Can UK and Irish manufacturing industry recover from the combined impact of Covid-19 and Brexit?
Hand sanitiser spike is here to stay, says BCMPA
Reimagining global supply chains
Ireland’s successful formula attracts big pharma investment
ÂŁ1.4 billion Northern Ireland polymers sector continues to expand
Combilift raises the bar
C o n t e n t s
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- 39 R OBOTICS & A UTOMATION
Can UK and Irish manufacturing industry recover from the combined impact of Covid-19 and Brexit?
Covid-19 and the new ‘norm’ for manufacturing.
M ANUFACTURING
P AGE 27 PAGE 3
- 5 S UPPLY C HAIN Reimagining global supply chains.
John F Whelan, Managing Partner, LinkagePartenrship.eu.
R EGULAR D EPARTMENTS
Hand sanitiser spike is here to stay, says BCMPA.
Processing & Manufacturing 7, 8, 19, 21, 26, 33, 35 & 42 PAGE 5
Ireland’s successful formula attracts big pharma investment.
Kilian Cawley, Trade Director Ireland, OCO.
Advertising: Garreth Thompson, Darren McHugh, Darren Mahon, Rachel Howerd, Keith O’Brien Production Manager: Sylvia McCarthy
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Manufacturing & Supply Chain is published by Premier Publishing Limited, 51 Parkwest Enterprise Centre, Nangor Road, Dublin 12. Tel: + 353 1 612 0880 Fax: + 353 1 612 0881 E-Mail: info@prempub.com Website: www.manufacturing-supply-chain.com Premier Publishing Limited can accept no responsibility for the accuracy of contributors’ articles or statements appearing in this magazine. Any views or opinions expressed are not necessarily those of Premier Publishing and its Directors. No responsibility for loss or distress occasioned to any person acting or refraining from acting as a result of the material in this publication can be accepted by the authors, contributors, editor and publisher. A reader should access separate advice when acting on specific editorial in this publication!
£1.4 billion Northern Ireland polymers sector continues to expand.
Adoption of emerging technology is key for the Irish manufacturing industry.
Martin McVicar, Co-founder & CEO, Combilift.
Managing Director: Colin Murphy Editor: Mike Rohan
- 31 A DVANCE M ANUFACTURING
I RISH
PAGE 45
Group Operations & Awards Director: Sylvia McCarthy
Rodney Steel, CEO, BCMPA.
- 37 M ANUFACTURING
Energy & Environment . . . . . . . . . . 23 & 25
Information Technology . . . . . . . . . . . . . 48
- 27 D ATA C ENTRES
Barry Kennedy, CEO, Irish Manufacturing Research (IMR).
Storage & Logistics . . . . . . . . . . . . . . . . 10
Robotics & Automation. . . . . . . . . . 40 & 41
Top 50 Pharmaceutical Companies in Ireland.
New Host in Ireland report busts data centre carbon emissions myth.
Combilift raises the bar.
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- 9 C ONTRACT M ANUFACTURING
- 13 P HARMACEUTICALS
- 45 E NGINEERING
Garry Connolly, President & Founder, Host in Ireland.
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Top 50 Pharmaceutical Companies in Ireland.
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I MANUFACTURING
Can UK and Irish manufacturing industry recover from the combined impact of Covid-19 and Brexit? By John F Whelan
In the almost inevitable global recession facing the UK and Ireland in the years ahead, the responses to the Covid-19 pandemic by national governments and the willingness of companies to adapt to the new norms of working and leisure will determine the depth and length of the recession. or manufacturing industry, international co-operation on trade and transportation will form a key ingredient in an early recovery. In Ireland the road to recovery is complicated just now by the formation of a new multiparty government involving for the first time political parties who have been foes since the formation of the state. However, the draft programme for government commits to wide ranging support for industry to enable early recovery from the Covid lockdown, which is now the bigger issue for all sectors of the Irish economy .Dipping into the EU’s Recovery Plan will enable low cost funding and grant aiding in a way unthinkable this time last year.
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Indicators An early indicator of the impact of the coronavirus on manufacturing industry emerges from Ireland’s recent CSO release which shows that in April the first full month of Covid lockdown, exports of industrial products to the UK fell by 30 per cent, but remarkably by only by 10 per cent to the rest of the world. Indicators show the UK has the world’s second highest death rate from the coronavirus, and comes out similarly in the OECD ranking for economic damage from the pandemic. Still under restrictive measures, the full depth of the economic and social damage has yet to be fully estimated. However, the Bank of England’s mid-June business survey gives weight to this grim picture, of a plunging economy and export sales (ref chart).
Source Bank of England Business Survey 18th June 2020 ‘No Deal’ Scenario Outside of the scope of the EU’s Recovery Plan, and potentially without an Agreement with the EU Member States on the movement of goods, people, capital and services between Great Britain
John F. Whelan is managing partner of international consultancy LinkagePartenrship.eu.
and the EU (as Northern Ireland will fall under the terms of the Withdrawal Agreement), the UK will need to quickly replace or replicate not only disrupted supply chains and investment, but also manage the severe uncertainties that a ‘No Deal’ scenario is bringing. Covid-19, contrary to conventional wisdom, has emboldened the UK Government rather than subdued it. The economic risks to the UK caused by a ‘no-deal’ Brexit are widely expected by economists to compound an already parlous economic situation caused by the coronavirus. In such a situation, rational business people would expect the UK Government to do everything to minimise the risk of further economic shock, such as seeking an extension to the transition period. However, following Boris Johnson’s video conference with Commission president Ursula von der Leyen earlier in June, it is clear the UK Government is wedded to the end of year deadline. National Recovery Plan Britain’s manufacturers are calling for a National Recovery Plan, including a much wider stimulus package than already announced, to boost investment and help save jobs on the back of a major survey showing that output in the sector plunged to a record low as the full impact of the crisis hit home. The Make UK/BDO
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Looking on the optimistic side, manufacturers responding to recent Bank of England and Central Bank of Ireland surveys continue to report lower fuel, energy and commodity prices and little change in the cost of imported materials. These factors have helped to offset an increase in some freight costs due to capacity constraints and a sharp rise in the cost of personal protective equipment and other sanitary measures.
Manufacturing Outlook Q2 survey comes on the back of the historic fall in GDP and shows the balance for output reached the lowest level in the thirty year history of the survey, surpassing the previous record lows seen during the worst of the financial crisis. Looking forward the survey shows the prospect for the next quarter and the rest of the year looks little better. Major Dilemma This has created a major dilemma for Ireland’s manufacturing sector, whether to try and recoup recently lost business in the UK, or shift plans to the more stable markets for their products in Europe and the US in the months ahead. Decisions will depend on how their finances have been affected by the pandemic, as well as other factors, such as the final deal on Brexit. Some contacts said they expected to have to streamline their business to adjust to a new normality, though others thought there might be opportunities to make acquisitions.
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Conclusions What conclusions, then, can be drawn from the current state of play and its impact on manufacturing industry on both sides of the Irish sea. There is no doubting the severity of the crisis facing manufacturers of all sizes and in all sectors right across the UK. Irish manufacturers are less exposed to the aviation and auto industry, the two sectors most devastated by the pandemic, but Ireland’s small and medium sized businesses are closely woven into the fabric of the UK industry and as such catch a flu when the UK sneezes. However, the dominant multinational manufacturing base in Ireland will take pragmatic decisions to protect their markets, which are increasing outside of the UK. But there is no denying the pandemic has inflicted the worst crises the industry has ever faced. J
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I SUPPLY CHAIN
Reimagining Global Supply Chains By Kilian Cawley, Trade Director Ireland at OCO here is no doubt that Covid-19 has impacted significantly on global supply chains and presented challenges to governments, SME’s and multinationals across the globe. The implications of the current crisis require an urgent review and adjustment of global supply chains and production footprints.
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Call for addressing supply chain resilience In the last decades we have seen huge shifts in many industries of production capacities to low cost regions in Asia, Eastern Europe or Latin America. While companies internationalized their operations to minimize their global cost structure, supply chains have become increasingly long and complex with only limited transparency. Those limitations have resulted in massive disruptions of global supply chains caused by the COVID-19 pandemic and there is now an urgent need for a thorough review to mitigate risks and address supply chain resilience in the future. Reshoring – the next big thing? The concept of re-shoring operations comes to mind instinctively by leading scholars, politicians and economic development organizations around the world. According to a recent industry survey by Thomas in April 2020, around 64% of North American manufacturers are “likely”, “very likely” or “extremely likely” to ‘re-shore’ production back to North America or develop local suppliers. Only time will tell how drastic the shifts are actually going to be, but we at least expect an increasing share of localization or
regionalization depending on each company and respective sector. In the case of the EU it is possible to see the EU block becoming more self sufficient in key areas such as medicines, PPE and other key supplies which suffered shortages during the pandemic. Rethink, Reassess, Reconfigure, Rebalance Let’s take a closer look at how internationally active companies can review their global operations. Based on OCO’s extensive experience in global operations advisory, we are helping companies to address supply chain resilience and sustain longterm competitiveness. Rethink global strategy Many companies still lack a clearly defined global operations strategy, they must rethink their global strategy, particularly looking at considerations to assess their overall operations resilience strategically. This includes looking at critical components and processes for increased diversity. Ongoing strategies to review and monitor strategy regarding location and market intelligence. Also, incorporation of risk parameters and an assessment of risk appetite within key areas of the business. Reassess global set-up After developing a clear strategic path, it is necessary to create a data-driven reassessment of companies’ global operations setup. This includes stress testing and testing the resilience of existing supply chain, completing gap analysis and sensitivity analysis to address potential bottlenecks in the company’s current setup. This will facilitate a set of measures to address potential future challenges, such as potentially reshoring part of production, making alternative buying decisions and utilizing innovative production technology.
