills shortage.
The continued challenge for manufacturers is evident, with 98% of companies expressing concerns that their business will suffer if they can’t hire the right engineers or technical biased employees. New graduates often struggle with the ability to apply their theory to actual problems as their education has not been geared towards problem solving. This leaves that seismic shift when experienced engineers at the top are replaced with new engineers.
That’s where collaboration with suppliers and manufacturers is key, the new approach in an antiquated industry. It’s ignorant to think that companies should have an inhouse team that make technical calculations, designing in isolation with the desired outcome of delivering the best system that performs at the optimal level for the customer project. Minimising disruption by working with external experts in niche areas is one way to make an instant positive impact to your business, with no training or recruitment required. Incredibly valuable if those businesses are working on time-sensitive projects or need to avoid any impact on production delays.
It’s a matter of adapting or perishing for businesses that rely on their technical product selection teams. Adapt by working collaboratively and utilising the skill sets of other businesses, businesses such as Axair that can understand the industry needs and anticipate solutions, suggesting potentially creative business enhancing fan components that could create opportunities for greater market share and customer satisfaction, or perish by losing competitive advantage through falling behind on technological advancements and relying on inhouse teams that lack the application knowledge without giving them the support from these experts. At the end of the day, no one ever beat a competitor by staying the same, speed and adaptability is the new key performance indicator in today’s economy. The antiquated approach of we’ve always done it this way simply doesn’t hold weight.
The inauguration of E-Cells Lab, a research centre for electrochemistry within the University of Bologna, was held today. The laboratory, which was set up under the university’s scientific direction, aims to build knowledge of the materials, and the chemical and physical properties, of lithium cells.
It marks an important contribution to the electrochemical research, thanks to the collaboration with the University of Bologna with whom a dedicated space with cutting-edge equipment to conduct advanced analyses. Ferrari has FERRARI
also promoted and supported the laboratory through the exchange of expertise with the university and its partner; it strongly believes in the great value the project holds for the local area, and for the automotive segment in particular.
The applications developed in E-Cells Lab will be shared with leading electronics company NXP, technology partner and supporter of the project. This collaboration between different organisations, which in future may extend to new companies, will be of vital importance in extending the scope and value of the research activity.
The laboratory consists of two areas: the first is dedicated to preparing electrochemical materials, the second to analysis, tests and determining the characteristics of the materials themselves. There will be a particular focus on solid states, fast charging, thermal charging, cell safety and performance. The results will help Ferrari to develop a shared language with its cell suppliers, with the aim of optimising the performance of the batteries that will be assembled in the Maranello plants.
“E-Cells Lab represents an exciting beginning and demonstrates our
E-Cells Lab represents an exciting beginning and demonstrates our commitment to education and research.
commitment to education and research. The project also reflects the importance that the confluence between the academic and business worlds has always had for us,” said Benedetto Vigna, CEO of Ferrari. “Today, from this confluence comes a laboratory that will make an important contribution to studies in the field of electrochemistry, generating innovation in our local area and building the skills of the future.”
The Chancellor of the University of Bologna, Giovanni Molari, commented: “I am pleased that Ferrari has chosen the Alma Mater for this important project
in scientific and educational innovation. I’m sure that this collaboration will be fruitful and herald significant results. This agreement encapsulates many characteristic facets of the Alma Mater: the will to remain at the cutting edge of both teaching and research; dialogue with the Italy’s most important public and private institutions; the desire to promote new synergies that can act as a model and a driver for key areas in our collective development.”
“Close collaboration across industry and academia allows us to accelerate the research on safe, efficient and sustainable battery innovations significantly,” said Jens Hinrichsen, EVP and GM of Advanced Analog at NXP. “Through the combined efforts of NXP, Ferrari and University of Bologna, we expect to set new benchmarks for performance and sustainability to reach our common goal of a greener, brighter future.”
“In the year ahead, we’ll see more additive technology at work on factory floors around the world…”
In 2023, global events coupled with the cost of living crisis have motivated manufacturers across a range of industries to re-think their centralised production models. We’ve seen more companies integrate technologies like additive manufacturing (AM) into their factory floor operations to work alongside traditional processes, enabling more immediate and costeffective manufacturing on-demand – helping to meet the challenges head on.
Advances in technology are helping to drive this shift away from shortterm solutions-led thinking toward a more strategic approach – using AM for the sustainable production of certified end-use parts, which we’ll see more of in the year ahead.
This article explores trends in manufacturing practices, along with Markforged’s Senior Product Marketing Manager Daniel Leong’s predictions for the role of AM in 2024.
The continuing trend of personalised and on-demand manufacturing
On-shore production and localised manufacturing practices are already providing businesses with greater flexibility, responsiveness, and resilience in the production process, which I believe is set to continue in the coming year.
I predict we will see more designers, engineers and manufacturers across a variety of industries adopting AM to design, test, create and customise the parts, tools and products they need, when and where they need them.
This AM-fuelled drive toward ondemand manufacturing will also help businesses to reduce their transportation and shipping costs, environmental impact, and product lead time, increasing efficiency.
Additive technology is getting smarter. This is due in large part to advances in connected AM platforms that allow machines to collect – and learn from –information with each build. In essence, AI is helping to solve hardware problems with a software solution, creating new opportunities and challenges for AM.
In the year ahead, we will see further integration of data-driven technologies such as sensors, feedback, analytics, artificial intelligence, and the Internet of Things (IoT) continuing to enhance the quality, reliability, and efficiency of the AM process and products.
These data-empowered, Smart AM platforms will add another layer of insurance against supply chain challenges, untimely holdups and failures, helping to perfect designs that allow manufacturers to get the best performance and business returns from every part they print.
Smarter AM also means faster AM. In-built calibration and inspection technologies not only optimise part design and accuracy, but help to speed up the 3D printing process. In addition, increased material capacities and automated material changeover capabilities found in the latest machines like Markforged’s
FX10 reduce human intervention and bottlenecks, keeping things running smoothly.
Faster, more accurate prints reduce the time and cost of AM and increase its ROI, making it even more competitive than traditional manufacturing methods. This acceleration also helps new adopters of the technology to learn, test and iterate through faster prototyping, enhancing the innovation and learning potential of AM.
With advancements come new challenges, and two which I believe will have an impact on the adoption rate of AM in the year ahead are regulatory issues and tighter budgets.
Collaboration is essential to help address and overcome these obstacles.
While standards bodies like ASTM have developed a range of AMspecific global standards, there is still work to be done. A lack of clear and consistent guidelines, certifications, and quality assurance can pose risks and barriers to widespread adoption of the technology in industries like aerospace. I’m hoping we’ll see all parties sit around tables in the coming year to address these issues and challenges and work together to establish workable standards. We will no doubt see more restricted budgets across industries in the new year, making it even more essential for any technology to prove ROI. AM providers and their customers can help to advance adoption rates by highlighting the benefits at
board level by documenting their successes, sharing proof of concept wins and developing case studies illustrating increased efficiencies and innovation.
With the global temperature in 2024 set to be the warmest year on record, it will be harder for governments and business to ignore the growing social, and governance (ESG) agenda. While these are complex issues, especially when it comes to manufacturing industries, I believe investors and consumers alike will continue to encourage the development of a circular economy and the reduction of carbon emissions. AM’s role in local and
While standards bodies like ASTM have developed a range of AM-specific global standards, there is still work to be done.
on-demand manufacturing can help to reduce the monetary and environmental costs of waste, energy consumption, and shipping, but there is more to be done.
The industry is already asking questions and exploring issues
like: how plastic from processes like 3D printing can be reused, how production waste can be recycled and how we can develop strong, robust filament from recycled materials. I think we will see a move in the AM community toward research and advances in more sustainable materials and processes not just in 2024, but in the years ahead.
As it continues to become smarter, faster, more accurate, efficient, and – undoubtedly – more sustainable, AM will become a more integral part of production lines and manufacturing processes. I believe that in 2024, we will see more additive technology at work on factory floors around the world.
For further information, please visit https://markforged.com/
Achieving Net Zero by 2050 essentially means completely phasing out fossil fuels in under 30 years. We can’t do that without copper, say Bruno De Wachter and Fernando Nuño, representatives of the International Copper Association and members of the advisory board of international electrical engineering trade show, CWIEME Berlin. Here they discuss the challenges facing our relationship with this ancient metal.
Humanity’s history with copper goes back around 10,000 years. Neolithic peoples first used native copper in tools, weapons and decorative items, and smelting of copper kicked off the Bronze Age about 5,000 years ago. The Romans mainly sourced it from Cyprus, calling it aes cyprium, ‘metal
of Cyprus’. This subsequently became cuprum, the origin of the English word copper.
In Roman times, copper was predominately used in the empire’s coins and to make brass for specialised uses like ornaments and some aspects of plumbing and architecture. Today however, more than two thirds (70 per cent) of modern copper production is earmarked for electrical applications. Copper is involved at every stage of the electricity system: generating it, transferring it, and using it.
On the journey to Net Zero, electricity is our main tool, and the backbone of our electrical system is copper.
Copper is the second most conductive known metal after silver, and more conductive than gold, but the scarcity and price of these two precious metals make them unsuitable for the millions of tonnes required for a global energy network. Copper’s physical properties, such as its ductility and resistance to corrosion make it ideal for countless components like cables, connectors, and coils. Finally, it’s the 25th most abundant element in Earth’s crust and it can be recycled without any significant loss of quality.
Copper’s unique properties solidify its position as the essential material for electrification, the energy transfer system that underpins humanity’s path to Net Zero.
As electrical infrastructure develops and standards of living improve around the world, we’ll naturally need more megawatts of power to meet demand. But a side effect of the green energy transition is that each megawatt of electricity end use will be more copper intensive than fossil fuel alternatives.
The main reason is that renewable electricity generation is much more dispersed than conventional thermal generation from fossil fuels, making it more material intensive. For example, each wind turbine of 1 to 5 MW has its own generator, while a coal fired thermal power plant has one generator of typically 400 MW. A more dispersed generation also means that the grid for transferring electricity from where it’s made to where it’s needed must expand.
In addition, generating electricity from sustainable sources is often weather-dependent. While coal can burn nearly 24/7, wind power needs a consistent breeze and solar power only works during the daytime. To compensate for natural low-output periods, we’ll need extra production capability and storage to keep up with demand, meaning more copper for more renewable energy systems. This is another reason why we need a stronger grid: the better all sites of generation and consumption are interconnected, the easier it becomes to tap the electricity from where it is available at that moment.
Clean electricity will be the largest consumer of copper by 2040, but copper is also used for some of the non-electrical systems that aid the transition to Net Zero.
Generation is one thing, but Net Zero means decarbonising energy at the other end of the chain too: the end user. Carbon-free end-use energy on the roads, for instance, means more electric vehicles, but each requires 2-3 times more copper than an internal combustion engine powered vehicle.
Clean electricity will be the largest consumer of copper by 2040, but copper is also used for some of the non-electrical systems that aid the transition to Net Zero. For example, as an excellent thermal conductor, copper is often used in heating and cooling systems, such as those found in heat pumps, which are playing a major role in reducing fossil fuel use for heating.
Finally, the quest for energy efficiency itself is copper intensive. According to Joule’s law, energy lost as heat in an electrical wire
is proportional to resistance and resistance is inversely proportional to wire diameter — so the thicker a copper cable is, the less energy is wasted as heat and therefore the more efficient the system is. This includes the windings of transformers and electric motors. Essentially, the more copper we use in each application, the more energy we save.
The International Energy Agency has published two scenarios for future copper demand. The Stated Policies Scenario (STEPS) is based on what governments have already pledged to do, and the more aggressive Sustainable Development Scenario (SDS) is based on reaching Net Zero by 2050. Both scenarios see annual copper demand increasing to 40 Mt by mid-century (from around 26 Mt nowadays), either in 2050 for STEPS or 2040 for SDS.
Considering these lofty figures, it is natural to wonder whether Earth has enough copper to meet our requirements. The short answer is yes. Enough resources exist to support the energy transition and meet society’s needs. The question is whether we can extract that copper quickly enough to align with STEPS or SDS.
Primary copper production currently sits at 22 million tonnes (Mt) annually. Together with 4 Mt of recycled copper, this meets current demand of 26 Mt. Demand has grown by about 3.3 per cent per year for over a century, doubling about every 30 years. In the past, the drivers for copper demand were population growth, electrification deployment and electricity usage. Today, it is the green energy transition and improving global standards of living. At present, we have about 41 years’ worth of copper reserves — copper in the ground at operational mines — and up to 250 years’ worth of predicted, but currently unexploited resources.
Surprisingly, the number of years’ worth of copper reserves has been roughly the same for decades. Just like with oil, the scarcer it becomes, the more effort goes into finding more.
It may be possible to reduce our reliance on copper by developing alternatives such as aluminium. Aluminium is about three times lighter than copper, so might be advantageous for use in electricity overhead lines, for example. On the other hand, in space and weight constrained applications, the increased volume of aluminium and surrounding structure required to provide the same functionality as copper makes it unsuitable.
Another area of research is graphene, which is also three times lighter than copper but more than twice as conductive and made from carbon, which is ten times more abundant. It’s promising, but the uses of graphene in the electrical industry is a field currently dominated by research and it will likely be decades before graphene becomes a mainstream alternative to copper.
If growth continues at historical rates and copper production increases in line, as it has done for over 100 years, there’s nothing to be concerned about. Meanwhile, changes in the way we produce copper are being introduced.
It’s essential that we maximise copper recycling to keep secondary copper in circulation. Electrical copper’s properties, such as purity,
favour recycling and doing so is much less impactful than mining. However, current recycling of pre- and postconsumer scrap (10 Mt) provides just a third of today’s demand and a fifth of 2040’s SDS. Furthermore, post-consumer scrap only becomes available after the lifespan of the equipment has passed, around 30 years for a transformer, for instance.
For now, at least, mining existing resources for primary copper is essential. In fact, without mining there can be no Net Zero. While zero impact mining is impossible, mining must be responsible — a careful balance of economic, environmental, political and social challenges.
In some cases, that balance is hard to strike, as evidenced by the closure of one of the world’s largest openpit copper mines in late 2023. In response to nationwide protests ranging from environmental concerns to corruption suspicions, Panama’s top court ruled that Canadian miner First Quantum Minerals’ contract at Cobre Panama was unconstitutional and forced it to shut down operations at the mine. The site in Donoso employed 7,000 people, accounted for around five percent of Panama’s gross domestic product and one per cent of global copper output.
International collaboration and sharing of ideas and expertise at events like CWIEME Berlin, help the industry collaborate and do its part to maximise the benefits of copper use and reduce the environmental impact of copper production.
For example, 0.2 per cent of global carbon emissions come from the production cycle of copper, from mining to refining and production. While this is much less than the emissions copper helps prevent, the members of the International Copper Association have committed to the ambition of reaching Net Zero for Scope 1 and 2 emissions by 2050. Or consider The Copper Mark, an industrywide standard to encourage the responsible production, sourcing and recycling of copper and other critical metals. Based on 32 indicators, the certification is designed to cover social and environmental themes, from social engagement and prevention of child labour to responsible use of water and management of resources.
Humans have been using copper to make life better for thousands of years and, with the right approach, we can continue using it for thousands more — perhaps its greatest era is still to come.
If you’ve been gripped by the brutish award-winning series Succession, you’ll be forgiven for picturing every top-level management transition as a dynastic psychodrama. Yet, as technical toolmaker and trade moulder Cybertools can testify, the retention struggle for UK SMEs in the manufacturing space can be eased with some sensible forward planning combined with the support of external industry training.
Succession planning is something that every business needs to face. Whether through retirement or an unexpected shift in personnel, having a plan is strategically crucial. However, it is not an overnight process.
Marking an important phase in the company’s growth and having just secured a 40-percent share in a Chinese-based tooling factory, founder and leader of Cybertools Paul Brown has put in place a robust plan for the Buntingford-based firm’s business continuity. Investing heavily in his workforce, the forward-looking MD is one of the strongest advocates of removing development barriers and nurturing talent internally.
Rather than reacting and filling positions passively, Cybertools is instead developing its workforce to grow into these future gaps. Part of this process includes incrementally adding responsibilities and booking team members onto the IOM3accredited Sumitomo (SHI) Demag Academy courses run by Darren Vater-Hutchison.
Mould Setter Leo, accompanied by Quality Control Production Trainee Jiji, are now on an accelerated progression journey at Cybertools, with a vested interest in carrying forward the company’s legacy.
As the third largest employer in the UK, the plastics industry comprises a high proportion of SMEs. Like Cybertools, most of these are lean, family-run businesses, headed up by owners looking to retire in the next decade or sooner.
With the industry’s technical education and skills system still teetering on a precipice, and conscious that time is ticking, Paul took the proactive steps to invest in his teams’ future, earmarking several colleagues for progression and booking them onto three Academy courses. Leo is three quarters of the way through his development program at the Daventry facility, with just the Advanced Injection Moulding course to complete. Jiji is close behind.
The reciprocal, and equitable benefits of investing in development, are multiple, exclaims Paul. “We
are creating a work environment where everyone can feel they can give their best and that this will lead to a fulfilling career pathway. By extension, it increases their confidence in our business, which increases loyalty. The more skilled team members become, the more I can delegate and step back from the day-to-day management tasks.”
Returning from their respective Sumitomo (SHI) Demag Academy courses at the end of 2023, both Leo and Jiji expressed heightened confidence in operating the injection moulding machines and a more detailed understanding of advanced setter processes.
Although subtle, the productivity benefits are also evident states Paul. “Confidence results in quicker set up times. This probably gives us 2-3 hours more of production capacity each week. However, the most
We are creating a work environment where everyone can feel they can give their best and that this will lead to a fulfilling career pathway.
noteworthy benefit is the swift return on investment. Knowledge equals expertise; expertise equals value; and valued people feel more seen and appreciated.”
Tapping diverse perspectives
The result is a contagious culture. “Positive and driven colleagues motivate others. When my team return from a course sharing everything they have learned with their production peers, it only reaffirms the importance of investing in skills,” adds Paul.
Examining the wider challenges, Paul encourages leaders who are scouting for talent to look for potential rather than pedigree. “Given the scarcity of academic technical training, utilising well-respected development
frameworks designed by people who understand the ins and outs of our industry can help our future leaders to define and steer their career pathway. Another sideline benefit is we are empowering future mentors.” Industry trainer and one of the masterminds behind the winning 2023 Plastic Industry Awards training & development program, Darren Vater-Hutchison concurs. Having delivered courses to over 700 industry colleagues at Sumitomo (SHI) Demag’s IOM3-accredited Academy, Darren expands: “High quality industry training can help to address the lack of curriculum investment and provides a more direct and immediate solution to local and national skills shortages. Machines make parts. However, knowledge creates value. This value increases markedly as knowledge moves up the scale. Most importantly, this accumulative knowledge is being passed onto to future leaders.”
