SOUTHERN MANUFACTURING & ELECTRONICS TRADE FAIR - 48 The UK's premier engineering show
INDEPENDENT TOOL CONSULTANTS LTD -26
Respected speciality supplier of high-end alloys
HANDHELD TEMPERATURE
SENSORS & PROBES - 58
Specialists in temperature measurement products
Editor’s Choice
3D PEOPLE
Raising the bar for additive manufacturing with expert service & delivery — beyond the status quo
SEW-EURODRIVE UK
Automated Guided Vehicle (AGV) systems
KAMAN
High-precision non-contact displacement sensors provide accurate and reliable measurements for advanced research applications
ANALOG
‘Diagnostics and real-time decisionmaking’ and ‘5g and manufacturing’.
BURCKHARDT
Plug Power partnership with Burckhardt Compression yields successful hydrogen liquefaction
EMS
Can environmental monitoring satellites revolutionise climate action? Here’s how advanced motor technology is helping to power the fight
JOHN CRANE
Advancing the energy transition through collaboration, innovation, and talent development
VERICUT
Schunk ensures maximum process reliability through nc simulation with vericut
SPELSBERG
Building design and installation: ensuring fire safety for electrical connections
SWINDON
How custom IC sensors enhance safety and quality
• Continuous diagnostic: Full coverage of your critical assets at all times.
• Early diagnostics: Monitoring of imbalance, wear and overall vibration.
• Maximum efficiency: Permanent diagnostics helps keep your assets running efficiently.
• Easy integration: ifm provides individual solutions suited to different types of machines. Reducing costs, avoiding unplanned downtime and optimising processes: The ifm application solutions. ifm – close to you!
The leading source for innovators in Technology, Manufacturing and Maintenance within the Engineering & Processing industry worldwide.
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Every issue of the magazine contains the latest news, in-depth features, together with product innovations and case studies showing how process engineers are implementing new technologies to reduce costs and impact on the environment.
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When it comes to process optimisation in industrial production, it’s hard to overlook the gripping and clamping technology specialist Schunk. The family-owned company stands out for its innovation, top quality, and solution expertise. This is also reflected in their own manufacturing, where the team works daily to produce the best possible components and products on high-quality machine tools, ensuring both process reliability and economic efficiency. Alongside CAM programming and automation, the simulation of manufacturing tasks before real machining, using Vericut, plays a crucial role.
When it comes to equipping robots and production machines, Schunk is a go-to partner for many industries worldwide. Whether it’s smartphones, airplanes, vehicles, machines, knee joints, or nasal sprays: high-tech components from Schunk are often key players in their production.
Founded in 1945 by Friedrich Schunk as a small mechanical workshop, today Schunk is an international technology company with 3,700 employees in over 50 countries and is led by the third generation of the family, Kristina I. and Henrik A. Schunk. The family-owned company boasts extensive expertise in clamping technology for tools and workpieces, gripping technology, and automation technology. “Our components, applications, and services support our customers and partners globally in process optimisation,” emphasises Fatih
Gülgönül, Head of Engineering. He adds, “In addition to individual high-tech components, we provide intelligent complete solutions for robotic systems as well as for various production and automation processes—all from one source for custom client applications.”
Due to its extensive product portfolio of over 13,000 standard components and 2,000 customerspecific parts, Schunk’s main production sites in Lauffen and Hausen—north of Stuttgart—
emphasise high manufacturing depth. “For us, each step of the process must deliver maximum efficiency with the highest quality. That’s why we keep all necessary competencies inhouse and control every process step ourselves,” says Production Manager Steffen Gotzmann, highlighting the importance of inhouse manufacturing at Schunk.
At the Lauffen plant alone, about 250 skilled workers and over 150 CNC machines work in three shifts to efficiently produce various components, mainly for clamping technology, from different materials. A walk through the production halls offers a great insight into Schunk’s high-quality standards. In addition to well-organised production lines, the cleanliness and orderliness of workstations stand out. Whether turning, milling, grinding, or eroding, only top-tier machines from leading manufacturers are used.
“All core machines in our main production lines are CAMprogrammed. This keeps downtime to a minimum,” says Gotzmann. Schunk employs a total of 68 CAM programmers—nine of whom focus on custom clamping technology for smaller batches and order-specific production. “In this department alone, we create around 3,000 NC programs annually for approximately 2,000 customdeveloped, designed, and produced products,” Gülgönül explains.
For both department heads, maximum process reliability is critical for a cost-effective production process, as waste is something Schunk cannot afford. Alongside CAM programming and automation, the simulation of production tasks before actual machining plays a significant role. “Machine simulation is a key element for a safe machining process. The simulation integrated into the CAM system is not enough for us. It’s crucial that the simulation we run in the office perfectly matches the real processes on the machines, including the kinematics of the equipment. Only then can we
Vericut provided the complete package: the software delivers exactly what we need for efficient and safe production, and the Vericut team offers reliable support with their expertise,
ensure that what we’ve programmed will be executed exactly as intended,” Gülgönül explains why Schunk uses the Vericut simulation and optimisation software.
“Vericut provided the complete package: the software delivers exactly what we need for efficient and safe production, and the Vericut team offers reliable support with their expertise,” explains Steffen Gotzmann. CAM
administrator Juri Buling adds: “When machines are idle, it costs a lot of money, and we want to avoid that. That’s why investing in Vericut was the logical step.” With Vericut, the entire clamping situation—including the blank, clamping tools, machining tools, and the machine itself—can be simulated. According to Buling, this virtual machining process has significantly increased process reliability in Schunk’s production.
An Integral Part of the Process Chain A key feature of Vericut, according to Hans Erkelenz, Managing Director of CGTech Germany, who led the project, is the fully independently developed software: “Since 1988, Vericut has been considered a benchmark in machining production, leading the field in machine simulation, verification, and optimisation for all types of CNC machining, as well as additive and hybrid manufacturing processes. The software operates independently and integrates with all common CAM systems.” Moreover, its core simulation engine is the fastest and most accurate in the NC simulation field.
Currently, Schunk simulates 34 machine tools with Vericut in Lauffen: “We can simulate and optimise all our machines, including automated multichannel turn-mill centres—with 100% accurate kinematics. We can also simulate features like engraving or transferring parts from main to counter-spindle— so Vericut is an essential part of our process chain,” says Buling.
Erkelenz adds: “Vericut simulates the real machine environment with precise multi-axis and highspeed movements, multiple setups, and complex tool shapes, providing insights into potential collisions with holders or fixtures.”
Due to the wide variety of customerspecific solutions at Schunk, frequent setups are necessary.
“Thanks to CAM programming and Vericut simulation, we manage to keep these setup and downtime as low as possible. The NC program is already prepared on the machine, and we know it works because we’ve verified it with Vericut,” Gotzmann explains. This allows Schunk to use available resources as efficiently as possible.
According to the production manager, having a verified NC program also gives machine operators more confidence, allowing them to run new parts faster and more effectively. “Not to mention that we can optimise programs through Vericut without having to test them directly
on the hardware—a significant advantage in times when continuous productivity increases are essential to remain competitive.”
Optimising NC programs is especially crucial for series parts.
Since implementing Vericut, collisions have been eliminated at Schunk, and unnecessary costs due to downtime are avoided. “The project was challenging, so it’s all the more remarkable that Vericut fully met the timeline,” emphasises Fatih Gülgönül. “Schunk is undoubtedly a special client for Vericut due to its scale and tight schedule,” notes Erkelenz. “Thanks to excellent support from Schunk, we were able to integrate the first 30 machines into the simulation within a year— this was challenging for our entire team! I’m proud we were able to meet all expectations 100%.”
The next steps for Schunk are already clear, as Buling concludes: “Our goal is to increasingly digitise all production sites and equip them with Vericut—ultimately securing our competitiveness.”
Scan to learn more:
• Leaner and faster production using cleverly designed modules which are standadized across different product categories.
• Modular and flexible design with a wide range of configuration options, optimizing response time to your specialized requirements.
• More agility, products can be ordered and manufactured faster than ever before with item prices and availability information easily accessible.
• The platform-base design enables faster conformity adjustments to ensure GEMÜ products are always optimized with the latest features.
Menzel Elektromotoren is a onestop shop for high-output electric motors, on request also offering various complementary services. A recently completed pump motor with all accessories as well as installation and commissioning is a finalist for ‘Project of the Year’ in the 2023 AEMT Awards of the Association of Electrical and Mechanical Trades. This project also stands out as the motor has been equipped with a short-circuiting and brush-lifting device. The three-phase slip-ring induction motor drives the peak load pump for Baden-Württemberg state water supply, a German
special-purpose association. Due to the brush-lifting device, the motor carbon brushes are only used during motor startup and then lifted off the slip rings. This minimizes wear and tear and allows significantly longer maintenance intervals because the brushes no longer need to be replaced regularly and the slip ring compartment rarely needs to be cleaned of carbon dust. In addition to a slip-ring motor with brush lifting, the scope of supply also included a motor base frame, coupling, liquid starter and cabling to the nearest switchgear. The size 800 motor with a nominal output
of 6200 kW at 5000 V nominal voltage drives the peak load pump in the summer months and is becoming increasingly important due to climate change and higher daily water requirements. Menzel fully tested the motor in the presence of the customer and then installed it and put it into operation at the waterworks. By replacing the original motor from 1969, the customer has ensured the reliable continued operation of the plant for the future.
More information and project video: www.menzel-motors.com/ article/single-source-supply/
One-stop shop: Menzel built a slipring motor with a brush-lifting device, base frame, coupling and liquid starter, dismantled the old motor and installed and commissioned the new pump motor
NEW ELECTRIC MOTOR PLANT FROM JANUARY 2024
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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
Am Alten Walzwerk 2 | 16761 Hennigsdorf | Germany
menzel-motors.com info@menzel-motors.com
As global economic uncertainty challenges the manufacturing supply chain, Expromet Technologies Group continues to buck the trend, achieving impressive growth under the leadership of CEO Rob Guest. In this interview, Rob shares how the group has strengthened its resilience, expanded globally and embraced long-term growth strategies to meet evolving customer needs.
Q1 In your first year at the helm, Expromet has shown impressive growth despite a challenging global market. To what do you attribute this success?
Rob Guest: Expromet is more than just a manufacturer. Our in-house technical expertise combined with our extensive UK manufacturing capabilities and global supply chain mean we can offer a one-stop, long-term partnership to our customers.
This strategic approach, alongside heavy investment in our people and facilities, has helped Expromet continue to grow despite the global challenges faced by the manufacturing industry. In the last financial year we achieved growth and now have a healthy pipeline for the future: we are on track to achieve our £100 million turnover target by 2030.
Q2: You mention the challenges for global manufacturing supply chains. How has Expromet adapted to ensure it is a resilient manufacturing partner?
Rob Guest: The geopolitical climate has created significant uncertainties: Tier 1 manufacturers and OEMs are now more focused on de-risking their supply chains by partnering with companies that offer broad capabilities and diverse global sourcing options.
Expromet’s capabilities include a wide range of metal manufacturing options, including a variety of precision casting and machining processes, as well as end-to-end management and technical support. On top of extensive in-house capabilities, we have a trusted global supply chain which now includes our new facility in the Philippines – supporting our resilience and de-risking the supply chain for our customers.
Q3: Expromet’s customer base spans a wide range of sectors. Does this diversity benefit customers?
Rob Guest: Yes, the diversity of our customer base gives us resilience, which means customers can trust us to deliver despite market fluctuations. Expromet serves customers across sectors from aerospace and defence to energy and industrial
The
geopolitical climate has created significant uncertainties:
Tier 1 manufacturers and OEMs are now more focused on de-risking their supply chains by partnering with companies that offer broad capabilities and diverse global sourcing options.
automation. Since we are not heavily reliant on any single sector, we able to adapt quickly to market changes and continue to deliver for our customers.
Q4: How will Expromet’s investment in Southeast Asia benefit customers?
Rob Guest: Our new facility in the Philippines is a key component of our strategy to de-risk supply chains for our customers. By expanding our global footprint, we are able to offer more sourcing options and tap into lower tariffs and production costs. This ensures that our customers can maintain flexibility while enjoying cost savings and more efficient supply chain management.
Q5: What about your investment in Expromet’s business development team, will customers benefit?
Rob Guest: Our investment in business development is about ensuring that we are proactive in understanding and meeting our customers’ needs. By restructuring the team and bringing in new talent, we’ve been able to enhance key account management, ensuring personalised support for our customers. We’re also better equipped to manage new product development, with a stronger core technical team driving innovation. This investment has already contributed to a strong pipeline of new business, particularly for 2025.
Q6: Looking ahead, what are your goals for Expromet?
Rob Guest: My goals are to deliver ever more value to our customers, and to deliver long-term growth for the business. By continuing to invest in our people, processes, and global presence, we are positioning ourselves as a resilient business partner with broad capabilities. As demand for high-quality manufacturing partnerships grows, we’re focused on extending our influence as a trusted supplier to performance-critical sectors. We have the expertise to remove pain-points for customers by providing end-to-end technical support and management, derisking and simplifying their supply chain. It’s a win-win for customers and for Expromet.
Q7: Is your focus on supporting existing customers or developing new business?
Rob Guest: Both! As Expromet Technologies Group grows, and with our investment in additional technical support and development, we are able to help existing customers find costdowns through DfM, by optimising manufacturing methods for existing or new products, or by offering extra services through different companies within the group.
Expromet’s capabilities include a wide range of metal manufacturing options, including a variety of precision casting and machining processes, as well as end-to-end management and technical support.
New customers are attracted by the broad capabilities of our advanced precision casting and machining businesses, able to deliver world-class engineering solutions through trusted and versatile supply chains. Our resilience and expertise are winning new business across demanding sectors, and we have built a strong reputation for highquality, precision components and technical support. I am proud to say that we are both growing our market share with existing customers and winning new business, which is a sign that Expromet is doing well.
Q8: Operational excellence is clearly key to continuing success at Expromet. What steps are being taken to ensure that each group company maintains high standards in quality, safety and environmental performance?
Rob Guest: We maintain rigorous operational and manufacturing excellence across all our companies. The first 10 years of my career were spent in technical and quality roles, so I know how critical this is to long term success. Haworth Castings, Investacast, and Metaltech Precision are regularly reviewed to ensure that our design and manufacturing processes meet the highest standards of quality, safety and environmental performance. We hold ISO accreditations and are continually extending our range of approved standards to reflect our capabilities and commitment to excellence. We’ve also implemented comprehensive health checks across each business to ensure that everything from shift patterns to apprenticeships and personal development are fit for purpose.
Q9: Finally, how would you summarise your first year as CEO of Expromet?
Rob Guest: It has been a great year for Expromet, in spite of the local and global challenges for the sector, for our group companies, and for our hardworking teams. I would like to thank everyone for making me so welcome here, for working together to build the teams and deliver the investments that will drive success in the coming years.
What matters most to our customers is that the components we supply are delivered on time, with perfect quality and a reasonable price, and that we can provide the expertise and partnership to support our customers longterm. Our existing customers are delighted with our enhanced support, and we have a significant pipeline of developing business. I am confident that Expromet Technologies Group will continue to deliver world-class engineering solutions whatever the global challenges of the next decade.
When it comes to the dosing, metering or transfer of aggressive chemicals or abrasive solid laden mixtures there is often only one logical choice – a peristaltic pump.
With innovations in pump technology being few and far between, operators have often been left to create their own control functions, integrate logic and separate custom control panels for pump control.
However, a new locally mounted integrated control function available on the range of peristaltic pumps supplied by North Ridge Pumps is helping to revolutionise pump operation.
Serving users ranging from small scale start-ups who don’t have the time, expertise or resource to set up and configure additional controls, to nationwide operators where the simplicity in design, operation and adjustment means that users are far more likely to demand their equipment, than opt for designs which may take significant time or expertise to maintain is revolutionising processes.
It is such a step change in control that in some areas of industry – it is being necessitated in particular by rental companies where monitoring, sampling or water treatment equipment may be required in an emergency or for short periods of time where extensive training or users with a PHD in pump operation & maintenance are not available. Users who need the pump to simply “work”, handle the abuse from onsite use and make fine adjustments quickly at the touch of a button.
Peristaltic technology is well known for its ease of maintenance which can be readily undertaken by non-technical personnel with very little or no training. Its ruggedness due to the lack of internal seals and dry run making it practically bomb proof, and because of its slow working motion ensuring it is barely affected by abrasive, dry liquids which contain suspended solids.
The new control function available Integrated across the full peristaltic family of pumps, can be fitted on both new and existing peristaltic
pumps of both low pressure roller or high pressure shoe design to enable the precise, linear and repeatable metering of gaseous, viscous, and shear-sensitive media containing particles up to 16bar.
Specifically It enables the following functions:
• Metering Method – Modes can be set to alter how the pump meters from amounts dosed over a set amount of time –(timed metering), to volume proportioning to meet a required concentration based on feedback from an external probe or sensor
connected directly to the pump automatically adjusting the volume of chemicals for PH Correction.
• Operation – Start and Stop can be controlled remotely via external input such as a float switch on a tank, a control signal from process, or 4-20ma analogue control directly connected to the unit. If required accelerated maximum metering can be achieved by the pressing of a single button should an external sensor malfunction.
• Access & Control – Menu functions can have access limited by passcode, or functions hidden, with the unit accessed remotely. It can be controlled by industry leading process control systems such as PROFIBUS®/Profinet /CANbus as well as being IOT Capable.
• Built In User Interface –Eliminating the need for separate Human Interface (HMI), the locally attached display enables full control of the pump via intuitive touchscreen displaying current
flow, operating pressure, warnings in case of hose rupture, as well as stopping the pump prior to pump leakage. Should maintenance be required, it visually guides users on how to replace the hose.
choose a Peristaltic Metering Pump?
Peristaltic Metering pumps offer various advantages over other designs of pumps. Due to its simple hose design, it enables the precise metering of gaseous, viscous, and shear-sensitive media, containing particles with ease without the use of valves, or seals prone to blockage, leakage or wear.
It is ideal for liquids ranging from Acids such as Sulfuric acid, hydrogen peroxide, chlorine, sodium hypochlorite, flocculants, coagulants, polymers and other aggressive chemicals.
Using this type of pump can mean reduced engineering for process skids, and on site processes through elimination of external accessories.
It ensures non return or pressure loading valves are not required, the predictive flow can eliminate the requirement for an external flowmeter and given the user interface it can also remove the necessity of a control panel.
Should any problems arise on site, visits by expensive onsite engineers to remote or difficult to access locations can typically be avoided as the unit can be accessed & controlled remotely, with onsite personnel guided over the phone or via on screen prompts on how to undertake maintenance of the one wearing part.
How much could your process save?
If you have an application requiring the dosing, metering or transfer of aggressive chemicals, abrasive ceramics, viscous polymers or solid laden sludge speak to North Ridge Pumps on 01773 302 660 or visit www.northridgepumps.com to see how we can help.
Mike Eason, Chief Technology Officer at John Crane
To meet our ambitious climate targets, businesses need to take the lead in advancing sustainable solutions. While global forums like COP29 have recently highlighted the urgency of these efforts, it’s at the industry level where tangible process can be made. Decarbonising energy systems, developing technologies for clean hydrogen, and transitioning to renewable energy require companies to go beyond their immediate goals and contribute to industry-wide progress.
It is integral that these values are the driving force behind any companies’ commitment to tackling the technical challenges of the energy transition. Even incremental improvements, such as optimising the reliability and efficiency of components, can significantly improve the scalability of clean technologies. It is, therefore, paramount that the industry works together to set clear objectives and share knowledge, creating solutions that benefit everyone.
John Crane’s partnership with the University of Sheffield underscores how industry and academia can work together to drive meaningful change. Through this multi-year initiative, we are funding PhD projects focused on advancing mechanical seals and ancillary equipment for high-pressure
hydrogen storage and low-carbon technologies. These projects are designed to address some of the most pressing challenges in clean energy, while fostering a deeper connection between academic research and industrial application.
By embedding researchers within development teams, businesses can create dynamic environments where academic insights and practical expertise converge. Partnerships such as this enable companies to accelerate the development of critical technologies. In this case it is important for the hydrogen economy, helping to enhance storage systems and ensuring the reliability of renewable energy infrastructure.