Kilian Cawley, Trade Director Ireland at OCO.
robust and resilient business base. Some of the ways of achieving this are to identify new geographical locations and regional consolidation. This does not mean moving completely from existing supply or production bases but developing new regional suppliers. It’s also important to relook at commercial supplier agreements and trade terms alongside current inventory policies and access to additional stock of key materials if required urgently. Rebalance global cost structure Rebalance of global cost structure requires a focus on operational efficiency to compensate additional cost from the implemented risk measures. This includes increased use of technology and digitization to improve production. Use of process efficiency programs such as Lean Business Improvement can have a dramatic impact in reduction of costs.
Reconfigure global operations The aim of reconfiguring global operations strategy is to build a more
Post-COVID-19 reality Realistically speaking, the entire impact of COVID-19 on global operations is still unknown. What we can say with certainty is, that the management of global operations just became significantly more difficult. Risk management suddenly became key focus of companies around the world, but it is still to be seen if those effects will last and if we will see the necessary cultural shift from short-term profits to ongoing risk minimization. For further information on how OCO can help you optimize your global operations and prepare your company for the post-COVID-19 world, contact me at kilian.cawley@ocoglobal.com. J
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PROCESSING & MANUFACTURING I PROCESS EFFICIENCY
Industrial support services from Endress+Hauser Ireland Shorten potential process downtime and get the most from your installed base with remote support from Endress+Hauser Ireland. ou cannot afford downtime or process interruptions when your Y application is critical. That’s where Endress+Hauser can provide you with the best technical support network to keep your operating systems, instrumentation or solutions running. Using their industrial support services, they care about your needs and can support you in emergency situations. The support ensures the availability of your plant, a reduction in outages and minimizes disruptions, helping you to focus on your business.
issues can be solved over the phone, via remote access or if on-site support is necessary. The remote service support reduces on-site visits, providing you cost and time savings. Benefit from an easy access to technical expertise to answer nearly all your service needs efficiently. This also allows you to minimize disruption and administrative work for your maintenance staff. Let us Endress+Hauser support your installed base - we also support you with our solutions that contain 3rd party components. J Endress+Hauser technical support experts ensure your installed base of instruments, software, and/or automated solutions keep running smoothly over time. With extensive service expertise and knowledge about instrumentation and application, their technicians can help you in critical situations quickly and sustainably to ensure continuous performance. Endress+Hauser service experts will execute and restore your device remotely or guide you through custom processes by direct access with a guaranteed prompt response. Reduce on-site maintenance costs
Many issues with process instrumentation and software can be solved remotely. This allows for quick determination on whether
Benefits of Endress+Hauser’s technical support include: • Technical support experts available to perform remote diagnostic and troubleshooting or to guide you through service operations • Remote support via live video transmission or direct connection to your device • Customized service agreements with guaranteed response time and availability • Health monitoring of the installed base to proactively inform in case of malfunctions • Customer support portal with support case system available online.
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PROCESSING & MANUFACTURING
Ultrasonic Technology – The safe and economic joining solution ltrasonic welding is a well proven and U reliable method for joining metal or plastic parts. The areas of application for
Low energy demand and a long service life
this technology are wide and varied and range from joining thermoplastic components and embedding metal inserts, through to joining wire cables, welding cable harnesses as well as securing packaging materials and other special applications involving foils and thin metal sheets. Although using ultrasonic technology may mean higher investment costs initially, when compared to other processes, it is very often more economic in the long term when the tooling costs, energy consumption and joining quality are taken into consideration. In this informative article, Telsonic UK highlight the benefits that the process can bring to many welding and joining applications. In comparison to other metal welding processes, when using ultrasonics the parts which are being joined do not become as hot, ensuring they never reach their melting point. This results in sever-
Connection between copper cable and MAK terminal welded using ultrasonics.
Different joining tasks require tailor-made acoustic tools.
al advantages compared to other joining techniques: other materials in the immediate vicinity such as wire insulation are not damaged. In addition, no structural changes occur in the boundary layer, such as embrittlement of the parts that are being joined at the transition to the solid material. 8
Ultrasonic welding is also very energy efficient. The ultrasonic system uses stateof-the-art high-performance electronics to convert the electrical energy into vibration energy and thermal energy in the fusion zone with a high degree of efficiency. This energy can vary between a few joules to several kilojoules. The welding force is usually generated by pneumatic cylinders. Depending on the application and the duty cycle, compressed air may also be required to cool the tools. A typical ultrasonic generator has an output of 3.6 kW, which is significantly less than the output of a resistance welding machine. Traditional resistance welding often also requires expensive water cooling with additional recycling and cleaning costs, or even a new power supply to provide the required power when multiple systems are used. The tooling costs associated with the ultrasonic process are also straightforward. The acoustic tools, known as sonotrodes, are typically made of aluminium, titanium or hardened tool steel. Aluminium is inexpensive and can be processed quickly and easily. Titanium may be more expensive, but it is extremely wear-resistant. All variants have an impressively long service life. Depending on the application, ultrasonic sonotrodes are capable of withstanding several hundred thousand cycles. Resistance welding tools on the other hand normally have to be changed daily in an automated environment. With plastic welding, the service life of the sonotrode work surface is significantly longer in some cases and can easily reach well over one million cycles with less abrasive materials. Ultrasonic welding is therefore an inexpensive joining method for the majority of thermoplastics and non-ferrous metals such as aluminium, copper, brass and nickel. However, failure to pay attention to having a suitable design for the part in question can result in extensive adaptations and loss of the financial benefits. Telsonic therefore recommends involving an ultrasonic specialist at an early stage of the design phase, in order to ensure that the design of the component and the joining zone is compatible with the ultrasonic process, avoiding the need for modifications and additional costs at a later date. Ultrasonic joining technology for plastics and metals is therefore safe, economic and ecological. It is now widespread in the automotive industry, since it actively supports weight reduction, energy efficiency and electromobility. It is suitable for virtually any lightweight material and is also used for the on-board power supplies of high-current applications in electric vehicles, where copper is increasingly being replaced by aluminium to save weight. Short cycle times, selective energy supply, flexibility in use and a high degree of process reliability are other criteria that characterise ultrasonic welding technology. Telsonic UK offer a comprehensive range of ultrasonic modules and systems for a variety of plastic and metal welding, cutting, sealing, cut’n’seal, food cutting, sieving and cleaning applications within a wide range of industries. J
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I CONTRACT MANUFACTURING
Hand sanitiser spike is here to stay, says BCMPA The BCMPA, the association for contract manufacturing, packing, fulfilment and logistics, has reported that significant increases in enquiries for personal care products are showing no signs of tailing off. nquiries to the BCMPA for personal care items rocketed by over 500 per cent shortly after the coronavirus lockdown was implemented, while enquiries across all sectors in April 2020 went up 60 per cent compared with 2019.
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Rodney Steel, CEO of the BCMPA
In the same month, interest in the production of hand sanitiser and antibacterial products represented 90 per cent of the total enquiries for personal care items. While the proportion of new hand sanitiser enquiries fell slightly in May, figures remain unseasonably high and the BCMPA predicts that similar levels of demand will continue for the foreseeable future. There is also a major new requirement
for members to collate and contract pack sanitation “kits” containing items like hand gel sachets and face masks, as schools, shops, airlines and businesses open again, and as restrictions ease and the country prepares to get back to work. Most current enquiries are for personal care products, with a significant increase in white label and private label enquiries – combined with a string of new members operating in the hand sanitiser or personal care sector.
Personal care production line at Xyfil Ltd, Preston, UK.