Earning the certificate in Toolsetting Technology (TSett) and Mould Mounting (MMount), Jiji, who joined Cybertools with no significant engineering knowledge, has reached the halfway point in his professional development program. Jiji comments: “The Academy courses have helped me to gain a better understanding of moulding processes and how
they relate to QC issues. I am more confident in my ability to get good results from the machines with an understanding of cause and effect in the processes. This is giving me the confidence to progress as a tool setter which will hopefully open up even more career possibilities in the future.”
Testament to the progression opportunities, Leo commenced his career with Cybertools as a temporary picker and packer. Now running the UK mould shop, he recently started to provide input into major project quotations. Leo comments: “The Academy training has given me a more advanced machine understanding and guidance on ways to be more precise with process adjustments.” Leo is eager to continue putting this advanced knowledge into practice, and hopes to shortly complete the Advanced Injection Moulding (AIM) course to further his knowledge and career.
Attesting to the importance of training, Paul says that when the right person comes along who clicks with your business and culture, you just know that making the investment is worth it. “Developing staff is a long game. Jiji proved straight away that he was good with detail, which is perfect for QC work. Having tuned his technical abilities, Leo is now running our mould shop.”
Paul cautions that failure to listen and address workforce needs could result in alienating and losing your future talents and company successors. “People need to have a workspace where they can feel they can thrive and progress. Much of this can be underpinned by clear development goals and a good training program.”
The Sumitomo (SHI) Demag Academy offers a mix of structured and bespoke polymer processing and industry-led training and development courses, aimed at all operational levels, from new starters to tool setters, engineers and asset care managers. All course content has been designed to enhance skills knowledge, workforce productivity and Overall Equipment Effectiveness (OEE).
Union Industries, the UK’s leading manufacturer of bespoke high-speed doors, has helped Britain’s largest bakery brand overcome adverse weather conditions with the installation of three Bulldoors.
Led by the fifth generation of the Warburton family, the company approached Union to assist in combating strong winds at its Burnley site, which already has a Bulldoor as well as two Matadoors from the range.
It first approached Union Industries in 2004 to install a Bulldoor, which continues to operate effectively and efficiently two decades later.
Union’s Bulldoors, regarded as the ‘reliable workhorse’ of rapid roll doors, are known to perform more than 1.4 million cycles per year, making them a popular choice across multiple sectors. They feature specialist ‘Crash-Out’ and ‘Auto-Reset’ damage protection facilities, and offer control outputs for options such as airlocks, traffic control systems and remote monitoring, whilst aiding temperature control for ambient and chilled environments.
If you are looking for a UK based toolmaker, then you need look no further than Cybertools. Cybertools are specialists in the design and manufacture of plastic injection mould tools. We have a fully equipped Toolmaking facility here in the UK and have over 25 years of toolmaking experience. We have quality standard ISO 9001 and ISO 14001 accreditation.
We are currently working towards ISO 13485 accreditation which is the medical industry’s optimal medical device standard. We have a range of plastic injection moulding machines on site from 35 tonnes to 300 tonnes including two precision all electric machines used for tool
The market-leading, bespoke, high-speed roller doors help to prevent the severe drop of ambient temperature in buildings, especially evident in the winter months, eliminating any potential impact on production environments.
Steve Moultrie, Technical Sales Engineer at Union Industries, said: “This collaboration marks the continuation of a longstanding partnership between Union Industries and Warburtons, dating back 20 years, which is testament to our dedication to durability and quality craftsmanship.
“We are proud to have provided Warburtons with a reliable solution to their operational challenges. Our doors are engineered to perform in demanding environments, ensuring continuous productivity and efficiency.”
Ryan Seddon, Asset Care Lead at Warburtons, said: “The triple Bulldoor installation has significantly improved our warehouse operations, particularly during adverse weather conditions. Union Industries’ doors are incomparable to any other doors we have installed, and their commitment to quality and innovation has made them a valued partner in our supply chain.”
trial and T1 first-off sampling as well as Factory Acceptance Test (FAT) and initial batch runs. We will work with you from initial concept and design through to production and assembly.
All projects are designed, specified and guaranteed by our UK team with manufacturing optimised across our UK and Chinese facility according to your projects technical, budget and delivery requirements. All mould tools are supplied warrantied and production ready. Cybertools provide a fast-response service for urgent repairs, with engineers available to visit your site to endeavour to minimise machine and tool
downtime to protect your manufacturing schedules.
We always work through a thorough Design for Manufacture (DFM) process and mould flow analysis prior to producing a full General Assemble (GA) drawing for customer approval. This is done before we start work on manufacturing your injection mould tool. Once we start work on the tool a T1 date will be set and weekly updates will be supplied in the form of a Gannt timing plan and images of the engineering progression.
www.cybertoolsltd.co.uk
email: training@bpma.org.uk
Subcon 2024, scheduled for June 5-6 at the NEC, Birmingham is the premier event for manufacturing buyers across all sectors. As a cornerstone event for the industry, Subcon provides an unrivaled opportunity to source your next manufacturing solutions from a variety of world-class exhibitors. With over 150 subcontractors and outsourced engineering services, Subcon is packed with possibilities for everyone.
This year’s event promises a refreshed and innovative format, with new developments introduced to adapt and enhance the experience for both visitors and exhibitors. Attendees can look forward to a dynamic programme featuring interactive CPD-accredited workshops, cuttingedge product demonstrations, and insightful keynote presentations. Additionally, you can engage in meaningful discussions through roundtable sessions that are designed to foster collaboration and ideasharing.
Whether you are aiming to benchmark your capabilities, seeking innovative solutions, or simply looking to stay ahead of industry trends, Subcon is your gateway to the future of manufacturing.
Meet with over 150 leading UK and international suppliers under one roof, showcasing the latest innovations and solutions available from sectors such as CNC machining, metal fabrication, electronics, component parts, and more, all dedicated to advancing the
capabilities of your supply chain.
Thousands of new products and innovations will be on display across the full range of advanced engineering technology, systems and services – from Additive Manufacturing and Metrology solutions to Frictionless bearings, cables and controls, and everything in between. This is a show geared to helping you increase capacity, optimise productivity, improve flexibility and remain competitive.
New for 2024, Subcon has announced a significant enhancement to its conference and workshop programme, with the introduction of a variety of different session formats that take place within three specialised areas; designed to cater to a diverse range of interests and professional needs within the manufacturing industry: the Innovation Zone, Workshops and Learning Space, and the Manufacturing Insights Theatre.
Additionally, the programme is now officially CPD accredited, ensuring attendees can gain valuable professional development credits while engaging with top industry experts and cutting-edge technologies.
Manufacturing Insights Theatre: Explore insightful keynote presentations and engage in
lively panel discussions at the Manufacturing Insights Theatre. This forum features thought leaders discussing the latest trends and challenges in manufacturing. Each session includes interactive Q&A segments, making it a dynamic platform for learning and engagement.
Workshops & Learning Space:
Dive into hands-on learning with roundtable discussions and sectorfocused peer-to-peer meetings in the Workshops & Learning Space. Tailored to address specific industry challenges, these sessions offer practical insights and networking opportunities, facilitated by industry experts.
Innovation Zone:
This area is dedicated to hands-on demonstrations, showing you how new technologies and products operate in real-time. It’s the perfect place to see the newest innovations in action and discover how they can enhance your manufacturing processes.
That’s not all! More NEW features include:
Motorsport Simulators & Prize
Draw: Compete in professional motorsport simulators operated by FP Zero. Dive into the thrilling world of Formula 1 racing right on the exhibition floor. The fastest lap will not only boast bragging rights but will also win a PalmerSport driving day experience valued at over £600!
Dedicated Work and Meeting Spaces: Need a quiet spot for a meeting or just to catch up on emails? Subcon now has dedicated spaces set up for exactly that. Stop by to meet
with peers or to take a break and grab a coffee.
Networking Drinks & Entertainment: All visitors, exhibitors, and speakers are invited to unwind at a welcome drinks reception, complete with entertainment, starting at 5 pm on the first day of the exhibition.
The Subcon Manufacturing Solutions Show Awards
Another feature new for 2024, the Subcon Manufacturing Solutions Show Awards, set to take place within the exhibition on Thursday the 6th of June. The Awards are designed to celebrate the best and brightest in the industry, are free to attend and are open to all visitors!
Award categories include:
- Start-up of the Year
- UK Manufacturing Partner of the Year
- International Manufacturing Partner of the Year
- Product Innovation of the Year
- The Rising Star Award
- Lifetime Achievement Award
7 Sessions You Don’t Want to Miss!
How can digital manufacturing, AI, big data and Industry 4.0 technologies support improvement in the workplace as well as wider society?
Thursday 6th June @ 11:00am | Manufacturing Insights TheatrePanel discussion
• Dr Nandini Chakravorti, Associate Director, Digital Engineering Group, Manufacturing Technology Centre
• Prof Jeremy Watson, Professor of Engineering Systems, Net Zero What Works Centre at UCL
• Prof Mercedes Maroto-Valer, Champion and Director - UK Industrial Decarbonisation Research and Innovation Centre (IDRIC)
What are the keys to building enduring supplier-buyer partnerships
Wednesday 5th June @ 13:15pm | Manufacturing Insights TheatrePresentation and Q&A discussion
“In today’s dynamic business
landscape, forging strong and lasting partnerships between manufacturing suppliers and buyers is crucial. The panel will explore the critical factors that ensure top-quality, long-term collaborations.”
• Andy Sandford, Editor, Engineering Capacity
• Anil Thomas, formerly General Manager - Business Transformation And Projects, Olympus
• Lyndsey Adams, Manager: Purchasing & Supply Chain Operations, Dennis Eagle UK
Top tips for improving your bottom line: A case study from BAE
Wednesday 5th June @ 12:00pm | Workshop and learning space - Round table discussion
“An insight into how business can improve its bottom line by focusing on improving flow. A systemic approach looking at how lean and TOC can work hand in hand to strive for the top line to become the bottom line in a company.”
• Alan Lothian, 3A Business Excellence
• Andy Watt, Goldratt
• Frances Shaw, Goldratt
• Senior Manager, BAE
Concept to commercialisation: Innovations and challenges with codeveloping disruptive technologies
12 noon Wednesday 5th June @ 12:00pm | Manufacturing Insights Theatre - Presentations and QandA discussion
“We will share an understanding of the challenges involved in commercialising an innovative product idea and how to avoid them, as well as a roadmap to follow to take your own concept and commercialise it successfully.”
• Daniel Bonilla, Senior Procurement and Supply Chain Leader, First Hydrogen
• Nigel Clarke, CEO, Morgan IAT Ltd, CEO at Zeus Sleep Ltd, Member of the Board at GTMA, Panel Member at Wessex Innovation
Supply chain and internal collaboration in the automotive sector
11:50 Thursday 6th June @ 11:50am
| Manufacturing Insights TheatrePresentation and Q&A discussion
“How can genuine internal collaboration create ways of working together to deliver corporate requirements, build in ESG policies and work effectively with your supply chain.”
• Andy Skelton, Head of Supplier Quality, Forseven
How to get started with automation
Thursday 6th June @ 14:40pm | Manufacturing Insights TheatrePanel discussion
“Most businesses know they have to automate—the question is how and when. With their extensive experience in automation, our panel will discuss the practical steps to getting started and how businesses can get the most out of automation and robot technology, including how to source reliable subcontractors.”
• Peter Williamson, CEO, Automate UK
• Søren Peters, CEO, Howtorobot.com
• Mike Wilson, Chief Automation Officer, Manufacturing Technology Centre (MTC)
• Troy Barratt, CEO, BAMUK Group
Efficiency, automation and adaptation in manufacturing Thursday 6th June @ 15:00 | Manufacturing Insights Theatre –Panel Discussion
“Where will AI optimise manufacturing processes? How digital twins are transforming the manufacturing industry “
• Sandeep Dinkale, Senior Business Analyst and Product Lifecycle Management Consultant, Jaguar Land Rover
Meet the Sponsors:
Registration Sponsor: Turkish Machinery:
• Stand: D75
• www.turkishmachinery.org/En
Machinery Exporters’ Association (Turkish Machinery) represents and promotes the interests of its 18,000 members. It does so by coordinating
and delivering sector-specific networking opportunities, business intelligence, and international events and trade missions.
The Turkish machinery sector has recorded robust growth over the past decade and has increased by more than 400% since 2003. It is now Turkey’s second largest exporter, worth some $25.5bn in 2022 – equivalent to 10% of total exports.
Centrally situated between Europe and Asia, Turkey is ideally located close to several of the highestgrowth industrial machinery markets. Turkish machines operate in more than 200 countries around the world with a particularly strong presence in the US and Europe.
Buyers are drawn to the strong emphasis Turkish machine manufacturers place on R&D activities, the rapid adoption of international manufacturing standards and new technologies, a highly educated and skilled engineering workforce, and highquality aftersales support.
Bag Sponsor: Onmidex
• Stand: B76
• www.omnidexcn.com
Omnidex is a British owned, singlesource provider for a range of metal and plastic fabrication, casting, machining, finishing, assembly and other manufacturing services from concept to completion.
Driven by a passion for quality for more than 20 years, Omnidex has provided world-class engineering outsourcing services at a competitive price. Its experience and expertise spans almost all sectors, including aerospace, automotive, consumer products, medical, oil and gas, and more. With customers in the UK, the US, South Africa, Australia and many more, Omnidex is a global business.
Underpinned by its highly skilled engineers and supported by a vetted network of subcontractors and
stringent quality control processes, the company invests regularly in the latest equipment and technologies to deliver cutting-edge, high-quality products and services to its customer base.
Lanyard Sponsor: NOTE UK
• Stand: B61
• www.note-uk.co.uk
NOTE produces PCBAs, subassemblies and box build products. NOTE is a competitive EMS provider and stable business partner to customers with high standards. NOTE’s products are embedded in complex systems for electronic control, surveillance and security, for example.
NOTE’s business model builds on delivering high end manufacture, custom logistics solutions and consulting for the best possible total cost through long-term customer relationships and partnerships. Its customer offering covers complete product lifecycles, from design to after-sales. Primarily, its customer base consists of large corporations operating on the global market, and enterprises whose main sales are in northern Europe.
NOTE has a presence in Sweden, Finland, the UK, Estonia, Bulgaria and China. Sales over the last 12 months were SEK 4,201 million, and the group has approximately 1,600 employees.
Badge Sponsor: Made Smarter West Midlands
• Stand: E77
• www.cwgrowthhub.co.uk
Made Smarter West Midlands is aimed at Connecting manufacturing
and engineering businesses with digital technology to transform the way they work and improve their productivity.
Coventry and Warwickshire (CW) Growth Hub, on behalf of the West Midlands Combined Authority and the Department for Business & Trade, leads the programme alongside Business Growth West Midlands and the Worcestershire, Stoke-on-Trent & Staffordshire, and The Marches Growth Hubs.
Made Smarter West Midlands also collaborates with a range of strategic partners, including the Warwick Manufacturing Group (WMG) at the University of Warwick and the Manufacturing Technology Centre (MTC) in Coventry, who help programme participants benefit from the expertise of their digital manufacturing specialists.
VIP Lounge Sponsor: Qimtek
• Stand: E67
• www.qimtek.co.uk
Qimtek proudly host 250 UKbased subcontract engineering suppliers, alongside 4,000 registered manufacturing buyers hailing from diverse industries. Our acclaimed Drag, Drop, Source! service is here to unite them all seamlessly.
Unlike traditional on-demand manufacturing platforms, Qimtek firmly believe in direct communication with your suppliers. No middlemen or barriers in your way; just a clear and transparent route to connect with new suppliers right from the project’s inception. Forge lasting partnerships with manufacturers you can trust.
Registration is Free!
Don’t miss out on Subcon 2024! Registration is completely free, offering an invaluable opportunity to connect with industry leaders, explore cutting-edge innovations, and participate in a variety of sessions designed to drive your manufacturing capabilities forward. Register today and discover your next manufacturing solution.
For further information, please visit www.subconshow,co.uk
A manufacturer of cooking sauces making small batches may be transferring the product from one container to another by hand. “We’re only moving small quantities so it’s not worth investing in a pump”. Correct? Perhaps initially, but as production increases there are many reasons to consider more than just the upfront cost of the pump.
Castle Pumps explain five reasons why upgrading to a barrel pump is much more beneficial than continuing to manually handle your product.
1. Increased productivity.
Using a barrel pump is quite simply quicker and more efficient than moving the fluid by hand. Manual transfer is very time consuming for an operator, so if your business begins to upscale production, it becomes less feasible for an operator to keep up. Using an electric barrel pump is less labour-intensive, freeing up your workers’ time to spend on more value adding tasks.
2. Safer for operator and workspace
A spill, which is much more likely during the process of manually scooping and pouring fluid, means wasted product and a clean-up. The fluid being stored in a drum or IBC can sometimes also be hazardous e.g. chemicals and flammable fluids, and therefore manual handling unnecessarily exposes operators to risk.
3. Accurate measurement
In many processes, a very precise quantity of fluid may need to be dispensed. For example, whilst packaging a final product, or dosing
Using a barrel pump is quite simply quicker and more efficient than moving the fluid by hand.
a specific amount of an ingredient into a mixture. Doing this by hand can cause measuring errors and inaccuracies, resulting in an incorrect or inconsistent final product. By using an electric barrel pump with a batch meter, not only is it much quicker for the operator but it ensures product consistency.
4. Product purity
Manually moving a fluid leaves it open to contamination from the
air or general environment. Very special care needs to be taken to ensure no external debris gets into the container being used to transfer it – which is absolutely vital in food and cosmetic industries. Using a food grade barrel pump keeps the product safely contained with the hose and pipework and protected from external contaminants.
5. Cheaper in the long run
Whilst manual handling may seem more economical at beginning of production, eventually demand and operator priorities will outgrow this. Using a pump means reduced labour from the operators, giving them more time to focus on other essential tasks, less product waste and less clean up required if a spill occurs. All of this adds up and saves money in the long term!
Scientists and engineers have developed a new coating for plastic particles that are used in 3D printing, which significantly increases their functionality and opens up new possibilities for commercial application.
Researchers from the University of Nottingham’s School of Chemistry and Faculty of Engineering have used supercriticial carbon dioxide to create an efficient, effective and clean process to coat PA-12 polymer particles used in a 3D printing process
The researchers have demonstrated that the new coatings have the ability to add colour and antimould and fungal properties to the printing process. The research has been published in Nature Communications.
One of the most common commercial 3D printing techniques is powder bed fusion or laser sintering. In this process a layer of free-flowing polymer powder is laid down and a laser is guided by a computer generated design and melts the powder layer-by-layer. A new layer of powder is applied to the previous layer and once again the laser melts the powder together whilst simultaneously anchoring it to the layer below. This process continues until the designed part is complete, often consisting of thousands of layers.