The future of industry isn’t just about the technologies we develop today. It is about the people who will lead this effort in the future, meaning that investing in talent is one of most valuable steps businesses can take. By supporting young engineers
Decarbonising energy systems, developing technologies for clean hydrogen, and transitioning to renewable energy require companies to go beyond their immediate goals and contribute to industrywide progress.
early in their careers, we can contribute to their growth and guarantee that the industry has a pipeline of skilled individuals ready to tackle future challenges.
The key to progress lies in equipping all people and teams with the skills, insights, and tools
to master even the smallest, most critical challenges. Partnerships, such as our collaboration with the University of Sheffield, foster creative and proactive thinking. They are as much about empowering people as they are about innovation. These PhD projects provide a platform for researchers to gain hands-on experience with industry-leading technologies, preparing them to address the evolving demands of the energy transition. It’s this combination of academic rigor and real-world application that creates solutions capable of delivering long-term sustainability.
As an industry, we have a shared responsibility to lead the way in decarbonising the global energy system. By encouraging collaboration, advancing critical technologies, and nurturing talent, we can accelerate progress toward a cleaner, more sustainable future. We must remain focused on perfecting the details that make this vision possible.
In the world of manufacturing, precision is everything. You will know how a consistent appearance, performance, taste and texture is vital in meeting your quality standards, reducing waste and protecting your brand with the consumer. Relying on the manual control of transfer is not only putting the burden on your production team (and we all know that time is money!), but also increasing the chance of recipe inaccuracies due to human error.
And that is why the accurate transfer of chemicals, process fluid sor ingredients combined with the AMP-CONTROL peristaltic pump really is a “batch made in heaven”.
Castle Pumps have recently solved two clients’ batching requirements with their AMP-CONTROL peristaltic pump. The first was a manufacturer of low calorie sweeteners looking to batch 10 litres of Glycerin at a time during the production process of their products. The second was involved in the treatment of industrial wastewater and wanted to dose 5-10 litres of ferrous sulphate and caustic soda at a time from an IBC into the water being treated.
Both wanted control over the speed at which they could transfer and the ability to accurately determine how much to transfer in each batch. And that’s when Castle Pumps knew the AMPCONTROL was the ideal solution.
Peristaltic pumps are often used for batching applications thanks to their smooth operation and ability to accurate dose even the
smallest volume of fluids at low flow rates. Another huge benefit of the peristaltic design is that with the inner hose being the only wetted part, there is only one component to wear and maintain without risk of seals leaking and valves blocking.
The AMP-CONTROL model in particular however had the intelligence to satisfy the companies’ requirements of automation and accuracy without the need for the clients purchasing and installing additional control equipment.
As well as its variable speed drive, the beauty of this pump is that it allows batching to be specified either by volume or by intervals, as well as a calendar for operation automation at set date/times. This peristaltic dosing pump also comes with configurable inputs and outputs that can be used for signal relays to determine
when the pump should operate for example when fluid in the receiving container has dropped to a set low level. These benefits allow for highly precise dosing of the additives whilst also freeing up operator time to carry out more value adding tasks.
As a fail-safe the AMP-CONTROL also comes with a hose leakage sensor to shut down the pump and alert the operator, as well as a hose replacement alert for preventive maintenance after a set interval to prevent downtime in production.
Getting the wrong pump for your process can result in inconsistency in the finished product, crushed solids, clogging, excessive wear, loss of productivity, waste of costly product or at worst, contamination. Always trust technical experts to specify the right pump for your application.
A pump may do the job, but only the right pump will save you excessive wear, process failures, product waste & operator time.
Get the RIGHT pump with our 15 years’ experience in:
✓ Solid-laden, viscous fluids without clogging/wear
✓ Safe handling of chemicals, fuels & flammables
✓ Highly accurate dosing of chemicals & ingredients
✓ Difficult to pump or delicate, shear sensitive fluids
✓ 99.98% barrel emptying to prevent product waste
Contact our technical sales engineers now!
Reduced
Customised
Proven
Choice
Larger
Our gas burner systems offer users reliable, high efficiency, process heating solutions.
From design, manufacturing and supply to installation, commissioning and ongoing support, we fulfill process liquid, oven and air heating needs for both new-build and conversion projects.
Heat
Choice of operating fuels
Packaged burner design Up to 40:1 turndown
Earth’s warmest year sends a vital message says HART
Recent research from Copernicus said 2024 was on track to be the warmest year since data was first analysed in 1940 writes Chris Dobson.
Indeed 2024 was on track to be the first year with increases above 1.5 degrees C . This increase is at odds with the target set at the Glasgow Conference of the Parties (COP) in 2021 which concluded “a future with only 1.5 degrees of warming is possible”. Well the 1.5 C ceiling has just been broken.
On a winter’s day it is hard to think in terms of ‘warmth’ but just think of the recent severe flash flooding in some areas of Europe and Polar sea ice reached its lowest monthly extent “continuing a series of large negative anomalies observed throughout 2023 and 2024” all contributing to Climate Change.
Walking passed a major supermarket the blast of escaping warm air prompted me to call Doug Hart, chairman, Hart Industrial Doors and ask him about the ever open door in industry and escaping heat.
“If it’s a heavy manual door or some sort of system that’s easier to leave open, then given the size of industrial doors the escape of expensively heated air will be huge. It’s a question of who notices this. If no one does, no one in the building be it a warehouse or a production facility, then the merry-go-round of the ever open door will continue.”
Which leads to Mr Hart’s Speedor, the high speed automatic door which is now in daily action worldwide. “It was blatantly obvious to me that a frequently used manual roller-shutter industrial door is easier to leave open than to open/ close every time access is needed.
“It was also obvious that the gaping hole of the open door is costly in terms energy which inevitably leads to a Climate Change contribution however small,” says Mr Hart.
“We use world-class technology in the manufacturing of our doors and as a result our Speedor range and its many variants are in use on every Continent backed up fire and security shutters which like Speedor are in daily use in sectors such as energy, high security, logistics, leisure, manufacturing and transport.
“With over 75 years as the UK’s leading door manufacturers, our industrial doors are used across many sectors, including manufacturing, energy, export, leisure, utilities and infrastructure.
“Whether you are looking for doors for high-traffic areas, energy-saving doors, or roller doors for clean rooms or warehouse/loading bays, during the manufacturing of our doors we design and custommake them for durability and reliability, vermin and dust control, heat-sensitive production processes, safety and security.
“Speedor is not just a high-speed door in external use but also within a building essential to maintain the required working environment.”
Bravo Speedor.
British design and manufacture, wide range of models covering high security, large doors with high wind resistance (3,000 to 5,000 pascals), fire and high speed automation with systems’ interface.
British design and manufacture, wide range of models covering high security, large doors with high wind resistance (3,000 to 5,000 pascals), fire and high speed automation with systems’ interface.
British design and manufacture, wide range of models covering high security, large doors with high wind resistance (3,000 to 5,000 pascals), fire and high speed automation with systems’ interface.
British design and manufacture, wide range of models covering high security, large doors with high wind resistance (3,000 to 5,000 pascals), fire and high speed automation with systems’ interface.
Hart protects people, products and premises through leading brands.
Hart protects people, products and premises through leading brands.
Hart protects people, products and premises through leading brands. Take control of your business environment.
Globally recognised Hart’s high speed doors and shutters deliver options and solutions for industry wherever you are.
Globally recognised Hart’s high speed doors and shutters deliver options and solutions for industry wherever you are.
Globally recognised Hart’s high speed doors and shutters deliver options and solutions for industry wherever you are.
Globally recognised Hart’s high speed doors and shutters deliver options and solutions for industry wherever you are.
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Call 0191 214 0404 info@hartdoors.com www.hartdoors.com
Call 0191 214 0404 info@hartdoors.com www.hartdoors.com
Hart protects people, products and premises through leading brands. Take control of your business environment. Call 0191 214 0404 info@hartdoors.com www.hartdoors.com
For over fifty years, Independent Tool Consultants Limited T/A INTOCO has supplied special stainless steels and nickel alloys with exceptional levels of service, speed and reliability. With a wealth of technical knowledge developed over the decades, INTOCO is now one of the largest on-site stockholders in the UK for specialist alloys such as highend nickel alloys and duplexes. Stainless Steel World sat down with Tony Preece Managing
Director and Nigel Johnson Head of Steel Division, to learn more about the company’s journey so far and its plans for the future.
As one of the largest independent stockists and distributors of specialised materials in the UK, the INTOCO team know the importance of offering consistently reliable, fast service to customers. They supply high-end alloys to customers who manufacture components for demanding
applications such as oil and gas, where quality and reliability are essential. After more than fifty years in the business, their smooth operations and calm, orderly factories may make it seem easy, but every process is backed up with quality control and a keen sense of responsibility to their customers.
The cornerstone of INTOCO’s ongoing success is its very high stocking levels, begins Mr Preece, who heads the company from its headquarters in Cheltenham, UK.
The stainless steels and nickel alloys it supplies range in size from 6.4mm to 764mm in diameter. “Our motto is: ‘If you don’t have it, you can’t sell it’, and this has stood us in good stead over the decades,” Mr Preece explains. “Our warehouses are fully stocked with around GBP 15 million pounds worth of stock, translating to around 2,400 tonnes of specialist alloys. As each order is processed, replacement stock is immediately ordered. INTOCO’s ongoing orders with steel mills with lead times of up to a year account for an extra 30% of stock incoming at any time. While markets may fluctuate, our customers know they can trust us to deliver what they need, when they need it.”
Worldwide rapid delivery “We’re renowned for rapidly shipping products anywhere in the world,” adds Mr Johnson. “Our specialised shipping department ensures products are delivered on time and in perfect condition, protected in top-quality packaging. More than half of our business is outside of the UK, with Europe being our largest geographical market. Following
Brexit, we adapted swiftly to overcome any logistical hiccups and continue to work closely with customers to meet their demands with a minimum of fuss. For example, our products reach customers in mainland Europe within 7-8 working days thanks to the dedication of our logistics team.” Global presence The main markets to which INTOCO supplies steel are the oil and gas industry, followed by the food industry. “In addition, our high-end alloys go into many demanding industries, often for critical parts and components. Our steel customer base includes very demanding applications, including the petrochemical, valve engineering, sub- sea, wind energy, and pharmaceutical industries.
We also have customers who are aerospacequalified and require some of our materials for that sector.” Demanding Quality Management System Traceability and certification are key to INTOCO’s success, and every product can be traced back to the mill that produced it. “INTOCO has been ISO 9001:2015 certified for many years,”
continues Mr Johnson. “We work and adhere to a very strict and demanding quality management system (QMS), and welcome external audits by clients.” Dedicated members of staff have roles solely focused on ensuring quality and technical expertise at all levels within the company. “These team members review all certificates and requirements to ensure we are always meeting or exceeding quality requirements. Regular internal audits ensure nothing is overlooked.”
Over the past twenty years, INTOCO has developed and worked to its own stringent specification for all incoming material. “We adhere very strictly to that specification,” explains Mr Johnson. “Some manufacturers are initially surprised by our demands because they are so high, but we expect the best of the best. We consistently monitor our suppliers to ensure they are meeting our expectations.” While the company’s accurate stock and order system ensures smooth operations, sometimes simple ideas can provide clever solutions.
For example, a colour coding system has been implemented to make identification of the various grades the company stocks easy and immediate. “The products are colour-coded on receipt for checking and confirmation,” explains Mr Johnson, “and this is backed up with colour- coded paperwork. The process starts in the office and finishes in the workshop, so every grade is associated with a particular colour. It’s a simple idea, but it works brilliantly.”
Selected manufacturers with such a laser-like focus on quality, it’s unsurprising that INTOCO works with a small, select group of suppliers for their materials.
“Every single one is thoroughly audited and understands exactly what our demands are,” explains Mr Johnson. “Striving for quality requires hard work and a long-term commitment from both parties.
As a result, we work with a select, stable group of suppliers who have worked with us for many years. This creates strong relationships built on trust. While we will occasionally take on new suppliers to fill any gaps in our product offering, they must go through a very thorough process before gaining approval.
As we’re constantly anticipating demand for more than a year head, stock projection is key to
fulfilling customer needs. Our trusted supplier pool allows us to anticipate demand and ensure the smooth continuation of supply.”
Fully cash funded Remarkably for such a large supplier of highend alloys, INTOCO works entirely without any external financing. “All
it’s fairly unique in the industry. Having large cash reserves means we can immediately purchase what we need, get it on the shelves, and ship it to the clients without delay. This has been the INTOCO policy for many years, and it applies to both the manufacturing and the distribution sides of the company.”
Our steel customer base includes very demanding applications, including the petrochemical, valve engineering, sub-sea, wind energy, and pharmaceutical industries. We also have customers who are aerospacequalified and require some of our materials for that sector.
of our operations are based on our extensive cash reserves, which are constantly increased to facilitate the purchasing of stock and provide services to our customers,” explains Mr Preece. “It’s very important to us that we are fully cash-funded, and
The INTOCO family with a reserved, almost humble attitude, the INTOCO management team is a no-fuss, hard-working group that quietly and consistently delivers an extraordinary level of service to demanding applications. However, one aspect of the business of which they are clearly very proud is their team, many of whom have been with the company for decades. Mr Preece: “We have people who’ve been on the factory floors for up to 40 years! It is truly unique, and the loyalty of our team is heartwarming and a testament to how much they enjoy sharing this journey with us. There is so much experience and expertise within our workforce. In today’s world, where employees may job-hop every few years, to have people choosing to stay with us for their whole career is quite remarkable.” This loyalty is the result not just of favourable working conditions, but also of the environment in which staff operate. “We truly are a family, all of us. It says a lot about a company when people are loyal.” Manufacturing experience =
technical expertise INTOCO is, in fact, two divisions operating within the same company. One division is a speciality steel supplier; the other is a manufacturing division targeted mostly to the aluminium extrusion press industry.
The divisions operate as completely separate entities. “Our manufacturing division, which specialises in tooling and press parts for aluminium extrusion presses, serves that application in almost every country in the world,” explains Mr Preece. “With that business dating back to our foundation over fifty years ago, it is the basis for our extensive knowledge in machining and manufacturing”.
Experts in adding value In addition to providing specialist alloys in a huge variety of sizes, INTOCO also has extensive machining capabilities to add value to raw materials.
The company’s vast in-house knowledge of machining gained and sharpened through its manufacturing division, has provided in-house capabilities and technical know-how to carry out extensive machining operations. “Our team has in-depth knowledge of machining and manufacturing far beyond that of a regular supplier, with our workshop able to handle components weighing up to 8 tonnes,” explains Mr Preece. “The team can machine everything from very small to extremely large items to provide some added value. These include activities as diverse as deep hole boring to heat treatment and a range of ancillary services. Our machines can provide highquality finishes on sawn products.” “An ongoing investment program ensures our capabilities are forever increasing to meet customer demands,” Mr Preece continues. “Usually, we are asked to rough-machine raw materials to a certain point. However, we’re careful not to encroach on our customers’ activities. We will never compete with them by producing finished products; our activities are limited to helping
them save time and machining costs.” Future developments The company’s steady success over the years means the INTOCO team is accustomed to planning ahead.
Upcoming developments include a significant expansion of the warehouse and office facilities to increase stock levels; and plans to expand into more demanding applications requiring high- end alloys. Mr Preece explains: “We recently acquired land to build a new largescale facility. Our plans include expanding our product range to include additional grades of alloys, which will lead to an expansion in our customer base.
We’re also considering expanding fully into the plate and aerospace sector. Our current pool of suppliers can already provide us with the alloys required for this, while our internal systems and quality control are already up to the standard required to serve this exceptionally demanding sector.”
“We place high value on the quality of our products and the integrity of our business. So we welcome open conversations which can be the start of a longlasting relationship based on respect, integrity and stability. That is exactly how INTOCO has become a trusted supplier of special stainless steels and nickel alloys.”
The Measuring Division of Kaman Precision Products, Inc., a global leader in high-performance position measurement systems, is pleased to highlight its Advanced Magnetic Sensing (AMS) family of high-precision non-contact displacement sensors, specifically designed for the materials research and development market. These sensors are engineered to deliver high precision with root mean square (RMS) resolution down to 1 micron, providing extremely
accurate measurements essential for research applications.
This system’s non-contact measurement capability is crucial for maintaining the integrity of delicate materials. Kaman’s AMS sensors are wellsuited for applications such as surface finish inspection, crack and defect detection, and other critical measurements in materials research. In addition, these sensors significantly enhance research and
development capabilities by offering precise measurements without affecting the subject of study.
A key advantage of Kaman’s AMS sensors is their DIN rail configuration, which allows for easy integration into laboratory setups and research equipment. Additionally, these sensors can be customized for OEM requirements, ensuring adaptability to specific research apparatus or experimental setups. This flexibility is vital for researchers who require tailored solutions to meet their unique measurement needs.
Designed to withstand the demanding conditions of research environments, the AMS sensors are IP-67 rated and available with a variety of hermetic options. They are offered in standard configurations, including threaded, flanged, AS4320 pressure port compatible, and bolt head styles, and can be tailored to semi-custom and custom OEM integration needs.
For more information about Kaman Precision Products highperformance position measurement systems, visit https://www. kamansensors.com/productcategory/high-precision-sensors/.
Cooling
In the drive for sustainability and efficiency, many industries are turning to technologies that deliver operational cost savings while reducing environmental impact. CPA Engineered Solutions are the UK’s exclusive distributor of Breezair, an award-winning evaporative cooling solution. Backed by decades of expertise, we provide tailored support for both new and existing customers—offering expert advice, professional installation, and reliable maintenance services.
Breezair’s proven evaporative cooling technology delivers energyefficient climate control across diverse industries, fully supported
by CPA’s exceptional service and technical expertise. With CPA, you gain not just a product, but a partner committed to delivering bespoke cooling solutions tailored to your business needs.
Why Choose Breezair?
Unmatched Energy Efficiency
- Breezair utilises the natural process of water evaporation, consuming significantly less energy than traditional cooling systems. Recognised as the world’s coolest, quietest, and most energy-efficient evaporative cooler, it sets the gold standard in sustainable cooling.
Eco-Friendly Operation
Unlike conventional systems that rely on synthetic refrigerants, Breezair cools the air using only water, making it a truly environmentally friendly choice.
Designed to address hot spots in large spaces, Breezair delivers cool, fresh air directly where it’s needed, improving comfort in warmer areas.
Breezair promotes a healthier and more productive work environment by maintaining consistent, optimal conditions.
Industrial Versatility
Perfect for a variety of commercial and industrial environments, Breezair offers effective climate
control for a variety of industries, whether it’s manufacturing facilities or warehouses, the lowmaintenance, high-efficiency design ensures minimal carbon impact while maintaining reliable performance.
How Does Breezair Work?
Breezair Evaporative Cooling works by drawing warm outdoor air through watersaturated cooling pads. As the water evaporates, it absorbs heat from the air, effectively cooling it before distributing it throughout the facility.
The technology relies on highquality, fully saturated cooling pads and appropriately sized fans and motors to ensure optimal airflow tailored to the space. This innovative design maximises cooling efficiency while keeping energy consumption to a minimum.
Breezair is more than just a cooling system—it represents a forward-thinking approach to climate control. By combining exceptional energy efficiency with environmentally responsible design, Breezair helps industries achieve their broader sustainability objectives. Choosing Breezair is a commitment to sustainable practices that contribute to a greener future for your organisation and the planet.
At CPA Engineered Solutions, we are proud to be the exclusive UK distributor of Breezair evaporative cooling technology. With a deep understanding of climate control systems, we ensure that your cooling solution is expertly tailored to your needs and performs at peak efficiency.
Whether you are a new customer looking at Breezair for the first time or an existing customer needing to optimise your current setup, CPA is your trusted partner. We provide
• Comprehensive Guidance - Our team works closely with you to understand your specific cooling challenges and recommend the best Breezair solution for your environment.
• Professional InstallationWith our skilled engineers, you can be assured of a seamless installation process, minimising disruption to your operations.