Impressive Response The BCMPA has been hugely impressed by the speed at which its members have changed filling lines to cope with the increased volumes and different requirements and specifications, altering their production to supply much-needed PPE. Rodney Steel, CEO of the BCMPA, said: “The Covid-19 situation has created an inevitable shift in production and enquiry trends, right from the beginning. Although some sectors have obviously suffered, personal care has gone through the roof, and we believe that trend is here to stay. “Not only have enquiries shot up and remained high, but the size of production orders has seen a massive increase. Orders that were typically for 20 or 30,000 units are now in the hundreds of thousands or millions.” Indeed, one BCMPA member had to
take down its website after struggling to cope with the high demand for hand sanitiser. He added: “The increase in enquiries, membership and the positive trend towards outsourcing is a reflection of changing consumer behaviour. The excellent relationship we have with our members means we are fortunately in a very good position for matching new enquiries with the right suppliers, and so easing the whole supply chain process at a time when it’s most needed. “The manner in which our members have responded, demonstrating incredible flexibility and quickly adapting to new lines while prioritising staff safety, has been exceptional.” Businesses looking for an outsourcing partner can visit the BCMPA website at www.bcmpa.org.uk/send-an-enquiry/ or email info@bcmpa.org.uk. J
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STORAGE & LOGISTICS I TRAINING & APPRENTICESHIPS
Uptake on the Logistics Associate Apprenticeship (LAA) increases ince the launch of the Logistics S Associate Apprenticeship (LAA) in TU Dublin in September 2018 the number of apprentices participating on the programme has significantly increased. This is not a surprise, explains Anna Gorecka the Project Manager of the LAA. “The programme has become the perfect entry point into the Freight, Logistics, Shipping and Distribution industry not only for school graduates but also for those who wish to change their careers and get into the sector. It also offers upskilling opportunities for the existing employees, many of whom ended up working in the sector entirely by coincidence,” says Anna. They have years of experience, but the lack of relevant qualifications prevented them from progressing their careers in the past. Initially 27 apprentices commenced their journey on the programme since its official launch in 2018 with 17 employers signed up for the programme. Since then, an additional 63 apprentices have been recruited, and over 40 employers have joined. In 2019 Cork Institute of Technology (CIT) became the second education provider for this apprenticeship. This apprenticeship model provides the academic education and practical training across the air, sea and road freight, logistics, shipping and distribution sectors. Apprentices attend college one day per week throughout the academic year and stay with an employer for the remaining four days. Apprentices get a broad overview of all the relevant aspects of logistics. As part of the programme they will complete a
work-based project in year 2, which will help them to develop their analytical, problem solving skills. The work-based project will also directly benefit employing organisations. Each apprentice is assigned a work-based mentor by their employer who will be an experienced member of staff, and a College Academic Supervisor. The work-based mentor will use their specific organisational and industry knowledge to guide the apprentice helping them to navigate corporate culture and gain an understanding of their role and duties in the organisation. The blended learning approach makes complete sense, apprentices gaining valuable work experience while at the same time learning the theory behind the practice. On successful completion of this 2-year programme a person is awarded with the Level 6 Higher Certificate in Logistics. From that point there are many routes of progression either into Level 7, or even Level 8 programmes - a person can apply for entry onto year 3 of a 4-year degree programme
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Apprenticeship model
e.g. Bachelor’s degree in Supply Chain Management to continue the study. Little public knowledge of how the industry operates or of associated rewarding careers is one of the main reasons why people do not consider it as a career choice. The LAA programme has started changing that perception, a lot of time and effort has been put into promoting the sector to the younger generation by increased engagement with Career Guidance Professionals at secondary schools and attending various career, apprenticeship and job fairs events across the country. It is vital to promote the sector to the younger generation and attract new entrants, the industry has a lot to offer in terms of career opportunities, well paid jobs in a high level of job security sector. “Goods will always have to be moved and there are numerous office based roles associated with managing this process throughout,” explains Anna. Key benefits of the apprenticeship for employers: - Upskilling opportunities for existing employees - Build loyalty amongst staff - Offers career progression opportunities - Help with succession planning - The programme is built around work related experience and work specific projects - Attracts new entrants into the sector. Benefits for Apprentices: - Level 6 Award ‘Higher Certificate in Logistics’ - Earning while learning - Gaining valuable on the job experience - Accessing the Third level Education - Clear ladder of progression. The programme has already been recognised and won the 2019 ‘Innovation Award at Fleet Transport Awards and ‘Logistics & Transport Team of the Year Award’ at the Irish Logistics & Transport Awards 2019. This helps in raising awareness and gaining recognition for the industry. For more information please visit www.laa.ie or contact Anna Gorecka on 01 8447516 or email agorecka@laa.ie. J
I PHARMACEUTICALS
Ireland’s successful formula attracts big pharma investment Reflecting Ireland’s position as a global pharmaceutical manufacturing and R&D hub, the launch issue of Manufacturing & Supply Chain magazine presents a ranking of the Top 50 companies, ranked according to turnover, in the country, while also assessing the latest developments within the sector. he world’s ten leading pharmaceutical companies have all established substantial operations in Ireland. Five of the world’s eight top selling drugs are currently produced in Ireland and the country has become the third largest exporter of pharmaceuticals globally. Indeed, Ireland is now recognised worldwide as a centre of excellence in pharma.
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Allergan has just been acquired for $63 billion by another global
pany has assembled an impressive product portfolio and now sells to customers in more than 110 countries. Global Giant Employing about 2,000 people in Ireland, top ranked Allergan is a global giant focused on developing, manufacturing and commercialising branded pharmaceutical, device, biologic, surgical and regenerative medicine products for patients around the world. Allergan has expanded its Irish operations significantly since opening its first plant on a greenfield site at Westport in County Mayo in 1977, with just 25 employees. Headquartered in Ireland, Allergan currently operates four facilities – its manufacturing plants in Westport and in Clonshaugh, Dublin, as well as an international supply chain office in Earlsfort Terrace, Dublin, and a site in Galway following the acquisition of Zeltiq, a global leader in proprietary controlled-cooling technology for non-invasive fat reduction, in April 2017. $63 Billion Acquisition Allergan has just been acquired for $63 billion (Eur58 billion) by another global pharmaceutical giant, Abbvie. Headquartered in the
pharmaceutical giant, Abbvie.
The Top 50 listing (see Table) includes global giants such as Allergan, Pfizer, Perrigo, Sanofi-Genzyme, Bristol-Myers Squibb, GSK, Alexion Pharmaceuticals and Roche. The 50 companies range in scale from the Eur14.8 billion turnover Allergan down to 50th ranked Trinity Biotech with annual revenue of Eur88.7 million. Companies with annual revenues in excess of Eur1 billion occupy the top 13 places in the league table. Headquartered in Bray, County Wicklow, Trinity Biotech was founded in 1992 and specialises in the development, manufacture and marketing of diagnostic test kits. Through a combination of sustained, organic growth and an acquisition-led strategy, the comThe National Institute for Bioprocessing Research and Training (NIBRT) in partnership with industry supports the development of the biopharma sector in Ireland and internationally.
Headquartered in Bray, County Wicklow, Trinity Biotech was founded in 1992 and specialises in the development, manufacture and marketing of diagnostic test kits.
United States, AbbVie employs about 600 people in Ireland across its five sites located in Sligo, Cork and Dublin. Ireland’s second largest pharmaceutical company, Shire, also changed hands recently after being acquired by Takeda for $62 billion in 2019. Takeda, which is Japan’s largest pharmaceutical company and operates Irish facilities in Wicklow and Dublin, subsequently decided to divest Shire’s biologics manufacturing facility at Dunboyne in County Meath that had cost Eur375 million to develop Takeda’s Irish subsidiary officially opened a new cutting-edge manufacturing facility at its site at Grange Castle in Dublin in July 2019. The high containment, state-of-the-art production facility is dedicated to the manufacture of Takeda’s oncology treatment.
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nomic assessment by EY DKM conducted in 2019 indicates that Allergans’ Eur160 million capital investment programme in Ireland over a three years period contributed Eur23 million to Ireland’s GDP in 2019 and added Eur7 million in exchequer revenues. In 2018, Allergan’s significant Irish operations delivered a GDP impact of Eur308 million, supported 3,485 jobs in Ireland’s economy, and contributed exchequer revenues of Eur76 million.
Earlier this year Allergan opened a Eur160 million state-of-the-art Biologics facility at its site at Westport, bringing the company’s investment in Ireland to over Eur750 million.
Heavy Investment The Irish biopharmaceutical industry has invested approximately $10 billion in new production facilities in Ireland, most of which has been spent in the last ten years. For example, earlier this year Allergan opened a Eur160 million state-of-the-art Biologics facility at its site at Westport, bringing the company’s investment in Ireland to over Eur750 million. Creating 63 jobs, the new facility further enhances Ireland’s position as a strategic global hub for Allergans’ flagship products, including the botulinum toxin brand. Another recent expansion project is the new Eur300 million manufacturing facility opened by Janssen Sciences Ireland, part of the Johnson & Johnson family of companies, at Ringaskiddy in County Cork, leading to the creation of 200 jobs. Johnson & Johnson is one of the largest life sciences and R&D investors in Ireland and is part of a thriving biopharma sector in Cork. New €27 Million Global R&D Centre In County Limerick, Wyeth Nutritionals Ireland, which produces a comprehensive range of infant formulas, growing-up milks and prenatal nutritional products at its facility in Askeaton, has opened a Eur27 million Global R&D Centre. The new R&D facility will focus on scientific research to support innovations in the development of milk-based maternal and infant nutrition products for the global market. Established in 1974, Wyeth Nutritionals Ireland is ranked 21st in the Top 50 and had been a part of Nestlé, the world’s leading health and wellness company, since 2012. The new centre will benefit from Nestlé’s global R&D network and help to position the Swiss food giant at the fore of infant and maternal nutritional product development, one of the group’s most important growth drivers. It will increase the pace of Nestlé’s innovation capacity by enabling scientists to explore new nutritional solutions for the crucial first 1,000 days of life. It represents Nestlé’s first R& D Centre in Ireland. Of course, such foreign direct investment in Ireland has major benefits for the local economy. For example, an independent eco-
Takeda’s Irish subsidiary officially opened a new cutting-edge manufacturing facility at its site at Grange Castle in Dublin in July 2019.
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Successful Formula The reason for Ireland’s pre-eminence in developing a thriving pharmaceutical sector is chiefly due to access to talent, the tax regime and a strong track record of pharma companies operating successfully in the country. IDA Ireland has played a key role in developing Ireland as a global pharmaceutical manufacturing and R&D hub and attracting foreign direct investment in the sector. Securing investment for regional locations across Ireland has been, and remains, a key focus for IDA Ireland. Ireland has also been successful in attracting major
Top 50 Pharmaceutical Companies in Ireland
Company 1 Allergan 2 Shire 3 MSD 4 Pfizer 5 Perrigo 6 Icon 7 Alexion Pharmaceuticals 8 Gilead Sciences 9 Jazz Pharmaceuticals 10 BD 11 Uniphar 12 Depuy 13 UDG Healthcare 14 Sanofi Genzyme 15 Elie Lilly 16 Alkermes 17 Bristol-Myers Squibb 18 Servier (Ireland) 19 Cook Ireland 20 GSK 21 Wyeth Nutritionals Ireland 22 Phardiag 23 Teva Pharmaceuticals 24 GE Healthcare 25 Boots
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Revenue (€) 14.8 billion 13.7 billion 11.9 billion 7.4 billion 4.4 billion 2.5 billion 2.3 billion 2.1 billion 1.9 billion 1.9 billion 1.4 billion 1.3 billion 1.2 billion 839.5 million 705 millionE 662.9 million 660.3 million 629.3 million 572.1 million 466 millionE 455.7 million 436.9 million 400 millionE 390.9 million 386.2 million
overseas businesses by making education, training and investment in its biopharma workforce a priority. The National Institute for Bioprocessing Research and Training (NIBRT) in partnership with industry supports the development of the biopharma sector in Ireland and internationally. NIBRT’s mission is to support the development of the bioprocessing industry domestically and to attract additional bioprocessing companies to Ireland by: training highly skilled personnel for the bioprocessing industry; conducting world-class research in key areas of bioprocessing; and providing a critical mass of multi-purpose bioprocessing facilities. NIBRT operates a purpose-built, multi-functional 6,500 sq m research and training centre which incorporates the most modern industrial bioprocessing equipment and technology.