Polyamide-12 (PA12) is a strong plastic that is often is often used in the 3D printing industry to print complex and detailed
parts, commonly deployed in the automotive or aerospace industries.
The real benefit of 3D printing or additive manufacturing is in the design and production of bespoke and unique objects, but its limitations are in the materials and palette of available properties that limit the overall application space. This new process provides an easy route to the development of a wide range of material capabilities without compromising processability.Professor Christopher Tuck, Professor of Materials Engineering in the Centre for Additive Manufacturing in the Faculty of Engineering
Two key capabilities the new process can deliver are the addition of coatings for colour and anti-fungal and anti-mould properties. Currently the only options for manufacturers are grey or white powders and colour is added afterwards, now the team
have created a range of coloured polymers that coat the PA-12 particles.
There are a few challenges facing the 3D printing industry due to limitations on the functionality of the polymers used. To tackle some of these challenges we have created a simple but effective approach to adding functionality by coating the particles. We’ve designed the coloured shell polymer so that it matches the mechanical and thermal properties of the printing polymer. Most importantly we’ve demonstrated this with the key polymer (PA-12) that is ubiquitous to the industry. Our new coloured polymeric powders work perfectly in the existing commercially deployed machines.Professor Steve Howdle, Head of the School of Chemistry
Currently objects made using PA-12 can’t be used in moist environments due to the growth of mould and fungi. The new shell coating can also be used to develop coatings that prevent this from happening, opening up new possibilities for the use of 3D printed objects in new areas.
Professor Howdle adds: “A key benefit of this process is that it can easily be incorporated into current commercial 3D printing processes and this could be potentially transformative for the industry in widening scope by introducing new functionality, simplifying processes and importantly achieving all of this sustainably.”
For further information, please visit www.nottingham.ac.uk
CURTISS-WRIGHT
Chemically Assisted Surface Enhancement, or CASE, is an isotropic superfinishing process which has been developed as a metal surface treatment to provide components with excellent bending and contact fatigue strength, together with resistance to high loading.
With isotropic superfinishing, a component is firstly shot peened, to create multiple indentations in the surface using the spherical shot media from which it draws its name. As each indentation is made, the surface will try to yield, but is restrained by the substrate, introducing a residual compressive stress and removing any prior manufacturing-related tensile residual stresses. This proven technique makes the surface resistant to crack initiation and propagation.
Secondary processing by further shot peening (or dual peening) at a lower intensity with modified shot size will have the effect of reducing surface roughness and increasing the compressive stress and cold working of the near surface.
Final processing is then carried out in a controlled and gentle manner using non-abrasive finishing stones together with oxalic acids: here, the most positive or peak surface areas are progressively removed, producing a mirror-like surface finish with an extremely low surface roughness.
Some of the most common applications for isotropic superfinishing by Metal Improvement Company include the
manufacture of gears, transmission shafts, bearings, cams and cam followers, journals, seal faces etc. Key benefits of isotropic superfinishing include achieving the optimum surface roughness and stress characteristics, being
more
able to produce mirror-like finishes, the reduction of contact/surface fatigue and the prevention of micro and macro pitting. CASE is just one of many surface finishing options available by Curtiss-Wright Surface Technologies.
Protection & life extension of your critical components throughout any crisis!
Protection & life extension of your critical components throughout any crisis!
COATING SERVICES:
COATING SERVICES:
l Thermal Spray & HVOF Coatings
l Thermal Spray & HVOF Coatings
l Dry film lubricants - MoS2, PTFE, Graphite, WS2
l Dry film lubricants - MoS2, PTFE, Graphite, WS2
l Coatings for corrosion, chemical & environmental protection
l Coatings for corrosion, chemical & environmental protection
l Titanium anodising
l Titanium anodising
l Zinc rich coatings for corrosion protection
l Zinc rich coatings for corrosion protection
l Impingment coating processes for ultra thin solid film lubricants
l Impingment coating processes for ultra thin solid film lubricants
l Nonstick/release coatings for low coefficients of friction
l Nonstick/release coatings for low coefficients of friction
l Primers for rubber and plastics for sound absorbing and dampening materials
l Primers for rubber and plastics for sound absorbing and dampening materials
l High temperature resistant coatings
l High temperature resistant coatings
l Rare earth magnet coatings
l Rare earth magnet coatings
l Coatings for EMI/RFI shielding provide highly conductive coatings and platings to control electromagnetic interference
l Coatings for EMI/RFI shielding provide highly conductive coatings and platings to control electromagnetic interference
l Ultra thin conformal parylene coating to reduce friction and protect against contamination
l Ultra thin conformal parylene coating to reduce friction and protect against contamination
l Pre-treatments including Ti Anodising, Phosphate
l Pre-treatments including Ti Anodising, Phosphate
Conversion Coating and Chilled Iron Blasting, Aluminum Oxide Blasting and Vapour Degreasing
Conversion Coating and Chilled Iron Blasting, Aluminum Oxide Blasting and Vapour Degreasing
Founded over 35 years ago, we now have a production facility that occupies over 11.700 sqm2. Our broad range of products are designed, manufactured and constantly developed under the same roof, to meet the needs of our worldwide customers.
TST is a fully integrated manufacturer of quick connect/disconnect couplings, for hydraulic, pneumatic, vacuum, gas, chemical fluid and water applications, in addition to multi couplers, fittings, hoses and accessories.
The latest technologies are utilized to manufacture and assemble our wide range of products to the required specifications to achieve zero defects and 100% delivery performance.
A compressed air line can be connected to compressed air tools using a pneumatic coupling. This coupling enables easy connection and disconnection of a tool to a hose or pipe even when it is pressurized. The system comprises of two components: the quick coupling (female part) and the plug-in or nipple (male part). When disconnected from a component, the coupling automatically closes the line to maintain system pressure.
Our hydraulic quick couplers are specifically engineered to facilitate the rapid attachment and detachment of hydraulic hoses, eliminating the necessity for supplementary tools, system bleeding, valve closure, gas purging, or fluid recharging.
Our Ex Oetiker Quick Connectors (QC) are an innovative connecting solution for pressure lines carrying media. They enable significant savings in assembly time, space required, assembly costs to be made, reduced warranties, and reduced injuries due to repetitive motion. These two stage couplings seriously reduce the risk of accidents in the workplace.
The installation of a variety of quick release connectors onto a single multicoupling plate enables the rapid and simultaneous linking of various services such as air, water, hydraulics and electricity.
Technological advances have become ever more crucial as manufacturing firms in all sectors of industry strive for commercial success, and key to that success for TR Fastenings is the need for superior performance fastenings. The efficient and effective operations of everything from automotive applications, domestic appliances to industrial machinery will inevitably depend on the need for reliable screws, bolts, washers, clips and more. TR’s latest product launch of the new Plas-Tech 30-20® screws is another indicator of the company’s determination to increase its range that is currently available in the market, to give their customers yet more advantages in their production processes.
Manufactured in TR’s own facilities, the Plas-Tech 30-20® has been developed by TR’s in-house technical engineering teams across global locations to complement the existing Plas-Tech® range. This new product has an optimised thread profile which gives an advanced performance in a wide variety of plastic materials to meet customer requirements.
An important addition to an already successful product range Plas-Tech 30-20® screws are new to the market, but are part of the company’s established and popular Plas-Tech® range, and are available with various protective coatings. They are of particular importance in the automotive, tech & infrastructure and health & home markets.
The Plas-Tech 30-20® has been specially developed to offer several advantages over conventional
thread-forming screws in plastic, such as:
• A 20% finer pitch and lower flank angle to improve axial resistance.
• A reduced thread angle to lessen axial displacement.
• Up to 25% higher thread fill to improve maximum joint strength.
• A smoother installation that heightens resistance to vibration.
Key features of the Plas-Tech 30-20® include:
• Minimal radial stress: the faceted thread profile directs material flow to reduce radial stress.
• Superior vibration resistance: the full engagement of the selflocking, angled thread design avoids loosening.
• High torsional strength and tensile strength: a large core thread profile provides high strength.
• Optimal thread pitch: ensuring fastener engagement with a minimum number of rotations, keeping installation times to a minimum.
• High reusability: the fastener can be removed and re-installed a number of times.
The Plas-Tech 30-20® screw range includes pan head, flange head and countersunk head varieties, enabling TR customers to choose the ideal
option for each application. Thread diameters are 3mm, 4mm, 5mm and 6mm, and available lengths range from 6mm to 30mm. The innovative design allows for the screw threads to displace the surrounding plastic, in the process strengthening the fix. And as always, TR Fastenings can provide bespoke engineered products and a diverse selection of related components as well.
The screws can be installed with a calibrated pneumatic or electric driver and are particularly suited to robotic assembly processes. With standard drivers, installation is quick and stress-free, and thanks to their sturdy construction, Plas-Tech 30-20® screws can be reused many times over.
Product engineers who are keen to find out more about their usage can obtain all the information they need via TR’s excellent installation guide and product animation video below.
Installation guide: https://www.trfastenings.com/ knowledge-base/fasteners-forplastic/plas-tech-30-installationguide
Product animation video: https://www.youtube.com/ watch?v=xxL2WkkOGwA
For further information, please visit www.trfastenings.com
We are pleased to announce the launch of the new Plas-Tech 30-20® Screws to our product range. These products have been developed by TR to complement our existing range of Plas-Tech® products
We are pleased to announce the launch of the new Plas-Tech 30-20® Screws to our product range. These products have been developed by TR to complement our existing range of Plas-Tech® products
Minimal radial stress: the faceted thread profile directs material flow to reduce radial stress
Minimal radial stress: the faceted thread profile directs material flow to reduce radial stress
Superior vibration resistance: the full engagement of the self-locking, angled thread design avoids loosening
Superior vibration resistance: the full engagement of the self-locking, angled thread design avoids loosening
High torsional strength and tensile strength: a large core thread profile provides high strength
High torsional strength and tensile strength: a large core thread profile provides high strength
Optimal thread pitch: ensuring fastener engagement with a minimum number of rotations, keeping installation times to a minimum
Optimal thread pitch: ensuring fastener engagement with a minimum number of rotations, keeping installation times to a minimum
High reusability: the fastener can be removed and re-installed a number of times
High reusability: the fastener can be removed and re-installed a number of times
Suitable for robotic assembly
Suitable for robotic assembly
For further information on the Plas-Tech
please visit our
For further information on the Plas-Tech 30-20® please visit our website
Pan Head Recess T Drive
This June, the NEC Birmingham will host the much-anticipated Smart Manufacturing & Engineering Week (SM&E Week) 2024, offering an expansive educational program across two engaging days. Scheduled for the 5th and 6th of June, this event promises a deep dive into the future of manufacturing and engineering, with a particular emphasis on digital transformation and technological integration.
SM&E Week 2024 incorporates two summits and eight education theatres, each aimed at addressing critical needs and innovations within the industry. The Manufacturing Digitalisation Summit and the Industrial Data and AI Summit will bring together thought leaders and industry experts to discuss the evolving landscape of manufacturing
technologies and data-driven strategies. These summits will feature a robust schedule of keynote presentations, panel discussions, and roundtable sessions, designed to foster in-depth understanding and peer-to-peer learning.
In addition to the summits, nearly 150 free-to-attend sessions will be available across the eight solution theatres. These theatres cover a range of topics, including Digital Transformation, IIoT & Connectivity, Industrial Data & AI, Innovation, Maintenance, Drives & Technology, Air-Tech Solutions, and Fluid Power & Systems. The educational content is curated to ensure it addresses the vast spectrum of challenges and opportunities within the manufacturing and engineering sectors.
Highlights from the educational theatres include presentations from industry leaders such as Neelofar Ansari from BAE Systems, who will discuss Human Augmentation in manufacturing environments, and Roy Haworth from Airbus Defence & Space, who will delve into the use of CAD data for data fusion and 3D visualisation. These sessions are designed not only to inform but also to inspire attendees to implement innovative solutions within their operations.
The educational program at SM & E Week 2024 is complemented by a series of live events and networking opportunities that underscore the event’s commitment to industry advancement.
In addition to the summits, nearly 150 freeto-attend sessions will be available across the eight solution theatres.
The Connect+ Live Hosted Meetings Programme, for instance, offers a tailored networking experience that enhances visitor engagement with solution providers, ensuring that every interaction is meaningful and directly relevant to attendees’ specific needs.
SM&E Week 2024 is more than just a conference and exhibition— it’s a comprehensive platform for education, innovation, and collaboration. With its array of summits, educational theatres, and networking events, the week promises to equip attendees with the insights and tools needed to navigate the complexities of the modern industrial landscape. For professionals invested in the future of manufacturing and engineering, this event is essential , providing unparalleled access to the trends and technologies shaping the future of the industry.
Registration is completely free.
Unicar and Multicar are network monorail track systems with autonomous trolleys or cars which can move anywhere on the track network. The track can be installed horizontally, vertically and at any gradient. Unicar has a carrying capacity of up to 15kg, whilst the larger Multicar system can carry up to 45kg including any load handling device.
The ability to transport payloads both horizontally and vertically without any requirement to transfer the payload to a separate lifting mechanism delivers an innovative and extremely flexible intralogistics solution.
Both Unicar and Multicar can be routed at high level and within service areas where the track can be kept well away from production floors and other logistics systems, only dropping to load/unload areas in the immediate vicinity of the process to be served. This has the significant benefit of keeping the working floor clear of obstructions and traffic, and makes the most efficient use of the process space.
Both Unicar and Multicar transactions can be initiated either through HMI
(touchscreen terminals) or integrated with SCADA and WMS for automated control. Interface with other automated systems, such as automated load/unload stations is easily delivered through local PLC interfaces. The trolleys themselves also present both power and digital I/O for sophisticated load handling systems if required.
A feature of both Unicar and Multicar is the ability to keep the payload perfectly
horizontal during transportation, no matter whether the trolley is moving horizontally or vertically. This can be achieved either using a gravity pendulum system or a dynamic powered solution.
Both Unicar and Multicar are well established solutions in Europe and beyond and are now available in the UK through Quirepace. Contact us today and find out more about these innovative and flexible systems.
In this issue of PECM, we are delighted to showcase Sibor as our New Year Spotlight company.
Sibor has a long history, spanning over thirty years providing leading process control, engineering and project management expertise. Established in 1992, to originally provide process control systems and industrial automation to many industrial applications, such as large blue-chip companies, the company has been focusing on the energy sector more recently, notably the anaerobic digestion renewable energy sector.
Sibor provides turnkey design and build service solutions across manufacturing and automation control, including the following services:
• EIC/mechanical design and installation services
• Process control services
• Process instrumentation services
• Atex design and installation services
• Project management services
• Software development services
• Support services
With a vision for providing automated control systems that provide manufacturing benefits and added assurance throughout, Sibor are trusted professionals throughout the project. From initial requirements analysis, expert software engineers define user-needs from the offset, through to application design and software, component selection and assembly for a successful outcome.
Sibor runs applications as local stand-alone systems or alternatively, as Ethernet/IP networked solutions.
Utilising cutting-edge Supervisory Control and Data Acquisition (SCADA), Sibor ensures streamlined services across all customer applications.
We caught up with Managing Director: Rob Mockridge to find out more,
“We have always enjoyed organic growth and over the last 12 months, the company has gone through a major transition and has now been accredited with ISO 9001 and 14001 and we have also been accredited by safe contractor.
We have gone from strength to strength completing many major
upgrade projects for the MOD and several renewable energy companies, ranging from replacing old for new to major electrical infrastructure and controls installations.
We have seen a 40% increase in business over the last 12 months- an accolade to our strong team.
We are very excited for the year ahead in the anaerobic digestion renewable energy sector and we have just signed two major contracts with renewable energy companies to provide LV power distribution design and installation combined with control and instrumentation design and installation. With a pipeline of projects to follow, allowing us to keep investing in our staff and business activities.
Our growth in control and automation projects is a tribute to our innovative approach to design and comes from our long history in many industrial sectors.”
The expanding market for plastic tubes is projected to grow to $1.56 billion by 2031 with a five per cent compounded annual growth rate (CAGR). This represents an immense opportunity for industries to switch to small-diameter composite tubes, renowned for their strength, durability and versatility across industries.
Here, Lauri Turunen, product business owner for tubes and telescoping poles at composite manufacturer Exel
Composites, explores the pivotal role of pull-winding in shaping smalldiameter tubes, their remarkable resilience, and the future of these tiny-tubes.
Small-diameter tubes are integral components in diverse industries, offering lightweight yet resilient solutions tailored to specific applications. In robotics, these tubes form articulating arms and
manipulators, providing high axial stiffness for precise movements and structural integrity essential for intricate tasks.
Similarly, in drones, they serve as lightweight yet sturdy frames, enabling agile flight maneuvers and payload management while withstanding dynamic forces.
Customizable to meet design needs, the tubes find applications in both
hobbyist drones and commercial UAVs for tasks like aerial surveys and package delivery.
Precision instruments, such as surgical robots, also rely on small-diameter tubes for stability and support during delicate procedures. Their role in maintaining rigidity minimizes vibrations, ensuring surgeons perform surgeries with precision and safety. Across these applications, smalldiameter tubes strike a balance between weight and strength. This versatility highlights their ability to enhance performance and efficiency across industries.
Composite materials offer several advantages over traditional materials. Their superior stiffness and strengthto-weight ratio make them ideal for applications requiring lightweight yet robust solutions. To put it into perspective, glass fiber composites
Rigorous measures ensure reliability and consistency, with advanced testing techniques verifying dimensional accuracy, mechanical properties, and adherence to any industry standards.
have a density of 2g/m3 compared to aluminum’s 2.7g/m3, making it almost half the weight of aluminum while maintaining a similar mechanical strength. Carbon fiber, on the other hand, has a density of 1.55g/m3, with a much greater strength and stiffness than aluminum or glass fiber composites.
Continuous manufacturing technologies like pultrusion and pull-winding offer significant benefits for small-diameter tube production. Pultrusion typically results in wall thicknesses of two millimeters and above, whereas pull-winding, a form of continuous filament winding, can achieve much thinner walls, as thin as 0.5 millimeters.
Pull-winding involves the simultaneous application of resin and reinforcement fibers, such as glass or carbon fiber, onto a mandrel. As the crosswinder winds fibers helically around the static mandrel, a composite material is formed, exhibiting augmented strength and resistance to bending. Additionally, axial fibers along the length of the small-diameter tube ensure the mechanical integrity of the tube and, together with wound transverse fibers, gives the possibility to optimize the structure of the tube while concurrently reducing both weight and material usage. This combination of techniques ensures a high output rate and consistent quality, making pull-winding an ideal choice for industries requiring lightweight yet durable solutions.