• Ongoing Support - We believe in building long-term relationships with our customers.
By combining exceptional energy efficiency with environmentally responsible design, Breezair helps industries achieve their broader sustainability objectives.
That’s why we offer best in class aftercare services, including maintenance, technical support and product optimisation.
• Customised Solutions - Each project is unique. Our expertise allows us to adapt Breezair systems to meet the specific requirements of different industries and facilities, ensuring maximum impact and efficiency.
At CPA Engineered Solutions, we recognise that sustainability is more than just a trend, it’s a responsibility. By choosing Breezair, our customers are making a tangible contribution to reducing their carbon footprint while enhancing operational efficiency. As your partner, we not only deliver best in class technology but also provide the insights and support needed to achieve your broader sustainability objectives.
Partner with CPA Engineered Solutions and discover how we can help you transform your approach to cooling. With our exclusive UK distribution of Breezair evaporative cooling and our commitment to customer service, we are uniquely positioned to provide eco-efficient cooling solutions tailored for your needs.
Contact us at sales@cpa-group.com to explore how Breezair; helped by CPA’s expertise, can transform your cooling systems and support your sustainability goals.
For further information, please vist www.cpa-group.com
According to data from product risk consultancy RQA, the UK’s food product recall figures in 2023 were the lowest for over six years. Sensors are crucial in improving safety and regulatory compliance, but not all sensors offer equal levels of performance. Here, Ross Turnbull, Director of Business Development and Product Engineering at ASIC design and supply specialist, Swindon Silicon Systems, explores the advantages of opting for a custom integrated circuit (IC) solution for food and beverage processing sensors.
Product recalls are a hugely costly occurrence for food and beverage manufacturers. Not only can recalls take a financial toll due to the costs associated with identifying, collecting and disposing
of faulty products, but they can also cause huge reputational damage and prolonged periods of production downtime.
RQA’s data reveals that, after allergen-related labelling errors, some of the main causes of 2024 product recalls by the UK’s Food Standards Agency (FSA) included microbial contaminants such as listeria and e-coli.
Sensor technology has an important role to play in preventing these issues during processing and packaging, by helping to precisely monitor parameters such as temperature and pressure. Given the highly regulated nature of the industry, implementing sensors also ensures that food and beverage manufacturers comply with exacting safety standards.
Introducing IC-based sensors into the production process is beneficial as there is no need for data linearisation, which helps to decrease measurement uncertainty.
This is especially useful when it comes to temperature monitoring, as many foodborne pathogens thrive within certain temperature ranges. Take for example listeria, which was responsible for around ten per cent of the food recalls recorded in RQA’s data and often affects dairy products such as milk. To avoid this, milk should be pasteurised, which means heating it to 72°C for between 15 and 25 seconds. The specific temperature and time period make accurate measurement vital.
IC-based temperature transducers produce outputs as a current or voltage value proportional to absolute temperature, facilitating calibration and improving accuracy. Additionally, semiconductorbased sensors respond quickly to temperature changes, which is essential in time-limited applications such as pasteurisation.
Chip-based sensing technologies are also beneficial when performing alternatives to pasteurisation, such as high-pressure processing (HPP). As a cold processing method best suited to ensuring the safety and extending the shelf life of meat and juice products, HPP utilises sustained, high pressures of up to 87,000 pound per square inch (psi) to neutralise pathogens.
IC-based pressure sensors can be precisely calibrated to measure and monitor these high pressures, ensuring the process is carried out consistently and assuring the effectiveness of sterilisation. As one of the main challenges of HPP is achieving uniform pressure across the entire batch of food, the quick response time of IC pressure sensors help to detect changes almost instantaneously. Manufacturers can then act on this feedback, allowing them to ensure sustained pressure. This level of precision is crucial in reducing spoilage, product recalls and customer dissatisfaction due to compromised packaging.
Even after the food and beverage products have been processed, sensors still have an important role to play. For example, gas sensors are vital for modified atmosphere packaging (MAP) applications, where manufacturers change the proportions of atmospheric gases to preserve minimally processed fresh goods such as meat and fish. Semiconductor-based gas
sensors ensure the correct gas composition within each package, preventing spoilage and extending the product’s freshness.
Unlike off-the-shelf ICs, applicationspecific integrated circuits (ASICs) can be tailored for the exact demands of individual applications. Consequently, opting for an ASIC is preferable for applications with high performance needs, improved system integration and cost effectiveness over time.
The fully optimised chip design of an ASIC means that any unnecessary components can be eliminated, allowing more power to be focused precisely on the features that matter most for the application. Beyond the performance gains, this streamlined design also reduces the bill of materials, lowering the cost per chip.
Within food and beverage processing applications, ASICs offer a wide range of advantages. For example, ASIC-based gas sensors customised for the unique requirements of MAP can monitor
gas flow and composition at micro levels, flagging inconsistencies that may not otherwise be detected. Custom IC temperature sensors can be tailored to specific food storage, heating or cooling processes detecting even slight temperature variations. This targeted design makes ASICs ideal for specific industry demands where standard ICs might lack the necessary precision or range.
Tailoring sensors to fit exact needs reduces calibration time, increases system efficiency, and enhances quality control — making ASICs an ideal choice for food and beverage manufacturers looking to maintain high production standards and comply with industry standards.
Sensors are essential for keeping food and beverage production quality high and product recalls low. Opting for a custom IC solution ensures that sensors tasked with ensuring safety, quality and regulatory compliance achieve maximum performance and effectiveness.
NORD DRIVESYSTEMS draws a consistently positive conclusion after SPS 2024. The renewed increase in visitor numbers at the automation trade fair in Nuremberg was also noticeable at the stand of the North German supplier of drive solutions.
Once again, SPS has proven to be the “summit of the automation experts”, as its organisers describe it, and has again attracted more visitors than last year. For NORD, this year’s trade fair presentation in Nuremberg also has proven to be a successful platform for contact with customers. “Our focus topics efficient electric motors: IE5+ and decentralised drive electronics were in high demand among trade fair visitors”, concludes Gernot Zarp, Sales Manager at NORD. “We were able to welcome a large number of interested visitors at our stand, which resulted in inspiring discussions and valuable contacts.”
NORD’s presentation focused on:
IE5+ synchronous motors: They exceed the highest defined efficiency class and achieve efficiencies of up to 95%. In combination with its NORDAC frequency inverters, NORD offers one of the most efficient drive systems currently available on the market.
Decentralised NORDAC ON/ON+ frequency inverters: Being the latest member of the product family, NORDAC ON gets new functional safety features in the form of SLS, SMS and SSM.
The NORD DRIVESYSTEMS team would like to thank everyone who visited the stand at SPS for their interest.
The decentralised NORDAC LINK SK 250E frequency inverter:
With this, NORD offers a freely configurable inverter with full plug-in capability for wallmounting close to the motor.
The revised NORDCON parameterisation software: In line with the mobile app, the newest Windows app now features an individual dashboard. Together with new additional features, NORDCON now enables even easier parameterisation and monitoring of NORD drives –both stationary and mobile.
With its focus topics and displayed products, NORD emphasised its solution expertise for changing requirements in the industry.
“We support our customers with innovative drive systems that
help them in solving challenging problems”, says Zarp. The conversations at the trade fair confirmed that there is a great demand for that. “The framework conditions, for example in terms of energy and cost efficiency, are changing. With our industry knowledge, which comprises more than 100 industries, and our modular system, we can therefore make a significant contribution to our customers’ continued success.”
Finally, Gernot Zarp thanks all visitors of the NORD stand. “We were happy about the lively interest and intensive exchange.” The Sales Manager also thanks the SPS and stand team in Nuremberg. “You played a major role in making the trade fair a success for NORD.”
To be continued in the next year. Then, SPS will take place from 25 to 27 November 2025.
l Ultra thin bio compatible protection
l Outstanding chemical, moisture and electrical barrier protection
l High lubricious dry film conformal coating
l Metals, Elastomers, Electronics and Plastic
l Proprietary Dimer is 99.7% pure
l CW Parylene: USP Class VI and ISO10993 tested
l MAF No. 1176 on file with the FDA
In engineering and construction, the demand for fasteners that can withstand dynamic forces, vibrations, and harsh environments is critical. Huck® fasteners, known for their strength and reliability, stand out as a preferred solution across various industries. This article compares Huck® fasteners to traditional threaded fasteners, highlighting the strengths and limitations of each fastener type, with a focus on durability, maintenance, and efficiency.
Unique Engineering Principles of Huck® Fasteners
LockBolts® are a relatively modern innovation in the world of fasteners, developed in the 1940s by Louis C. Huck. Initially known as the HuckBolt®, this revolutionary concept was created for the U.S. Navy and railcar industries to address the persistent issue of self-loosening in conventional nuts and bolts subjected to severe vibration. Huck’s groundbreaking design culminated in the first LockBolt patent granted in 1950, and he subsequently established the now-renowned Huck® brand.
This unique fastener design provided effective solutions to common challenges, including: Loss of preload under service load,
• Setting and relaxation effects in threads, Self-loosening under vibrational loads, and
• Relative movement in the thread-bearing area.
The innovative fastening technology quickly gained popularity among manufacturers of mechanical structures and transportation vehicles. Its advantages over traditional joining methods made it a preferred choice in industries demanding reliability and performance.
Today, LockBolts are utilized globally across a wide range of industries by manufacturers seeking to minimize maintenance on bolted joints, eliminate the hazards and risks associated with welding, or simply streamline their assembly processes for greater efficiency.
Huck® fasteners are engineered to deliver unmatched resistance to vibration and loosening, a feature achieved through their mechanical locking mechanism. Unlike traditional fasteners such as nuts and bolts, which rely on friction to maintain tightness, Huck® fasteners use a combination of pre-loaded tension and a swaging process to create a permanent, vibration-proof connection. LockBolts offer distinct advantages over traditional threaded fasteners. Their unique strength stems from two key principles:
The Huck® LockBolt consists of a high-strength bolt (also known as a pin) and a corresponding collar made from a softer and more ductile material than the pin. The
locking grooves are an essential feature of LockBolts and differ from conventional screws in their flatter groove geometry, which results in a larger stress crosssection with the same nominal diameter and a lower notch sharpness. As a result, LockBolts have a significantly higher fatigue strength than threaded fasteners. The collar is smooth (unthreaded) on the inside and, unlike a nut, is not processed by turning, but is axially pressed firmly into the grooves of the bolt by the processing tool, which generates the clamp force on the one hand and creates a non-detachable connection on the other.
The swaging process generates a predetermined preload and clamp load. The result is a permanent, vibration-resistant lock that eliminates gaps or play between components, the end result creates a unified structure capable of withstanding extreme stresses.
• Huck® fasteners are manufactured from high-strength, quality materials, which provide superior resistance to shear and tensile forces. They have a high resistance to environmental factors, such as moisture and temperature fluctuations, this ensures long-term durability even in harsh conditions.
Traditional bolts depend on torque to maintain tension,
which can vary significantly due to installation inconsistencies or material properties. Huck® fasteners are designed to generate a uniform clamp force during installation, ensuring joint stability and reliability.
These principles make Huck® LockBolt fasteners a secure, maintenance-free connection capable of withstanding high shear and tensile loads.
Examples of Huck LockBolts include, BobTail®, MagnaGrip®, C6L®, C50L®, C120L®, and Hucktainer®. Each differ in design, diameter, grip range, material, plating, and purpose.
Traditional fasteners, such as nuts and bolts, rely on friction to maintain their hold. Over time, vibrations, dynamic loads, or thermal expansion and contraction can cause self-loosening, compromising joint integrity and leading to potential failure. Consequently, joints secured with traditional fasteners require regular maintenance and re-tightening.
Huck® fasteners address this issue through their mechanical locking system, which does not rely on friction. For example:
• Huck® LockBolts: The swaging process creates a direct metal-to-metal lock.
• Huck® Structural Blind Rivets: These retain the pin within the rivet body (sleeve) postinstallation for extra strength.
Additionally, blind rivets require access from only one side of the application, simplifying installation. This process is fast, clean, and safe, delivering consistent results without the need for skilled personnel.
Huck® structural blind fastener brands include Auto-Bulb®, BOM®, FloorTight®, HuckLok®, Magna-Bulb®, Magna-Lok®, Magna-Tite®, and Penta-Lok™.
The installation process for Huck® fasteners is another area where they excel:
• Traditional fasteners require precise torque control to achieve the correct tension, with over-torquing or undertorquing potentially leading to failure or unnecessary stress.
• Huck® fasteners utilize specialised tools to ensure consistent tensioning. LockBolts are tensioned directly using accurate power tools that set the preload through the swaging process.
This design eliminates assembler skill variability and the effects of friction coefficient variations, reducing human error and ensuring uniform performance across all fasteners in a project.
Traditional fasteners often require regular maintenance to remain secure, particularly in high-vibration environments. Over time, environmental exposure, wear, and material fatigue can compromise their performance.
Huck® fasteners, by contrast, are designed to be virtually maintenance-free. Their permanent mechanical lock ensures long-term stability without periodic adjustments, translating into significant cost savings over the life of the joint by minimising maintenance and downtime.
Standard Nut and Bolt
The following table highlights the advantages of Huck® fasteners compared to traditional fasteners:
Feature Huck® Fasteners
Vibration Resistance Mechanical lock; resistant to loosening.
Installation Quick, consistent, and requires no re-tightening. The swaging process is completed in a single step, taking only a few seconds per fastener.
Maintenance Maintenance-free.
Durability High resistance to shear, tensile forces, and corrosion.
Cost-Effectiveness
Reduced long-term costs due to reliability and durability.
Assembler Training Requirements Minimal.
Ability to be Retightened Not required.
LockBolts are ideal for use in applications where access to both sides of the joint is available and Huck® structural blind fasteners are used where only one side of the project is accessible. They provide an excellent alternative to screwed or welded connections, particularly in situations requiring high safety standards throughout the service life of the joint. Their exceptional static load-bearing capacity under shear and tensile forces, combined with outstanding fatigue strength, makes them a reliable choice for demanding applications. This durability makes them suitable for demanding applications such as:
Railway Systems: Huck® fasteners are extensively used in track connections, joints, and carriage assemblies. Their vibrationresistant properties ensure safety and significantly reduce the need for frequent maintenance.
Aerospace: Lightweight and durable, Huck® fasteners are essential in aircraft assembly, where weight savings and structural integrity are critical.
Traditional Fasteners
Friction-based; prone to loosening under vibration unless a wedge lock washers or pre-applied, high strength thread adhesives are used.
Installation often involves multiple steps, including torque application, inspection, and periodic re-tightening. These processes are prone to human error and inconsistencies, which can compromise the joint’s performance.
Regular inspection and tightening required.
Variable; depends on material and design.
Higher maintenance and replacement costs.
Assembler skill plays an important role in controlling torque settings, so ongoing training is generally required.
Yes, unless if high-strength thread lockers and adhesives used.
Heavy Machinery: In industries such as commercial vehicles, construction, mining, and agriculture, Huck® fasteners provide reliable connections for components subjected to intense loads and vibrations.
Renewable Energy: Huck® fasteners are integral to turbine assemblies, where they withstand dynamic loads and environmental stresses. They are also used in solar racking systems, where maintaining fastener preload and clamp load throughout the life of a photovoltaic (PV) installation is critical to the reliability of PV racking joints in service.
Infrastructure: Huck® fasteners play a significant role in infrastructure projects, including bridge construction and highway and road infrastructure components.
Marine: In shipbuilding and ship repair, Huck® fasteners create strong, corrosion-resistant connections for various marine structures and vessels.
As can be appreciated from the list of industries utilising
Huck® fasteners; they are highly versatile, offering endless possibilities for installation across a diverse range of applications.
To Conclude, Huck® fasteners exemplify engineering excellence, offering unparalleled strength, durability, and vibration resistance. Their innovative design and efficient installation process make them superior to traditional fasteners in critical applications. By eliminating the risks associated with vibration-induced loosening, Huck® fasteners ensure the long-term reliability of connections, reduce maintenance costs, and enhance safety.
As industries continue to demand robust and maintenance-free fastening solutions, Huck® fasteners stand as a testament to the power of innovation and precision engineering, providing a secure foundation for the world’s most demanding applications.
For further information contact Star Fasteners (UK) Ltd, the UK’s largest Huck® fastener and tooling distributor.
Markforged Holding Corporation (NYSE: MKFG), the company strengthening manufacturing resiliency by enabling industrial production at the point of need, today announced the FX10 Metal Kit, a print engine that brings metal printing capability to the FX10. With this kit, the FX10 becomes the world’s first industrial 3D printer that can print both metal filaments and composites with continuous fibre reinforcement.
“Customers no longer have to choose between a metal and a composite
printer. Years of R&D investment and field experience have come together to provide an all-in-one solution for 3D printing to provide immediate return on investment once installed on a factory floor,” said Shai Terem, CEO of Markforged. “The FX10 supercharges other equipment on the factory floor to be better utilized and run more efficiently, increasing productivity and reducing potential line down events.”
The FX10, released in November 2023 as a composite only printer, was
designed to be the most versatile tool on the factory floor and has received tremendous feedback from early customers. With its modular architecture, upgrades like the Metal Kit enable customers of the FX10 to gain additional value from the machine after purchase.
Markforged also announced a new 316L stainless steel metal filament to be used with the FX10 Metal Kit. Users will also be able to print in 17-4PH with additional support for other Markforged metal filaments in the future.
“We designed the FX10 to be a modular platform, so that we are able to release new innovations and upgrades without customers having to purchase a new printer every year,” said Terem. “Along with new software capabilities we release regularly, the FX10 Metal Kit is poised to provide continuously growing value on factory floors for years to come.”
The FX10 Metal Kit consists of a swappable print engine that includes a metal-specific print head, material feed tubes, routing back, and dual pre-extruders. An FX10 can be swapped between metal and composite as many times as needed, and the swap takes about 15 minutes.
Years of R&D investment and field experience have come together to provide an all-in-one solution for 3D printing to provide immediate return on investment once installed on a factory floor.
Similar to the 5th Generation Continuous Fiber Reinforcement (CFR) print system in the FX10 that prints nearly twice as fast as previous composite printers, the 2nd Generation Metal FFF engine, built on years of Markforged’s experience printing metal, prints significantly faster than previous Markforged metal systems. FX10 combines faster print speed with a print volume twice as large compared to Markforged’s prior industrial metal printers.
Metal prints are built from the metal filament and a ceramic release filament. The ceramic release is extruded as an interface between the part and supports for ease of separation and removal. Once metal prints are complete, they must be washed and sintered in Markforged’s Wash-1 and Sinter-2 solutions.
Eiger, Markforged’s slicer and print management software automates the process, including scaling parts to account for shrinkage during sinter.
The Digital Forge is the additive manufacturing platform that enables every aspect of the FX10 and is purpose-built to integrate into existing manufacturing ecosystems. With the Digital Forge, users can share parts across their organization, and monitor fleet performance from a central location.
Markforged will showcase the FX10 Metal Kit at the International Manufacturing Technology Show in Chicago, Illinois from September 9-14 at booth 432305 where it will be printing in both continuous fibre reinforced composites and metal.
Markforged (NYSE:MKFG) is enabling more resilient and flexible supply chains by bringing industrial 3D printing right to the factory floor. Our additive manufacturing platform The Digital Forge allows manufacturers to create strong, accurate parts in both metal and advanced composites. With over 10,000 customers in 70+ countries, we’re bringing ondemand industrial production to the point of need. We are headquartered in Waltham, Mass where we design the hardware, software and advanced materials that makes The Digital Forge reliable and easy to use.
Countless businesses have set their sights on achieving a true 'digital transformation' over the past decade, but many have struggled to turn these ambitions into reality. The exact reasons for this will vary from company to company, but one common thread is that they’re held back by poor planning and a lack of a solid framework. However, a key tool has emerged that can help manufacturers make these plans a reality: Process Analytical Technology (PAT).
As with so many business concepts, the exact definition of digital transformation is not the same for everyone. When it comes to the manufacturing sector, however, the generally agreed upon meaning is a business-wide transformation that leverages process and product data to boost business profitability, product quality, and manufacturing efficiency.