BD, which ranks 10th in the Top 50, is the longest established medical technology multinational company supported by the IDA.
MSD is currently constructing a second manufacturing plant at its existing site in Carlow.
2019. The French company, which reinvests 25% of its income (excluding generics) into Research and Development, first established a presence in Ireland in 1974. Servier (Ireland) (ranked 18th) recently integrated a CDMO capability in Arklow focused on highly potent drugs. Indeed, 100,000 Irish patients benefit from a Servier innovative treatment every day. Alexion Pharmaceuticals (ranked 7th) is a more recent arrival, establishing its manufacturing facility at Blanchardstown, Dublin,
Top 50 Pharmaceutical Companies in Ireland
Pfizer, the world’s largest biopharma company, has established a significant
Company 26 Merck Millipore 27 Liberty Medical Services 28 Mylan 29 Baxter 30 McKesson 31 Recordati Ireland 32 Alere International 33 Bausch & Lomb Ireland 34 Takeda 35 AMCo Ireland 36 Norbrook Laboratories 37 Novartis Ireland 38 Bimeda Animal Health 39 Helsinn 40 Zimmer Orthopedics 41 Ipsen Manufacturing 42 FMC 43 Novartis Ringaskiddy 44 Rottapharm 45 Barclay Chemicals 46 Johnson & Johnson 47 Roche 48 Sam McCauley Chemists 49 Natus Nicolet 50 Trinity Biotech
presence in Ireland.
Source: Irish Times Top 1000. E= estimate.
The facility was opened in June 2011 following investment of Eur57 million. Long Established BD, which ranks 10th in the Top 50, is the longest established medical technology multinational company supported by the IDA. Having commencing production at Drogheda in 1964, BD now also operates manufacturing facilities in Dun Laoghaire and Enniscorthy. Pfizer, the world’s largest biopharma company, has established a significant presence in Ireland. Ranked 4th in the Top 50, Pfizer’s Irish business celebrated its 50th anniversary last year. Ringaskiddy in County Cork was the first location of Pfizer in Ireland and the company has since expanded to six sites across the country including: Little Island in County Cork, Newbridge in County Kildare, and Grange Castle, Ringsend and City West in Dublin. From an initial investment of Eur10 million in 1969, Pfizer's total investment in Ireland now stands at Eur8 billion, including a $30 million New Product Technology Lab at its Ringaskiddy site. Servier, an international pharmaceutical laboratory run by a Foundation, with its headquarters in Suresnes in France, marked 30 years of manufacturing at its Arklow site in County Wicklow in
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Revenue (€) 352.2 million 351.6 million 343.4 million 335.8 million 321.3 million 296.4 million 258.8 million 255 millionE 225.5 million 221.3 million 210.7 million 202.1 million 183.3 million 161.4 million 147.4 million 143.5 million 133 millionE 112.1 million 110.3 million 102.3 million 101.2 million 96.1 million 94.5 million 92.5 million 88.7 million
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The largest ongoing capital investment project within the Irish biopharma sector entails the construction of a $240 million vaccine production facility by WuXi Vaccines in Dundalk.
in 2013 with 60 employees. The Blanchardstown site serves as the group’s Global Supply Chain and Operations headquarters. Following a number of expansions in Ireland, Alexion Pharmaceuticals now employs hundreds of staff across three facilities, including a Eur100 million aseptic vial fill-finish facility in Athlone, County Westmeath. Alexion’s Eur450 million spend at its biologics manufacturing facility in Blanchardstown is one of the largest investments in healthcare in the history of the Irish State. Ongoing Investment Despite industry consolidation globally, the pharma sector in Ireland continues to invest in future growth with the emphasis on
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biopharmaceutical manufacturing, high end chemical synthesis and product and process development. Recent and ongoing investment projects are of two types – expansions to existing operations by companies present in Ireland for some years, and greenfield developments by new entrants to the Irish pharma sector. The expansions to existing plants are often for further product or process development. However, other projects are designed to facilitate advanced biopharmaceutical manufacture, such as the new synthesis plant at Pfizer’s Ringaskiddy facility. MSD, known as Merck in the US and Canada, is currently constructing a second manufacturing plant at its existing site in Carlow. The new 13,000 square metre facility will focus on the production of vaccines and biologics. It is scheduled to commence manufacturing operations in 2022. MSD Ireland, which ranks 3rd in the Top 50, has been in operation for over 50 years, and currently employs approximately 2,300 employees across five sites in Carlow, Cork, Dublin and Tipperary. $240 Million Vaccine Production Facility The largest ongoing capital investment project within the Irish biopharma sector entails the construction of a $240 million vaccine production facility by WuXi Vaccines, a subsidiary of WuXi Biologics, in Dundalk, County Louth. Based on the recently established WuXi Biologics Campus in Dundalk, the facility will bring 200 additional new jobs to Dundalk over five years. WuXi Biologics is also currently developing a contract manufacturing facility on the campus, which is scheduled for commercial production in 2022. The new, additional investment, which is being supported by the Irish Government through IDA Ireland, will bring total employment on WuXi Biologics’ Dundalk Campus to 600 by 2024. J
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PROCESSING & MANUFACTURING I CLEANROOMS
UltraTech Versatile Single-source Cleanroom Solutions ingspan Cleanroom Systems are innovative, high-end and versaK tile cleanroom solutions tailored to your individual project requirements. With over 50 years of experience in the construction industry, Kingspan offer the ultimate high performing cleanroom solutions. UltraTech Cleanroom Systems are backed up by exceptional 360° support and service. From initial concept and specification through product layouts using our in house BIM software (subject to product choice and project demands), to transport coordination and installation guidance, we are with you every step of the way. Our UltraTech Versatile system features our advanced QuadCore® insulation core technology, delivering superior fire, environmental and thermal lifetime performance. QuadCore® is Kingspan’s new hybrid insulation core technology with a unique formulation that creates microcells with unrivalled thermal performance, superior fire protection and enhanced environmental credentials. QuadCore® provides the highest level of certification and approvals, as well as being the first closed-cell insulated panel approved to FM 4882 for smoke sensitive occupancies. Versatile and Versatile Flush systems are high performing systems that benefit from: • QuadCore® technology providing the highest level of certification and approvals, as well as being the first closed-cell insulated panel approved to FM 4882 for smoke sensitive occupancies. • Ultra fast build speed • Quick delivery turnaround • Production sites with ISO certification. Product Features
* Full flush floor detail – Factory engineered base detail allowing a recessed based and the ability to have a fully flush wall to floor detail; * Integration with flush services – With specialist adaptor profiles you can integrate the features you would only usually see within a fully flush build such as; electrical raceway, service conduits and air return panels; * Doors and Windows – Semi-flush allowing them to be fitted retrospectively speeding up the build process, flush options also available using the interface profiles.
Case Study
Why is FM 4882 so important for smoke-sensitive occupancies?
In many fires, it is quite common for the monetary losses associated with smoke damage to be many times greater than those associated with direct flame damage, especially for smoke-sensitive occupancies such as cleanrooms. In fact, the indirect damage and impact caused by smoke generation in a cleanroom environment could be significant and widespread, leading to: • Loss of stored and in-process products • Damage to expensive equipment • Significant business interruption and • Decontamination of building contents – smoke damage is very difficult, time-consuming and expensive to clean In summary, there are many benefits associated with the specification of FM 4882 approved Class 1 low-smoke insulated panel systems including: • The only wall and ceiling panels in the world tested and certified for use in smoke sensitive occupancies such as pharmaceutical, food processing and other smoke sensitive industries • Reduced fire loss, significant reduction in smoke related loss, and reduce business down time • Strong enough to be power washed • Sprinkler protection may be reduced or eliminated if the occupancy allows. FM 4882 approved Class 1 insulated panel systems limit selfpropagation of fire and generate less smoke. Kingspan’s UltraTech Versatile range is FM 4882 approved to the pharmaceutical manufacturing & storage, food prep & storage and similar occupancies standard. J
* Sonaca Aerospace * Sector – Government * Products – UltraTech Versatile walls & Ceilings, UltraTech Semi-Flush Doors This industrial cleanroom houses a crane for lifting heavy parts of commerical aircraft. 8.5m spans were used for the high walls, while our 10m spans were used to create a fully walkable ceiling. The project features UltraTech Versatile semi-flush wall panels, UltraTech Versatile semi-flush ceilings and UltraTech semi-flush doors.