Small-diameter pull-wound composite
tubes offer tailored solutions across industries, including robotics, aerospace, and medical technology, meeting specific client needs with customizable parameters for the specific application. This adaptability ensures tubes are precisely suited for each application, from precise movements in robotics to agile flight maneuvers in drones.
Quality control is paramount throughout manufacturing. Rigorous measures ensure reliability and consistency, with advanced testing techniques verifying dimensional accuracy, mechanical properties, and adherence to any industry standards. This approach guarantees that tubes meet or exceed performance expectations.
As Industry 4.0 continues to revolutionize manufacturing processes, the demand for lightweight yet durable materials, such as smalldiameter tubes, is expected to soar. Small-diameter pull-wound tubes offer exceptional strength-to-weight ratios, making them ideal for applications in robotics and automation. These tubes provide the structural integrity needed for precise movements and intricate tasks, contributing to the efficiency and flexibility of automated systems. As industries increasingly adopt robotics and automation technologies to enhance productivity and reduce costs, the role of small-diameter tubes in driving innovation and efficiency is poised to expand significantly.
Small-diameter composite tubes, often underestimated, prove their might across industries, whether it be in robotics, medical science or even in drone design. It’s clear to see that good things truly come in small packages and may even be delivered by a drone made of composite materials.
To find out more about pultruded and pull-wound composite tubes and the engineering solutions they present to common problems, visit exelcomposites.com and enquire about how these tubes can be used in your industry.
For further information, please visit www.exelcomposites.com
OAKMOUNT CONTROL SYSTEMS
We are an automation business, passionate about solving your most challenging automation problems using the latest cutting edge technology
Looking for a company with more than 35 years combined experience that can Design, Manufacture, Install and Commission Bespoke Industrial Automation Machinery? Look no further...
We take pride in designing and manufacturing high quality special purpose machines for our UK and International customers. Here are some examples of projects we have worked on:
• Full Production Lines
• Automatic Vision Inspection Machines
• Laser Marking Machines
• Assembly Machines
• Pick and Place Machines
• Flow/Leak Testing Machines
• Industrial and Collaborative Robot Solutions
Our capabilities include:
• 3D Mechanical Design using Solidworks
• Electrical Circuit Design using AutoCAD
• Mechanical & Electrical Assembly & Commissioning
• Tool Making Facilities – We have 5 off Vertical Machining Centres, 3 off XYZ Proto-Trak Milling Machines, 1 off Proto-Trak Lathe, 1 off 4 Axis CNC Lathe, 1 off Surface Grinding Machine & 1 off CNC Horizontal Bandsaw.
• Fabrication
• MIG & TIG Welding
• Aluminium Profile Systems Design & Manufacture
• PLC Software
• HMI & SCADA Software
• PC Software Development
We are a Siemens Solution Partner for Automation Drives, a Bosch Certified Excellence Partner for their Assembly Technology range and we have recently become a Solution Partner for Kassow Robots who have partnered with Bosch Rexroth.
purpose machines for our UK and International customers.
ABB Robotics announced it is collaborating with UK-based tech start-up AUAR, to advance the use of robotic micro-factories to build affordable, sustainable low energy timber homes.
AUAR’s transformative approach to integrating robotic automation into the building process will tackle skills shortages, boost sustainability, and improve health and safety by deploying robots in a global network of local microfactories. These micro-factories will construct energy-efficient, affordable buildings from sheet timber. AUAR reports today that it has completed a £2.6M seed round led by deep-tech and AI fund Miles Ahead, alongside ABB Robotics & Automation Ventures and several other investors.
“The increasing capabilities of robots enabled by vision and AI, coupled with their inherent speed, flexibility and consistency, makes them the ideal solution for meeting the growing need for affordable, high quality, sustainable housing,” said Craig McDonnell, Managing Director Business Line Industries, ABB Robotics. “With 95 percent* of building firms in our recent market survey describing sustainability as ‘important’ or ‘very important’ to their businesses, and 38 percent* seeing robots as a way of reducing waste, our collaboration with AUAR opens new possibilities for homebuilders to deliver affordable sustainable homes at scale.”
ABB is already heavily involved in helping construction companies automate their processes. ABB
robots are widely used in a range of modular assembly and 3D printing building projects worldwide, as well as academic projects researching new ways to integrate robotic automation into construction.
The collaboration with AUAR follows the announcement by ABB working with German management consulting firm, Porsche Consulting, to develop innovative new practices in modular housing manufacture.
AUAR is the brainchild of two architects, Mollie Claypool (CEO) and Gilles Retsin (CTO/Chief Architect) who have worked for over 10 years on robotics, automation, construction, and architecture. During that time, they have relied extensively on support from ABB Robotics to realize their vision.
The relationship has already seen ABB Robotics win the prize for ‘Best Use of Robotics or Automation in Construction’ at the 2023 Robotics & Automation Awards.
AUAR’s automated micro-factory approach provides a solution to many of the challenges facing building companies, including supply chain issues, project delivery and quality and skills shortages.
Conventional buildings consist of thousands of different components shipped from around the world, making it almost impossible to automate construction. In contrast, AUAR’s goal is to work with one type of material and one type of machine to dramatically simplify the supply chain.
The production process uses standard sheets of timber. A robot cuts the sheets into components and assembles them into units that are transported to site, enabling
The collaboration with AUAR follows the announcement by ABB working with German management consulting firm, Porsche Consulting, to develop innovative new practices in modular housing manufacture.
complete customized homes to be built in a matter of weeks.
While many of the assembly tasks are automated, AUAR’s approach supports local jobs by promoting the use of micro-factories close to construction sites, where local contractors and suppliers can coordinate delivery.
The micro-factory approach is flexible enough to meet whatever each market demands. Each facility can be scaled to reflect local needs, with the ability to ramp up production by adding modular robot cells.
“With the focus on the dual needs of building more affordable homes and minimizing the environmental footprint of buildings throughout their lifetime, automated modular construction presents a great opportunity to rethink the way that the buildings are constructed,” added McDonnell. “Our collaborations with AUAR and Porsche Consulting mark an exciting step in our efforts to accelerate the use of robotic automation in the construction industry to help address its challenges and deliver the sustainable buildings of the future.”
*ABB Robotics global market survey, 2023
For further information, please visit https://go.abb/robotics
The Engineering Recommendation
G5/5 has extended the values for planning and compatibility levels to the 100th order (5 kHZ), but most power quality measurement and mitigation devices are yet to catch up. Because most metering devices still work to the old standard of 2.5 kHz (50th order), these cannot provide a complete picture of the spectrum — leaving engineers in the dark. So, how can operators ensure they choose the right meter? John Mitchell, global sales & marketing director at CP Automation, explores.
Anomalies such as sags, swells and harmonics are an ongoing threat in electrical circuits — and a common cause of equipment downtime. Power quality meters strategically sample the AC voltage at different points and track slowly changing variations in the electrical waveform. Using this information, operators can root out any issues before they cause lasting damage.
When it comes to electrical matters, the need for rapid detection is clear: transients can appear, cause damage, and disappear in a few millionths of a second. Similarly, a voltage spike typically lasts one to 30 microseconds and can reach over 1,000 volts.
Therefore, acting quickly to install a measurement device is critical, but so is choosing a meter that tells you what you need to know.
Usually, the dashboard warning lights in your car will tell you if your oil pressure has dropped, if the fuel level is low, or if there’s an issue with your steering lock. However, they won’t tell you if your cambelt is worn, and
you might not find out something’s wrong until it’s too late. The point is that you don’t know what you don’t know — and the new Engineering Recommendation has opened a blind spot by extending the values for measurement.
Visibility of issues across the frequency spectrum is critical, so try to select a power quality meter that captures as many parameters as possible. Usually, low-level power and energy meters will measure things like voltage, current, and maybe power factor but not much else. Even if you purchase a slightly more expensive meter that provides basic harmonic data and frequency values, it’s unlikely that this will measure beyond the 50th harmonic, leaving operators back at square one.
Class A meters and analysers can facilitate more advanced troubleshooting of complex electrical systems, and many will measure up to the 100th harmonic. These are the gold standard of power quality meters, and operators will need their accuracy to inform discussions with the distribution network operator (DNO).
Fixed or portable?
There’s also the matter of duration and how long operators plan to monitor the system. If a circuit board randomly fails or alarms trip, installing portable meters can help engineers perform spot checks by gaining insights at different locations. For example, these meters could detect any changes in low-voltage, medium-power systems, such as spikes in energy consumption. With G5-5 now in place, blind spots in the frequency spectrum are an issue for portable meters because most will only measure up to the 50th harmonic.
Some fixed meters and analysers, like the PQube3 and Janitza’s UMG range, can not only measure beyond this point but also facilitate rootcause analysis by mapping long-term trends. Operators can strategically install fixed meters at different locations and record data over several weeks, or even months. For example, with multiple fixed meters in place, a power quality engineer can pinpoint a time when harmonics were detected in the system, and when this caused a spike in energy consumption.
The latest Engineering Recommendations present a challenge for equipment operators because the goalposts for power quality measurement have shifted. However, this also grants an opportunity to improve uptime by detecting a wider range of issues early on.
To help you choose the right power quality measurement and mitigation solution for your application, visit the CP Automation website.
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
PRODUCT NUMBER
PRODUCT NUMBER
6ES7136-6DB00-0CA0
6ES7136-6DB00-0CA0
6ES7155-6AU01-0BN0
6ES7136-6RA00-0BF0
6ES7155-6AA01-0BN0
6ES7510-1SJ01-0AB0
6ES7550-1AA01-0AB0
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6AV2124-0JC01-0AX0
6ES7322-1FF00-0AA0
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6ES7135-6HD00-0BA1
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6ES7515-2AM02-0AB0
6ES7331-7KB02-0AB0
6ES7212-1CA00-0XB0
6ES7134-6GF00-0AA1
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6ES7241-1AH32-0XB0
6SL3210-1KE15-8AF2
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6SL3210-1KE21-3AF1
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6ES7972-0BB51-0XA0
6ES7515-2FM02-0AB0
6ES7513-1FL02-0AB0
6ES7315-2AH14-0AB0
6ES7153-2BA10-0XB0
6ES7134-6GD01-0BA1
6ED1053-1BB00-0BA1
6ES7512-1CK01-0AB0
6ES7512-1CK01-0AB0
6ES7511-1CK01-0AB0
6SL3244-0BB12-1FA0
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6ES7517-3AP00-0AB0
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6SL3210-1KE14-3UF2
6SL3210-1KE15-8AF2
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6ES7516-3TN00-0AB0
6ES7522-1BL10-0AA0
6ES7522-1BH10-0AA0 1071153 10713518 1044125 1023546 1041114 1056430 1018601 1023891 1026287 1026820 1028934 1028936
Artificial intelligence (AI) is taking the world by storm, with every industry across the globe destined to be impacted in some way. Within manufacturing, AI is already being deployed to great effect, and will continue to scale.
So far, we have seen the rise of the fourth industrial revolution (Industry 4.0), which has not only introduced significant opportunities for manufacturers but also helped with optimizing processes, costs and streamlined operations. These successes are prompting manufacturers to tap into the power of these advanced technologies and reap the benefits.
The applications of AI and machine learning (ML) in electronics manufacturing environments in particular are more common, with those on the ground using advanced predictions and quality assurance, to waste reduction and more. As these technologies are broadly implemented and continue to evolve, it is crucial that organizations recognize AI as a way to introduce greater efficiencies into existing processes, while also identifying challenges on the factory floor that could be improved in the future.
Inefficient maintenance and downtime have long been a concern for those working with technology in manufacturing environments. Factory equipment requires frequent maintenance, and without
regular monitoring and updates costly repairs and replacements could be needed. Additionally, inadequate visibility into operations makes it difficult to detect abnormalities and predict required maintenance, which can lead to unplanned downtime.
Manufacturers must detect and address product defects and quality issues early in the product lifecycle to meet volume and avoid scrap. Relying solely on human inspection can be lengthy and costly, yet is often necessary to meet quality standards. However, the human eye cannot catch every imperfection in a product going through the production line. This can result in
unplanned interruptions later, that cost significant amounts of money, cause delays in output, and are disruptive to customer relationships.
AI and ML can play a vital role in tackling the challenges faced by electronics manufacturers. These advanced manufacturing technologies have quickly become essential tools for optimizing the manufacturing process. For example, manufacturers can deploy AI and ML for predictive maintenance, which detects and alerts manufacturers to potential failures in their factory equipment so that they can be resolved with minimal downtime. AI and ML algorithms also support quality control, and can provide insights into process optimization to make the manufacturing process faster and more efficient.
Products that require visual inspection are traditionally inspected by human workers as they
travel through the manufacturing line. Yet, as product demands and timeline speeds have increased, it becomes more difficult for the human eye to detect anomalies. Moreover, electronics products have components—such as printed circuit boards (PCBs)—that are highly complex with hundreds, or even thousands of parts that are difficult for the human eye to see.
AI/ML-based defect detection systems are designed to use deep neural networks to detect defects that cannot be seen by conventional visual systems or human inspectors. This streamlines inspection processes, resulting in greater efficiency performance while optimizing factory floor space by making room for other lines and solutions through the elimination of legacy inspection stations.
Inspection staff can receive training in managing new technologies ahead of full adoption, which provides employees with advanced career opportunities and opens up new roles and skill sets within a business.
AI and ML algorithms also support quality control, and can provide insights into process optimization to make the manufacturing process faster and more efficient.
AI and ML technologies will continue to fundamentally change the manufacturing industry, but will only realize their full potential if manufacturers embrace their adoption across different areas of their businesses.
While doing so demands a substantial investment of time, effort, and resources, as well as upskilling workers to work with new technologies, the window of opportunity to integrate AI into
production processes is closing fast— those who have not started are at risk of being left behind.
Of course, there are still challenges ahead, from data readiness—where the quality of an AI/ML model is only as good as the training data—to quantifying the return on investment of AI/ML implementations, which can be tricky. Organizations need to identify the right use cases for the business, find relevant data, process it, and then develop, fine-tune, and eventually deploy models. These steps all take time, but they are vital to reaping the greatest benefits from an investment in AI/ML solutions.
AI is already here and will be a mainstay of the factories of the future. Skillsets are still in short supply, so there is value in implementing it sooner rather than later. Manufacturers today are successfully leveraging AI and ML in their manufacturing processes, and while hurdles remain, advanced technologies are at the forefront of Industry 4.0 and have the power to transform production and operations on every level.
ALRAD Instruments Limited (established 1970) has been serving the Industrial, Automation, Scientific, Medical and Instrumentation markets for over 50 years and has a wealth of experience in all aspects of Machine Vision, Automation and Scientific Imaging.
Our product areas cover imaging, machine vision and automation components, Industrial and Scientific cameras for UV, Visible and Infrared wavelengths, thermal cameras, image sensors, photonics components including laser products, vacuum and related
products, embedded AI and deep learning vision systems. We also provide standard and bespoke imaging software and complete system solutions together with our integration partners.
Our imaging technology operates in a wide spectrum from Ultraviolet through Visible to Infrared and Thermal wavelengths. We supply the latest camera technology and vision components including illumination products covering the complete spectrum from ultraviolet through visible to Infrared. These products are suitable for applications in Machine Vision, Automation, Scientific Research, Medical imaging, Agriculture, UAV/Drone, security and Search and Rescue applications.
For further information, please visit www.alrad.com
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 accuracy, and upholding safety standards. This collaboration extended to Zytronic, a leading touch sensor company, resulting in the development of an exclusive touch screen solution.
Supplied Components:
AUO 15” Panel with 15” ZYTRONIC PCAP
Touch Sensor: The AUO panel provided clarity, while Zytronic’s PCAP touch sensor, layered with 0.75mm polycarbonate, ensured resilience in challenging conditions.
Embedded - ASROCK SBC-210N: Coupled with custom gold-plated LVDS and LED cables, the ASROCK SBC-210N effectively powered the LCD display.
Advantages:
• Durability: The PCAP touch sensor’s polycarbonate overlay guaranteed longevity, mitigating the risk of glass contamination or substrate damage.
• Hygiene and Safety: Harford Control’s stainless-steel touch screen terminals, combined with Zytronic’s PCAP touch sensor, facilitated easy cleaning while adhering to food safety standards.
• Data Accuracy: Harford Control’s direct data
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.
For more information visit www.displaytechnology.co.uk
In response to the evolving energy efficiency landscape and the increasing demand for environmental responsibility, global motor manufacturer WEG has launched its new W23 Sync+ ULTRA motor. Having released the W23 Sync+ general line in November 2023, the new ULTRA variety boasts IE6 efficiency —going one step further than its predecessor that is available in efficiency ratings up to IE5.
The W23 Sync+ ULTRA combines permanent magnet (PM), ferrite or neodymium magnets, and synchronous reluctance (SynRM) motor technologies to deliver unparalleled efficiency across all speeds. The key to the W23 Sync+ ULTRA motor’s exceptional efficiency lies in this PMSynRM technology, which effectively reduces electrical losses through the strategic use of magnets.
This results in a motor that maintains high efficiency levels even under varying speed and load conditions. Compared to conventional induction motors, the W23 Sync+ ULTRA experiences minimal efficiency loss, demonstrating a decrease of less than two per cent when load and speed are reduced by 25 per cent.
Designed to surpass current European Ecodesign regulations, the new flagship IE6 model reinforces the transformative benefits of the new PMSynRM technology, emphasising its ability to exceed ultra-premium efficiency levels while reducing environmental impact.
The motor will be available in a range of frame sizes from IEC 80 to
operational lifespan and decreased maintenance requirements, aligning perfectly with the growing global commitment to sustainability.
WEG strives to increase efficiency, reduce costs, improve quality and reduce the raw materials used in products.
450 (NEMA 140 up to 7000). Able to operate over a wide speed range at constant torque, without the use of forced ventilation, it is available in speed ranges from 750 up to 6000 revolutions per minute (rpm). The motor’s output rating ranges from 0.75 to 1250 kW, while it is compatible with a 220/380 volt (V), 230/400 V, 240/415 V or 400/690 V power supply.
“The W23 Sync+ ULTRA IE6 efficiency motor represents a significant milestone in motor technology,” explained Marek Lukaszczyk, European and Middle East marketing manager at WEG. “An IE6 motor has another 20 per cent reduction of losses compared to an IE5 motor. The W23 Sync+ ULTRA’s hybrid design not only ensures higher efficiency across all speeds, but also contributes to reduced CO2 emissions, prolonged
www.weg.net
“As traditional induction motor technology nears its maximum efficiency capabilities, the necessity for alternative solutions became increasingly evident to WEG. Attaining higher efficiency standards requires electric motors to accommodate exceedingly high levels of inrush current, thereby requiring the implementation of new starter mechanisms and protective systems when replacing older motors.”