This approach puts data at the heart of any digital transformation effort. That means that if a project is to succeed, it must incorporate three key factors that link the digital world with the physical:
• Accurate, traceable, and verifiable data: Every piece of data must be correct, traceable back to its source, and confirmable for authenticity. Accurate data helps in making informed decisions, traceability allows for quick issue identification and resolution, and verifiable data ensures that the information used is trustworthy and can withstand scrutiny.
• Data with batch context: Even accurate data loses a lot of value if it’s presented out of context. Ideally, it should come bundled with all the associated metadata —information like time and date stamps, machine ID, batch number, etc. This ensures that any data-driven decisions made downstream are made with a full understanding of the wider picture.
If you haven’t encountered it before, PAT is a framework for designing, analysing, and controlling manufacturing processes through real-time measurements of critical quality attributes (CQAs) and performance parameters.
When used as the backbone of digital transformation projects, PAT can help businesses achieve substantial productivity and optimisation gains.
• Total data integrity: The completeness, accuracy, and reliability of data must be maintained throughout its lifecycle. Data integrity ensures that information remains unaltered in unauthorized ways, accurate, and consistent from the moment it is recorded until it is archived. This is essential for regulatory compliance and making reliable, data-driven decisions.
By focusing on this data, PAT ensures that product quality is consistently monitored throughout a process, rather than relying on traditional manufacturing methods that use empirical testing carried out after its completion. By collecting and analysing data as it is generated, manufacturers can make swift adjustments to maintain optimal quality, reduce waste, and enhance efficiency.
This ability to systematically collect, categorise, and learn from product quality data helps to distinguish PAT from more conventional PLC/ SCADA and DCS setups.
While these systems are effective for basic control and monitoring tasks, they typically lack advanced data analysis, real-time quality management, and adaptive control capabilities. In contrast, PAT-based systems are capable of systematically collecting, categorizing, and learning from product quality data, enabling more sophisticated process control and optimisation.
It also makes it an ideal tool for businesses looking to launch digital transformation projects.
Of course, plenty of manufacturers make use of PAT without enacting a full digital transformation. However, the framework’s ability to capture, analyse, contextualise and make available both real-time and historical data allows it to play a key role in enabling a smooth and effective digital transformation.
This role can be broken down into several key areas:
• Data capture and analysis: PAT enables the collection and analysis of data in real time, which is crucial for developing and refining the manufacturing models necessary for the digital transformation of a business. This continuous improvement loop helps improve processes over time.
• Support for traceability and compliance: PAT systems are designed to support traceability and compliance with regulatory standards, such as good manufacturing
practices (GMP). This ensures that products meet stringent quality and safety standards.
• Transformation of data into actionable information: PAT technology helps transform raw data into actionable insights. This conversion is vital for making informed decisions and driving continuous improvement in manufacturing processes.
• Holistic data sharing and standardisation: PAT makes it easy to share data globally, ensuring compliance and standardisation from the laboratory to production. This capability is essential for multinational companies that need to maintain consistent quality standards across different locations.
• Support for continuous manufacturing: PAT supports continuous manufacturing by providing real-time data that helps maintain optimal production conditions. This leads to significant business
and quality benefits, including reduced waste, rework and downtime; and improved product consistency.
Ultimately, PAT frameworks empower manufacturers to stay competitive by maintaining high standards of quality and efficiency. They support continuous improvement, compliance with regulatory standards, and effective data management. When used as the backbone of digital transformation projects, PAT can help businesses achieve substantial productivity and optimisation gains.
Businesses ready to take their manufacturing processes to the next level, should consult with a respected PAT expert like Optimal Industrial Technologies. The company uses its extensive experience to guide customer through the implementation of PAT systems, helping to unlock new levels of operational excellence and fully realise the benefits of digital transformation.
Vision Engineering, UK designer, manufacturer and exporter of ergonomic microscopes and measuring systems, today announces a new sub £1k entry point for its patented optical stereo microscope technology with the global launch of OPTA, plus it has enhanced a number of its product ranges.
Available for only £900, with a choice of three stands and two lenses, OPTA redefines the entry point for users to benefit from Vision Engineering’s exceptional image quality, ergonomic design and ease of use.
Additionally, Vision engineering announces exciting advancements across its popular EVO Cam, Lynx EVO, and Swift PRO product lines. These enhancements broaden the appeal and applications of these powerful tools, making them more accessible to a wider range of industries and users.
The EVO Cam series now boasts a wider range of configurations, offering even greater flexibility for digital inspection tasks. With the launch of a new, simplified ICON model, users can now choose from multiple software configurations and ergonomic stands to perfectly tailor their EVO Cam system, enabling effortless image comparison, capture, measurement, and reporting.
Award-winning Lynx EVO range extended for Superior 3D Viewing Building upon its reputation for unparalleled ergonomic design and stunning 3D stereo imaging, the Lynx EVO series has been extended to include a simpler, non-zoom variant to appeal to a more price conscious market. This makes the benefits of Lynx EVO accessible to a much wider audience who
have applications demanding exceptional image quality and clarity, useable working distance, and exceptional user comfort.
PRO – Precision Measurement with a new EDGE
Vision Engineering has enhanced the Swift PRO metrology line, its flagship range of bench-top optical measuring systems, with the release of the new Swift PRO EDGE. Featuring a 6.5x zoom, the EDGE enables quick, precise measurements of a wide range of part sizes and features without time-consuming lens changes for different measurement tasks. Using our industry standard, user-friendly Metlogix software, operators of all skill levels will operate the EDGE more efficiently and more productively.
Commenting on the upcoming product launches, Paul Newbatt, Group Sales and Marketing Director at Vision Engineering says “These products are the combined result of listening to our customers and continuously developing our innovative products. By bringing OPTA to market now, and enhancing the value propositions of our EVO Cam, Lynx EVO and Swift PRO ranges, we are confident that these new solutions will significantly broaden the appeal of our Inspection and Metrology portfolio. This enables a much wider range of customers in existing and new markets to better achieve their inspection and measurement objectives with Vision Engineering solutions.”
Advanced technology from mechanical engineering and electrical/electronic industries in approximately equal measure awaits visitors to the next Southern Manufacturing & Electronics trade fair, which will take place from 4th to 6th February 2025 at the Farnborough International Exhibition & Conference Centre. The event is on track to be a sell-out, according to the new owner of the show, Easyfairs, with more than 500 stands expected to be booked for the first time. The larger number of exhibitors will create an even more dynamic and informative environment for visitors, allowing people to explore a greater variety of products and services.
The abundance of new engineering technology across such a wide spectrum of technologies makes the venue highly functional for anyone involved in design, manufacture, procurement, training or management looking to source multiple products and services in a time-efficient way. Although the
industries represented throughout the hall are multifaceted, there are no barriers between the areas, allowing easy cross-over between the different disciplines. Many of the 9,000+ visitors each year say it is an aspect of the show that is particularly useful, as it encourages a wide-ranging itinerary around the stands, often leading to discovery of firms specialising in technologies that would otherwise probably not be encountered.
Widely regarded as the largest and most comprehensive annual industrial expo in the UK, as well as being a major global showcase for engineering and manufacturing technology, the event moved to its present location in 2008 and was the first to be held in the new, world-class exhibition centre when it was built a decade later. The show is important enough to attract big-name manufacturers, but is also very accessible to the rich ecosystem of engineering SMEs, as the organisers operate a policy of open access discouraging larger firms from dominating the space to the detriment of smaller vendors. Easyfairs says that it intends to maintain the intimate look and feel of the exhibition, which is a defining quality that gives it a unique, vibrant
atmosphere fostering collaboration, learning and discovery. Testament to its effectiveness as a place to do business is the very high rate of return stand bookings. Many participants are regular returnees and some have supported the show since it started in 1997.
This year’s event will reflect the ongoing growth in digitalisation of production, a prevalence in Industry 4.0 manufacturing systems, an emphasis on reshoring of production, plus new ecological technologies such as green energy generation, power-saving machinery and efficient under-floor heating. On the mechanical engineering side, there will be the latest machine tools, tooling, workholding and other production hardware, plus suppliers of castings, plastic injection and rubber mouldings, fasteners, pressings, wire forms, springs and gaskets. On the electronics side, featured will be PCB design and manufacture, box build services, cables and connectors. Spanning both disciplines will be mechatronics assembly, electromechanical components and systems, controls, displays, HMIs and data acquisition systems,
sensors, drives and encoders, illustrating just how intertwined the two engineering sectors are.
Robotics and other forms of autonomous handling will feature strongly, driven by a skills shortage in Britain and across Europe. Additive manufacturing continues its progress towards becoming a mainstream production technique and there will be many companies offering equipment, consumables and bureau services. Testing, inspection and measurement serving all industry sectors will be in evidence, as will production planning systems, engineering and business software, materials and consumables. Additional products and services will include oil and coolant, waste recycling, environmental control equipment, packaging and storage, labelling, hand tools, adhesives, and diverse
services from freight forwarding to financial consultancy. The current exhibitor list is available to view at: www.southern-manufacturingelectronics.com/en/exhibitor
Over the three days, visitors will be able to take advantage of an extensive programme of freeto-attend technical seminars covering a wide range of topics to give visitors valuable learning opportunities, with a particular focus on the technical, managerial and environmental issues facing manufacturers today. All sessions will be CPD-approved to ensure they meet specific quality standards. It is an aspect of the exhibition that Easyfairs intends to expand, as promoting education is one of the company’s core beliefs. The Institute for Interconnecting and Packaging Electronic Circuits (IPC) hand
soldering competition returns in 2025, as does AutoAero, a specialist thread that runs through the main programme concentrating on matters important to automotive and aerospace engineering. Both sectors directly contribute billions of pounds to the UK’s GDP, while supporting numerous industries and businesses in the supply chains and providing much needed employment for highly skilled people.
There is free car parking at the Farnborough site, which is well served by road and public transport links, making the venue easy to access. A regular, complimentary bus service runs between the two local railway stations and the showground. Admission to the exhibition is also free. Register today at: https://register.visitcloud.com/
BABCOCK WANSON
by Etienne Fourie, Technical Sales Manager, Babcock Wanson
There’s no denying that process heating systems are large consumers of energy. With sky high energy prices to contend with and Net Zero on the horizon, efforts to reduce energy consumption, improve efficiency and reduce emissions are centre stage. When it comes to Firetube boilers, manufacturers of these systems have been working hard to improve overall efficiency and control of boilers and burners. Here we look at the key developments that, combined, could increase your Firetube boiler efficiency by 45% - a substantial figure.
Electric motors used on boiler feed pump and combustion air blowers traditionally operate at a constant speed. However, boilers are rarely operated continually at full capacity, so maintaining the motor at the same speed at all times is wasteful. Where process load demands are variable, motors can be fitted with a variable speed drive (VSD) which can increase efficiency by up to 30% (based in reduced electrical consumption).
A VSD is an electronic device used to adjust the rotation speed of an electric motor according to the needs of the application. In a Firetube boiler they can be used to vary the pump or fan speed according to demand, ramping up or down the frequency and voltage to the motor, reducing overall energy consumption.
A further benefit to be had from the use of a VSD is equipment longevity. The inherent soft-start function of a VSD, means the motor starting current can be reduced, which decreases thermal and mechanical stresses.
Economisers are essentially heat exchange devices that extract the residual heat from the exhaust gas generated by the combustion process. That recovered heat is usually fed back into the process, typically to the boiler feed water thereby optimising the overall efficiency of the plant in the most compact and cost-effective manner.
By using economisers, you can expect to increase efficiency of your Firetube boiler by 15-20%. Babcock Wanson offers a broad range of exhaust gas economisers perfectly matched to the boiler to which they will be fitted, incorporating ultra-robust extended surface tubes, which ensure the best practicable heat transfer and allow boiler thermal efficiencies of 98% and greater to be achieved. So efficient are they, that the return on investment can be as little as a single year.
Different types of economisers are available to meet a wide variety of processes and site needs, including economisers that can be mounted in a drawer in the back box of the boiler and those suitable for mounting in casing on the smoke outlet, plus economisers with feed water exchanger, and those that come with fumes / water / combustion air exchanger.
By swapping to one of the latest generation of micromodulating burners you can improve operational efficiency of a Firetube boiler by 5%.
Traditional burners are often imprecise and not well matched with the boiler. The new style micro-modulating burners, such as our Optimo range, achieve very accurate control of low excess air levels throughout the turndown range resulting in an excellent combustion efficiency no matter what the process load.
Furthermore, the latest burners have been designed with a very high turndown ratio, enabling the burner to adjust its output to meet the needs of the process. This avoids the costly energy losses incurred by continual stop/start cycles.
Variable environment conditions, such as air temperature and humidity, as well as fuel quality fluctuations, have negative effects on the combustion process, efficiency and emissions. Not enough or too much air leads to the risk of CO production. Too much air also reduces efficiency. To protect against climatic variations,
Efficiency can be increased by 0.9% by incorporating O2 control and CO measurement equipment. A combined probe measures the residual O2 and the CO level in the flue gas and communicates the information to the O2 and CO transmitter which sends a correction 4-20 mA signal to the BMS in order to adjust the combustion air damper position, or combustion air fan inverter speed. This makes for optimal excess air, ensuring complete combustion.
Firetube boilers have been around for nearly two centuries, but only in recent years have we seen a truly concerted effort to reduce energy consumption and emissions. By their very nature, firetube boilers will remain one of the major energy consumers in any plant, but we can – and must! - take steps to reduce that energy.
Babcock Wanson offers a complete range of products and services for boiler houses and other process heating needs.
SEW-EURODRIVE UK
At a time when recruitment in manufacturing continues to prove difficult, automation is becoming even more essential for the factories of today
Andy Turner, sales and operations manager at SEW-EURODRIVE UK, explores why automation will revolutionise the industry moving forward.
Amongst the many things that are shaping the state of manufacturing, the ability to recruit new and younger people into the workforce is continuing to be an obstacle for those operating in various sectors, including us here at SEW-EURODRIVE UK.
Industry 4.0, and even Industry 5.0, are terms which we’re hearing more and more in the manufacturing industry. They reflect a shift towards the adoption of AI, automation, and other digital technologies,
prioritising skilled human employees who can work in tandem with collaborative robots and advanced technology.
To fulfil gaps in labour, manufacturers have been turning to Automated Guided Vehicle (AGV) systems, which can revolutionise the way their factories operate. Made up of versatile, mobile, autonomous, and cooperative robots, AGV systems can help ease the workload of employees, allowing firms to focus on promoting more skilful work.
Minimising the need for manual input
Ideal for use across logistics and factory environments, AGVs pick up and transport loads, calculating individual routes through facilities based on the order they’re carrying.
A big part of the appeal of automation is its ability to reduce labour requirements, cutting down costs in the long run, and taking the pressure of managers desperately looking for new manual workers. It’s therefore important that an AGV system can operate without any human input – which is where load detection systems come in.
Whether an AGV is picking up a small load or a huge pallet, reliable load detection systems
ensure goods can be moved with ease, removing the need for manned transportation, and relieving the strain on staff.
Ensuring the seamless integration of AGVs into manufacturing facilities
The safety of AGV systems within manufacturing environments has become important too, with firms needing to ensure that humans and robots can cooperate without obstruction or injury.
Safety sensors are used to identify and assess proximity to humans or machinery, whilst free contour navigation and parking functions allow for precise movement in factories, meaning there’s no need to establish safety zones.
Beyond good safety mechanisms, some AGVs also come with the option to adjust processes and paths manually. This means operators can respond quickly to changing requirements within production lines, reducing the risk of downtime, and increasing overall efficiency.
As the industry moves forward through 2025 and beyond, it’s important for all manufacturers to consider bringing an AGV system into their production environment.
At a time where many are struggling to recruit, we can stay one step ahead by maintaining high-quality and efficient operations, while easing the workload on staff.
Quirepace are an SME manufacturer and supplier specializing in the niche markets of Pneumatic Tube Systems and Vacuum and Pressure products for Industry and Healthcare applications and are based at their HQ, factory and warehouse in Fareham, Hants.
Under the BVC – British Vacuum Cleaners – brand, Quirepace specialise in manufacturing Industrial Vacuum Cleaners for industry. The BVC brand is best known for the heavy-duty UK manufactured units that deliver the best of traditional, solid, British manufacturing and engineering.
The UK manufactured range of BVC Industrial Vacuum Cleaners consists of machines rated at 1kW to 15kW, with the largest machines being at the limit of what can usefully be called “portable” machines. Fitted with robust wheels and casters, the complete range is capable of being easily manoeuvred to wherever it is needed to be used.
In the industrial workplace, hazards from dusts and spilled product fall into two distinct categories; the first is dusts that are
hazardous to health. This category includes obvious products like asbestos and silica dust, but any dust that can be breathed in by the operator or other personnel in the workplace is likely to be hazardous to health to a degree. Industrial Vacuum Cleaners with M-Class and H-Class filtration ensure hazardous dusts are appropriately handled when being recovered.
The second category is dusts that are hazardous in the environment. The obvious category is dusts that can potentially cause an explosive atmosphere, particularly organic products like sugar and flour. Some products fall in to both categories such as wood dusts, which are
both hazardous to health and potentially explosive. ATEX rated Industrial Vacuum Cleaners must be specified for use in ATEX zones.
The latest innovation in the range of BVC Industrial Vacuum Cleaners is the introduction of a completely cordless vacuum cleaner with 1.5kW of industrial cleaning power. This is achieved by using the new and revolutionary Honda eGX electric engine, which delivers 1/2hr to 1hr cleaning power without the need to “plug in”. With a swappable battery and fast charging combined with a continuously rated motor and turbine the new cordless BVC IV60 eGX delivers a unique solution.
At the heart of most of the BVC range of Industrial Vacuum Cleaners is a BVC multi-stage turbine manufactured here in the UK at Fareham. Quirepace also supply a range of sidechannel exhausters and blowers manufactured in Italy by Esam.
Together, the UK manufactured BVC multistage units plus the Esam side channel machines offer a range of units to satisfy every potential requirement for the supply of both positive and negative pressure air to industrial manufacturers and processors.
The choice of which type is more appropriate for the application depends to some extent whether it is more important to maintain either a consistent pressure, or a consistent air flow as demand changes; A side channel will tend to vary the pressure against any resistance to maintain a constant flow, whereas a BVC multistage unit will tend to vary the flow to maintain a constant pressure. Quirepace’s expert sales team can guide the user towards the most appropriate solution.
An advantage of multistage exhausters and blowers is their robustness and resilience in harsh environments and an ability to cope with some contamination of the air without destroying the impeller.
BVC Multistage vacuum pumps are ideal for smaller centralised vacuum cleaning installations. Typically these will have 2-3 simultaneous operators and a fixed pipework network distributed around the facility to serve the various use locations.
Central vacuum cleaning systems may either use a portable BVC vacuum cleaner to provide motive air or may be configured with static plant and collection hoppers, discharging in to FIBC, drums, etc.
Quirepace design and build central vacuum cleaning systems up to around 30kW, with configurations for hazardous dusts and ATEX environments. A wide range of hoses and tools is available to suit all requirements.
Pneumatic tube systems are the best solution for moving small payloads up to around 3kg quickly between multiple locations within a facility. In industry, the principal use for Quirepace pneumatic tube systems is to transport samples for QC testing from the production floor to the on-site laboratory or testing location.
A range of different systems is offered to meet all possible requirements, from the simplest point-to-point “Diana” system, to complex computercontrolled networks. Tube sizes range from 60mm to 200mm, with 75, 110, and 160mm diameters being the most common sizes.
Using a pneumatic tube system for rapid transportation of small payloads, is not only efficient, it also enhances health and safety by removing the requirement for people to walk samples through production areas.
‘Diagnostics and real-time decision-making’ and ‘5g and manufacturing’.
Comments
Fiona Treacy, Managing Director, Industrial Automation
“With advanced diagnostics, factories are collecting richer data, which helps improve realtime decision-making and allows operations to run smoothly. A significant part of this is driven by the health and status information gathered from IoT devices at the Intelligent Edge of networks, where data processing and computation are performed closer to the devices and sensors that generate the data. Vibration sensing, predictive algorithms and machine-vision cameras are being used here to help monitor both product quality and machine performance.