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PROCESSING & MANUFACTURING
Data Rich Processing – The growing necessity of R&D to GMP Manufacture mproved diagnosis is driving precision in Iulation treatment, accompanied by increasing regstringencies from the likes of the MHRA and FDA. This, in turn, ensures processes as well as the products themselves, are fully understood during every step of the manufacturing process. The requirement for both the R&D and manufacturing processes to be ‘data-rich’ has become a pre-requisite for drug product manufacturers, and purchasers of drug products, alike; a phenomenon driven not only when things go well, but where an irregularity might have occurred, even when confirmed to be within the validated ‘Design Space’ parameters. Where the products are usually very expensive to manufacture, manufacturers are always keen to use the data to prove, even if an irregularity took place, the batch can still be released rather than simply quarantined and/ or rejected. From a regulatory perspective, the above method of data interpretation and auditing for corroborating a product is safe for release, is also hugely beneficial. From Theory to Practice
US based, SP Scientific, has put data necessity at the forefront of its breakthrough suite of new lyo/freeze drying technologies named Line of SightTM, supported in the UK, Ireland, and France, by Biopharma Group. Line of SightTM encompasses process analytical technologies (PAT), designed to assist pharmaceutical developers/ manufacturers in achieving drug commercialisation objectives, whether for scale-up or scaledown. All aspects of the range are designed for use at R&D scale, but capable of use at full GMP production too.
patible at manufacturing scale. ControLyo® Nucleation Technology o Precise control of the freezing point in all vials simultane ously, including vials with a thermocouples o Increasing nucleation tempera ture, lowering supercooling, saving time and money o Larger ice crystals – giving a reduced cycle time and faster reconstitution times o To discover more about the improvement in cake appear ance, reduced protein aggregation, skin formation, and vial cracking, watch a short video https://youtu.be/JM00HTm8XaU This allows scientists to know from the outset of an R&D programme that the technology can be scaled up successfully – it is imperative technology can work at the commercial scale, as well as R&D. Some of the most significant freeze drying data interpretation tools for key data post-processing are: AutoMTM/SMART™ Freeze Dryer Technology This is a primary drying cycle optimization tool for in depth product information to determine: o The ice interface temperature o Product resistance (Rp) o Cycle optimisation LyoFlux® TDLAS Sensors Available for use at any scale for the accurate measurement of vapor mass flow in the calculation of critical product attributes such as: • Primary and secondary endpoints • Average product temperature & resistance • Heat transfer coefficients, such as Kv • Assists with engineering freeze dryer performance qualification
LyoCapsule™ This freeze dryer enables accelerated freeze drying cycle development with as few as 7 vials and has all of the functionality listed above which is particularly beneficial when small scale development is required due to: • High costs of the product being trialled • Low availability of the product itself – allowing R&D to occur with very small sample volumes, creating data that can be used efficiently at larger scale. As can be seen from the importance of PAT at the heart of Line of SightTM, whilst the science of freeze drying remains King in the production of viable product, it is apparent that one of the most necessary/ critical elements of processing is the availability of auditable data, which, no matter how good your product looks and performs post-process, generates both regulatory and consumer confidence in the product and subsequently the manufacturer. To discover more about PAT and Line of SightTM, speak to a Biopharma Group specialist http://bit.ly/BPS Contact or see freeze drying equipment via www.bpscrowthorne.ie. J
Tempris® Wireless Sensors All Line of SightTM freeze dryers are compatible for use with Tempris probes. Wireless probes allow the same probe type to be used for R&D and production, whereas wired probes used for R&D are not comMANUFACTURING & SUPPLY CHAIN, VOL 1 ISSUE 1
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ENERGY & ENVIRONMENT I ENERGY EFFICIENCY
Busch vacuum Solutions Deliver lower energy consumption and reduced production costs usch Vacuum Solutions is committed to developing vacuum B pumps and centralized vacuum supply systems that operate with the highest possible levels of energy efficiency, enabling customers in all industry sectors to benefit from lower energy consumption and reduced production costs. All manufacturing sites of Busch use the latest manufacturing techniques, machinery and equipment. The quality management procedures surpass DIN EN ISO 9001 requirements and offer all necessary certifications to meet the specific requirements of all clients. Especially the proven R5 vacuum series by Busch, with more than 3 million pumps in operation worldwide, is proven and reliable for countless vacuum applications. The robustness and operational reliability of oil-lubricated R5 rotary vane vacuum pumps have long made them the industry standard. Every day over 3 million R5 vacuum pumps worldwide provide dependable service under the harshest industrial conditions. Rotary vane technology has been continuously developed and optimized by Busch over the decades, with the emphasis on operational relia-
Busch Genuine VSD Retrofit Kit – the performance and efficiency boost for R5 RA 0630 rotary vane vacuum pumps.
bility and efficiency. R5 rotary vane vacuum pumps are known throughout the industry for their modern and energy-efficient vacuum generation, in a wide range of applications. These compact R5 vacuum pumps owe their robustness to proven rotary vane technology with recirculating oil lubrication. This guarantees a consistently high vacuum level which can cope with the toughest operating conditions. When fitted with a gas-ballast valve, vapours can be pumped without condensation. With Busch Genuine VSD Retrofit Kits it is even possible to boost the performance and efficiency for R5 rotary vane vacuum pumps. By retrofitting a variable speed drive existing vacuum pumps can be operated up to 40% more efficient. The adjustment of the pumping speed to the required level via frequency control brings more flexibility to the process. Even the performance of the pump can be improved with an increased pumping speed by 20% up to 750 m3/h. By retrofitting the existing vacuum pump the customer has an economical solution because there’s no need to change the whole vacuum pump and no extra control cabinet necessary. The installation is easy and electrical and mechanical components can be directly connected. Busch offers different retrofitting kits to upgrade the R5 vacuum pump to maximum efficiency. To maximize their effectiveness, such a
retrofit requires a detailed understanding of both the vacuum solution and each customer’s production process, to find the right custom solution for each situation. The vacuum experts of Busch can analyze the process together with the customer and then give advice how to upgrade the performance and efficiency of the vacuum pump. With its new R5 RA 0760 A PLUS, Busch recently introduced a pioneering rotary vane vacuum pump to the market, suitable for many industrial applications. Able to run at constant speed or with pressure control, it is exceptionally energy-efficient. Acting either as the sole vacuum pump or as a vacuum module in a central vacuum supply, the R5 PLUS makes sure a specified pumping speed is maintained at a prescribed rotational speed. It can also accurately sustain the required vacuum level, regardless of how the process conditions change. Thanks to its variable speed drive, the vacuum pump covers a pumping speed range from 440 to 760 cubic meters per hour and reaches an ultimate pressure of 0.1 millibar. All operating data is constantly recorded and saved. This data can be accessed directly on the built-in display or transferred via a Modbus TCP/IP client/server protocol. As a result, the vacuum pump can also be controlled remotely from a PC. Busch's new vacuum pump is thus ready for Industry 4.0. J
The new rotary vane vacuum pump R5 PLUS from Busch is exceptionally energy-efficient, while its connectivity features make it ready for Industry 4.0.
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ENERGY & ENVIRONMENT I SUSTAINABILITY
Caldor Solar installs a Solar PV system to assist a pharmaceutical plant in Limerick meet its green goals ith an increasing need to improve W green credentials and become more sustainable for many businesses, sustainable energy company Caldor Solar was approached on behalf of a pharmaceutical plant in Limerick to provide a system that would generate renewable electricity from solar panels on the roof of their building. A Solar PV system for businesses like this is a fantastic investment as these systems provide green electricity to offset the purchase from electricity providers. This saves money long-term (on average, a solar PV system can save up to ?4,500/kWp installed) whilst also reducing the average
client, consultant engineer, main contractor and various other stakeholders to integrate the design into the overall building without any problems. They also procured the full system, delivered it to the site and installed it. Once the system was fully installed, the renewable energy company tested it thoroughly and certified the system to ensure its total compliance with the required standards. The finished system was made up of 312 panels in total, had a capacity of 84.24kWp and an expected annual yield of 76,000kWh per year. The installation on the site only took 4 days to provide minimal interruption to the client’s day-to-day business. If such an installation were a retrofit, it would be eligible for the SEAI Accelerated Capital Allowance scheme, which would allow the total cost of the system to be written off at the end of the first year. Solar PV System
unit cost for electricity. Not to mention the fact that these systems are great for the environment and they provide complete peace of mind against rising energy costs. The pharmaceutical company also wanted the system to last a long time, with major system components having up to a 25-year design lifespan. The Project
Caldor Solar completed all of the project aspects from the client’s brief, providing a full turnkey system and managing it from concept through to handover. A dedicated project manager was assigned to ensure seamless integration within the clients existing operations from start to finish. The experienced Caldor Solar Team also supplied the client with the initial detailed design and they regularly liaised with the
A Solar PV System like the one installed by Caldor Solar on this project works by converting sunlight into a direct current. It’s important to note that Solar Photovoltaic cells work on sunlight rather than heat from the sun, so getting enough solar energy in Ireland isn’t a problem - Ireland actually has the same annual irradiation levels (solar radiation) as many parts of central Europe. This makes the photovoltaic panels used in the project the most appropriate solar panels. The final stage is the use of a solar inverter to turn the solar radiation into usable renewable electricity (AC power) for the client. With over 15 years of professional experience and expertise, Caldor Solar offers a wide choice of sustainable energy choices for Ireland. Caldor Solar will assess the energy usage on the premises MANUFACTURING & SUPPLY CHAIN, VOL 1 ISSUE 1