The environmental impact of the W23 Sync+ ULTRA extends beyond energy savings, contributing to broader reductions in greenhouse gas emissions and aligning with sustainable practices. The motor’s energy efficiency directly translates to reduced demand for natural resources and minimised environmental impacts, making it an ideal choice for industries striving for efficiency, reliability and sustainability.
The W23 Sync+ ULTRA motor line is available globally, supported by WEG’s comprehensive technical support and services. Its compact design and compatibility with existing installations make it an ideal choice for a wide range of applications, from compressors and pumps to fans and conveyors.
Visit WEG’s website for more information on the W23 Sync+ ULTRA and the company’s impressive range of energy-efficient electric motors.
Motor customers in the UK are currently particularly pleased with the fast delivery capability of German manufacturer Menzel Elektromotoren. In early June, the family-run company received two orders for large machines within one week.
Due to motor failures, the water supply to 30,000 households was threatened and production in a cement plant was halted. After delivery times of only six and ten days, respectively, both
the pump and the cement mill could be restarted in the shortest imaginable time. Faced with unexpected downtime due to equipment failures, customers often cannot afford to wait for a motor manufactured from scratch – standard delivery times in higher output ranges start at six months. Menzel has proven itself to be a strong partner in an emergency, quickly configuring suitable motor systems for a wide range of highoutput applications from its large, diverse stock of motors, cooling
units and ancillary equipment – such as the current two jobs for British customers.
The squirrel cage pump motor has a nominal output of 1380 kW operating at 3300 V. The slip-ring motor for a cement mill delivers 2000 kW at 11 kV. Its special features are increased ingress protection rated IP55 and a closed cooling system with a top-mounted air-toair heat exchanger (cooling type IC 611), ideal for dusty environments and large temperature fluctuations.
www.menzel-motors.com/article/large-lv-mv-hv-motors/
NEW ELECTRIC MOTOR PLANT FROM JANUARY 2024
SUPPLIER OF LARGE MOTORS FOR ALL UK APPLICATIONS
MORE THAN 20.000 MOTORS AVAILABLE FROM STOCK!
MORE THAN 20.000 MOTORS AVAILABLE FROM STOCK!
Motors up to 25 MW and 13.8 kV
Motors up to 25 MW and 13.8 kV
• Low voltage slip-ring and squirrel cage motors up to 3,000 kW
• Low voltage slip-ring and squirrel cage motors up to 3,000 kW
24,000 m 2
24,000 m 2
• Medium voltage slip-ring and squirrel cage motors up to 15,000 kW
• Medium voltage slip-ring and squirrel cage motors up to 15,000 kW
• Direct current motors up to 2,000 kW
• Direct current motors up to 2,000 kW
• Frequency converter-proof drives
• Frequency converter-proof drives
• In-house load test facility up to 13.800 V, 2.300 kVA, 120 Hz
• In-house load test facility up to 13.800 V, 2.300 kVA, 120 Hz
Customized special designs
Customized special designs
• Custom designs for special applications and operating conditions
• Custom designs for special applications and operating conditions
• Optimized motor design for higher efficiency
• Optimized motor design for higher efficiency
• Mechanically and electrically interchangeable motors
• Mechanically and electrically interchangeable motors
• Commissioning worldwide
• Commissioning worldwide
MENZEL Great Britain Ltd. | UK Branch Office
27 Hunt Drive | Melton Mowbray | Leicestershire LE13 1PB
Martin Rooney | Tel.: +44 1664 500 844 | Mobil: +44 7957 618046
martin.rooney@menzelgb.co.uk NEW ELECTRIC MOTOR PLANT FROM JANUARY 2024
MENZEL Great Britain Ltd. | UK Branch Office 27 Hunt Drive | Melton Mowbray | Leicestershire LE13 1PB Martin Rooney | Tel.: +44 1664 500 844 | Mobil: +44 7957 618046 martin.rooney@menzelgb.co.uk
MENZEL Elektromotoren GmbH
German Headquarters
MENZEL Elektromotoren GmbH German Headquarters
Am Alten Walzwerk 2 | 16761 Hennigsdorf | Germany
Am Alten Walzwerk 2 | 16761 Hennigsdorf | Germany
menzel-motors.com info@menzel-motors.com
menzel-motors.com info@menzel-motors.com
AROUND THE CLOCK, AGAINST THE CLOCK!
AROUND THE CLOCK, AGAINST THE CLOCK!
Postgraduate training that is personalised, flexible and taught by experts – that is what’s on offer from the Nuclear Technology Education Consortium (NTEC), whose unique course aims to create the UK’s next generation of nuclear experts, with the skills to secure a sustainable and safe nuclear industry.
Seven educational organisations in the UK who work together as the Nuclear Technology Education Consortium (NTEC), to support the UK nuclear energy programme. Established in 2005 after consultation with the nuclear industry, NTEC provides a wide choice of Master’s level course units for students with a science or engineering background, or relevant work experience, that are looking to enter the nuclear industry. The units are delivered in a short-course format of one-week duration that are suitable for full-time or parttime study. As well as the full Master’s option, students can also study for a PG Diploma (eight units) or PG Certificate (four units) or take individual modules for continuing professional development.
The units cover a broad range of topics including nuclear policy and regulation, decommissioning, environmental remediation, radiological protection and reactor physics and are therefore suitable for students with a wide range of backgrounds and career aspirations. We engage with our Industry partners to establish which new skills/units are required and we are looking at introducing three new units to the portfolio for 2024-25; Control & Instrumentation and
Functional Safety; Tritium and the Fusion Fuel Cycle; Primary Circuit Materials and Manufacturing.
Control and Instrumentation and Functional Safety covers the design, validation and verification, safety justification and assessment of C&I, focusing on its use in the nuclear industry. The unit spans topics from hazard identification and analysis, through the implementation of C&I systems, to the impact of developing technologies such as AI and quantum computing. Delivered by academic staff, industrial partners and former Office for Nuclear Regulation inspectors, the unit offers the chance to develop detailed knowledge of how C&I is applied in practice in the context of a functional safety process.
Tritium and the Fusion Fuel Cycle gives students an introduction to the growing nuclear fusion industry and the key tritium science and technology that underpins commercial fusion power. Tritium science is an inherently multi-disciplinary field, and this unit brings together nuclear physics, radiological protection, physical and chemical processing, and environmental impact considerations. It provides a well-
rounded overview and enables learners to join the fusion industry with a solid understanding of the uses of tritium and its associated challenges. The unit includes experimental work and a guest lecture from the UK Atomic Energy Authority’s world-leading H3AT centre for tritium research.
MSc - 1 year full time MSc - 2 or 3 year
Primary Circuit Materials and Manufacturing provides a comprehensive overview of the welding and cladding processes used in the fabrication of primary circuit components for pressurised water reactors. The unit starts from the physics of heat source-material interactions for the different processes used, moving through the metallurgy of welding and specific considerations for primary circuit materials. Links between manufacturing choices and throughlife structural performance are considered, as well as strategies for inspection and quality assurance. Case studies are used to demonstrate how the principles are applied in practice, as well as the issues that can occur.
Designed to create a generation and scientists with the skills and safe future for nuclear
Designed to create a generation and scientists with the skills and safe future for nuclear MSc - 1 year full time MSc - 2 or 3 year PG Diploma • PG Short Courses for
Key features: Demand-driven •
Course delivered by:
Course delivered by:
The University of Birmingham • University of Central The University of Manchester • The University
The University of Birmingham • University of Central The University of Manchester • The University
With the consortium approach, students have access to a very wide range of academic and industry experts that provide challenging vocational modules but also support the students through their studies, in preparation for a career in the nuclear industry. Students are helped with the transition from university to industry by completing an industry-based project as the final part of their degree.
It’s an exciting time to join the nuclear industry.
MSc - 1 year full time
MSc - 2 or 3 year part time
PG Diploma • PG Certificate
Short Courses for CPD Key features: • Demand-driven
time part time Certificate for CPD For more information: email: info.ntec@manchester.ac.uk or visit www.ntec.ac.uk
info.ntec@manchester.ac.uk
info.ntec@manchester.ac.uk
visit www.ntec.ac.uk
Daysoft only makes and sells daily disposable contact lenses because these are the healthiest type of contact lens to wear.
• From just 20p per lens delivered
Here at daysoft® we’re focused on what matters: providing simple, affordable vision solutions that are kinder to the planet without compromising on quality.
Daysoft only makes contact lenses because healthiest type of
• From just 20p per
• Simple to use; no cleaning so no cleaning solutions
• Made in the UK; over 1 billion sold
We believe healthy eyesight should be affordable for everyone
• Brand switch to daysoft® with no optician refitting needed
So we cut out the middleman and pass the savings to you. daysoft® lenses are made to rigorously high standards in our UK lab and then sold online, straight to you. As the only company in the world that design, make and sell contact lenses directly to customers, we’re able to replace other brands for half the price without compromising quality.
We’re the environmentally conscious choice
daysoft® is a Registered Trade Mark of DAYSOFT Limited
We’re conscious that single-use daily disposables have an impact on our planet. That’s why we’re working towards innovative solutions to reduce our carbon footprint.
We’re trailblazers in innovation and expertise
We’ve always been ahead of the curve when it comes to innovation and design. Our chairman, Ron Hamilton, invented daily disposables and built the world’s first laboratory dedicated to making them. We continue to innovate and improve, using patented daysoft® technology and our unique SoftEdge™ design to offer you the safest way to wear lenses at an amazingly affordable price.
Our unique INPAC technology enables us to reduce excess plastic waste by up to 50%.
Designed and manufactured in the UK, our contact lenses have a lower carbon footprint than those that are shipped from across the globe.
made medical devices
Safe, accessible, healthy eye care for everyone is at the heart of our vision at daysoft®. Our contact lenses are
• Simple to use; no
• Easy to buy; either subscription or pay-as-you-go
• Easy to buy; either
We’ve always been ahead of the curve when it comes to innovation and design.
• Made in the UK; over
• Brand switch to daysoft® refitting needed
Order online at
medical devices, and as such are required to meet strict standards, measured through a rigorous regulatory framework.
daysoft® is a Registered Trade
1
ALL OF OUR CONTACT LENSES ARE:
• Manufactured under the control of a certified Quality Management System, compliant with ISO 13485:2016.
• Approved under the European Medical Devices Regulations (Directive 93/42/EEC) under The Medical Device Regulations (Canada), licence #61427
• We’re also subject to regular audits by SGS Belgium Ltd, to ensure we continue to meet regulatory requirements, including stringent checks on the effectiveness of our sterilisation process.
we make
daysoft’s® manufacturing process has been designed around the high specification details of the contact lens itself. Our state-of-the-art facility in Blantyre, Scotland only makes daily-disposable lenses and our processes, along with a highly skilled workforce allow us to supply you with the highest quality lenses at the most affordable price.
During chemical reactions, whether it’s reactor heating, polymer processing or distillation, maintaining the delicate balance of temperatures isn’t just a matter of efficiency, it’s a matter of safety — particularly when working with heat transfer systems. Here Tim Powell, thermal oil specialist at Global Heat Transfer, explores how effective health and safety protocols can contribute to a safer and more efficient work environment when working with heat transfer systems.
Historically, facilities opted for steam-based heat transfer systems because water is readily available, affordable and seemingly sustainable. However, achieving the temperatures needed for industrial processes required the system to operate at extremely high pressures of around 1200 psi (83 Bar). This meant that, without adequate steam ventilation, the pipes ran the risk of bursting and gaskets failing, allowing hot steam to escape, which put workers at risk.
Thermal fluids, on the other hand, can safely maintain temperatures at much lower pressure and can be tailored to applications. They are suitable for both heating and cooling applications, with temperature ranges spanning from -90 to 600 degrees Celsius.
While they offer a safer alternative to steam and are designed to deliver prolonged and efficient service, facilities employing heat transfer fluids should still adopt preventative measures to extend
fluid lifespan and meet safety standards.
To comply with industry regulations, manufacturers using heat transfer fluids must take proactive steps to assess potential risks and implement measures, such as a Thermocare® maintenance plan, to eliminate them as much as possible. Thermal fluid is classed as a dangerous substance, but when monitored routinely and proactively managed, it will give great service for many years.
While heat transfer fluid has an effective life expectancy of many years, its efficacy decreases as it nears the end of its lifespan. This decline can lead to the introduction of by-products into the system. Specific regulations outline guidelines for health
and safety managers to reduce the potential risks linked to this degradation, but this is often easier said than done. This is because once thermal fluid is introduced into the heat transfer system, it is no longer visible, allowing any underlying problems to remain unnoticed until they disrupt production.
To manage risks effectively, health and safety managers should closely collaborate with thermal fluid specialists to monitor fluid condition. Engineers should take a closed fluid sample when the system is hot, live and circulating, so they can accurately assess the fluid’s status. Quarterly sampling and thermal fluid analysis help engineers monitor its condition and inform health and safety managers on how to adjust procedures to minimise the risk of incidents.
In addition, facilities have the option to employ remote condition monitoring, which can improve proactive maintenance efforts. Cloud-based remote monitoring systems use live, real-time analytics to diagnose potential issues. As soon as the system detects an anomaly, it warns maintenance personnel by sending an alert to their smart devices. This pioneering technology empowers engineers to prolong the safe and effective use of thermal fluid.
For support and advice on how to get the most out of your heat transfer system, and prolonging the life of your thermal fluid, contact Global Heat Transfer.
For further information, please visit www.globalhtf.com
The new bar code reader. Perfect performance on the conveyor line.
Our new BCL 200i bar code reader is specialized for guided container and tray identification. Its especially compact design is optimally tailored for stationary use in confined spaces. Integrated industrial interfaces and simple configuration offer you perfect performance at the best price.
www.leuze.com/bcl200i
• ‘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
• professional development
• Webinars and seminars for knowledge sharing
• This selection of specialist publications and many
Also... EEMUA Seminar – Engineering Energy Transition – London, UK – 6 June 2024
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
From day one, Learners on the EEMUA MIPC® training build a unique workbook of mechanical integrity know how tailored to each Learner, site and company. Combining live online classes, e-learning, and one-to-one sessions with expert Tutors, enhanced by Mentor support and guidance throughout, EEMUA's Mechanical Integrity Practitioner Certificate course gives professionals the flexibility to learn on-site or on-call.
Deeveloped and verified by industry to satisfy industrial engineering’s requirements for primary containment in old and new equipment – including pressure systems.
Keeps practitioner-level engineers on top of industry developments and good practice
so that valuable practitioners are most effective wherever they’re needed on-site.
Enterprise-class, blended, live online system for productive learning – on-site or on-call.
Adapts to the engineering needs of each Learner and their company via an Induction of 2 hours prior to the course – to fit work schedules from September 2024
In-depth training to fit work schedules – 4 hours per week for 27 weeks.
CPD-approved with i industry recognised 5-year certification via robust exam.
For more information please contact online-learning@eemua.org +44 (0)20 7488 0801 www.eemua.org
Registration open now. Learning starts 21October 2024. . . . . . . MIPC® shortlisted for the
Your Fire Prevention and Measuring Technology partner for over 30 years!
GreCon Limited makes people and places safer and enables the ‘smart factory’ as the leading provider of innovative industrial fire prevention and process measurement solutions.
GreCon Limited is located near Newcastle upon Tyne and is a member of the Fagus-GreCon Group. With a wealth of experience as a global market leader, GreCon demonstrates a strong understanding of customer needs and provides turnkey solutions for many industries, including recycling, manufacturing, biomass, pharmaceutical, food, and hygiene.
The company focuses on developing sustainable customer relationships as a strategic partner. Customers depend on GreCon for consultative and problem-solving sales engagement and first-class customer service. In addition, a fast response is possible due to comprehensive local stockholding and a strong engineering team with national coverage.
Fire Prevention to enable uninterrupted production
GreCon’s fire prevention technology protects industrial premises, processes and people, detecting and extinguishing ignition sources in mechanical and pneumatic conveying systems, filters, dryers, silos and other production areas, making workplaces safer and enabling uninterrupted production.
Fire Prevention or Fire Protection?
The adage, ‘prevention is better than cure, ‘ rings true. GreCon believes that early detection of ignition sources is critically important. Once a fire starts, the results can be catastrophic. When
companies are unaware of GreCon’s technologies, they rely on more conventional fire protection systems, which do not always provide the best defence.
A comprehensive range of industrial process measurement solutions equips the ‘smart factory’, helping customers improve product quality in their production processes, using proven German engineering to reduce raw material and energy costs, ultimately maximising operational efficiency.
GreCon focuses on anticipating customer requirements in a technology roadmap, with a proven track record of bringing innovative products to market.
Customers are particularly interested in the DLD 1/9, a highly sensitive spark, ember and hot particle detector for protection against fire and explosion in industrial processes. Intelligent Detection Technology IDT® provides optimal detection performance for all ignition sources in any environment and enables the detector to distinguish
between dangerous sparks and harmless ambient light.
Demonstrations started in 2022 of the GreCon IEM, the Intelligent Extinguishing Module, as an exciting addition to an intelligent fire prevention solutions portfolio. Critical benefits include more rapid extinguishing of sparks and harmful ignition sources. In addition, integrated intelligent extinguishing technology (IET®) enables highly precise extinguishing process monitoring and predictive maintenance control.
Today customers all over the world rely on GreCon. Please get in touch to discuss how we can help:
Email: sales@grecon.co.uk T: 0191 414 7200 www.grecon.co.uk
• Standard and bespoke specification chambers designed to meet any needs.
• Sizes ranging from containers, walk in rooms, floor standing & bench top.
• Temperature, humidity or combined solutions available.
• Service, Calibration and Installation.
A family run business that has been in operation for over 25 years. Originally set up by Four Donnelly brothers back in 1995, the company has expanded, and continues to expand, to become a one-stop-shop for all steel fabrication needs. With our wide range of services, we can take a design and have the material cut, pressed, fabricated, painted, and delivered to your door.
We currently own 5 Bystronic Lasers and an Esprit Plasma Cutter that are in operation day and night to meet demand. We work with a wide range of materials, typically mild steel, and have a cutting capacity of 4x2m plate and 20mm thickness on the lasers and 8x2.5m plate and 50mm thickness on the plasma. We offer cutting services, creating flat kits for customers, packaged to their specifications. Our 7 Bystronic Pressbrake machines, combined with our skilled staff with 20+ years of experience, make light work of all bespoke folding operations, working with a wide range of materials with a capacity of up to 6.2m length at any thickness within the weight capacity of the machine. Folded parts can be built to create sub-assemblies or part kits, made and delivered to your requirements.