“AI algorithms analyze this data to provide insights that can predict problems like overheating, voltage fluctuations, or mechanical wear. Machine learning constantly improves these models by learning from past data, making interventions more accurate and timely.
“In practice, AI-driven predictive maintenance enables machines to automatically diagnose and respond to potential issues. These systems can adjust
how the equipment operates to avoid complete shutdowns, keeping things running until a technician can make the
necessary repairs. For example, AI can optimize throughput and maintain high productivity, even during maintenance windows, to minimize disruption.
“As AI technologies evolve, predictive maintenance will become even more powerful, using better real-time data to reduce the need for manual intervention and ensure factories remain operational and efficient.”
“With more than half of the world’s energy being consumed by the industrial sector, there is an urgent need to double the efficiency of factories around the globe. Achieving this level of efficiency requires the ability to communicate faster, more reliably, and more securely on the factory floor. This means having timely access to data. 5G can enable this level of efficiency within factories thanks to its high bandwidth and low latency.
With more than half of the world’s energy being consumed by the industrial sector, there is an urgent need to double the efficiency of factories around the globe.
“For digital factories to succeed, machines need to be able to securely sense, measure, and interpret the real world. The realtime communication capabilities of 5G help machines sense and therefore navigate their surroundings in real-time, reducing errors and improving productivity.
“This requires converting analog data, such as pressure measurements or vibrations, into
digital data to allow for more signal processing. The highest quality data can be found at what we call the Intelligent Edge, where data processing and computation are performed closer to the devices and sensors that generate the data. 5G enables us to harness these insights at the edge and make better decisions, thereby enhancing overall efficiency.
“Take a gigafactory, for example. In battery manufacturing, a robot must apply a uniform coating, which requires a high degree of precision. This precision can be ensured through data from the Intelligent Edge.
“Moreover, with devices becoming increasingly mobile and portable, 5G’s enhanced connectivity can enable the creation of a centralized control system, allowing for greater monitoring and improved overall productivity.”
LABFACILITY
For more than 50 years we’ve been leading the way in temperature measurement excellence. Here’s to the next 50...
From small beginnings in 1971, Labfacility has grown and evolved into the UK’s leading ISO 9001-accredited manufacturer and supplier for the complete temperature chain. From Temperature Sensors, Thermocouple Connectors and Cabling to supporting instrumentation and components, we are the GO-TO people for temperature measurement products.
To sustain longevity, you have to evolve...
Ask the experts...
Our sales team goes above and beyond to provide swift, expert technical advice and support for sensing and instrumentation as and when YOU need it – help is freely available.
Our Sales Team has a mass of experience, plus they are approachable and reliable – just one of the reasons major PLCs and international industry leaders like working with us. Rest assured, you’re in safe hands and not just when it comes to support and advice...
Why choose us?
10 good reasons why it makes sense to choose Labfacility
Expert technical product advice when you need it
• 1500+ Labfacility products available via Farnell/Avnet worldwide
• Short lead times – get your product when you want it
Approachable and reliable (not to mention friendly)
• Extensive range of products stocked
• Global reach via www.labfacility.com
State-of-the-art manufacturing capabilities
Excellent Independent Trustpilot Reviews
• A strong new product introduction programme
• More than half a century’s experience in our field.
In industrial settings, choosing between a soft starter and a variable frequency drive (VFD) can be pivotal in optimising motor performance, efficiency and cost-effectiveness. Both technologies serve the purpose of controlling motors, but their application, benefits and limitations vary significantly. Here Ali Khalil, development sales manager for high voltage solutions at industrial equipment manufacturer WEG explains that deciding when to use a soft starter instead of a VFD involves assessing four key
factors: speed control, price, size and energy efficiency.
The motor starter market is poised to reach USD 13 billion by the end of 2026, growing at a CAGR of five per cent during this period. While VFDs are versatile and suitable for almost all applications, soft starters are more specific in their use cases. This doesn’t mean that VFDs are easier to specify, install and commission — it simply means they are applicable to a wider variety of scenarios. Let’s explore when you should choose a soft starter over a VFD.
The primary distinction between a soft starter and a VFD is to the way they control speed. A soft starter gradually ramps up the voltage to allow the motor to start smoothly, minimising torque and mechanical stress during the startup phase. However, once the motor reaches full speed, a soft starter cannot provide any additional speed control. This makes soft starters ideal for applications in conveyors, pumps and fans, where motors only need to operate at full speed and the primary concern is reducing inrush current and mechanical stress during startup.
Therefore, when an application requires consistent speed adjustments and torque control throughout the motor’s operation, a VFD is the clear choice. However, for applications that do not need speed control beyond startup, a soft starter is a more efficient option.
the cost of simplicity versus advanced control
Cost is another critical factor when deciding between a soft starter and a VFD. Soft starters are generally more affordable due to their simpler design and functionality. A soft starter uses silicon-controlled rectifiers (SCRs) to connect the AC input line to the motor. In contrast, VFDs incorporate more complex components including a diode front end, DC bus and insulated-gate bipolar transistors (IGBTs), which increase costs.
This additional complexity makes VFDs more expensive, often two to three times the price of a soft starter, especially for larger horsepower applications. However, the higher initial cost of a VFD can sometimes be justified by its potential to deliver long-term energy savings, particularly in applications where motors frequently run at partial loads or variable speeds.
The next consideration should be size. Soft starters also offer substantial savings in physical size and volume compared to VFDs. The additional components in a VFD and its cooling system not only cost more but also take up more space. The volume savings with a soft starter depend on the power rating. In industries where space is limited, such as shipyards or small manufacturing facilities, the smaller footprint of a soft starter can be a crucial advantage. The reduced size and complexity also mean that soft starters are easier and quicker to install, further reducing operational costs.
Instant efficiency gains or long-term savings with speed control
Finally, energy efficiency should be considered. Soft starters can achieve up to 99.5 per cent to 99.9 per cent efficiency. After the starting process, a soft starter with an integrated bypass activates an internal contactor, allowing current to flow through it efficiently. In contrast, VFDs are around 95 per cent efficient because active components like IGBTs are always on during start, run and stop phases, leading to lower efficiency. However, VFDs offer more opportunities for energy savings by controlling both voltage and frequency.
The motor starter market is poised to reach USD 13 billion by the end of 2026, growing at a CAGR of five per cent during this period. While VFDs are versatile and suitable for almost all applications, soft starters are more specific in their use cases.
When operating at full speed and properly loaded, soft starters are more efficient than VFDs. Once up to speed and bypassed, the motor current flows across the bypass contactor in a soft starter, with no active solid-state components generating heat. Conversely, a VFD remains hotter due to its active components constantly managing voltage and frequency.
It’s clear that properly selected soft starters can yield significant cost, size and energy savings over VFDs. The latter can be two to seven times more expensive and
two to eight times larger than soft starters, but application characteristics are critical when choosing between the two options.
Both can start a motor with reduced voltage and current, but the unique aspects of your application will determine the best choice, allowing you to right-size either a soft starter or a drive. Regardless of the motor control method you choose, consider additional factors such as installation, commissioning and the need for extra filters or circuit protection when specifying a soft starter or a VFD.
• Core with color display
• Incl. touch panel
• 1,000 cd/m2 (typ.)
• WIFI, LAN, RS-485
• 4 relays
• 8 inputs
• RS-232
• 4-20 mA / 0-10 V
At Texim Europe we constantly invest in people, gather knowledge and expand our worldwide network, so we can select quality devices, modules and platforms that suit every application in the industry.
+44 (0)1522 789 555 www.texim-europe.com uk@texim-europe.com
For nearly 40 years, Elmeridge has specialised in designing, manufacturing, and distributing custom low-voltage cables for various demanding applications. Below are some examples that highlight our durable and innovative cable solutions:
Polyurethane Cable: Supplied to a North Sea fish farm, this cable has outlasted expectations, still operational over 20 years later. Made with a highly resilient, hydrolysis-resistant compound, it is favored by underwater and offshore industries for its toughness and flexibility.
Termite-Proof Compounds: Elmeridge developed termite-resistant cables using compounds like Hytrel, Polyurethane, and Polyethylene. These cables withstood a lab test against aggressive Australian termites, demonstrating their durability.
Glass Fibre Reinforced Plastic (GFRP): Known for exceptional durability, Elmeridge’s pushrod cables for pipes and drains incorporate a unique GFRP rod, allowing for extended push distances without compromising strength.
London, demonstrating strength with a 750kg breaking load.
36-Core Umbilical Cable: Designed for a ship’s radar system, this flexible umbilical cable withstands folding during navigation under low overhead structures.
Steel Wire Armour: Custom-designed for the Spanish Navy, this cable uses a combination of Kevlar yarn and Nitronic 50 steel wire armour for high-strength applications.
Rodent-Resistant Rail Cable: Developed for the Hong Kong Metro and later widely adopted by the London Underground, these cables help protect critical rail systems from rodent damage.
Single Core and F1 Cables: Elmeridge supplied Formula 1 with single-core cables in durable compounds, solving issues with in-car camera cables by preventing vibration-induced wear. Buoyant Fibreoptic Cable: Recently, Elmeridge produced a 5km buoyant
Medical Silicone Cable: Elmeridge combined two silicone cables into one, reducing the diameter without sacrificing flexibility for medical applications.
Sensor Cables: Featuring inner vent tubes for pressure sensing, these cables serve industries in India, Europe, and the UK.
Copper Braid: Elmeridge supplied the Royal Air Force with copper braid sheaths to ground aircraft during refueling, reducing static electricity build-up and fire hazards.
CTD Cables: We are also proud to work with the British Antarctic Survey (BAS), supplying cables of 8,000 and 10,000 metres of CTD (Conductivity Temperature and Depth) Cables for the RRS Sir David Attenborough (pictured), and RRS James Clark Ross..
SPELSBERG
To protect electrical junctions in buildings from the threat of fire, embedding connections in concrete has been one of the possible solutions in the past, depending on the building design. While concrete is fire resistant, the challenges of access make inspection, as well as installation, more complex to achieve. Instead, fire-protected enclosures mounted directly onto a wall surface can make maintenance and installation significantly faster while maintaining the required safety standards.
Chris Lloyd, Managing Director at Spelsberg UK, explains the advantages of fire-resistant, surface-mounted enclosures.
In the event of a building fire, safety systems must continue operating for a prolonged period. As well as alarms to warn occupants and alert emergency services, lighting must remain active to highlight a safe exit route. Smoke and heat extraction systems might be relied on, as well as water booster systems to supply extinguishers, while dedicated elevators might need to safely transport fire crews.
All these systems need electrical power and protection of their supply during a blaze, potentially for an hour or more after a fire has taken hold. To achieve this, cable junctions and distribution boards have historically been designed and embedded within concrete
protection. However, installing electrical connections within fireprotected enclosures mounted directly onto walls can offer equivalent protection – and in some cases can provide greater security.
The concrete challenge
While concrete is fire-resistant, the protection it provides to embedded electrical junctions depends on its thickness, and whether additional insulating materials are used in combination. Moreover, embedded electrical junctions might not sufficiently contain a fire should an electrical failure occur inside a concrete wall. In a case like this, the fire could spread through cavities or reach flammable materials if the integrity of the wall is compromised.
Threats also remain in the longer term. In the event of any high temperatures, concrete can conduct heat and retain it over an extended duration, sufficient to degrade or damage any enclosed electrical connections. Embedded electrical connections could also be exposed to hidden moisture or damp conditions, which could corrode and damage junctions. However, to deal with either of these situations, the inherent challenge of embedded systems is inspection: the only way to make a visual check is to drill in or completely expose the electrical junction.
Using enclosures manufactured from specially treated polycarbonate resistant to flame and heat can protect electrical junctions in the event of a fire. As polycarbonate is non-conductive during fire or heat exposure, the enclosures also prevent the risk of short circuit. Protection features such as ceramic terminal blocks inside the enclosure, resistant to high heat, also help to protect the connections.
Combining these features in a surface-mounted enclosure can ensure electrical integrity for up to 90 minutes, according to the E30-E90 electrical functional integrity standard. This testing and recognition are the hallmark for fire-and heat-protected enclosures like the Spelsberg WKE Lifeline cable junction and connection box.
However, an enclosure designed specifically for fire protection and wall mounting also needs to form a barrier against more than flame and heat. These special junction boxes need to withstand water ingress from sprinkler systems and high-pressure hoses, so an IP66 rating is also key. An IK08 impact protection rating should also apply to defend electrical connections from force, which is another advantage of designing with high-strength polycarbonate.
While appropriately designed, externally fitted enclosures can provide sufficient fire defence, the significant advantage of easy access also enables frequent
inspection to ensure long term integrity. For example, the Spelsberg WKE fire protection box can be rapidly accessed by maintenance and safety teams via four screws positioned in the enclosure cover. This lid is held in place by a cover retainer lanyard to prevent loss during inspection while unauthorised access can be prevented thanks to a safety seal.
To speed up a project for installers, wall-mounted, fire-resistant enclosures really come into their own. Just like a standard junction box, these casings can be installed wherever required or convenient for the environment, without needing to make precise design plans in advance. In the case of the Spelsberg WKE, the enclosure can be quickly mounted in situ by two external lugs that can be rotated 90 degrees.
Inside the box, the terminal block can also be adjusted through three positions, including 0, 45 and 90 degrees, and cables can be quickly and securely inserted with additional metric cable glands.
Depending on the design of the building or installation, enclosure specification for fire protection can often gain from specialist support. This could range from advising on the right type of enclosure to meet the electrical connection needs of the installation, whether that’s a high-rise block of flats or an underground railway, as well as ensuring that the required safety compliance is met for the environment.
Achieving fire safety for electrical connections is essential for building managers, maintenance teams, and electrical installers. At the same time, project time pressures for rapid installation always remain. However, wall-mounted enclosures that meet E30-E90 fire and heat resistance, and also enable rapid installation and maintenance access, are an ideal solution to meet these challenges.
Whether degreasing, classic component cleaning or high-purity applications - the demands on cleaning solutions have increased in all areas of the manufacturing industry. Ecoclean is responding to these changed market requirements with an even broader and more modularized product range. The focus is on higher cleaning quality, improved costs, and more energy-efficient processes.
Component cleaning is a critical step in manufacturing, ensuring that downstream processes meet quality standards across all industrial sectors. The diversity in cleaning applications has increased, driven by factors like new and modified products, increasingly compact and complex geometries, and a broader variety of materials. Workpiece dimensions can vary from less than a millimeter to several meters. Depending on production stage, product, and industry, requirements for cleanliness and process complexity differ. For instance, final cleaning in high-tech industries, such as semiconductor manufacturing, medical technology, and precision optics, requires the removal of particulate contamination at the nanometer level and nanolayers of residual film. Conversely, in general industries, the focus is often on removing large quantities of chips and machining media at high speed. In all cases, cleaning processes must be economical.
To effectively tailor cleaning solutions to specific tasks, it is essential to consider various
product and company-specific criteria in addition to cleanliness standards. This necessitates a flexible product range in terms of cleaning media, plant design, and process technologies. Ecoclean, as a full-range supplier, covers the entire spectrum of wet-chemical processes using water-based media, solvents, and modified alcohols. This comprehensive approach allows the company to efficiently customize cleaning processes and systems to meet specific product and company requirements, whether for batch or individual part cleaning. Ecoclean’s process design is supported by in-house Test Centers, including cleanroom facilities for high purity applications.
Modular systems, such as EcoCvela for water-based cleaning and EcoCstretch for solvent-based cleaning, offer efficient solutions for tasks requiring special equipment. The modular concept includes different chamber sizes and a variety of process technologies, such as spray cleaning, ultrasonics, injection flood washing (IFW), Pulsated Pressure Cleaning (PPC), and plasma cleaning. These systems are designed for both general industry and high-purity applications, ensuring short process times, high cleanliness levels and energy-saving operation.
In the field of multi-stage ultrasonic immersion cleaning, Ecoclean offers modular solutions
through its UCMSmartLine, UCMPerformanceLine, and UCMHighLine series. These systems, comprising standardized modules for cleaning, rinsing, drying, and more, can be easily configured and commissioned. They are also designed for high-purity applications, with appropriate equipment for cleanroom operation.
With its diversified portfolio, Ecoclean enables companies across various industrial sectors to adapt to changing cleaning requirements in a cost-effective, energyefficient, and future-oriented manner. This approach not only ensures compliance with stringent cleanliness standards but also supports sustainable and resourceefficient manufacturing practices.
EFFICIENT CLEANING AND DEBURRING SYSTEMS FOR VARIOUS INDUSTRIAL PARTS AND COMPONENTS.
Aqueous Cleaning
Solvent Cleaning
Ultrasonic Cleaning
High-pressure
Waterjet Deburring
Surface Processing & Selective Cleaning
Since 1922, Castell Safety International has been a global pioneer in trapped key interlocking systems. Founded by James Harry Castell, the company developed the first interlocking solutions to safeguard people and assets during London’s electrification, setting the benchmark for industrial safety.
Today, Castell offers the world’s most comprehensive range of industrial safety interlocking systems. Their solutions ensure that industries across the globe can maintain safe operations, protecting both workforce and infrastructure.
As part of the Sentric Safety Group, Castell delivers robust, reliable
safety solutions tailored to the most demanding environments and uphold an unwavering commitment to protecting businesses operating in harsh and safety-critical environments.
Castell products serve a diverse array of sectors and applications worldwide and support professionals across health and safety, compliance, project management, operations, logistics, procurement, engineering, and more. A tried and tested brand with experts that understand the
safety issues found in modern industrial locations, Castell Safety International can and will safeguard your people and enhance operational safety.
The never-fade, never-wear alternative to traditional signs
Our LED projected safety signs are harder to ignore, longer lasting & more cost-effective than painted & printed signage.
No contamination
Consistent and never-fade
Adaptable and versatile
Reduce sign blindness
Completely customisable
Find out more or book a site visit at
Businesses in the food and drink sector are replacing printed and painted signs with projected alternatives which improve food hygiene and safety. That’s according to Projected Image, who have worked with companies including Coca-Cola and Dunbia.
Projected Image supplies LED gobo projectors that shine bright safety signs onto surfaces, including floors, walls and doors. The image is provided by a glass ‘gobo’ which can be customised for specific health and safety signage needs.
“Projected signage tackles many challenges faced by the food and drink industry. Unlike painted signage and safety markings, projected signs don’t risk producing contaminants,
such as paint chips, when cleaned regularly or subjected to heavy foot and forklift traffic. They don’t fade or harbour bacteria either” says Ian Spoors, MD of Projected Image.
The experts say LED projected signs are clearer, brighter and more consistent than traditional signage, reducing ‘sign blindness’ for a safer, more hygienic workplace.
“For Dunbia, we produced projected signage for handwashing stations and they’ve reported an increase in sign visibility throughout their factory. Many companies are finding that projected safety signs are the long-term, low-maintenance solution for safer, cleaner workspaces” says Ian.
Projected Image is the UK’s only dedicated provider of LED projectors and custom-made gobos. The low-energy projectors can be installed by qualified electricians in any commercial or industrial environment.
• High quality materials
• Innovative designs
Union Industries, the UK’s leading manufacturer of bespoke industrial doors, has helped Sonoco introduce more efficient operating procedures with the installation of its high speed Ramdoor.
It represents a first for the paper mill in Halifax, West Yorkshire, which recycles wastepaper and cardboard - converting it into a range of useful products.
With efficiency in mind, Union’s rugged Ramdoor replaced a slow and outdated roller shutter door, at the same time helping with the segregation of pedestrian and vehicular traffic.
Sited in a section of the warehouse leading to the waste yard, the newly installed Ramdoor has enabled Sonoco to increase the frequency of both large machinery and forklift traffic through this entranceway, in line with changes to their operating procedures.
Due to the large volumes of wastepaper processed, it is important that the Ramdoor seals quickly, preventing the ingress of debris. A Class 5 wind resistance rating provides extra benefit - helping maintain operations during more challenging weather conditions.
Sonoco, a multi-billion-dollar global provider of consumer packaging, industrial products and packaging supply chain services, has been a customer of Union Industries for almost 30 years, having previously fitted four Matadoors.