and make proposals to reduce the company’s energy spend. Caldor Solar has multiple funding options available. The opportunity for the systems to be purchased outright is there, however there are also some funding options that means there will be absolutely no up-front capital cost with guaranteed reductions in energy spend. Call today to find out how you can start saving on your energy spend with Caldor Solar on 01 25 333 49, email at info@caldorsolar.ie or visit the website at www.caldorsolar.ie. J
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PROCESSING & MANUFACTURING
The Future of Hygiene is in Our Hands! By Conor McGauran, Founder & CEO of Advanced Hygiene Technologies Ltd. ne thing that COVID-19 has taught the world is that handwashO ing will never be (or allowed to be) the same again. There’s just too much riding on it, whether it be from a Public Health, Business or Safety perspective. As exclusive Ireland/UK distributors for the CleanTech® touch-free automated (soap & water) handwashing technology from Meritech®, we are proud to support handwashing performance improvement for all the sectors we serve, including Life Sciences, Food Manufacturing, Healthcare, Cleanrooms, Food Service and Hospitality. The “New” Normal - Hard Facts
- Handwashing is the first and most important step in preventing the spread of COVID-19 and other business-damaging infections like Norovirus (the winter vomiting bug, which is not inactivated by hand gels/sanitisers - the only recommended hand hygiene prevention is proper soap and water handwashing). - People should wash hands properly and often (every time they move about a building, go to a canteen/toilet, engage with other team members, touch surfaces/equipment etc.) - Washing hands properly is not achievable on a consistent basis (even in healthcare where they are regularly trained and monitored) due to the complexity of performing a proper handwash (8 steps and 13 different actions to do it effectively). Transforming Handwashing through Automation
This is why CleanTech® touch-free soap and water handwashing exists, and thrives. CleanTech® was invented by Meritech® and is soap and water handwashing, but CleanTech® fully washes the hands FOR the user in just 12 seconds (vs 35-40 seconds for a proper manual handwash, according to WHO) and is the only hand hygiene automation technology clinically proven to remove >99.9% of pathogens (with 20+ efficacy studies conducted in an independent laboratory). CleanTech® is one of the best protections employers, employees and customers can be offered in the fight against COVID-19 and other infections. And because it only takes 12 seconds the equipment pays for itself (normally within 12 months) by: - Returning 20+ seconds to operations/business for every single handwash - Saving up to 70% of the water associated with manual handwashing - Less soap usage due to just 5ml (a teaspoon) of UltraPure handwashing solution being dispensed per cycle In addition to the above the CleanTech® UltraPure handwashing solution contains an emollient which promotes skin health and moisturises users hands, preventing skin irritation even with multiple washes per day, which will be particularly helpful in the “New” Normal world of multiple handwashes per day. For further details contact info@cleanhands.tech or visit www.meritech.com. J 26
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I DATACENTRES
New Host in Ireland report busts data centre carbon emissions myth A new report from Host in Ireland, in association with Bitpower, projects that due to the de-carbonisation of the electricity grid and renewable first purchasing policies of the Irish data centre industry, data centre CO2 will level off at about 2.2% of Ireland’s total emissions by 2025. he increase is expected to slow further as the transition to renewable electricity generation accelerates in order to meet the targets in the Government’s Climate Action Plan. Using data from the Sustainable Energy Authority of Ireland (SEAI), the Irish Wind Energy Association (IWEA), the Environmental Protection Agency (EPA) and EirGrid, the report provides an in-depth analysis of the impact of data centres on Ireland’s carbon emissions historically and also looks ahead to the next five years.
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Garry Connolly, President and Founder of Host in Ireland.
COVID-19 Impact The Q1 2020 Report also explored the effect of COVID-19 on data centre development activities and found a 10-15% impact on data centre investment projects. While demand remains strong, this will result in ?200 million spend being delayed due to the pandemic. Host in Ireland still anticipates an additional ?6.7 billion in investment in the industry by 2025. “As the data centre industry evolves and the renewable energy targets set out by the government come into clearer focus, it is important to ensure the models we put forth in the Host in Ireland Quarterly Report are constantly improving,” says David McAuley, Founder and CEO of Bitpower. “In Q1 2020, we revisited our database to fine-tune the numbers based on the latest information. This provided an opportunity to examine the impact of COVID19 on investments in the industry, the carbon impact of data centres and the scale and growth of the industry as a whole, making the report more accurate and timely than ever before.” Market Updates Since 2017 Host in Ireland, in association with Bitpower, has issued quarterly market updates to give reliable, timely and accurate information on the data industry in Ireland. Host in Ireland is an award-winning strategic global initiative created to increase awareness of the benefits of hosting digital assets in Ireland as well as Irish companies that are designing, building, and operating data centres globally. Bitpower is an expert in data centre power. For more information about Host in Ireland, visit www.hostinireland.com. J
The model predicts that by the end of 2025, there will be 1,700 MW of data centre capacity operational in Ireland. It also takes into account the SEAI historical data showing the CO2 per unit of electricity has almost halved over the past 15 years and the impact that has on CO2 attributable to data centres in Ireland in the future. New Normal “From Netflix to Zoom to homeschooling, data centres are creating and maintaining the new normal amidst a global pandemic. With this added purpose comes added responsibility both to global citizens and towards the decarbonisation of Ireland’s electricity supply,” says Garry Connolly, President and Founder of Host in Ireland. “The growth of the Irish data centre industry will go hand-inhand with the development of green electricity to meet power availability demands. Wind generation is virtually an untapped resource of green electricity within Ireland’s borders and coastline and provides limitless opportunities for both Ireland and the industry,” Garry Connolly continues.
A Host in Ireland report shows the carbon impact of data centres is to level off at 2.2% of Ireland’s total emissions by 2025 despite strong growth in data centre capacity.
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I ADVANCED MANUFACTURING
£1.4 billion Northern Ireland polymers sector continues to expand Polymers is now recognised as being one of the most important advanced manufacturing sectors in the Northern Ireland economy. t comprises over 80 firms, has a combined turnover of around £1.4 billion and employs 10,000 people – equivalent to around 16% of the manufacturing workforce in Northern Ireland. “The polymers sector also contributes to the local knowledge economy, with increasing numbers of graduate and post graduate engineers being employed throughout the sector,” points out Gerry McNally, Director, Innovation Research and Competence and Principal, Advanced Polymer Academy at NIPA (Northern Ireland Polymers Association), the industry representative body for the polymers sector in Northern Ireland.
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NIPA supports and encourages innovation, competitiveness, exports and R&D by its members and the broader polymers sector.
NIPA supports and encourages innovation, competitiveness, exports and R&D by its members and the broader polymers sector. “Around 40 of the NIPA members export to over 30 countries and are recognised as being global experts in design and manufacturing in continuously expanding product ranges for the world market,” he adds. The main manufacturing areas NIPA members cover include extrusion (pipes/tubes, sheet and film), injection moulding, composite components and assemblies, thermoforming, blow moulding, stretch blow moulding, and rotational moulding. Markets served cover the full industrial spectrum encompassing aerospace, transport, medical, packaging, consumer, building and construction, utilities, food and drink. Key Developments The polymers sector in Northern Ireland is continuing to expand and evolve. This is reflected by the recent recruitment of around 500 new employees and investment of about £60 million in the latest equipment and facilities in order to improve productivity and enable companies to expand into new markets. The sector is expected to continue to perform well supported by continuing internal investment and recruitment. “It is now well recognised throughout industry that jobs are created by innovation and investment and that it is improved understanding that enables the confidence which encourages and pro-
motes innovation,” explains Gerry McNally. “It is also recognised that the real expertise in processing and knowledge of materials resides with the highly experienced engineers within the industry. It is also noticeable that many new engineering graduate recruits no longer have the required knowledge of polymers since modules on materials and processing are no longer being taught at the level required by industry.” To address this issue, NIPA established its own Advanced Polymers Academy in 2016. The Academy now delivers specialised bespoke knowledge transfer courses for companies as well as a Diploma in Advanced Polymers Processing and Applications. Advanced Manufacturing The Northern Ireland polymers sector compares well with its counterparts in other countries throughout the world in terms of industry investment in R&D and innovation, and the adoption of advanced manufacturing technologies. This is reflected by the continued global exports of companies in the sector. Gerry McNally comments: “Most of the AMME (Advanced Manufacturing, Materials & Engineering) businesses, by their very nature of meeting the definition of AMME, are innovators. R&D is core to their activities and many companies now have developed the confidence and networks to access research expertise, from a wide range of sources. This research is driven by the needs of product development and the launch of new products into international markets. Generally many companies within the sector no longer engage with Universities since one of the main worries about separating research and R&D from production activities is that the feedback mechanism is interrupted or dampened and this can be a frustrating process for individual companies.” He elaborates: “Certainly not all innovations end up as patents or publications and it is the experiences and insights gained from manufacturing activities during production scale trials that often
Gerry McNally, Director, Innovation Research and Competence and Principal, Advanced Polymer Academy at NIPA.