We have created all scales of fabrications for many different industries, our dedicated workforce has a wealth of knowledge and skill to meet all customer requirements from prototyping, fine component welding to large fabrication assembly. All components and assemblies go through rigorous control measures to make sure our customers receive the highest quality from our services. We have
We strive to make the process as simple as possible to streamline your production and meet all customer demands within a timely manner.
invested heavily into state-of-theart robotic welding units, with a total of 3 at present, which are a game-changer when it comes to larger fabrications. The addition of this completely removes all human error from the process and creates perfect welds every time. Once a program has been created, this can run independently, increasing productivity, reducing lead times, and reducing consumable usage, meaning
we can offer lower prices for our clients.
We operate solely within our 71,000 square foot factory grounds in Magherafelt, Northern Ireland, with our own selection of privately owned vehicles, we are delivering products across the UK and Ireland. We are eager to form new connections within different industries as we continue to grow and expand.
With great investment into top of the range laser cutting machinery, our 5 Bystronic machines run day and night to meet demand, cutting up to 20mm with our lasers and 50mm on a plasma.
Through expansion and investment, we have grown a large team of skilled professionals, expert problem solvers, that work closely with customers to create high quality products with ease.
We own 7 Bystronic Press brakes with a capacity of up to 6.2m length at any thickness within the weight capacity of the machine, to complete intricate bends, achieving bespoke designs.
Our latest innovation has come from the investment into stateof-the-art robotic welders to create consistent high quality on a large scale, with reduced wait times
We’re capable of all projects big or small to streamline your product development
We are a family-run business based in Northern Ireland. Set up originally by four Donnelly brothers who continue to work alongside their employees on site. Established in 1996, we have continued to grow and expand to provide services for many different sectors of engineering from Quarry products, Chassis manufacturing and many more.
With over 25+ years' experience in the industry, we strive to bring you the best solutions as we pride ourselves on our close customer relations. Create a bespoke product or kit and have it delivered to your door with reduced costs and zero waste. We have invested heavily into state-of-the-art equipment, so you don’t have to!
WISEMAN THREADING TOOLS LTD
We have been supplying threading tools and gauges since 1987.
Together with supplying plain plug and ring gauges this is all that we do, we therefore consider ourselves to be specialists in this field.
We supply worldwide.
We hold extensive ready stocks that include all of the standard stuff that others offer, but also includes taps, dies, die nuts, die head chasers, thread rolls and gauging for threads not normally available 'off the shelf '.
Our real time stocks can be checked and purchased online at www. threadtools.com Just enter the thread details into the search box on the home page.
You will be directed to the item, if stocked, or to our specials, (custom manufacture), sales team. who will quote to supply at competitive rates, in good time.
As an account holder you can also order online from our listed in stock items, at your normal terms. We realise that you need the right item at the right price and quality, and in a reasonable time frame.
We are geared to provide that.
We can ship stocked items same day.
Our experienced sales staff can assist and advise you on any technical issues.
We welcome enquiries from resellers and can offer terms to suit.
WISEMAN THREADING TOOLS LTD
11 Padgets Lane, South Moons Moat, Redditch B98 0RA UK
+44(0)1527 520 580 sales@threadtools.com www.threadtools.com
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
THREAD GAUGES all types. Large stocks for standard and SPECIAL threads. Any non stocked can be quoted for custom manufacture.
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.
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!
AFT Fluorotec Ltd is a group of Engineering companies based around the outskirts of London in Welwyn Garden City and Kent, with over 120 dedicated individuals, each bringing their own strengths, skills and experience to our work.
AFT Fluorotec is a specialist processor of PTFE and VICTREX PEEK® materials and manufacturer of complex precision machined components in engineering plastics.
Established in 1986, we’re proud to be pioneers in the processing and machining of PTFE, PEEK, PCTFE and hundreds of other engineering plastics using the very latest technology. This includes a vast range of our in-house developed blends and compounds in PTFE and PEEK materials adding strengths to physical properties to suit specific applications.
‘Tornos Deco’ sliding head 10 axis turning centres, Mazak Integrex
fully robotic machining centres supported by traditional Mazak CNC lathes and state-of-the-art Hass Machining centres give AFT Fluorotec an unrivalled range of machining resources to produce cost competitive machined parts to the very highest standards, regardless of the complexity, batch size or component dimensions.
AFT Fluorotec offer a complete design and manufacture service for their range of PTFE spring energised seals for specialist sealing applications, as well as a range of PTFE slide bearings and skidway systems for pipeline, ship building and construction projects.
• Seals
• Micro Connectors
• Valve seats
• Spring energised seals
• PU seals
• Elastomeric seals
• Back up Rings
• PEEK Bearing Cages
We are proud to supply our services to virtually all branches of industry, large and small:
1. Aerospace
2. Medical
3. Oil & Gas
4. Microwave
5. Defence
6. Automotive including F1
7. Communications
8. General Manufacturing
AFT Fluorotec boast an advanced coating facility.
As Specialist approved coaters of Whitford, PPG and VICTREX PEEK® coatings systems as well as supplying a wide range of industries with AFT developed house stock coating systems, our expertise and range of products means we can tailor the properties of different coating materials to suit your individual application. PTFE, VICTREX PEEK, FEP, PFA, ETFE, Halar ECTFE, Teflon and Xylan are all standard coating systems offered by AFT Fluorotec.
INDUS Engineering Services is proud to offer a wide range of custom control panels, automation systems and special purpose machinery. After working on major control and automation projects for several of the south’s leading brands, the company has recently acquired a new premises with the aim of increasing production capacity of bespoke and sub-contract, control panel manufacture. The new premises will also allow us to support the wider range of engineering
activities carried out by the company, such as the design, manufacture, and testing of special purpose machinery. Also, to further our goals to reduce our carbon foot print we will be installing a high efficiency solar PV array in the coming months. For more information on the services that are available please do not hesitate to contact and we will be happy to discuss your project needs and requirements.
www.indusengineering.co.uk
Totalkare’s ergonomic positioners are single or double column devices that enable the lifting and rotation of a product during welding and assembly operations.
With overall capacity from 2,000 - 90,000kg to suit, they are both compact and flexible.
Expert supplier of new and used sheet metal machinery: Supporting the circular economy with exceptional customer service
Machinery Supplies UK Ltd is a supplier of new and used sheet metal machinery, service spares consumables and accessories.
Established in 2020, though still a new company, owner Andy Naylor brings a wealth of experience spanning over 35 years. The resident expert team of machine operators, software engineers and electronic & hydraulic engineers are on hand to help match customers with the right machinery and parts, even if they aren’t in stock.
With a focus on premium customer service, Machinery Supplies UK offers a 24/7 Support Network for customers around the country and prides itself on its ‘can do’ winning attitude.
“I have been working with sheet metal machinery since I left school in the mid-1980’s and now we sell the machines I used to operate. With a truly international outlook, we have sold machinery to the USA, Taiwan, Europe as well as all over the UK. The latest cutting-edge laser welding machinery is coming from China and I travel there regularly to meet with these high-end manufacturers,” explained Andy.
With a focus on premium customer service,
Machinery Supplies UK offers a 24/7 Support Network for customers around the country and prides itself
on its ‘can do’ winning attitude.
Machinery Supplies UK provides the following new and used machinery and solutions to customers, both in stock and on-site available for demonstration with our team of experts:
• Fiber Laser cutting machines
• CNC Punching Machines
• Press Brakes
• Used Machinery
• Material storage solutions
• Deburring equipment
• Laser cleaning equipment
• Fiber laser welding
• Laser parts and maintenance
• Laser accessories
We are delighted to showcase Machinery Supplies UK Ltd with our Production innovation Award.
Machinery Supplies UK Ltd is a supplier of new and used sheet metal machinery, service spares consumables and accessories.
Fiber Lasers are widely used across industrial environments for a range of actions from marking, welding, cutting, cleaning, drilling, and much more and are renowned for advanced-precision. Furthermore, many companies appreciate the smaller carbon footprint, low maintenance and operating costs of Fiber Lasers. The engineers at Machinery Supplies UK offers support across most makes of Fiber Lasers and currently have the following two machines for sale:
Established in 2020, though still a new company, owner Andy Naylor brings of experience spanning over 35 years. resident expert team of machine operators, software engineers and electronic & engineers are on hand to help match customers with the right machinery even if they aren’t in stock.
With a focus on premium customer Machinery Supplies UK offers a 24/7 Network for customers around the country prides itself on its ‘can do’ winning attitude.
“I have been working with sheet metal machinery since I left school in the mid1980’s and now we sell the machines to operate. With a truly international we have sold machinery to the USA, Europe as well as all over the UK. The cutting-edge laser welding machinery coming from China and I travel there to meet with these high-end manufacturers,” explained Andy.
• NEW compact 3M x 1.5M 3kW Fiber Laser: Manual pullout table complete with chiller, extraction filtration system, with Maxphotonics laser source. Full price: £59,000: including installation and warranty.
Machinery Supplies UK provides the new and used machinery and solutions customers, both in stock and on-site for demonstration with our team of S Fiber Laser cutting machines
S CNC Punching Machines
S Press Brakes
S Used Machinery
• NEW 3M X 1.5M 6kW Fiber Laser: Changeover table, chiller, extraction filter, with Raycus laser source. Full price: £119,000: including installation and warranty.
S Material storage solutions
S Deburring equipment
S Laser cleaning equipment
S Fiber laser welding
S Laser parts and maintenance
S Laser accessories
Innovation Award
There is also a selection of used laser machines available of various kw and size ranges with chiller, extraction, software and fully installed package. This is a great addition to the circular economy, for those looking to invest in second-
Fiber Lasers are widely used across industrial environments for a range of actions marking, welding, cutting, cleaning, and much more and are renowned for advanced-precision. Furthermore, many companies appreciate the smaller carbon footprint, low maintenance and operating costs of Fiber Lasers. The engineers at
Expert supplier of new and used sheet metal machinery: Supporting the circular economy with exceptional customer service
Machinery Production supplier machinery, accessories.
new
a wealth years. The operators, hydraulic match and parts, service, Support country and attitude.
metal midmachines I used outlook, Taiwan, The latest machinery is there regularly manufacturers,” following solutions to on-site available experts:
industrial from drilling, for many carbon operating at
Machinery Supplies UK offers support across most makes of Fiber Lasers and currently have the following two machines for sale:
S NEW compact 3M x 1.5M 3kW Fiber Laser: Manual pullout table complete with chiller, extraction filtration system, with Maxphotonics laser source. Full price: £59,000: including installation and warranty.
S NEW 3M X 1.5M 6kW Fiber Laser: Changeover table, chiller, extraction filter, with Raycus laser source. Full price: £119,000: including installation and warranty.
There is also a selection of used laser machines available of various kw and size ranges with chiller, extraction, software and fully installed package. This is a great addition to the circular economy, for those looking to invest in secondhand, reconditioned machinery, as part of sustainable best practice.
cartridges, multitools, collars, die adaptors and expert advice as well as spares and consumables.
“Our DEBURRING machines also offer exceptional value, adding the final finish and touch to the laser cut parts. From simple deburring to regraining, our process of materials solutions are available to fit customer requirements.”
“We are forever liaising with our NEW equipment suppliers in order to bring only the premium UK market high quality sheet metal working equipment, coupled with our faultless aftersales support.”
“Our new state of the art East Yorkshire showroom will be opening later this year, when we will invite new and existing customers from across the industry. Watch this space!” added Andy.
For more information, please see the contact details below:
T 01482 420491
T 07743 989565
info@ukmachinery.uk https://ukmachinery.uk https://www.linkedin.com/in/andy-n-629859a0 https://twitter.com/usedmach
Machinery Supplies UK goes further than other suppliers by offering additional services such as Laser Slat Cleaners: designed to reducing part scratching and keep extraction flowing, part and parcel of laser bed longevity. This includes the 240v/415 v models for varying kW laser powered machinery. Furthermore, the Rhino Parter Hammer is renowned for making the removal of tabbed laser cut parts much easier, using a handy automation impact vibration to break the tabs.
hand, reconditioned machinery, as part of sustainable best practice.
The wide selection of Press Breaks include makes such as Amada, Trumpf and Bystronic from small compact to large tonnage and bed sizes, all fully checked tested, serviced and prepared and comes with a full warranty. The team can provide tooling at an extra cost and all machinery is installed on-site, with full training given to operators. These press brakes can bend thick materials across various applications from construction, automotive, aerospace, agriculture to oil and gas.
TRUMPF is widely considered to be the pinnacle of German machinery manufacturing across the entire machine tool, laser and electronics sectors. Regarded as a worldleader in machine tools for flexible sheet metal processing, the TRUMPF CNC Punching Machines are in high demand across the UK and further afield. The expert engineering team at Machinery Supplies UK provides an extensive range of TRUMPF accessories from
Machinery Supplies UK goes further than other suppliers by offering additional services such as Laser Slat Cleaners: designed to reducing part scratching and keep extraction flowing, part and parcel of laser bed longevity. This includes the 240v/415 v models for varying kW laser powered machinery. Furthermore, the Rhino Parter Hammer is renowned for making the removal of tabbed laser cut parts much easier, using a handy automation impact vibration to break the tabs.
automotive, aerospace, agriculture to oil and gas.
team at Machinery Supplies UK provides an extensive range of TRUMPF accessories from cartridges, multitools, collars, die adaptors and expert advice as well as spares and consumables.
“Our DEBURRING machines also offer exceptional value, adding the final finish and touch to the laser cut parts. From simple deburring to re-graining, our process of materials solutions are available to fit customer requirements.”
“Our new state of the art East Yorkshire showroom will be opening later this year, when we will invite new and existing customers from across the industry. Watch this space!” added Andy. sponsors this issue of Best Practice – see them on pages 4-5 9
The wide selection of Press Breaks include makes such as Amada, Trumpf and Bystronic from small compact to large tonnage and bed sizes, all fully checked tested, serviced and prepared and comes with a full warranty. The team can provide tooling at an extra cost and all machinery is installed on-site, with full training given to operators. These press brakes can bend thick materials across various
TRUMPF is widely considered to be the pinnacle of German machinery manufacturing across the entire machine tool, laser and electronics sectors. Regarded as a world-leader in machine tools for flexible sheet metal processing, the TRUMPF CNC Punching Machines are in high demand across the UK and further afield. The expert engineering
“We are forever liaising with our NEW equipment suppliers in order to bring only the premium UK market high quality sheet metal working equipment, coupled with our faultless aftersales support.”
Sulzer introduces rental test equipment for agile and cost-effective process development
MCE test loop at Sulzer’s
To streamline process development initiatives and empower the green transition in industrial manufacturing, Sulzer introduces a comprehensive range of rental test equipment to support the development of bio-based products.
Sulzer’s rental equipment makes process development agile and costeffective by minimizing investment, start-up, and maintenance costs. The selection caters not only to traditional wood and pulp-based intermediates but also novel feedstocks such as mixed and virgin textiles, agri-waste, and biomass from various sources.
Testing can be conducted at Sulzer’s full-scale development center in Kotka
Sulzer’s rental equipment makes process development agile and cost-effective by minimizing investment, start-up, and maintenance costs. or at the customer’s site, providing flexibility in testing environments. Additionally, Sulzer offers the possibility of co-development projects if specific equipment needs are not met by the existing rental selection.
With a long history in research and development in a network of leading forest industry companies, academics and research institutes, Sulzer stands as a committed partner for process development. The company ensures scalable solutions for partners’ development initiatives with unmatched application expertise and a versatile portfolio of process equipment.
With a legacy of innovation and strong experience as an equipment supplier, Sulzer continues to drive advancements in various industries, offering cutting-edge solutions for the evolving needs of its partners worldwide.
For more information, visit www.sulzer.com
Cross+Morse is a Birmingham based manufacturer of Mechanical Power Transmission products and solutions with over 100 years of history, right in the centre of the engineering hub in the West Midlands region in the United Kingdom. We operate in a 5000m2 fully integrated factory with a dedicated and loyal staff who have amassed a depth of technical expertise and engineering experience over their many years of continued service.
Cross & Morse are Mechanical Power Transmission solution specialists and at this present time we have £1.5m worth of finished stock on our shelves such as Roller Chain and Sprockets in both stainless and carbon steel, Gears, Racks, Couplings, Torque Limiters, Sprag Clutches, Timing & V belt Pulleys, timing & V Belts, Inverted Tooth Chain, Silent Chain, Sealmaster Bearings, McGill Cam followers, Shaft Clamping Elements, Freewheel & Overload Clutches.
We value innovation highly at Cross+Morse, which is why we constantly invest in new machinery and technology as well as training programmes and apprenticeships to maintain the highest standards of quality and service we are well known for. With our
in-house team of application and design engineers at your disposal Cross+Morse are able to provide bespoke technical solutions to your power transmission problems in the most cost-effective way.
Have a specialised or ambitious requirement? Send us your drawings and
application details and we will do our utmost to find the best solution possible, we welcome a challenge! We have been providing solutions for the food and drink, oil & gas, agricultural, pharmaceutical, quarrying, energy and environmental industries, bottling and packaging plants and many more for over 100 years. Our customers come from the widest range of industries and include original equipment manufacturers for packaging, conveying systems and material handling applications. We also export our quality products all over the world, through our network of long standing distributors or directly to the manufacturers and end users of mechanical power transmissions on every continent.
At Cross+Morse we consider customer support along with in-house design and manufacture an essential element in our service to industry, please browse our website for details and more information on our manufacturing capabilities as well as our stringent quality control. We are certified to ISO 9001:2015 and have been for over 30 years.
Call or email us now to solve your mechanical power transmission problems.
Macsa ID UK is targeting the engineering and industrial markets with its newly launched SPA2 series of modular laser coders. Featuring several technologies and multiple power options, the simplified platform delivers maximum marking resolution and definition at higher speeds, more consistently over time. The advanced systems are versatile and reliable, as well as cost effective to own, maintain and operate. Kind to the environment, laser coder technology is fume, waste and consumable free, and uses less power and energy.
Boasting a modular design, Macsa’s flexible SPA2 lasers can be easily integrated with any production line or application, and adapted to meet changing needs of the user. Providing high quality marking on a range of materials, such as wood, thermal labels, board, metallised board, glass, ceramics, metals, rubber and plastics, the SPA2 platform is available with CO2, DPSS and Fiber technologies (several wavelength options). Plus, laser power from 3w-250w, enclosures for standard, dusty and wash down environments, extra powerful performance and high speed heads.
Macsa’s SPA2 F pulsed fiber laser model in particular is widely used for marking onto plastic or metal-coated materials, such as aluminium beverage cans, making it ideal for engineering and industrial applications. The new XQS high precision printhead ensures clear and legible codes even on curved surfaces with information applied continuously at high speed while maintaining integrity of the substrate.
The SPA2 series is also available with a HPD printhead for high resolution
images, difficult substrates, product modification and marking areas above 250mm2. Digital galvos make calibration, trouble shooting and replacement much easier. A UHS printhead is available for very high speed lines and longer, more complex messages.
Due to the innovative EEP® (easy exchange printhead) feature, operators can switch printer heads on site using just two connectors, allowing the laser system to be adapted to the requirements of the production line at all times.