This is the first Ramdoor to be installed at the site - features include a variable speed drive motor with
We are delighted to continue our longstanding partnership with Sonoco by providing them with a flexible and highly effective solution.
frequency inverter for greater control, thick Ramhide door blade material with anti-static additive and a ‘Crash Out’ system which reduces the potential of bottom beam damage - helping to minimise downtime and repair costs.
The heavy-duty wind-bar system, combined with the extra-deep side-guides, provides added strength, and contributes to the Ramdoor’s ability to cope with high wind loads and pressures.
Paul Hindley, Engineering Manager at Sonoco, said: “The installation of the Ramdoor at our Halifax facility is a game-changer. It allows for quicker, safer, and more efficient movement of our large machinery and vehicles. This has enabled us to introduce changes to our operational procedures, creating more efficiency. This upgrade is part of our commitment to continuously improve both our operational processes as well as our safety standards.”
Rob Howe, Technical Sales Engineer at Union Industries, said: “We are delighted to continue our longstanding partnership with Sonoco by providing them with a flexible and highly effective solution.
“The Ramdoor offers superior performance and durability, and in this instance has allowed Sonoco to ensure that this external entrance can cope with increasing traffic flows, effectively future proofing its requirements and allowing for future growth.”
Union Industries, the UK’s leading manufacturer of highspeed industrial roller doors, is celebrating its 10th anniversary as an Employee-Owned Trust (EOT).
Incorporated as Union Industries in 1972, the Leeds-based manufacturer has gone from strength to strength since founders Isobel and Paul Schofield took the decision to safeguard the future of the company by selling their majority share to the Union Industries EOT.
In the last decade, the business has paid more than £3m in tax-free bonuses; in the last five years alone, employees have each received an annual bonus of £3,600, and in 2024 that rose to £6,500 per employee. It has also achieved
record levels of revenue and profit, with profit soaring from £130,000 in 2013/2014 to £2.4m in 2023/2024.
Employees also have a vested interest in its success, particularly following the establishment of an Employee Council, full voting rights and representation on the board of Trustees.
Under the scheme, every employee can buy into the business at an annual dealing day, while new starters receive shares after 12 months of employment.
Andrew Lane, Managing Director at Union Industries, said: “10 years of success for any business is a major milestone, but 52 years of business and for 10
of those, the most profitable ones, to be as an EmployeeOwned Trust is remarkable.
“Although we have always benefited from a committed workforce, becoming employeeowned has further empowered the team; everyone now also has an added financial incentive as a result of an annual tax-free bonus and the Employee Council ensures everyone is involved.”
For further information, please visit www.unionindustries.co.uk
Machine safety is critical in industrial settings to protect workers, ensure operational efficiency, and comply with legal regulations. Recognising that each machine and operations have specific demands, Safety Systems has designed and delivered a diverse range of safety solutions that comply with current machinery safety legislation including PUWER, BS, EN & ISO Standards.
“All our projects focus on enhancing the safety of often aging machinery, and updating both guarding and electrical systems to meet current standards. As safety regulations have advanced significantly since many of these machines were originally constructed, our work ensures they comply with today’s stringent requirements,” stated Allan Harris, Director.
Safety Systems, in its current form, has been operating since 2014 when Mark Smailes took over as Director after the company was divested from TUV SUD Ltd. However, the roots of Safety Systems trace back to 2001, when Roger Scott founded the company as a supplier of machinery safety components, including interlocks, safety relays, and light curtains. Since then, the company has grown organically, evolving from a component supplier to a full-service provider, offering design, supply, installation, and validation of comprehensive safety solutions using products from a wide range of leading safety component manufacturers and innovators.
“We are a specialist engineering company dedicated to upgrading the safety of both new and existing machinery to ensure full compliance with current UK and EU machinery safety standards and regulations.
This includes modernising older machines with outdated safety devices and adapting new machinery, often manufactured outside the European Economic Area, that does not meet UK/EU standards. Recently, we successfully re-engineered three new machines built to American standards, bringing them into compliance with key UK regulations such as EN60204-1, EN ISO 13849, and EN ISO 14120, ensuring they can be safely put into service,” added Allan.
Safety Systems are experts in delivering bespoke machinery safety solutions and effectively act as a one-stop shop for machinery safety issues, offering everything from initial assessments such as PUWER and CE/UKCA audits, design and implementation of safety upgrades through to final signoff and validation. Unlike other machinery safety companies that only focus on guarding or electrical safety, Safety Systems offer a full package with complete turnkey solutions.
Recently, the company has invested in a couple of upgrades to its test equipment, enabling them to offer Stop Time Testing for ESPE devices. Stopping time is crucial for machines with dangerous motions when positioning protective devices like light curtains, safety scanners, and two-handed controls because it determines the safety distance
needed to prevent the operator from reaching the danger point before the machine stops. Using the HHB Safetyman® DT2 time meter means stopping time and distance can be tested to ensure safety devices are correctly positioned and functioning. The company’s Functional Safety Engineers can perform this testing on-site, or provide the equipment for hire if you prefer to conduct the tests yourself.
What’s more, Safety Systems also provide testing of permanently installed electrical systems to machinery in accordance with EN60204-1. Section 18 of EN60204-1 outlines the need to verify the safety of a machine’s electrical equipment through inspection, testing, and proper documentation. This includes checking for compliance with electrical documentation, examining equipment for damage, ensuring protection from electrical contact, and conducting tests like continuity of the earthing system, insulation resistance, and functional performance. Using the company’s advanced GOSSEN METRAWATT ProfiTest Prime testing machine, they can thoroughly check and validate the electrical safety of your machinery, ensuring it meets the required standards.
Safety Systems is dedicated to enhancing workplace safety with its expertly designed and supplied machine guarding solutions. We asked Allan, how do they tailor machine guarding solutions to meet the unique needs of different industries. He responded:
“With extensive experience across various industries, we design tailored safety solutions that meet specific requirements, such as
hygiene standards for food and pharmaceuticals or corrosion resistance for chemical and saline environments. Our skilled Design Engineers use the latest Autodesk Inventor Professional 3D software to custom design all guarding systems. This advanced modelling allows us to visually represent machinery and solutions, helping to ease operator concerns by demonstrating how the guarding will impact their interaction with the equipment. This visualisation is also valuable for business leaders when implementing safety upgrades.”
Of course, every industry comes with its own challenges. We asked Allan what are the current compliance challenges companies face and how does Safety Systems help businesses to overcome them. He answered:
“Understanding how to address issues in a timely, cost-effective, and compliant way is crucial. While many companies have on-site engineering teams, these teams are often focused
on keeping machines running and may not have the time to delve into the complexities of machinery safety standards. Since we work with these standards daily, we are well-versed in interpreting them and can quickly develop solutions that align with the latest guidelines, ensuring their machinery stays safe and compliant.”
Safety Systems is a tight-knit group made up of colleagues that have worked together for between 10-30 years. Evolving from a safety component supplier to a comprehensive safety solutions provider, their combined deep industry knowledge and adaptability underscores their expertise in the industry. Their proactive approach to solving safety issues ensures that solutions are both timely and compliant.
“When collaborating with clients, we begin with a comprehensive risk assessment of their machinery, conducted by a qualified professional to identify potential
hazards in accordance with relevant standards. Following this assessment, we apply innovative engineering to develop tailored safety solutions. This often involves integrating various technologies to create a robust and effective Safety System that addresses the identified risks,” said Allan.
Looking ahead, Safety Systems is currently investing in new software to help its internal processes and to streamline workflows. “From this, we will hopefully see an improvement in our productivity and reduction in our paper work,” added Allan.
In conclusion, Safety Systems exemplifies excellence in machinery safety through its unwavering commitment to innovation and compliance. By seamlessly integrating advanced technologies and tailoring solutions to meet specific industry needs, they not only enhance safety but also ensure operational efficiency across diverse environments.
WISEMAN THREADING TOOLS LTD
We have been supplying threading tools and gauges since 1987.
We have been threading tools since 1987.
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.
Together with supplying plain plug and ring gauges this is all that we do, we therefore consider ourselves to be specialists in this field.
Together with supplying plain plug and ring this is that we we therefore consider ourselves to be specialists in this
We supply worldwide.
We supply worldwide.
We supply worldwide.
We hold extensive ready stocks that include of the standard stuff that others offer, but also taps, dies, die nuts, die head chasers, thread rolls and for threads not normally available 'off the shelf
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 '.
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.
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.
Our time stocks can be checked and purchased online www. threadtools.com Just enter the thread details the 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.
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.
You will be directed to the item, stocked, to our specials, (custom manufacture), sales team. will quote to at rates, in good time.
As an account you can also order from our listed in stock items, at normal terms. realise you need the right item at the price quality, and in a reasonable 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.
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 to provide that.
We are geared to provide that.
We are geared to provide that.
We can ship stocked items same day.
We stocked items same day.
We can ship stocked items same day.
Our experienced sales staff can assist and advise you on any technical issues.
Our sales can assist and advise you on any technical issues.
We welcome enquiries from resellers and can offer terms to suit.
We enquiries from resellers and can offer terms to suit.
We welcome enquiries from resellers and can offer terms to suit.
Our experienced sales staff can assist and advise you on any technical issues.
WISEMAN THREADING TOOLS LTD 11 Padgets Lane, South Moons Moat, Redditch B98 0RA +44(0)1527 520 580 sales@threadtools.com www.threadtools.com MACHINING &
+44(0)1527 520 580 sales@threadtools.com www.threadtools.com
WISEMAN THREADING TOOLS LTD
11 Padgets Lane, South Moons Moat, Redditch B98 0RA UK
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 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.
THREAD CUTTING AND ROLLING HEADS and parts and repair service
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!
Nano Dimension, a leading supplier of Additively Manufactured Electronics (“AME”) and multidimensional polymer, metal & ceramic Additive Manufacturing (“AM”) 3D printing solutions, today announces the launch of its Exa 250vx Digital Light Processing (DLP) 3D Printer for micro applications. Developed to enable the creation of superior resolution micro parts at high production throughput, the high-speed Exa was unveiled today for the first time globally at Formnext in Frankfurt, Germany (Hall 11, Stand D22).
Designed using insights gathered from users of Nano Dimension’s proven and established Fabrica Tera and Fabrica Giga systems, the Exa 250vx has been engineered to deliver the highest productivity in the industry for exceptionally precise micro parts. Built to support the demands of service bureaus and OEMs alike, the Exa 250vx Micro 3D printer provides a reliable and cost-effective alternative to traditional micromanufacturing methods, including micro-injection molding and micro-CNC.
Leveraging resin-based DLP technology to achieve precise layer heights and exceptional surface finishes, the Exa is an ideal solution to meet the exacting needs of manufacturers
across an array of vertical sectors and applications. These include connectors and other miniaturized components for electronic devices; medical devices like micro needles, micro filters, and components for minimally invasive surgeries; plus applications for optical uses and micro-decorative items – including gold coated – for the jewelry sector.
Further benefits are assured due to Exa’s compatibility with Nano Dimension’s range of resins for high resolution micro parts , starting with D-810 . This enables the production
of durable, rigid parts with high structural integrity – perfect for creating intricate and precise components in the aforementioned application areas. As with the other Fabrica systems, there is an open system policy, allowing users to work with third party resins.
“Manufacturers producing micro parts are facing a trade-off between precision and productivity,” says Nir Sade, Senior Vice President of Additive Manufacturing at Nano Dimension. “As part of Exa’s development, we worked closely with customers to address a host of needs such as highvolume parts production with micro level detail for parts larger than the 50mm build limit we currently have on the Tera. The result is a system that provides the perfect balance of quality, productivity and cost, making it a game changer for the industry.”
With its larger 100mm x 100mm x 70mm build volume, 7.6µm XY resolution, and layer thickness of just 10 microns, the Exa combines sought after attributes that deliver rapid production and high resolution, allowing manufacturers to produce the specific micro parts to meet their particular engineering requirements.
Available now for preorder, the Exa is set to ship in Q2 2025.
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.
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
The business of manufacturing continues as it always has, and typically brings successes and challenges across the workflow. The evolution of how manufacturers produce and deliver their applications is a particularly interesting factor to consider as the number of manufacturing processes available and their capabilities increase and improve. One of the more disruptive technologies to emerge in recent decades is that of additive manufacturing (AM) or industrial 3D printing. This technology set itself incorporates a range of processes, a continually growing palette of materials, and software that enables the technology and improves efficiencies. Utilising industrial 3D printing for any manufacturing discipline, whether for rapid prototyping, tooling, or, increasingly, production on demand, does not come without its own set of challenges, but deploying AM can also bring great advantages.
The benefits of AM are well documented, in essence allowing manufacturers to exploit the ability to build complex parts, in one piece, which were previously impossible. This in turn enables the consolidation of existing parts, reducing assembly requirements and reducing overall costs. In addition, with explicit design for process knowledge, AM parts can also be made stronger and lighter making them more efficient across their life cycle while also reducing material consumption. For low and medium production runs, AM can eliminate the need for tooling, making it a faster and more cost-effective manufacturing option. These advantages mean that AM has become a viable option for many manufacturers.
However, while all of these advantages are enabled by the additive systems that build the parts, in reality, the AM hardware is actually just one piece — albeit a vital piece — of
an ecosystem of technologies that enable success with AM.
The building of the parts utilising AM is the essential core of the manufacturing workflow, however what happens before and after the build are also vital to delivering high quality parts in the most efficient and cost-effective way.
Here, we are exploring how a specialised bureau can raise the bar for AM with quality services that extend beyond just the 3D printed parts themselves.
Experience and expertise go a long way to alleviating the challenges manufacturers face when using AM. Working with a specialist AM bureau ensures that both come as part of the service from beginning to end. Look for an innovative business model that delivers high quality end-to-end processes including fast, automated ordering
and tracking at the beginning and dedicated post-processing and finishing capabilities at the end.
Automation is a technology area that has also progressed significantly in the last decade. A forward-looking AM service bureau will have grasped this opportunity to develop and embed enhanced efficiencies into its ordering system to improve user experience. A dedicated automated ordering system will greatly streamline the ordering process, allowing clients to place their orders quickly and intuitively, while also providing full tracking capabilities.
An intuitive automated ordering platform should enable customers to upload their files, select material/s, and specify finishes with ease. It should then be able to provide immediate pricing feedback based on material cost, print time, and complexity. Once the order is confirmed, the system can then provide status updates of all orders in real-time, greatly improving transparency and communication.
By leveraging technology to automate ordering, AM service providers enhance customer satisfaction and operational efficiency, making AM more accessible and speeding up the front end of the workflow significantly.
While we’ve established that the printing process is pivotal, the finish of the parts that come off the AM system often determines its quality and, importantly, its usability. Dedicated post-processing services are also essential for ensuring that 3D printed parts meet client expectations.
It’s probably important to note here, that post-processing is actually an umbrella term for a number of stages that AM parts may need to go through after they come out of the AM system and before they are fit for purpose.
This is especially true for powder bed fusion (PBF) AM processes. The term “post-processing” is often used interchangeably with “finishing”, which is somewhat of a misnomer. With any PBF process there are a series of essential post-processing steps that are non-negotiable and must be undertaken prior to the AM-produced part finishing stages, which are optional. Thus “finishing” is actually an important subset of post-processing, not a term that should be used interchangeably with it.
Post-processing for PBF parts typically involves:
• Depowdering / excess material removal
• Cleaning
Of note for polymer PBF processes, support removal is typically not required as the powder bed acts as the support system. Neither are heat treatments to cure the materials.
Finishing of parts can include any or all of the following to improve the aesthetics of the surface finish and, for some applications, the mechanical properties of the part:
Surface finishing
- Vibro polishing
- Vapour Smoothing
- Bead blasting
- Sand blasting / Sanding
• Machining
• Colouring (Dyeing / Painting) Plating
• Inspection.
For AM production applications, finishing of parts is often a considerable, but overlooked, section of the workflow that can significantly impact the overall cost-per-part and project timelines. This is especially true if the final part characteristics need to be enhanced in terms of functionality and/or aesthetics.
Investing in dedicated finishing capabilities allows an AM service provider to offer a superior product quality, which is vital for industries where precision and aesthetics matter significantly.
Quality finishing, quite simply, differentiates an exceptional part from an average one. Any AM bureau that prioritises high-quality finishing can cater to specific client requirements, under one roof, to raise the bar for AM parts.
Any business looking to utilise the services of an AM bureau should identify one that is committed to the highest quality 3D printed parts but that also understands how to add value before, during, and after the build. The team at 3D People continues to deliver parts in this way to a growing constituency of clients that recognise their expertise in these areas. We welcome any questions — or, indeed, any challenging applications — from anyone that wants to know more.
R M FOWLER
R M Fowler Limited specialise in linear guides and ball screws from one of the world’s leading manufacturers of linear technology NSK. They have large stocks of NSK linear products in their warehouse based in Knutsford, Cheshire and have precision cutting facilities available on site to cut linear guides and ball screws to bespoke lengths quickly and efficiently.
R M Fowler have expanded their product range further by being the sole UK distributor for the American based Inverted tooth chain company: Ramsey Products Corporation and also an authorised distributor for Nippon Bearings (NB).
NSK has continued to develop and supply motion solutions and automotive products. Only the best quality raw materials from ethical sources are used to make NSK products and with their advanced production techniques and precision grinding NSK Linear products are built to a high specification as standard, as a result NSK linear off- the-shelf products are suitable for most applications without the need
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 our many years of continued service.
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 costeffective way.
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
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 25 years.
Call or email us now to solve your mechanical power transmission problems.
In February 2024, global temperatures surpassed 1.5 degrees Celsius for the first time on record. With climate scientists warning our window to act is “rapidly shrinking”, pressure is mounting on governments world-wide to find new cutting-edge solutions to mitigate climate change. Here, Dave Walsha, Director of Sales and Marketing at drive system supplier Electro Mechanical Systems (EMS), explains how environmental monitoring satellites could be just that solution.
From 11 to 22 November 2024, world leaders and organisations met in Baku, Azerbaijan, for the 29th session of the Conference of the Parties to the United Nations Convention on Climate Change — or COP29.
Two interlinked pillars upheld this year’s conference: to enhance ambition and to enable action through increasing investment in climate action projects. Through this framework, the conference aims to achieve rapid and sustained emissions reduction, lowering global temperatures.
much attention was paid to the growing potential of environmental monitoring satellites to transform our knowledge of and approach to mitigating and monitoring the effects of climate change.
During the conference, NASA, the European Space Agency, the UAE’s satellite solutions provider, Yahsat, and Space4Climate, in partnership with the UK Space Agency, all provided evidence of the benefit of environmental monitoring satellites for guiding nations’ emission reduction strategies.
Satellites use remote sensing to capture data samples emitted through electromagnetic radiation and reflected from the Earth’s environments, providing precise, timely data and high-resolution imagery, that can be used to support proactive climate action.
Over 50 per cent of climate variables can be measured from space. Sensors, such as Active Synthetic Aperture Radar (SAR) and Hyperspectral, can collect optical data through thick clouds and acquire imagery in hundreds of spectral bands. The Radio Frequency satellite sensors can even identify illegal activities such as unauthorised deforestation or mining while providing key atmospheric data.
However, this technology faces technical hurdles, specifically in terms of component durability, longevity, and energy usage.
In contrast, last year’s COP28 focused on “transforming our current course” through supercharged solutions. In this vein,
Following the progress made at COP28 and in line with COP29’s focus of enabling ambition, environmental monitoring satellites took a more central role during the annual COP session of the Subsidiary Body for Scientific and Technological Advice (SBSTA 61).
Motors are an essential component of a satellite: controlling its position and orientation, deploying its solar panels and antennas, and stabilising its cameras for imaging and sensor readings.
A satellite is launched into space at a speed of at least 25,039 miles per hour and, once in orbit, must balance its velocity with the Earth’s gravity. Throughout this journey, a satellite’s motor endures intense vibration, vacuum, temperature extremes, cosmic radiation and long storage. The smallest fault could cause the satellite to fail. As a result, manufacturers must select the optimal motor during design.