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issue, but rather survival issue.” NIPA in collaboration with the British Plastics Federation, led a UK-wide initiative to secure a waiver of 80% of the Climate Change Levy to level the playing field of the UK polymers sector with other industries such as the glass and paper. This initiative was successful with many of the local companies in the Northern Ireland polymers sector benefitting from this in terms of securing a waiver of 5% of electricity costs in exchange for committing to further energy reduction plans. A group of companies was subsequently established within NIPA to carry forward the Climate Change Agreement (CCA) plans. “This grouping has been very successful in its outputs for the industry,” points out Gerry McNally. “During the programme there were estimated energy savings in the region of £1.520k (reduction of 1000 tonnes CO2) and a further £1.186 million through The launch of the new Diploma in Advanced Polymers Processes and Applications at the NIPA Polymer improved manufacturing efficiencies with a Academy. consequent overall reduction in the carbon footprint of 21.3% throughout the local trigger ideas for newer innovations at the front-end. Many of these polymers sector. These savings were achieved as a direct result of in-house research and development programmes are involved in the sector working collaboratively and attending meetings and improving processes, the use of new, improved performance mate- briefing sessions organised through the NIPA Energy Special rials and design and manufacture of new products. These pro- Interest Group, which was established as part of the activities of the grammes are now being increasingly funded by using the successful programme.” R & D tax credits initiative by HMRC.” Adapting to COVID-19 Reinvestment NIPA companies have adapted very swiftly to the new governmenOne of the greatest strengths of the Northern Ireland polymers sec- tal safety demands regarding the COVID-19 pandemic. Many tor is that over 90% of companies involved are privately owned and companies had established staff furloughing and quite a high poras such profits are generally reinvested back into improved facilities, tion of staff have been working from home since the first week of according to Gerry McNally. Furthermore, decision making in cru- ‘lockdown’ and this has so far been very successful. New space laycial areas such as investment and recruitment is fast. outs regarding social distancing were also immediately implemented on the factory floor and in office spaces. Companies have also Major Challenge supplied PPE to employees where required. Since the industry’s technology is primarily based on the melting of NIPA companies have been actively involved in designing, develpolymers at high temperatures one of the major underlying chal- oping and manufacturing products related to COVID19 PPE. lenges facing the sector is the high cost of energy. “Northern There has also been a dramatic increase in the production of bottles Ireland has one of the highest energy costs in Europe next only to and trigger sprayers in the sector for use as hand sanitizer products. Montenegro,” he says. In order to mitigate against these high costs “Some NIPA staff have been involved in a consultative capacity many companies have established energy management controls and with many companies in NI and ROI on the design and manufacfor most plastics processors energy management is a real business ture of PPE masks for the NHS. It has also been recently reported issue. Energy costs now represent the third largest variable cost after that around 100 companies have expressed interest in manufacturmaterials and labour and in some sites it is the second largest vari- ing PPE for a wide range of sectors, not only healthcare but also the able cost. This is no longer a green issue or a carbon foot print hospitality and beauty sectors,” he concludes. J
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PROCESSING & MANUFACTURING
EMC – Suppliers of Electrical, Mechanical, Pneumatic and Industrial Components MC Ltd, founded in 2001 and based in E Galway, is a leading and trusted supplier of Electrical, Mechanical, Pneumatic and Industrial components supporting the Medical Device, Pharmaceutical, Plastics, Food and general manufacturing sectors. Over the years EMC have grown and developed the company into becoming a single source supplier for many customers. EMC’s focus is always on offering tailor made solutions to deliver services and strategies that best suits client’s needs. EMC’s internal sales and technical support teams are known in the industry for their attention to detail and diligence in delivering on each product or project requirement. Customer Satisfaction
Kevin Carty, Managing Director of EMC, has built a culture that places the emphasis on customer satisfaction. This ensures that an order for one replacement part receives the same high level of attention and service as does a regular contract for 100 parts per month. EMC build a personal relationship with each of their customers and are available to them whenever they have a requirement. EMC support customers through the entire life cycle of their equipment from
machine building stage, to ongoing preventative maintenance to end of life and obsolescence strategy. From their 20+ years of experience in stock control EMC provide advice and manpower to ensure that clients’ maintenance stores are run efficiently and provide strong support to production. Products
EMC’s products, sourced from over 100 leading suppliers, include Sensors, Valves, Cylinders, Air Prep Equipment, Process Control Instrumentation, Panel Products, Temperature Controllers, Melt Pressure Controllers, Pressure Transducers, Rupture Discs, Melt Pressure Analytical Equipment, Cartridge, Band and Plate Heaters, Thermocouples and Chart Recorders. As part of their portfolio of products EMC has partnered with leading manufacturers within the Polymer & Plastics Industry. Working with Dynisco, Eurotherm, Tempco, KIT and Gary Duncan allows EMC to become a “one stop shop” for high quality spare parts and instruments for the sector. Dynisco, known worldwide as a market leader in pressure and temperature measurement products for the plastics extrusion and moulding industries has been a core partner to EMC for over a decade. Dynisco
The EMC stand at the recent Northern Ireland Manufacturing & Supply Chain Conference and Expo in Belfast.
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sensors, controls, and analytical instruments are proven to offer better control, reduced downtime, minimum scrap, and unmatched reliability and working life. EMC now has two Dynisco PolyClean demo units available for customers to trial in their facilities. The PolyClean is a fluidised temperature bath that will clean tooling 2 to 3 times faster and safer than traditional cleaning methods, such as an oven. The system uses aluminium oxide sand (heated up to 600c) and air to surround the tooling and gently break down the polymer. Dies, breaker plates, capillaries, and screen packs can be cleaned in 50-60 minutes while pressure transducers only require 8-10 minutes! Recent Addition
A recent addition of Bosch Rexroth to EMC’s portfolio has been timely in the current climate of Covid-19. Many of EMC’s customers are using the Bosch profile system to make protective barriers and screens to ensure their employees are kept safe during this time. EMC stock the four most common sizes of Rexroth aluminium profile: 20mm, 30mm, 40mm and 45mm. The Rexroth modular profile system is an ultra-flexible assembly system offering quick and complete solutions for every industry. From flow racks and frames made of aluminium profiles, enclosures, ergonomic assembly workstations through to fully automated manufacturing lines with transfer systems: based on decades of practical experience, the sophisticated and uniquely versatile assembly technology from Bosch Rexroth is continuously being further developed. The team at EMC is ready to meet your unique business challenge. Contact EMC and let them work with you to save your company both time and money. J 33
PROCESSING & MANUFACTURING I ELECTRONIC, ELECTRIAL & INDUSTRIAL COMPONENTS
RS Ireland - By Your Side: Helping to keep your business operations undisrupted through these unprecedented times hat started as a small family W business in 1947 selling radio valves and TV spares next door to Mulligan’s in Poolbeg street, the company moved to Hatch Street in the 60’s and in 1970, moved to its current offices and warehousing in Rialto. Radionics Ltd, now trading as RS Ireland, has been supporting industry in Ireland for over 70 years, the company has become the country’s leading distributor of electronic, electrical and industrial components. The transformation of Ireland’s industrial manufacturing sector in the 70’s was an opportunity for Radionics to become a distributor for RS Components and its customer base began to change as the company supported both the consumer and industrial market space. The product paper catalogue was a staple item for the RS customer, which has now evolved to the industry leading website, allowing users to see stock availability and pricing, the digital environment has revolutionised how RS Ireland brings its product offer to the market. Gary Bradley, Country Manager commented: “The channels through which we interact with customers today have evolved in line with technology and demand. RS has adapted at each stage of this evolution – from creating a CD catalogue in the mid-90’s to developing an award winning digital channel. The continual investment in our online offer ensures that the customer journey is as seamless as possible, giving them access to the right product, the right technical specifications and stock availability.” Strong Relationships
RS has strong relationships with suppliers, working closely with them to ensure the latest products are available and that the right level of product support can be offered to their customers, guiding them through the buying process and keeping it as simple as possible. Bringing new technology to customers is key, with the developments in robotics and Industry 4.0, or Industrial Internet of Things (IIoT) this has become even more important. IIoT covers the use of various technologies to connect devices to create and exploit data. This offers companies numerous potential benefits in terms of MRO, not least that they can shift from a preventative and reactive maintenance culture to a predictive one. IIoT makes it possible to increase productivity while reducing machine downtime
and the time needed for repairs, manufacturers are increasingly aware of the benefits of increased connectivity. RS actively collaborate with manufacturing customers to talk about the huge range of IIoT technology available so that they can find solutions that will help them improve their operations. Making use of the knowledge that suppliers have about this of equipment puts RS in a great position to advise on the best technology to meet your specific needs. Hub of Knowledge
The evolution of buying behaviour is something RS is in tune with, making purchasing easy for customers both online, with click and collect and by a personal ‘walk in’ experience at RS’s trade counter which is a hub of knowledge. The recently refurbished RS Local Dublin branch in Rialto is open Monday to Friday, 8am - 5.30pm, showcasing innovative solutions that will help them meet customers varying needs in all stages of projects with over 1,000 products on display from brands including Siemens, TE, SMC, Stanley, Facom, 3M, Schneider Electric, Fluke, Wera Tools, Rocol to name a few and the RS PRO range, with also access to thousands more in the locally stocked warehouse. The team are there to help you with your queries, providing technical help, and information on kitting and calibration services. The “Innovation Room” can provide you with an insight into other new technologies with demo areas on 3D printing and Raspberry Pi projects on request. Providing these key valued added services differentiates RS from its competitors. J
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I IRISH MANUFACTURING
Adoption of emerging technology is key for the Irish manufacturing industry Manufacturing & Supply Chain spoke with Barry Kennedy, CEO of Irish Manufacturing Research (IMR), about the strengths and weaknesses of the Ireland’s manufacturing sector, how it is likely to be impacted by the COVID-19 pandemic and Climate Change, and the outlook for the industry over the next five years.
ning; and Sustainable Manufacturing including the Circular Economy. It has industrial test beds and pilot lines and works with companies on rapid prototyping of new products in its advanced 3-D and IOT areas.
Barry Kennedy, CEO of Irish Manufacturing Research (IMR).