Exceptionally easy to install, program and operate, online help videos, technical guides and tips can be accessed via a new 10- inch handheld touchscreen controller designed to make programming quicker and to eliminate operator errors. The lasers can also be controlled direct from a PC via an ethernet link or PLC with Profinet or OPC-UA.
The enclosure has been redesigned with a flat front surface allowing simple integration of vision systems and other devices. With models that meet IP54 and IP65 standards, the SPA2 lasers are designed to operate in dusty or
damp environments and in extremes of temperature.
The novel RAF® (reverse airflow cooling) system means that filters are changed less frequently and not at all in some circumstances. A sealed air system transfers heat from the laser to the cooling air itself. This eliminates the risk of dust being deposited directly into the system component. Part of the exhaust air is blown over the focusing lens keeping it dust free so that print quality is maintained without the need for operator intervention.
The surface recognition feature, which is included within its 3D printing kit, allows printing on multi-level surfaces, ensuring an optimal focal point at all times. An external Z-axis controller enables operators to adapt the SPA2’s vertical coding axis in order to vary the height between print cycles and adapt it to different products.
The SPA2 connector box offers a wide range of communication ports, enabling the system to be integrated with all elements of the production line. The lasers support Macsa’s Optima software for real time control and compatibility with desktop printers, label printer applicators and label applicators.
Macsa’s SPA2 laser coders are available with a comprehensive range of software, accessories and services, and backed by advice and consultation services, installation assistance, training, technical support and extended warranty.
For product information please contact: sales.uk@macsa.com or telephone 01462 816091.
Vision Engineering Ltd, a multinational designer and manufacturer of innovative, patented ergonomic stereo optical and digital instruments has relocated its anodising arm, Milturn Finishing, to a brand new facility in Measham, Leicestershire following its acquisition in 2022. The Leicestershire location is beneficial as the Midlands serves as a major hub for UK manufacturing, innovation, and skilled workforce.
The new ISO9001 certified site delivers modern new facilities which include large 3m x 1.5m anodising tanks, which accommodate larger work pieces, enabling efficient processing of entire components without needing to break them down. This reduces processing time and cost. Larger tanks enable deeper immersion for uniform anodising. The increased depth allows for complete submersion of parts, ensuring consistent coating thickness and quality across the entire surface and reduced handling needs for smaller parts, meaning that batch processing of smaller parts becomes more efficient, minimising handling time and potential damage.
The Leicestershire location is beneficial as the Midlands serves as a major hub for UK manufacturing, innovation, and skilled workforce.
Milturn Finishing’s high load crane delivers safe and efficient handling of heavy work pieces, improved productivity and throughput including faster handling of parts, and handling multiple parts at once, boosting productivity.
Services include accurate masking and demasking of complex parts pre and post anodising which delivers high accuracy selective anodising, maintaining dimensional integrity, improving process efficiency, and ultimately contributing to consistently high-quality results.
Extensive experience and professional advice in anodising and finishing plus competitive pricing, fast track service, free delivery & collection, together with free quotation and sampling services complete the picture for the new Milturn Finishing offer.
Milturn’s long term customer base consists of manufacturers in a variety of industries, such as professional film camera, seagoing marine, automotive, high end shop and hotel fitting and others, who are characterised by a requirement for reliable, well finished components for intensive use, sensitive or harsh environment conditions.
Commenting on the launch of the new facility, Vision Engineering’s Director of Manufacturing, Steve Mead said ‘We are delighted to be adding these new modern finishing facilities to our Manufacturing Services offer. They enable us not only to improve the way we meet the needs of our existing finishing customers, but also present a real opportunity to attract new, Midlands based customers to Milturn Finishing’s customer base.’
Meet Mantis, THE stereo microscope brand trusted by thousands of customers globally to deliver excellent high quality images for a wide range of magnification applications, in an easy to use ergonomic system.
To see what you’ve been missing search vision engineering mantis, scan the QR code or call us on 01483 248300.
As a leading global protective packaging supplier Storopack recognizes the importance of ensuring goods are protected during transit and arrive in perfect condition.
Damaged goods not only incur costs for replacement orders but also affect businesses’ reputations. So while costs need to be kept to a minimum it is vital to choose the correct protective packaging type.
Usually a void fill packaging medium will suffice. However when the product is more sensitive to shock and vibration, such as engineering, electronics, aeronautical, and many other expensive products then more consideration has to be given to using the right type of in-thebox protective packaging.
Storopack’s FOAMplus® range is a perfect solution for companies that manufacture or ship products that require this highest degree of protection eliminating transit and handling damage.
The success of FOAMplus® polyurethane foam is based upon its huge versatility as a packaging medium. The foam can either be dispensed directly into the carton where the expanding foam will mould itself to the contours of the product shape or can be made into pre-moulded cushions to enhance presentation. The product will satisfy the most rigorous cushioning demands for high value, fragile and awkward shaped products. The light weight foam packaging also ensures that shipping costs are kept to a minimum whilst providing customers with total product protection.
As a space saving solution FOAMplus®, polyurethane foam packaging is ‘on demand’ and mixes two components together which then expands up to 200 times its liquid volume negating the necessity for large storage areas required for pre-fabricated packaging.
The benefits for customers are numerous. As well as an ideal solution
for protecting awkward and valuable products, customers with product design changes and new product line additions are able to quickly adapt the packaging without the need to carry a large range of bespoke cartons or fabricated packaging.
There are two dispensing methods available for the insitu protective packaging solution. Either FOAMplus® Hand Packer, a manually operated system, with a fully electronic microprocessor control to maintain consistent quality that delivers the foam direct into polythene lined carton via a foam dispensing gun.
Alternatively the Bag Packer² Foam-in-Bag dispensing system is fast, easy to use, efficient and economical. The machine can produce up to 23 foam-filled bags per minute at the touch of a button. Polyol B 5504R, foam B component is made from 30 percent recycled polyurethane.
www.storopack.co.uk
In manufacturing, efficiency is key to success. Improved efficiency results in greater productivity, less waste, fewer hours lost to downtime and lower costs. This is why automated technology such as sack-filling machines and palletisers is so valuable – these machines feature specialist gripping heads to handle items with speed and precision.
Gripping heads explained
The gripping heads found on palletisers are designed to hold bags, sacks and packages securely, allowing them to be moved quickly and efficiently without causing damage. Different gripping heads are available for handling different products and the most appropriate one will depend on the item’s shape, size, weight and handling requirements.
Common gripping heads may be vacuum operated, feature side clamps or magnets, or use a combination of all three.
Choosing the right robotic gripper
Where there is a flat top surface, such as on boxes and cartons, a vacuum gripper is often used. However, at PALpack, we prefer to use a physical mechanical gripper, for reasons
from changes in porosity to stability. All of PALpack’s palletisers are designed so that there are no change parts for different pack types.
Cartesian palletisers
World-leading manufacturer Lita offers gantry-style Cartesian palletisers which can pick and place items, often in complex pallet patterns. Several different gripping heads are available for handling different products. Because of the different gripping heads, both can handle RSC cases and shrink-wrapped packs of varying sizes and Robodue can also manage jerry cans.
Suitable for handling RSC cases, shrink wrapped packs, metal drums, bags, and sacks, Logico by Lita features a single arm with different gripping heads for different products. They can insert pads between layers and handle empty pallets as well as move packages.
Different types of bags or sacks have different handling requirements and gripper heads can be designed accordingly. Europack’s rotating beam palletisers have a 360o rotating gripper head that can be changed to suit different packages, while combined heads can deal with more than one type of product.
Using sack-filling and palletising technology along with specific gripping heads improves processes, saving time, reducing manual labour and helping manufacturers to improve their overall operations. PALpack can supply not only sack palletisers, but also VFFS sack filling machinery.
Tinytag Ultra 2 thermocouple data loggers are used to record temperature data during the heat curing of medical grade acrylic at Manchester Royal Eye Hospital.
NHS ocularists working in the Department of Ocular Prosthetics at Manchester Royal Eye Hospital are responsible for fabricating and fitting ocular prostheses, cosmetic shells and facial prostheses. Part of the fabrication process is the heat curing cycle, in which the medical grade acrylic which the prosthetic eyes are made out of is exposed to high temperatures so that it hardens and is suitable for wear.
The ocularists use Tinytag Ultra 2 thermocouple data loggers to monitor temperatures during the heat curing cycle to ascertain that the acrylic has been cured at the optimum temperature (a temperature range of 200°C to 1300°C for the correct amount of time).
If the acrylic is not cured properly, the material does not harden fully and remains porous, resulting in monomer leaking out of the acrylic and causing irritation for the wearer. It is therefore imperative that temperatures are recorded during the cycle. Tinytag thermocouple data loggers are ideal for use in this application, as their thermocouple probes offer fast response monitoring in temperatures from -200°C to +1370°C.
To monitor the heat curing cycle,
If the acrylic is not cured properly, the material does not harden fully and remains porous, resulting in monomer leaking out of the acrylic and causing irritation for the wearer.
the data logger’s thermocouple probe measures the temperature within the heat curing tank, while the data logger itself remains outside the tank recording the readings taken by the probe. The data from each cycle is downloaded, viewed and analysed using Tinytag Explorer software. If the temperatures are found to
have fallen outside the desired parameters, indicating that the acrylic may have not cured properly, the cycle is repeated to ensure that the prosthesis is properly cured.
Using Tinytags to monitor temperatures during the heat curing cycles gives the team at Manchester Royal Eye Hospital peace of mind that the acrylic has cured properly and therefore will give the best possible results for their patients.
Data loggers for indoor, outdoor and industrial/process applications
• Rugged and compact
• Rugged and compact
• Easy to use
• Easy to use
• Dust, splash or waterproof
• Dust, splash or waterproof
• Data downloaded to PC
• Data downloaded to PC
• Cost-effective
• Cost-effective
Accompanying probes are available for monitoring extremes of temperature, and for awkward to reach areas such as pipework.
Accompanying probes are available for monitoring extremes of temperature, and for awkward to reach areas such as pipework. For larger sites, Tinytag Radio and LAN loggers automatically gather data for viewing on a PC, across a
Logger
For larger sites, Tinytag Radio and LAN loggers automatically gather data for viewing on a PC, across a LAN or remotely across the internet.
or remotely across the internet.
where conventional measurement techniques fail. radiometric measurement systems for the chemical and pressure, and high-temperature environments require conditions. Due to the non-intrusive nature of the materials, the system is normally wear and tear free and, chemical & petrochemical plants.
is a system, which consists of a source that emits gamma radiation and a radiation. Gamma radiation is attenuated as it passes through the vessel or The amount of attenuation depends on the filling level or the product density: denser the product, the less radiation reaches the detector. In this manner, the influenced by pressure, temperature, viscosity, colour or chemical properties of the
measurement continuous level and level switch measurements monitor reliably. Customi sed solutions for the unique process and petrochemical industr ies are achieved with a sources in different arrangements and geometries, to insert sources into vessels. In critical switches in conjunction with continuous level increased process safety.
measurement
Berthold‘s radiometric measuring systems are used where conventional measurement techniques fail. Berthold is the worldwide leading supplier of radiometric measurement systems for the chemical and petrochemical industries. Corrosive, abrasive, highpressure, and high-temperature environments require a noncontacting technology that can withstand these conditions. Due to the non-intrusive nature of the radiometric measurement and the use of rugged materials, the system is normally wear and tear free and, thus, perfectly suited for the variety of applications in chemical & petrochemical plants.
Berthold is the worldwide leading supplier of radiometric measurement systems for the chemical and petrochemical industries.
affecting the flow properties of the measured material. A density switch can be used to alert the operator when the process reaches a predefined density value in order to take corrective action or to perform a quality check on production.
This results in a high level of reliability combined with freedom from wear and tear, and environmental conditions.
switch measurement measurement systems are used for continuous process vessels. Density, concentratio n or solids content intrusive manner, without affecting the flow properties density switch can be used to alert the operator predefined density value in order to take corrective check on production.
consists of a source that emits gamma radiation and a radiation is attenuated as it passes through the vessel or attenuation depends on the filling level or the product density: less radiation reaches the detector. In this manner, the temperature, viscosity, colour or chemical properties of the reliability combined with freedom from wear and tear, conditions.
continuous level and level switch measurements monitor reliably. Customi sed solutions for the unique process and petrochemical industr ies are achieved with a sources in different arrangements and geometries, to insert sources into vessels. In critical switches in conjunction with continuous level increased process safety. switch measurement measurement systems are used for continuous process vessels. Density, concentratio n or solids content intrusive manner, without affecting the flow properties density switch can be used to alert the operator predefined density value in order to take corrective check on production.
measurements monitor for the unique process ies are achieved with a arrangements and geometries, vessels. In critical with continuous level
www.berthold.com
A radiometric measurement is a system, which consists of a source that emits gamma radiation and a detector that can detect this radiation. Gamma radiation is attenuated as it passes through the vessel or the pipeline and its contents. The amount of attenuation depends on the filling level or the product density: the higher the fill level or the denser the product, the less radiation reaches the detector. In this manner, the measurement is not influenced by pressure, temperature, viscosity, colour or chemical properties of the product to be measured. This results in a high level of reliability combined with freedom from wear and tear, even under harsh operating and environmental conditions.
measurement varies with increasing level height, for example, in gas bed reactors, a simple level measurement would not conditions. Here, a combination of a density profile provides better process visualisation and thus more
measurement varies with increasing level height, for example, in gas bed reactors, a simple level measurement would not conditions. Here, a combination of a density profile provides better process visualisation and thus more
continuous process concentratio n or solids content affecting the flow properties used to alert the operator order to take corrective
Berthold‘s radiometric continuous level and level switch measurements monitor processes safely and reliably. Customised solutions for
Berthold‘s density measurement systems are used for continuous process control on pipelines and in vessels. Density, concentration or solids content are determined in a non-intrusive manner, without the unique process conditions in the chemical and petrochemical industries are achieved with a variety of detectors and sources in different arrangements and geometries, including the use of drywells to insert sources into vessels. In critical applications, the use of level switches in conjunction with continuous level measurements provides increased process safety.
info.uk@berthold.com | www.berthold.com
and
When the product density varies with increasing level height, for example, in gas phase reactors or fluidized bed reactors, a simple level measurement would not correctly represent process conditions. Here, a combination of a density profile and level measurement provides better process visualisation and thus more improved process control.
Most customers will tell you just how efficient Sepura oil-water condensate units are. But did you know that our patented filtration media found inside every genuine Sepura unit is made from recycled glass bottles?
This not only makes the outputs from our units environmentally friendly but also our manufacturing process too.
Going green and achieving your targets doesn’t have to be a compromise.
Positive Displacement Pumps for the Waste Water and Sewage Industry designed to handle: Digester Feed; Thickener Feed; Long distance Sludge Transfer; RBC Feed and De Sludging; Inlet Dosing; Raw Sewage Transfer; Filter Press Feeds; Clay Slurry Pumping; Paper Mill Pulp; Effluent and more
Designed and manufactured ‘in house’ Energy Ram and Diaphragm Pumps have proved their worth time and again, not only through Energy efficiency, but also through clear, cost effective, robust and wholly reliable sludge and slurry handling on many Sewage sites throughout the UK and beyond. These amazing British Pumps are invaluable on many WwTW’s and popular with maintenance engineers for their ease of handling and longevity The Diaphragm Pumps will ‘run dry’dry’, never failing on maximum suction and delivery.
Energy Pumps range of Ram Pumps begins with the smallest 240mm mechanical Ram, through to the 460mm hydraulic Ram Pump. With many different sizes available it ensures that there is an Energy Pump for most STW
applications, including Quarries and Mines where Energy Ram Pumps are suited to tough grit and silt handling.
The Hydraulic Ram Pumps are controlled by our own software, also developed “inhouse”, so that we are able to tailor the Pump to your exact needs, ensuring maximum performance for the job in hand. Energy hydraulic Ram Pumps are also available in a duplex configuration which allows for higher flow rates, with pressures reaching up to 20 Bar.
The Energy Maxi, Major and Mastiff Diaphragm Pumps are the invaluable mainstay of many Sewage Treatment Works. They are competent in both primary and humus desludging and sludge transfer duties. Energy Pumps also have many applications in any industries which need to pump difficult sludge reliably and economically. The patented positive flow base of our Diaphragm Pumps, with patented anti-ragging, nonreturn Valves is designed to ensure that air quickly passes through the base, which then leads to an easier flow of contaminated materials. This, in turn offers low maintenance and ease of repair, when necessary. Energy Pumps are the obvious choice for many maintenance engineers.
The range of Energy Diaphragm Pumps varies according to the application. The Energy Hydraulic Mastiff Diaphragm Pump is ideally suited for those jobs which require pumping difficult sludge to higher pressures while retaining longevity and reliability, plus ease of maintenance as with Energy Mechanical Ram Pumps.
The reliable and versatile Energy Mastiff Diaphragm Pump is based on our highly successful Major. Our Mechanical and Hydraulic Mastiffs allow for greater flow rates and delivery Head. They are capable of processing materials much quicker than the Energy Major Pump, for those tough-handling jobs which require the more robust Pumps.
Being the smallest of the Energy Pumps the Energy Maxi Diaphragm Pump was initially the first to be designed for small STW’s. This Pump has also proven itself to be popular for pumping blood, strings and offal in Abattoirs and clay slip in Potteries. Energy Diaphragm and Ram Pumps are reliable Flood-Water Pumps and are popular with Farmers for pumping effluent and animal-feed for Agricultural purposes. Energy Diaphragm Pumps are fully portable and may be trailer-mounted.
Assembly Techniques Ltd
are a total component supplier to all industries providing an extensive range of products & services. In our state of the art MediClen Cleaning Facility we have a Class 100,000/ISO8 clean room for aqueous ultrasonic cleaning and a Class 10,000/ISO7 clean room for the assembly of critical parts. ATL are an ISO13485:2016 and ISO9001:2015 approved company committed to quality of service.
Scan QR code to visit our website
Tel: 0161 339 6060 / Email: sales@assemblytechniques.com
In our latest case study, we’re discussing a recent project for the supply of two pumps for a large power generation business with operations overseas.
A potential client got in touch with us about two light fuel oil pumps to be used for the transfer of light fuel oil, also known as diesel oil. It was to be pumped from main storage tanks to day tanks at their sizeable power generation facility abroad.
Light fuel oils or diesel oils are high value distillates that can be used to drive diesel engine power plants, both in stand-by operation and baseload applications.
There are various grades available depending on use, with low fuel duty variants of diesel known as red diesel due to the red dye incorporated in its mixture.
Red Diesel is often used in the forestry, rail and agricultural sectors.