Stepper motors are designed with multiple stator windings surrounding a toothed rotor. Their stepped movement is achieved through a series of controlled electromagnetic pulses. Each pulse activates specific windings in the stator, creating a magnetic field that pulls the rotor’s teeth into alignment. With each new pulse, the motor moves incrementally rather than continuously rotating.
This motion allows the motor to achieve high torque at low speeds and maintain precise
positions, making stepper motors the optimal choice for environmental monitoring satellites that require incremental positioning adjustments for precise sensor orientation.
Environmental monitoring satellites took a more central role during the annual COP session of the Subsidiary Body for Scientific and Technological Advice (SBSTA 61)
FAULHABER’s stepper motors, supplied by EMS, range between six and 66 millimetres and one to 125 grams, combining powerful performance and high acceleration speeds with
a compact design. This design choice increases the motor’s fuel efficiency, as every kilogram of weight that goes into orbit costs a hundred times its weight in fuel, potentially allowing the satellite to carry out longer missions.
Furthermore, stepper motors can operate under extreme temperatures, cosmic radiation, and outgassing, if modified, without degradation to the motor’s mechanisms, extending the motor’s service life. This capability makes these stepper motors a highly reliable choice.
With global temperatures rising, the urgency for innovative solutions to combat climate change has never been more critical. As COP29 draws to a close, the role of environmental monitoring satellites has gained some actionable momentum. However, for this technology to reach its full potential, it must be supported by reliable, high-performance components to ensure its success.
Designed specifically to meet the needs of the liquid hydrocarbon and gas measurement markets worldwide
The SFC3000 flow computer from Ex-i Flow Measurement Ltd,. is a highly versatile liquid hydrocarbon and gas flow measuring device capable of operating in a stand-alone single stream flow measurement system or as part of a highly complex multi-stream system.
The SFC3000 can be used in a number of ways, from a supervisory machine to a standalone flow computer or as a system component and requires configuring to meet the requirements of each application. With its touch screen VGA display and extensive processing capabilities, combined with simple to use controls and unique operating software, it can function as a complete station supervisor integrated into a flow computer housing.
Additional functionality can be added to a basic system including optional I/O boards. With the addition of a communication board data can be obtained from a gas chromatograph or other sources via the serial or ethernet ports. Flow measurement data can also be passed to other systems, such printers or DCS, via the communication board ports. Logged data can be stored internally or in an optional SD card.
SFC3000 flow computer key features:
• Measurement conforming to AGA, ISO, API standards of: dry and wet natural gas, hydrocarbon liquids, other gases e.g. nitrogen, other liquids e.g. water.
• NMi Certificates to: WELMEC 7.2 and 8.8, OIML R117, MID 2014/32/EU
• Standard Features: standalone flow computing function, flow computing combined with supervisory function, up to 2 G-byte additional memory for Alarm, Audit and Data Logging, optional SD card required.
transmitters with orifice or venturi measurements
• Configurable Display: system diagrams, Trending and graphical displays, Language options, Interfaces to most types of metering equipment and all popular GC’s, Easy Installation and interfacing
• Supervisory Features, Alarm/ Event/Data Logging and Recording, Printer Report Generation, System Diagram Display, Network Communication, Station Controller Functions, Valve Control and Remote Operation.
• Maintenance Functions: stream summation, pid/sampler functions, flow computer specification. The SFC3000 is packaged in an industry Standard Half Width
3U High 19” rack construction suitable for panel or chassis mount. It can accommodate up to 6 user plug-in cards and up to five measurement streams in the same chassis. Operating temperature ranges; -25°C to 55°C (-15°F to 130°F). Operating humidity to 90% non-condensing and meets environmental classes M2/E2.
Ex-i Flow Measurement specialises in researching, developing and manufacturing products for the gas and liquid measurement industry.
At QCT, precision and accuracy are at the heart of everything we do. We are proud to have held our ISO/IEC 17052:2017 Accreditation to calibrate to UKAS 10360 on Coordinate Measuring Machines (CMM’s) for 25 years, reflecting our commitment to the highest standards in measurement and calibration. But what does this accreditation mean for us and, more importantly, for you?
UKAS 10360 refers to the stringent calibration and testing standards set by the United Kingdom Accreditation Service (UKAS) for CMM’s. It is based on ISO 10360, the international standard for the acceptance and reverification of CMM performance, focusing on precision and reliability in measurement. This accreditation means that our calibration processes meet the highest possible level of traceability and accuracy, ensuring that all results can be trusted to the finest detail.
Standard calibration is a routine check against known calibrated artifacts calibrated to National Standards to ensure that the measuring machine is functioning and measuring linearly correctly. However, UKAS accredited calibration goes far beyond. It involves a comprehensive evaluation of the CMM, verified against recognized standards, also including probing uncertainties and the machines temperature & environment This level of scrutiny provides absolute confidence in
the machine’s performance, giving customers results that meet the most rigorous quality assurance criteria, with a full volumetric accuracy of the CMM. In short, UKAS calibration offers a higher degree of trust and certification.
QCT have been accredited to UKAS 10360 standards for over 25 years, and during that time, we have continually honed our expertise. This longevity demonstrates our ongoing dedication to precision and quality, reinforcing our place as a trusted leader in the calibration of CMM’s.
QCT’s UKAS calibration provides in-depth reports, detailing measurement uncertainties and the performance of your CMM across multiple parameters. You will receive a comprehensive summary of your machine’s capabilities, pinpointing areas of improvement, if necessary, and
certifying its volumetric accuracy for the most demanding tasks.
Volumetric accuracy is critical in 3D measurement, and our UKAS accreditation ensures that we evaluate this crucial parameter with utmost precision. Whether your CMM is used for large or small volumes, our calibration guarantees that your measurements will be accurate across the full working range of your machine.
Our UKAS accreditation encompasses several ISO standards, including:
• ISO 10360-2:2009. This covers length measurement accuracy on CMMs, ensuring precise linear dimensions.
• ISO 10360-5:2010 & ISO 10360-5:2020. Focuses on probing performance, a key factor in determining the accuracy of measurements taken by the CMM’s probe.
By adhering to these ISO standards, our calibration services provide you with the assurance that your CMM meets global benchmarks for accuracy and reliability.
In conclusion, our UKAS 10360 accreditation is not just a badge of honour, it’s a commitment to excellence. With this certification, we continue to provide the highest level of measurement accuracy and confidence to our customers, ensuring that every dimension, angle, and shape is measured to perfection.
Quality Control Technology are a one stop solution for all your business CMM requirements, we have the largest stock of New and Refurbished CMM’s in the UK, with over 30 years’ experience of CMM service, calibration and repair.
New CMMs
The ‘Quantum 4 CMM Range’ is built and designed at QCT’s UK works and is available in a variety of standard frame sizes, other sizes can be built on request. All CMM’s are supplied with our bespoke software and interfaces. The Quantum 4 offers outstanding build quality and cost to performance ratio.
New Ace Portable Inspection Arms
The ACE arm offers portable measuring capability for the largest of projects as well as the flexibility to take the measuring machine to the object. Like our Quantum range, the Ace measuring arm offers exceptional quality and is the perfect system for contact and noncontact 3D measurements with the addition of the laser scanning options.
Refurbished CMMs
At QCT we only select high quality used machines, completely strip and overhaul them. Each used machine is rigorously tested, with all pneumatic pipes replaced, air bearings removed, cleaned, serviced & refitted. Electronics are tested & unsupported items are replaced with new. The original interface and controller are replaced with QCT’s own along with a new computer and operating system. QCT refurbished machines are supplied as a full turnkey package, fully backed with a comprehensive warranty. Re-using the frame of a pre-used CMM means that fewer resources are required to produce them, reducing their carbon footprint.
Service and Calibration of all CMMs
QCT also offers an ongoing calibration and service contract package to ensure your CMM is operating at its optimum.
n Subcontract CMM Inspection n CMM
Making green hydrogen a readily available fuel relies on rapidly building production facilities. Companies like Plug Power are leading the way, creating an endto-end green hydrogen ecosystem. In this environment, effectively delivering sufficient hydrogen relies on large reciprocating compressors, which is why Plug Power has partnered with Burckhardt Compression, a leading supplier of compression solutions for sustainable applications, to provide specialized equipment for new projects.
Green hydrogen is produced from water by splitting the hydrogen and oxygen molecules using electrolysis. This process is powered by renewable energy sources such as solar, wind or hydro, and when the resulting gas is utilized in a fuel cell system, the only emission is water. Consequently, green hydrogen promises to decarbonize industry, vehicles, and the way we produce fuel. There is a catch though - hydrogen is an incredibly light gas which makes it challenging to deliver it in required quantities to the consumer. Therefore, it must be compressed, or like in this case, even liquefied before transport to filling stations.Big efficiency for large equipment
Oliver Franz, Sales Manager H2 for Mobility & Energy at Burckhardt Compression, explains the best approach: “To move large quantities of hydrogen efficiently, ring type compressors are a better choice than centrifugal. Our designs offer industry leading efficiency, which is an advantage especially in a
renewable energy project where maximizing production output versus power consumed is crucial.”
Considering this, Plug Power approached Burckhardt Compression to deliver a large quantity of H2 piston compressors in a phased order to support the construction of multiple new hydrogen liquefaction facilities. The first phase of compressors required the Burckhardt Compression team in the US to quickly grow its capacity.
“We have operated a facility in Waller, Texas, for eight years now, and assembling the piston compressors required for the project on-site meant we had to expand. Each compressor weighs more than 200,000 pounds (91 tons), which exceeded the capacity
of our cranage. Beyond equipment upgrades, we also needed to bolster our team,” says Michael Ciambella, Compressor Engineering and Manufacturing Manager.
The expectations from Plug Power were high and Burckhardt Compression planned to exceed them. Ramping up assembly was dependent on the ability to move around a fully built compressor to enable assemblies to be executed in parallel. Burckhardt Compression invested in a hydraulic gantry crane system with a 1-millionpound (450 ton) lifting capacity, which would allow the safe, slow movement of the compressors across the workshop. The company worked with experts to install and supervise all lifts during the project.
The investments paid dividends, as Michael confirms: “We were able to grow our assembly capacity at Waller by 50%, which allowed us to effectively meet the first phase of compressors and any afterwards. The assembly turnaround time for each compressor was reduced from six weeks down to four, and sometimes we delivered even faster than that! We managed to complete the first phase three days ahead of schedule with zero safety incidents.”
Eleven new personnel joined the team too, including a consultant and a project lead with 20-years’ experience in compressor projects. As a global company, the US team also received training from a Burckhardt Compression expert from Switzerland, who joined the company for six weeks to ensure transfer of know-how for the assembly work. Components for the compressors would be manufactured in Switzerland and delivered to the team in the US.
Burckhardt Compression was able to design a dry running piston compressor with a highly variable turndown arrangement to exactly meet customer needs. This will allow operators to match the compressor’s performance to the process requirements without any wasted energy.
Michael continues: “This is a dry design to ensure that no lubrication oil can contaminate the hydrogen and reduce fuel quality. With large diameter pistons for the first stage, there is a lot of heat from frictional forces, so the rider band must be able to withstand this and provide a long service life. We use proprietary polymer materials we have developed in-house. This enables over a year of operation before maintenance is required, which is unsurpassed in terms of uptime.”
The minimal weight pistons were designed with energy saving in mind, while still ensuring enough strength to compress the hydrogen. Compressor chambers are fitted with a fixed pocket, which can expand to increase internal space. Specially developed pressure packing further contributes to an extended service life. Ultimately, the design philosophy is to find the sweet spot in terms of gas temperature and required production output for the customer.
A monitoring solution from Burckhardt Compression’s digital experts PROGNOST Systems is also included. A suite of sensors constantly delivers data regarding the performance of suction and discharge valves, bearing temperatures and rod drop. Consequently, operators can monitor equipment condition and predict any preventative maintenance measures steps needed, improving uptime.
As of Q1 2024, Burckhardt Compression has successfully delivered the first order and has more projects underway. Following the expansion of its team and facilities, this partnership has let Burckhardt Compression lead the way in hydrogen production.
A significant factor in the success of this partnership has been the readiness of Burckhardt Compression’s service and its flexibility to operate both within and outside the country, thanks to the extensive setup in the US. This ability instilled confidence in Plug Power to opt for the ‘new’ technical solution. Burckhardt Compression’s ability to provide reliable and efficient services, coupled with the commitment to customer satisfaction, has played a crucial role in the successful implementation of these projects.
Michael adds: “We have 175 years of knowledge in compressors and over 50 years’ experience in hydrogen, so we can bring great expertise to a relatively young market. Our products support the entire hydrogen value chain,
The minimal weight pistons were designed with energy saving in mind, while still en-suring enough strength to compress the hydrogen.
from production operations all the way to the forecourt. Burckhardt Compression even supports third-party compressors with modernization solutions, tailored services and high-speed replicated parts. We are certain that the quality of our work speaks for itself, and that we can continue to support landmark renewable projects such as this.”
“Although the energy transition brings forth exciting opportunities, the challenges that it presents can be daunting to our customers. With a customer intimacy culture within Burckhardt Compression (US), Inc. we are committed to delivering the best business solutions for our partners such as Plug Power. Our successful completion of the first phase of units is an excellent testimony to Burckhardt Compression’s customer collaboration, product leadership, technical expertise and project capacity. We are super excited about our proven products and services supporting a sustainable energy future,” concludes Annie Savarimuthu, VP Systems Division, Burckhardt Compression (US) Inc.
Burckhardt Compression has released an exclusive timelapse video of the compressor lifting process at its facility, which can be viewed here: https:// youtu.be/2JORdJLask8
Burckhardt Compression invested in a hydraulic gantry crane system with a 1-million-pound (450 ton) lifting capacity, which would allow the safe, slow movement of the compressors across the workshop.
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.
Laser Lines has this month signed up PostProcess Technologies, with an agreement to distribute a range of solutions throughout the UK. These include the Demi 4100 resin removal system, the Base FDM support removal and the Demi X520 resin removal.
All products are a significant addition to Laser Lines’ already diverse portfolio and extend the range of options it can provide to additive manufacturers of all sizes. It has already installed a Demi X520 resin removal system into the Digital Manufacturing Centre in Silverstone and visits can be arranged to see the unit in action.
Mark Tyrtania, Sales Director at Laser Lines, says: “The Demi X520 resin removal system is a compact and versatile platform, which automates the process of removing support materials and is a perfect partner for the Origin Two. We know from our conversations with customers and prospects that these two products complement each other and there is a need in the market for this type of high quality, efficient and cost-effective solution. We are delighted to be working with Post Process Technologies and are looking forward to working on future developments, merging its team’s expertise with our own, to offer customers a total all-in- one solution.”
Accurate removal of surplus material is essential if you want
to produce an accurate part. The most effective solution is usually the simplest – at least where hands-on operation is concerned – as it eliminates the likelihood of operator miscalculation, which can spoil a finished part at the end of a full build process. This is where the Demi X 520 comes into its own, largely automating the washing process for any part that fits within its generous 36 x 36 x 38cm maximum envelope. With a detergent pump and drip tray, it keeps all fluids safely contained to reduce the chance of spills and keep users safe. It also has a safety enclosure with door sensor, and redundant over-temperature safety system to support worry-free operation.
a glance – and, if not, how far the machine has progressed through the overall washing process.
Printed parts are lifted into and out of the stainless-steel process tank on an adjustable build tray, courtesy of PostProcess Technologies’ Automatic Lift System. Once in place, the Submersed Vortex Cavity system (SVC) stimulates the chemical solution using proprietary agitation algorithms. These ensure the clean removal of excess resin and leave behind a clean, accurate part that’s a true representation of the original design. The whole process can be monitored through the LED-lit build chamber’s large front window. An RGB status indicator lets users see when the process has completed at
The Automat3D software, which is designed from the ground up to manage industrial-level resin removal, simplifies the process of dialing in the precise variables required for the current finishing job. Whether optimising the working temperature, setting the length of the removal process, or specifying the tank agitation rate, it takes the guesswork out of set up, so users can be confident that this crucial part of the 3D printing workflow will be accurately and fully completed.
Recognising that many users will find themselves printing multiple parts with the same materials, Automat3D incorporates a handy recipe system. Once the optimal settings have been identified for any material and resin combination, they can be stored for future use to save time when the Demi X 520 is next called into play.
Lutz Pumpen is set to present the B70H eccentric screw pump and the B3 battery-powered drum pump at the Pumps & Valves 2025 trade fair in Dortmund
Wertheim, 3 December 2024 –Bringing maximum flexibility and rapid operational readiness, especially in changing or unpredictable working environments, mobile pumping solutions are assuming increasing importance in industrial settings. Responding to this development, Lutz Pumpen will present the B70H eccentric screw pump, which can be flexibly mounted on a transport
trolley, and the battery-powered B3 Battery drum pump at the Pumps & Valves 2025 trade fair in Dortmund from 19 to 20 February 2025 (stand 5-L09 in hall 005).
The B70 series eccentric screw pumps are used in industrial applications to pump watery to highly viscous liquids with up to 100,000 mPas and media containing solids and shear-sensitive media.
This can range from diesel and oil in the raw materials industry, to caramel and pasta products in the food industry and toothpaste and creams in the cosmetics industry.
“The B70 series pumps are characterised by a gentle and low-pulsation pumping action, which ensures that the structure and properties of sensitive food products, pharmaceuticals,
biochemicals and polymers remain unchanged during transport”, explains Takumi Nasu, Head of Development at Lutz-Pumpen GmbH. The pumps work with an eccentric screw that rotates inside a static housing, thereby dividing the medium across individual chambers and conveying it along these chambers. This gentle pumping process only subjects the medium to a low mechanical load, which minimises the danger of shear stress.
The B70 series eccentric screw pumps also guarantee low levels of pulsation during operation. “The flow rate is constant and there are no sudden pressure peaks. This is advantageous not only for the stability of the transported medium but also minimises the dead time during which no liquid is pumped”, says Nasu. With a three-phase motor producing up to 900 revolutions per minute, the pumps achieve a flow rate of up to 120 l/min, a delivery head of up to 6 bar and are suitable
for immersion depths between 500 mm and 2,500 mm. It is also possible to measure the flow rate indirectly via the speed of the rotor. “Responding to the need of some users for a mobile solution that enables them to deploy the pump at several locations, we have launched the B70H for horizontal use on a transport trolley that can be easily pushed by one person. This solution is also suitable for confined spaces – for example in areas with low ceilings.”
Lutz Pumpen will present another mobile pump solution at Pumps & Valves 2025: the B3 Battery, a battery-powered drum pump suitable for mobile operation to empty liquids from drums, canisters and IBC containers. This new pump has a range of uses that include transferring acids, bases and solvents in the chemical industry, pumping liquids such as syrups, essences and cleaning agents in the food and beverage
industry and pumping fertilisers or pesticides in water treatment and agricultural applications.
“In developing the B3 Battery, we have succeeded for the first time in making the performance of a battery-operated drum pump comparable to that of cable-connected versions,” says Andreas Rössler, Head of Sales at Lutz Pumpen GmbH. The pump is equipped with a brushless 320watt DC motor offering a flow rate of up to 180 litres per minute and a delivery head of 11.8 metres of water. A single battery charge is enough to empty a 200-litre drum 14 times in just under 15 minutes. At a lower speed, for example, an IBC container with 1,000 litres can be pumped out 5.8 times in 51 minutes. The pump tube is available in different versions to convey as many chemicals as possible for water treatment applications. These include a polypropylene (PP) version for sodium hydroxide and a polyvinylidene fluoride (PVDF) version for chloric acid.
X-FAB
X-FAB Silicon Foundries SE, the leading analog/mixed-signal and specialty foundry, has just announced a major innovation in NVM data storage which draws on the company’s best-in-class SONOS technology. Fabricated on its highvoltage BCD-on-SOI XT011 platform, X-FAB can supply customers with an AECQ100 Grade-0 compliant 32kByte capacity embedded Flash IP, combined with an additional 4kbit EEPROMall implemented on a 110nm semiconductor process node. Larger cuts of 64 and 128kByte flash and larger EEPROM are planned from 2025 onwards.
for applications in which there is a need to write more frequently, increasing Flash endurance and flexibility. It can also effectively act as a cache, with data programmed onto it while operating conditions are not suitable for writing to Flash, before subsequently being
be shortened significantly, and the associated costs minimized. BIST modules and testing services can also be supplied by X-FAB if needed.