It is often employed in back-up power plants and installations on remote islands or in arctic conditions where it’s difficult and costly to supply cheaper alternatives. Light Fuel Oil requires less processing and produces a higher percentage of petrol and diesel than heavy oil. Its viscosity can range between 1 and 7cst, so it can be comfortably handled by a variety of technologies.
In a power generation plant, bulk fuel is usually stored in a large tank and then transferred to a smaller day tank near the engine.
The day tank is positioned between the bulk storage tank and the diesel engine, and the fuel is delivered
from the bulk storage to the day tank by a bulk storage delivery pump.
benefits
• Uninterrupted power supply
In critical applications such as hospitals, industrial plant and data centres, even a very short power interruption can have disastrous, even fatal consequences. Day tanks fill the gap between the main fuel storage tank and the generator. They ensure that there’s a continuous fuel supply so that the generator can kick in straight away if the main power source fails even briefly.
• Cost effectiveness
Day tanks minimise downtime and cut the risk of equipment damage caused by power interruptions. This all helps to boost overall plant efficiency and reduce the cost of unplanned power cuts.
Here at North Ridge Pumps, we’re not tied down to a single pump technology.
• Fuel quality and maintenance
By storing a limited amount of fuel, day tanks turn fuel over more frequently, reducing the risk of fuel degrading or becoming contaminated. In addition, day tanks often have built-in filters and monitoring systems which clean the fuel and give an early warning of any potential issues - enabling quick troubleshooting and maintenance.
• Efficient use of space
Where bulk fuel storage tanks usually need large amounts of space and infrastructure, day tanks are compact and can be fitted easily into small spaces. What’s more, their proximity to the main storage tank means there’s no need for long fuel lines, and less risk of fuel contamination or leaks.
Specific project requirements
As part of the project brief, our client specified the use of rotary gear pumps as part of the light fuel transfer set for their power generation application. They also wanted a capacity of 20 to 30m³h without having to alter their existing
3-inch pipework, which we could achieve with a pump speed of just 350rpm.
Here at North Ridge Pumps, we’re not tied down to a single pump technology. We use our expertise to offer a tailor-made solution, not something picked off the shelf. This means we can always select the best pump for any particular client and application - at the lowest lifetime cost.
The fuel transfer pump from the bulk tank to the day tank is generally a positive displacement gear pump positioned above the bulk tank.
When the pump is started, the air
in the suction line is removed and a vacuum is created. This lifts the liquid in the bulk tank up into the suction pipe and into the day tank.
Our FIG90 internal gear pump with 90° flange connections
For this light fuel transfer set, we quoted and supplied two of our industrial long-coupled internal gear pumps - our FIG 90 model.
The casing was manufactured from cast iron and the gears from ductile iron. This ensured that we could achieve an outlet pressure of up to 12bar. Our light fuel oil pumps were completed and despatched to the client in 8 weeks.
Our internal gear pumps are designed to handle clean lubricating fluids of various viscosities – ranging from 2 to 7 times the thickness of water. To handle this variety of fluids, we specified and supplied the pumps with a relief valve which would ensure a consistent flow regardless of fluid viscosity.
For this particular application, the pumps would be transferring light fuel oil. Our internal gear pumps can also be used for pumping resins, adhesives and greases.
efficiency
Our straightforward design with only two rotating components, together with the exceptionally tight clearances of the internal moving parts means that there is almost zero slip while the internal gear pump is operating.
This means that our gear pumps are not only highly efficient, but they use very little energy. This makes them the perfect solution for applications which require 24/7 continuous operation.
If you have an application or operation which involves the transfer of fluids, solids or viscous liquids, and don’t know which pump to specify, speak to North Ridge Pumps on 01773 302 660 or visit www.northridgepumps.com to see how we can help.
Over the last 30 years there has been a boom in the traceability and identification of manufactured components. Many industries want to directly laser mark these, however there are some parts that are just getting larger and larger.
Casting and pressing companies sometimes have such large parts that they simply cannot fit these into a standard sized Class 1 laser enclosure leaving many companies wondering how they can mark them.
Even though they launched a new range of large XXL-Box class 1 enclosures in 2022, SIC Marking saw this problem as a new challenge for 2023. They have now launched their Funnel Integrated Technology (F.I.T. for short) as a complete all in one solution that combines all of the necessary components and settings to mark larger parts in a simple, safe and economic way within the customers production line and budget.
The FIT tunnel eliminates the need to enclose the entire part for the laser marking process by enclosing just the marking area. The compact design allows for the FIT system to be retrofitted easily into an existing robotic cell.
This ready to integrate and secured laser marking system comes as a ‘Tunnel Style’ Class
1 compliant enclosure. It is a compact and easy to integrate solution with a single connection to a PLC. The F.I.T. can be mounted to a robot head for presenting to a stationary part – or fixed in position allowing the robot to present the part for marking.
Not only is the F.I.T. adapted for production environments with its maintenance drawer for the cleaning of the lens, it has built-in shock protection preventing the funnel from damage. The F.I.T. tunnel can be adapted to your marking needs with three window sizes available as standard: 24mm x 32mm, 100mm x 32mm and 100mm x 100mm. Custom sizes can also be accommodated.
The F.I.T. is available as a basic chassis or as a complete solution with protective covers, a cooling system, electrical cabinet and tooling as well as an optional integrated Cognex vision system for 2D verification / validation or 3D lens for marking curved or angled surfaces.
For a demonstration of the new F.I.T. and / or any of the other laser marking systems in SIC Marking’s extensive range, please get in touch with SIC Marking UK in Warwick, UK on 01926 830372 where one of the very knowledgeable engineers will
be happy to talk to you.
The SIC Marking Group was formed in 1992 and has been growing ever since, as a result of its development in new sectors, winning many local and international customers, in addition to many takeovers. The increasing number of its distributor partners and the opening of subsidiaries on the 3 continents have given it an acknowledged presence and international reputation.
It has 10 subsidiaries, mobilised for promotion, implementation and customer support in France, Spain, Italy, UK, Germany, Canada, USA, Mexico, China and Korea. They also deploy its marking and traceability solutions locally on behalf of international groups.
Furthermore, its 40 exclusive distributor partners enable it, overall, to serve more than 50 countries worldwide.
SIC Marking UK is one of 10 subsidiaries around the World. SIC Marking Group has developed innovative, permanent marking solutions and automated identification systems for the complete traceability of industrial components for over 30 years. SIC Marking has a wide range of the most robust and state of the art Dotpeen, Scribe and Laser Marking machines available on the market today. Whether Column Mounted, Integrated or completely Portable like our battery powered cordless eMark for example, we can provide a machine that is suitable for both your application and budget. SIC Marking is constantly adding to the range and re-investing into R & D. The new eTouch portable Dotpeen marker offers Icon style Touch screen technology and the Laser systems now have a range of modular Class 1 enclosures with the XXL-Box range – offering the ability to mark parts up to 1500mm in length as a standard product.
Our UK Team is based in Warwick, where we have dedicated Sales and Aftersales engineers with over 50 years’ experience who would welcome a call to discuss your marking application.
Please call 01926 830372 for further details or email us on salesuk@sic-marking.com
Save energy
Save money
Integrate the LHS 210/410 series air heaters with Leister’s new CHINOOK blower.
get in touch
Tel: +44 (0)1707 331111 info@welwyntoolgroup.co.uk www.welwyntoolgroup.com
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
For engineers and technicians working in many industrial sectors FOD will always be a real and present danger.
Keeping track of every tool and piece of equipment, especially when several storage cabinets are in simultaneous use, can be challenging.
Snap-on Industrial’s Level 5™ automated total asset management system minimises the risk of FOD by constantly tracking every tool, detecting which tools have been removed or returned.
It also enables engineers and technicians to quickly find every tool they need, when they need it, saving time and easing stress. Engineered to track individual tools by user, without bar codes, scanners, RFID tags or other add-ons, the system works at the speed its users demand.
Deltec is the leading Impact Socket and Bespoke tool manufacturer in the UK and specialises in Impact Sockets, Specialised Sockets, accessories and related tools for various applications in different industries, such as Automotive, Construction, Bridge, Marine building and maintenance, Wind, Oil & Gas, Mining etc.
With 45 years of experience, Deltec aims for the goal of zero defects. Deltec has gained confidence and long-term support from many global clients due to its excellent quality, service, competitive price, reliability and on-time delivery. Deltec is well reputed with its excellent products all over the world.
All our products are manufactured to International DIN standards. Deltec’s Technical & Design Department designs and develops custom sockets and prototypes. Deltec is also a pioneer in product research and development, engineering and manufacturing – Fast track service also available.
Factory Tours available Please enquire – See British Manufacturing at its Best.
www.deltecindustries.co.uk
Level 5™ boxes are network ready, using either Ethernet or wireless connection.
Powerful software enables users to review activity at all boxes in their location from one central computer, avoiding the need to inspect each box.
Major benefits of the system include:
• No individual tool scanning required;
• No RFID tags to install or replace;
• Intuitive interface, via touch screen;
• Audible voice confirmation of tool removal and replacement;
• Automatic locking for maximum security;
• Errors announced and displayed to
indicate incorrect tool position or advise when a drawer is not closed;
• Keyless access control for easy access by authorised users.
Says Richard Packham, Director UK & Europe for Snap-on Industrial: “Snap-on’s automated system takes tool management to an entirely new level, giving workshop managers and other authorised users easy access to the tools they need, while protecting against foreign object damage.
“The ability to monitor several boxes from one central computer offers managers a huge time saving advantage.”
LAUDA are proud to present the world’s first mobile, ultra-deep chest freezer – LAUDA MOBIFREEZE. Our commitment to reducing our impact on the planet and supporting a greener future are exemplified in our latest product.
The MOBIFREEZE guarantees safe and reliable deep-freezing. The mobile ultra-deep freeze chest freezer with active temperature control ensures that the cold chain is reliably maintained in intralogistics and for the inter-factory transport in road logistics. Thanks to excellent insulating properties, the ultra-deepfreeze chest freezer is the perfect solution for transporting delicate and temperature-sensitive materials.
We are proud to announce that this chest freezer gets down to -86°C without the need of hazardous dry ice. As well as providing protection for the environment, the risks of personal safety are also alleviated.
The re-chargeable battery is another environmentally friendly feature of this unit. High performance and integrated into the unit, it only takes a short time to charge up and can run for hours at the lowest temperatures.
This unit also boasts modern refrigeration technology and high insulation quality – vacuum panels with impermeable foamed polyurethane insulation provides high temperature stability with low power consumption. The interior consists completely of high-grade stainless steel and reliably prevents the cover seals from freezing on. The environmentally friendly, futureproof operating principle using
natural refrigerants without dry ice provides independence from consumables and phase-change materials.
The MOBIFREEZE is also highly versatile in a range of environments including;
Intralogistics – including all processes from incoming goods and storage to internal transport and outgoing goods. Our mobile ultra-deep-freeze chest freezer secures the cold chain during transport.
Cold Chain Logistics – The transport of temperature sensitive goods poses major challenges for everyone involved. The MOBIFREEZE provides significant advantages in this segment of low temperature management
though several ways. Transportation without dry-ice, idea product temperatures and active cooling.
Hybrid Use – The bridging of transport phases is guaranteed by the active, powered deep-freeze storage and excludes the health risks of continuous filling with dry ice. Flexible changing from storage to transport without transfer processes allows product-friendly logistics without the risk of damage and contamination.
If you’re eager to learn more about what the MOBIFREEZE can do, or want to hear more about our other temperature control products that are helping the environment, don’t hesitate to get in touch using the information below.
Oliver Valvetek’s unique approach to Subsea valve design and manufacturing is exemplary and world-leading. They partner with one of the leading Subsea Tree and Subsea Distribution Units manufacturers in the world and is supplying valves to the Exxon Mobil Guyana Futures field.
For the past 5 years, Oliver Valvetek has provided more than 3000 pieces of ½” 10,000psi rated Subsea Trunnion style Ball Valves for the full field development. Due to changes in production, control
system requirements, and an operation pressure increase, Exxon Mobil also required a 15,000psi rated valve.
Oliver Valvetek successfully qualified a valve to API6A PR2F and API17D 3rd Ed and included specialist testing and materials that were specific to the pressure and process media application.
For more information on Subsea valves, contact Oliver Valvetek on +44 (0)1565 632 636 or email sales@valves.co.uk | www.valves.co.uk
For the past 5 years, Oliver Valvetek has provided more than 3000 pieces of ½” 10,000psi rated Subsea Trunnion style Ball Valves for the full field development.
Rotaflow provide solutions that enable different fluids (including oils, fuels, corrosives, food) and/or air/steam to be transferred through awkward, and often, already established production infrastructure. With 40 years of experience, we have designed and manufactured swivels to withstand and perform effectively when faced with many tricky environmental factors: Overcoming issues with heat, pressure, size and material choice.
Swivel joints will allow the movement on a slowly rotating drum or remove the damaging effect of twisting on hoses.
A high proportion of our swivel joints are used on reeler applications. These are over a wide range of specifications, from single flow systems to multiple flows with or without facilities to incorporate an electrical slip ring.
To date Rotaflow swivel joints have been used in a wide range of reeler applications from umbilicals needing to reach to the depths of the sea, to controlling water for cooling a nuclear power station to supplying hot water to drill through ice in Greenland. Whatever your swivel joint requirements, send us your application details and we will endeavour to design a solution for you.
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
GEMÜ P600S
Introducing the GEMÜ P600S, a new modular M-block diaphragm valve with flexible connection system in the nominal size DN 20 and DN 25. Made from stainless steel the GEMÜ P600S compromises of one or more diaphragm valve seats. The individual modules can be combined together in any order to provide flexibility and shorter lead times by standardisation of common components. For use in aseptic applications with a sterilisation temperature max of 150 °C, the block provides a multi-functional solution for blending, diverting, draining and the preparation of media in the pharmaceutical, biotechnology and the food industry. The design is flexible and low maintenance, saving your time and money on the installation and welding work. Being modular also means that the compact design can be extended as required simply by installing multiple blocks together, future proofing your plant in event of change or growth.
Tel: 01925 824044
Email: customer.support@gemu.co.uk
Web: www.gemu.co.uk
Obsolescence issues beat on the door of any organisation that operates complex engineering equipment. Specialist equipment manufacturers such as Drallim already seek to ensure that their products provide a very long life, but this is now being driven even harder by end users aiming for greater sustainability and “green” credentials. In truth it just makes great economic sense to the user and creates real customer loyalty, while minimising global resource consumption. Drallim has been committed to longevity of its products throughout their 60+ years of trading. Indeed, examples of their Rotary Selector Valves, Compressor Desiccators and Cargo Hooks are regularly returned for service and repair with some having seen over 40 years continuous service. Obsolescence issues are inevitable over this sort of period, but careful management and planning have allowed them to provide these very long product support periods. Electronic equipment provides the most significant challenges and even over relatively short periods of just a few years component availability can dry up suddenly, as has happened for many users during the Covid crisis. Establishing long term support contracts with key customers allows planning ahead to mitigate problems arising by using smart procurement techniques, stocking of components and or redesign exercises. Increasingly Drallim Industries are seeing demand from new customers for obsolescence review and reverse engineering services to produce vital spare parts with a failed supply chain. Projects have included special manufacture of obsolete metals, redesign, and qualification of electronic assemblies through to reconstruction of specialist fabric assemblies and redesign of cast or forged components for low volume supply.
Contact sales@drallim.com for help and information. www.drallim.com
Portable ultrasonic flow metering offers a practical approach to non-invasive flow measurement, eliminating the need to cut into pipes. This makes them ideal for a variety of applications, particularly in situations where disrupting existing infrastructure is undesirable and they are very cost effective compared to other technologies when used on large pipelines. iCenta field tested the Metri Pro-Lite on a large diameter water transmission pipe, evaluating its performance and suitability for such applications.
The Metri Pro-used to measure the flow within a large diameter raw water transmission pipe. The reservoir was constructed in the 1980s and the pipe itself is made from Ductile iron and has a 10 mm cement liner. It is 1260 mm and was deemed to be in good condition. This test aimed to assess the suitability of the system, and gain insight into its performance using the standard sensors.
The Standard 1 MHz sensors, being a proven technology in production for several years, were the natural starting point. A small, medium and large sensor are available – the 1MHz sensor tested here would be considered to be the medium sized version.
Ultrasonic transit-time difference flow meters are pulse – echo systems where the two-way travel times of ultrasonic pulses are accurately measured. Typically, one pulse is sent at an angle to the flow (from precise wedge-shaped transducers) and a minute difference is measured between a pulse travelling upstream
compared to a pulse travelling downstream – the ΔT time difference. These measurements resolve time differences to parts per billion and as electronics becomes more capable and at a more reasonable cost, these meters now offer outstanding value for money.
Setting the meter up is a simple procedure where you measure the pipe circumference, and enter the pipe material, fluid type, the fluid temperature, them number of acoustic traverses and any liner details. The Metri Pro-Lite has the option of using a dedicated wall thickness gauge. It has a useful A-Scan display and really is a welcome addition to the system.
Initially, the sensors were installed in a single path or “Z mode” on opposites sides of the pipe. This configuration ensures optimal signal strength. Installation involved careful alignment using a bubble level and a ratchet strap to secure the sensors in place. A good signal was immediately detected.
This is a large pipe, and to further explore the capabilities of the Metri Pro-Lite, the Standard 1 MHz sensors were then tested but this time in a 2 path “V mode.” configuration, where the sensors are on the same side of the pipe. This mode offers an alternative configuration for signal transmission and reception, and the advantage is that the ΔT time shift is doubled. While the signal strength was marginally lower in “V mode” compared to “Z mode,” it remained sufficiently strong for accurate flow measurement.
The field testing successfully demonstrated the Metri Pro-Lite’s ability to measure flow accurately in large diameter (1260 mm) water pipes containing water. The tests revealed the Standard 1 MHz (ICUS-M10) sensors, although physically quite small, certainly “pack a punch” reliable results in both “Z” as well as the more challenging “V” mode. In terms of calibration, of course the water companies’ data is confidential and as we logged the data, with its real time clock, we could look at the flowrates from the reference meter, and we were able to confirm a close agreement to the actual figure, within 2% of reading.
In conclusion, field testing the Metri Pro-Lite on a large diameter water pipe proved its capability for non-invasive flow measurement in this challenging scenario. The Standard 1 MHz sensors showed their capability on one or the larger pipes in the UK, offering reliable and a very cost-effective performance. The user-friendly design and comprehensive data logging features further enhance the value proposition of the Metri Pro-Lite, making it a compelling solution for a wide range of flow measurement needs. iCenta have over 20 years’ experience within the ultrasonic flowmeter market which is continuously expanding. With experienced staff and a growing market, iCenta are well positioned to help with ultrasonic (and all other technology) flowmeters. Please bear in mind that ultrasonic flow meters are applicable to many process control environments and have matured into an accurate and cost-effective solution.
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