By taking a unique approach, both the Flash and EEPROM elements are located inside a single macro and share the necessary control circuitry. This means a much simpler arrangement is realized, leading to a smaller overall footprint for the combined elements and setting a new industry benchmark for grade-0, 1750C capable, 32KBytes storage solution.
The Flash offers customers the most advanced data access available on the market, having the ability to read data across its entire -40°C to 175°C temperature range, with the EEPROM also able to write up to 175°C. The EEPROM is beneficial
written onto the Flash when temperature drops below 125°C. Thanks to the combination of superior robustness characteristics, continued data storage integrity and significant space savings offered, this IP is designed to fit the requirements of automotive, medical and industrial applications.
The new NVM combo IP features a 64-bit bus with 8-bit ECC for the Flash element, plus a 14-bit ECC for the EEPROM element. This enables zero-PPM error performance in deployed devices integrating it. Dedicated circuitry for easy memory access and DFT allows test times to
“Through this new NVM IP leveraging our proprietary SONOS technology, X-FAB is enabling the highest levels of reliability. This IP will provide our customers with best-in-class data retention and temperature stability for embedded systems,” explains Thomas Ramsch, Director NVM Development at X-FAB. “By bringing together two different NVM elements onto a single macro, one Flash and the other EEPROM, we can now deliver an embedded data storage solution capable of coping with most difficult operational situations.”
“Through reduced-footprint and accelerated access time, our NVM combo IP will be pivotal in the development of high-logic content applications,” adds Nando Basile, Technology Marketing Manager for NVM solutions at X-FAB.
”This will enable next-generation smart sensors and actuators CPU system designs with greater functional scope - whether this is on established CPU architectures, like ARM, or RISC-V, or on customer’s proprietary designs.”
Prediction of phase composition and mechanical properties
BITO Storage Systems, part of the international BITO group, have a wealth of experience in supplying storage and handling solutions to help companies improve the flow of material in their manufacturing processes. BITO Solution Designers will be on Stand G270 of the Southern Manufacturing & Electronics Show to discuss techniques and products that play a crucial role in assisting manufacturers boost productivity.
Simple, low-cost solutions – such as multi-tier shelving systems, foldable containers and carton live flow racking– can contribute to reduced supply chain costs in manufacturing operations. Shelf bins that perfectly fit the shelving with no wasted space are another example of a product designed to help efficiency and maximise the usage of space in a factory.
Carton live flow racking to organise the movement of components in and around a facility can be used as standalone units to facilitate the implementation of a FIFO approach. Alternatively flow shelves can be retrofitted to pallet racking to create a solution of bulk pallet storage combined with non-palletised smaller unit picking.
Small parts storage - a range of shelving or trolley options complete with small parts picking
containers is available to provide static or mobile small parts storage & picking solutions for factories and workshops. A choice of styles and sizes is available, including SK, RK and CTB, C-item containers. As everything is made by BITO, the containers and shelving are designed to work well together with no wasted space.
The LEO Automated Goods
Vehicles - a family of simple, lowcost driverless transport systems designed to complement BITO’s core shelving and container products. The LEO Carrier at the show is an AGV with 4 shelf levels that can be used as part of an order picking process by moving items between locations within a facility.
Large SL container - also at the show is the 800x600mm half euro pallet plastic container. An excellent alternative to metal pallet boxes that is quieter and lighter but with a 500kg capacity. The fitted feet make it easily movable with a pallet or forklift truck.
Many of the products aimed at helping manufacturers are held in stock in BITO’s Nuneaton warehouse as well as being on display in their Experience Centre, also in Nuneaton.
Come along to stand G270 to discover more about BITO Storage Systems
Computer vision technology has rapidly replaced the human eye in logistical sorting processes. Cameras and artificial intelligence (AI) empowered software already reads labels, addresses, handwriting and barcodes on packages with incredible accuracy and speed.
Now, the increasing accessibility of high-quality cameras and graphics processing units (GPUs) is helping operators to look beyond what’s on the conveyor, unlocking a deeper understanding of warehouse processes. The rewards? Greater efficiency, less errors and easier jobs.
Lars Pruijn, Innovation Director, and Lorenzo D’Arsie, Computer Vision Product Manager at Prime Vision, examine computer vision technology and the new opportunities it provides in the postal and parcel sectors.
Today, computer vision technologies in warehouse logistics are primarily optical character recognition (OCR) functionalities to improve sorting efficiency, accuracy and throughput. Taking static images from cameras mounted above conveyors, OCR can read and understand labels, addresses, barcodes and symbols, as well as handwritten and printed text. This information is used by people, sorting machines and robots to move items to the correct destination. Products such as Prime Vision’s Address Vision and Barcode Vision are augmented with AI to reconstruct and interpret damaged or obscured package information.
While impressive, nowadays computer vision is presenting even more opportunities. Cameras with higher resolutions, improved colour and 3D depth of field are allowing high-quality images and video to be collected. GPUs now offer the raw processing power required to handle this increased data, while deep learning techniques for text and object recognition mean that it can be more efficiently quantified. Excitingly for warehouse operators,
these technologies are becoming more commercially accessible and less complex to implement.
With these kinds of capabilities, warehouse operators can now look beyond the conveyor. Instead of having one opportunity to read a label on a letter or parcel, what if warehouse staff could see and connect every event for a package travelling through the facility?
This is known as ‘scene understanding’ and it allows errors to be reduced in even the most controlled sorting environments. By combining all information at a network level, problems can be spotted early and the whole process appraised, enabling proactive reasoning and a better approach to dealing with exceptions that otherwise may incur increased costs to the business.
How would this work in practice then? Well, computer vision software would have access to all installed cameras in the facility, with an innate understanding of the relative position of each unit. This
intelligence means less calibration and easier setup. With this extended field of view, the system is free to identify and help solve problems.
The system could help resolve parcel no reads for example. There is also the possibility to spot packages that are on top of each other or have become stuck together. It could also highlight non-machinable items by assessing dimensions, shape or the instability of an object, quickly separating items before they can cause issues for equipment or become damaged. For operations that handle a high variability of items like in the postal market, this streamlines how different packages are dealt with, saving time.
Beyond the parcel stream, computer vision can track roller cages to confirm they reach the right destination. The system can see whether doors are open or closed, pointing out where improvements to efficiency or safety could be made. Cameras on loading bays can monitor trucks moving in and out, allowing delivery trends to be analysed and further logistical insights gained.
Furthermore, computer vision can identify when ergonomic rules aren’t being adhered to, an important safety factor in areas with machinery and heavy items. New efficiency opportunities and best practice can be identified and applied in day-to-day work, making certain tasks easier for the workforce. Across the warehouse, computer vision is a powerful tool for improvement.
As an expert in computer vision, Prime Vision is harnessing this technology in real-world applications, designing and implementing customised systems for specific tasks.
At one Prime Vision customer, operators were using a large parcel sorting machine inside a casing. Over time, debris collected within the casing, which would require the machine to be stopped so that maintenance personnel could conduct a visual inspection to find and remove it. This was a timeconsuming process. To alleviate this, Prime Vision installed a computer vision system underneath the machine that could quickly detect and locate any debris or small parcels that had fallen into the casing. Consequently, removal could be completed faster by staff, helping to promote uptime.
An internal research project involved using computer vision to support a manual sorting system. A complex sorting process was simulated, involving nonconveyable items being moved manually to 40 different locations - an approach that often results in a high number of sorting errors. Prime Vision tested a system to check if specific items were placed in the right cage and provide alerts if an item ended up in the wrong place. Results showed the system’s potential to dramatically reduce errors.
Computer vision systems can enhance the operation of a fully automated system too. Many warehouses are trialling the use of robot arms to load individual parcels onto conveyor belts in a logistical equivalent of pick and place. However, as a relatively new application in the sector, sometimes robots can pick up two items at once by accident, causing sorting issues. Computer vision can fix this by identifying when this occurs, providing alerts to operators or the robot, optimising the process.
Clearly, advancements in computer vision and the increasing ease of access will enable warehouse operators to better monitor, understand and optimise warehouse sorting processes.
Across the warehouse, computer vision is a powerful tool for improvement.
There are some considerations going forward though.
First is that warehouses are inherently conservative environments, where adoption of new technologies will be gradual. For example, many operations will continue to run off central processing units (CPUs) instead of GPUs because of the high upfront hardware costs of changeover. Big infrastructural changes won’t happen overnight, but the capability is definitely here today.
The other factor is privacy. Video surveillance and access to personal images is a complex subject, so any computer vision system needs to be focused solely on tracking objects and processes, not people. There are various solutions to achieve this, such as blurring out images, using black box AI systems with no visibility or positioning cameras accordingly.
If these conditions are met, computer vision offers the possibility to act as a helpful assistant to warehouse operators, making work easier and crucially, more efficient.
More from Prime Vision: https://primevision.com/ looking-into-future-computervision-opportunities-forwarehouse-logistics/
Schmersal’s innovative DHS door handle system combines the functions of a robust door handle with the signalling of machine status via illuminated handle or push-button.
The door handle system is designed for use with the AZM40 solenoid interlock or with safety sensors from the RSS36 and RSS260 series or as a stand-alone solution. The illuminating handle signals various machine conditions over its area using seven different colours, enabling the user to control the colours individually to signal the machine status.
In addition, a push button is available, which can be individually adapted to customer requirements using the coloured push button caps. The pushbutton can be used for tasks such as a reset function or a request to open the guard door.
Packaging Innovations & Empack 2025, the UK’s premier packaging event, is fast approaching.
Scheduled for 12–13 February 2025 at the NEC Birmingham, the event is set to welcome over 430 exhibitors and 7,000 attendees, making it an unmissable opportunity for professionals across the packaging sector to explore cutting-edge innovations and connect with industry leaders.
This event is a unique platform to discover technologies and sustainable solutions that are shaping the future of packaging. Attendees can interact with leading brands such as Waitrose, Diageo, and Kellanova, while gaining insights into trends like smart packaging, sustainable materials, and food service innovations.
A must-see feature is DEFRA’s Extended Producer Responsibility (EPR) Clinic, providing clarity on new regulations and their impact on the packaging sector.
Networking remains at the heart of the event, offering invaluable opportunities to collaborate with decision-makers and innovators.
“The event allows businesses to stay ahead of industry shifts while tackling critical challenges like sustainability,” says James
Montero MacColl, Senior Marketing Manager at Easyfairs UK.
Fresh features for 2025
Each year, Packaging Innovations & Empack evolves to remain at the forefront of the industry. The Smart Packaging Zone, debuting in 2025, will spotlight technologies like NFC chips, RFID tags, and augmented reality that enhance product tracking and customer engagement. Meanwhile, the Innovation Gallery and Packaging Start-Up Awards, sponsored by Ocado Retail, will showcase groundbreaking solutions pushing the boundaries of packaging design.
A packed conference programme
Over 70 expert speakers will present across the Circular Economy, Supply Chain, and Innovation stages, tackling issues such as sustainable materials, AI in design,
and the growing importance of the circular economy. Highlights include Miguel Arevalo from Google on plastic-free packaging, Tey Bannerman from McKinsey Design on AI’s role in creativity, and Lowelle Bryan from WRAP addressing sustainability challenges.
Celebrating talent and innovation
The Future Trailblazer Awards will celebrate emerging leaders in packaging, offering winners a oneyear membership to the Institute of Materials, Minerals, and Mining (IOM3). This initiative underscores the importance of fostering new talent to drive the industry forward.
Don’t miss this chance to gain actionable insights, connect with top brands, and explore technologies redefining packaging. Register now for your free pass and prepare to shape the future of packaging.
Introducing Revive | RF314 safety boot, Rock Fall’s latest addition to the world of engineering and manufacturing. To put it bluntly the Revive | RF314 is quickly becoming the hottest topic in safety footwear!
The Revive boot offers wearers a minimalist appearance, with hardwearing scuff cap and outsole that enhances durability while keeping weight to a minimum for allday comfort. Not only does the Revive boot provide durability and comfort, but it also has an extraordinary, sustainable, and contemporary twist!
What are the main safety features in the production of the Revive | RF314 safety boot?
First and foremost, the Revive safety boot was to be designed to meet industry requirements. Manufacturing footwear for shop floors, engineering, aerospace, automotive, airports, freight and logistics companies all require a range of safety features and composite products, including:
• Anti-Static
• ESD Certified
• 100% Non-metallic construction
• Protective Toecap: Fibreglass
• Scuff Cap: BASF PU
• Protective Midsole: Composite
• Footbeds: Activ-Step natural rubber sustainable anti-fatigue footbed
• Outsole: BASF PU
• SR Slip Rated
• Oil Resistant
100% non-metallic and ESD certified, the Revive safety boot features a protective toecap and midsole. It is a comfortable, extremely lightweight and made from sustainable materials.
Leaving a lighter footprint on the planet.
Developed using groundbreaking technology from Gen Phoenix, the uppers are made from highquality recycled leather called Aurora. Created from waste leather otherwise destined for landfill, the Aurora upper provides an 86% lower carbon footprint than traditional leather and is certified with the Global Recycled Standard. The sleek black finish exudes rugged elegance, perfectly meeting the aesthetic requirements of the Revive design while offering the demanding durability of a modern engineering safety boot.
durability, and circularity in a way that has never been done before.”
More information on Gen Phoenix, can be found online at genphoenix.com
In line with our core values, we have included other sustainable products in the Revive, such as rPET fabrics and an Activ-Step® anti-fatigue footbed made from bio-based materials and natural rubber, offering shock absorbing properties for enhanced comfort.
“We are incredibly excited to be collaborating with Rock Fall on the Revive | RF314 safety boot, as it represents a true step forward in both innovation and sustainability,” said Elyse Winer, CMO of Gen Phoenix. “By combining Rock Fall’s leadership in safety footwear with Gen Phoenix’s revolutionary upcycled leather technology, we’ve been able to create a product that not only meets the rigorous demands of modern industries but also leaves a significantly lighter environmental footprint. This collaboration is a powerful example of how we can drive positive change in the PPE industry, bringing together performance,
The Revive | RF314, an ESD certified mid-boot with ankle height and lace-up, working trials. Click here to view an interview about the Revive
We believe that the Revive engineering safety boot will be a valuable addition to PPE supplies in automotive and aerospace manufacturing, freight, and logistic industries.
When will the Revive | RF 314 safety boot be available?
The Revive is available now through all Rock Fall authorised distribution partners.
CNC turning center for bar stock work up to Ø 25 mm (1”) and also chucking work. The EMCOTURN E25. Uncompromising quality right down to the last detail at a very reasonable price. With an extremely solid machine base, a thermo symmetric spindle headstock, high precision spindle bearings, preloaded roller guideways in all axes, a fast 12 stn tool turret and your choice of Sinumerik 828D or Fanuc 0i TD. Available with driven tools, C axis for main spindle, Manual tailstock with automatic quill.
BIG PERFORMANCE FOR SMALL PARTS MAXX TURN 25
Universal turning center for the complete machining of small, precision parts. Available with Counter Spindle, C Axis, driven tools, integrated Y axis. The MAXXTURN 25. The perfect solution for the complete machining of small parts. Compact, economical and high precision. Suitable for bar parts up to a diameter of 25 mm and chucked parts up to Ø 85 mm. The tool turret has space for 12 VDI16 tool holders. The 36 indexing positions mean the number of tools can be increased to 42 cutting edges. The MAXXTURN 25 comes with a Siemens or Fanuc control.
• ‘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
• E-learning for continuing professional development
• Webinars and seminars for knowledge sharing and professional networking
• This selection of specialist publications and many more resources
Developed and verified ‘for industry, by industry’, EEMUA 231 Mechanical Integrity courses for industrial engineers at every career stage – to aid efficient hands-on work with primary containment (including pressure systems) and prevent loss of hazardous substances.
• Satisfy industry requirements at each competency level – Awareness, Basic application, Practitioner.
• Certificated up to 5 years.
• CPD-approved
• Flexible delivery to suit Learners and companies – Blended, Live online, Classroom, E-learning, or In-house.
• Available to all – free or discounted to EEMUA Members.
• Courses throughout each year, including:
Mechanical Integrity Practitioner Certificate (MIPC®) – blended, live online learning – on-site or on-call – 1:1s and Mentor Support – workbook builds from day-1 for immediate use in on-site application of EEMUA 177, 231 and 232 guidance, and the PSSR ACOP – certificated for 5 years via exam and portfolio assessment – in-depth learning for 27 weeks, flexible 4 hours per week – CPD of 110 hours The MIPC course adapts to the engineering needs of each Learner their company and site/s via a 2-hour induction (made to fit work schedules ahead of the course) – learning on the next course starts 3 March 2025
EEMUA 231 Mechanical Integrity Basics –Blended, online learning – at Basic application competency level – flexible 4 hours of learning per week for 3 weeks – 12 hours of CPD – certificated via exam – next course starts 3 February 2025.
EEMUA 231 Mechanical Integrity e-learning – set at Awareness level – with 1 hour of CPD –immediately available – on-demand.
EEMUA 231 Mechanical Integrity In-house training – at Awareness level – CPD – certificated – 1 day or 2 half-days – for your choice of: time, location, and method of learning – by arrangement.
EEMUA Conference 2025 – Cheshire, UK – 26-27 March 2025 online-learning@eemua.org +44 (0) 20 7488 0801 www.eemua.org
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.
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.”
Renishaw has enabled Cookson Industrial, a UK-based leader in precious metal additive manufacturing (AM), to significantly reduce the cost of 3D printing platinum rhodium, one of the world’s most expensive metals. Cookson Industrial can now produce platinum rhodium components on Renishaw’s RenAM 500S Flex AM system with exceptional material efficiency. High-temperature corrosion-resistant parts, for industries like glass fibre manufacturing, can now be viably manufactured with AM .
Cookson Industrial, a division of Cooksongold and a subsidiary of HM Precious Metals, brings over 30 years of expertise in the design and production of precious metal alloys. The company set out to redefine platinum rhodium’s use in additive manufacturing. However, with platinum rhodium prices averaging £80,000 per kilo, minimising material waste was crucial to making production commercially viable.
As standard, the RenAM 500S Flex is capable of achieving powder waste levels as low as 1.5 per cent. However, to align with Cookson Industrial’s requirements, customisations were needed to reduce it to less than 0.5 percen
“Achieving near-zero wastage of platinum rhodium powder was a top priority,” said Jason Morgan, Senior Applications Engineer at Renishaw.
accumulation, such as removing overflow bellows and optimising the rear overflow vent. Additional measures included chamber redesigns and the creation of specialised casings and covers, resulting in a 95 percent reduction in powder waste. Now, the RenAM 500S Flex allows Cookson Industrial to retrieve nearly all platinum rhodium powder, amounting to significant cost savings.
To meet this challenge, Cookson Industrial selected Renishaw’s RenAM 500S Flex, a laser powder bed fusion system designed for research and development applications. Renishaw’s AM engineering team worked closely with Cookson Industrial to adapt the system to the specific demands of platinum rhodium production.
“We collaborated with Cookson’s engineers to identify and eliminate potential ‘powder traps’ within the system, followed by rapid testing and redesigns to minimise waste while maintaining performance.”
Renishaw’s customisations included modifying internal system components to prevent powder
“Renishaw’s technology and expertise were crucial to this R&D success, enabling us to make platinum rhodium parts on a commercial scale,” commented Nikesh Patel, Head of Cookson Industrial. “The ability to minimise powder loss not only brings down our production costs but also makes large-scale production feasible, saving millions over the machine’s lifetime.”
“This success paves the way for Cookson Industrial to explore new applications for platinum rhodium AM, including catalysts and aerospace engine nozzles,” Renishaw’s Morgan added, “Our collaboration with Cookson Industrial highlights Renishaw’s commitment to supporting customers in every step of their AM journey, especially when working with novel materials.”
For further information on Renishaw’s RenAM 500 Flex AM system, visit the product page.