Strong Manufacturing Base According to Barry Kennedy, Ireland has a particularly strong manufacturing base in food, medical devices, pharmaceuticals, ICT and strong engineering manufacturing supplying into these sectors. Ireland also has very good sub-suppliers of component parts to the automotive and aeronautics industry, but these have been significantly hit during the current COVID-19 crisis. “Any manufacturer supplying food to retail are doing strongly but if dedicated to the hospitality sector are struggling,” he points out. “Suppliers of medical devices to elective surgeries have seen a dip but this is
stablished in 2014, IMR is a not for profit research organisation founded to primarily support the manufacturing industry in Ireland to increase productivity, efficiency, sustainability and to make it more competitive. It supports all industries across the manufacturing sectors and supply chains (see Panel). IMR investigates emerging technologies to demystify, de-risk and deliver practical solutions. Its research areas are across four broad themes - Design for Manufacturing; Automation and Advanced Control with special focus on collaborative robotics; Digitisation and Industrial Internet of Things covering areas such as digital twin-
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expected to rise again once hospitals start to get back to normal post COVID-19. Some manufacturers have been agile and moved into new markets manufacturing PPE for instance. Ireland’s manufacturing base as it has a focus on food, medical device and ICT should prevail on the international market but the size of market will be dependent on global sentiments and trends. Obviously changes in trade deals, strength of the EU etc will all have significant impacts on the resilience of Ireland’s manufacturing base as it is primarily export led.” Investment in R&D So how does Ireland compare internationally with regard to investment in R&D and progress in adopting advanced manufacturing technology? “Ireland is significantly behind in terms of investment in R&D as a percentage of GDP and this goes for both Government investment and private industry. Based on BERD, Irish industry invests 50% of OECD average and less than 20% of a typical German SME,” he replies. Barry Kennedy elaborates: “If Ireland is to grow a leadership and retain this strength of manufacturing, actors – industry and Government - will have to invest significantly more in innovation, research and development as if it ends up being a competition on cost, Ireland will likely lose as it is a high cost economy, though automation will help level balance these odds. However at this point Ireland is behind on adoption of technologies such as collaborative robotics.” Outlook Regarding the outlook for the Irish manufacturing industry over the next five years, he comments: “Ireland like the rest of the world will be challenged on the aftermath of the COVID-19 crisis and as such it could see shrinkage. However, as it has a strong manufacturing base across food, ICT and med devices it should be able to hold its own for now and should be well positioned to grow as confidence comes back into the international community.”
IMR Supporting Irish Manufacturing
IMR has a staff of circa 70 researchers and support personnel and continues to grow. It has over 43,000 sq ft of research space across two sites in Rathcoole, County Dublin, and Mullingar, County Westmeath. IMR has a public private partnership where its funding comes from a variety of sources from the State through Enterprise Ireland’s Technology Centres program, through competitive research programs such as the EU Research Programs and from direct industrial engagement. IMR is carrying out industrial research today for over 60 manufacturing companies in Ireland, 33 large scale multinationals and 30 SMEs. Established in 2014, IMR has one of the largest networks of manufacturers working collaboratively together in Europe. An international expert panel has assessed that the economic benefit to the work output has shown that over 200 person year equivalent jobs have been created or retained as a result of IMR’s engagement with industrial companies and that an additional number of 700 jobs are expected to be created by 2023 (data - prior to COVID-19 crisis). The independent review estimated that the positive financial economic benefit of IMR to the economy has been to date circa Eur50 million but is expected to rise to over Eur200 million over the next few years.
need for leadership to be shown in the area of sustainable manufacturing and the circular economy. Earth has only a limited amount of resources and these are quickly becoming depleted so the whole arena of circularity is coming to the forefront. This climate change though slowly creeping up on the planet is likely to have significant and even more far reaching consequences than COVID-19.”
Main Challenges Irish manufacturers face a number of major challenges, especially in the wake of COVID-19 but IMR is helping to overcome these. With COVID-19, supply chains have been and will likely continue to be impacted due to logistics delays and international supply shortages. Since the crisis began, IMR has set up over 100 B2B linkages to help in resolving these challenges. “Also, the use of technology to improve productivity and robotics to support the need for spatial separation among other technologies are where IMR can help guide, innovate and deliver real solutions,” says Barry Kennedy. “IMR is doing this with a significant focus on Climate Change and the
Adapting to COVID-19 IMR adapted rapidly to meet the COVID19 situation with over 95% of its employees currently working remotely. Indeed, by leveraging the best use of technology, it continues to deliver high impact research output and retain all its employees full-time. IMR has also played a leadership and key role in the fight against COVID-19. It has been instrumental in developing two different ventilators - one in partnership with MIT Massachusetts, Malone Group (SME Irl), and the other with Artesyn-Bio and international experts in the USA. IMR has also been involved in the development of two different face-mask solutions for use with front-line workers and has printed face shields and provided them to local and regional hospitals in Ireland. It will, as government and the health authori-
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ties allow, start to bring back into office some but not all employees. Some employees like the remote working and IMR intends to try and support this into the future. Adoption of New Technologies The IMR CEO expects the COVID-19 crisis to accelerate the adoption of new technologies and techniques, such as remote working, by manufacturers. “IMR is getting more requests from companies to understand what they can do. IMR has been demystifying these emerging technologies for companies such as AR/VR, collaborative robotics, development of digital twinning of systems to allow remote test and repair. Adoption of emerging technology is key for Irish manufacturing industry.” He continues: “A stark data point is shown from the International Federation of Robotics. Ireland does not even make the chart but is believed to be significantly below (over 50% of) the UK level. One of the issues emerging is that now as manufacturers get back up and running, there is now a noticeable impact to productivity, cost and time due to restrictions of operating in a COVID-19 environment so the introduction of enabling technologies will be key to alleviating these cost and time challenges.” J
I ROBOTICS & AUTOMATION
Covid-19 and the New ‘Norm’ for Manufacturing By Brian Cooney, General Manager, KUKA Robotics Ireland
If ever a global crisis proved to remind us that an over reliance upon scarce manual resources, and impractical overcrowded working conditions is unsustainable for the security of our supply chain and, survival of our manufacturing industries, the Covid-19 Pandemic has just surpassed it. hen eventually, our manufacturing sectors can return to work, the landscape will have completely changed. We must maintain social distancing within the workplace for the foreseeable future or until a vaccine is rolled out across the globe. Even then, social distancing within the workplace may become the new ‘Norm’ for manufacturing.
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Critical finished goods manufacturing and supply chain has come under scrutiny during this pandemic and, many of the flaws in low cost manufacturing in far flung continents has come to the fore, with serious shortages in finished goods and raw materials arising. As a result, reshoring of manufacturing is inevitable, with many countries governments already issuing policy statements encouraging companies to reshore their manufacturing and supply chain, with several countries already offering substantial financial enticements for companies to do so. However, whilst this will undoubtedly be welcome news, cost competitiveness will be even more important. Automation and robotics will be fundamental to maintaining cost competitiveness.
set to become the new ‘Norm’ with increased focus upon reducing the concentrations of workers in close proximity to one another and, providing continuity of production even in the event of another major interruption to manufacturing and supply chain. Sensitive and dexterous collaborative robots with small footprints will increasingly become our ‘co-Workers’. Research will be accelerated to develop new applications for robotics; faster deployment, flexible and, easy to use. Autonomous mobile robotics will become commonplace, not only in warehousing and logistics, but also in testing, sampling and, media preparation. Cleanliness and hygiene will take on a whole new importance in the workplace and, whilst automated robotic sanitising in hospital environments is in early development, it may become necessary to consider similar technologies in manufacturing facilities. Challenges There are many challenges to be overcome in this new ‘Norm’ which requires collaboration and, initiatives across all invested parties including; the end user, regulatory authorities (e.g. ISO/FDA), government
Brian Cooney, General Manager, KUKA Robotics Ireland.
bodies, research institutions, universities, machine builders and, automation/robot suppliers. Including, but not limited to: • Funded research - essential to develop new technologies. • The skills Gap - already a critical shortage exists of automation and, robotics engineers across a range of skills levels from apprentice to master’s degree. This needs urgent addressing across our educational facilities, both for skilling and, upskilling. • Workplace culture - operator acceptance of robot technology • Brownfield Plant Design - not always suited to the deployment of automation. For example, the deployment of mobile robotics can easily be accommodated during the design phase for a greenfield facility but, may be more difficult in a brownfield facility where multiple floor levels, lifts, airlocks and, shared pathways were not designed with automation in mind. • Government investment- support programs, particularly for smaller manufacturing companies and, solution providers. • Agile Innovation funding • Working capital loan schemes. Summary Robotics and automation companies, such as KUKA, have already risen to the challenge in the fight against Covid-19. Providing robotics to manufacture; Covid19 test kits, automated sampling machines, PPE manufacture, automated temperature testing and, mobile disinfection robots. As countries struggle to rebuild their economies, and manufacturing companies work to adapt to the new ‘Norm’ in manufacturing, robotics and automation companies will be there to help. J
The New ‘Norm’ Automation and the use of robotics is also MANUFACTURING & SUPPLY CHAIN, VOL 1 ISSUE 1
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ROBOTICS & AUTOMATION
Cobots.ie making big strides in automation obots.ie entered the automation market in 2018 as a distributor C of the collaborative robot, manufactured and engineered by the reputable Danish company Universal Robots. Since then they have been making big strides in the automation sector in Ireland. Cobots.ie have formed partnerships with some of the biggest names in robotic accessories including PickIT, Robotiq and OnRobot for vision systems and a large variety of end-of-arm tooling. Although, Cobots.ie was only set up in 2018, it brings with it a wealth of experience in both engineering and automation technologies with their sister company I.T.S. being in operation in the automation sector since 1993. It has been a busy year so far for the thriving East Cork robotics company. Earlier this year Cobots.ie took part in the annual Manufacturing and Supply chain exhibition in Dublin, where they launched their new dedicated UR training academy, the only UR training facility in Ireland. Martin Buckley, CTO at Cobots.ie says: “We wanted to offer people the chance to get hands on experience in real life practical applications that add real value to a company’s ability to capitalise on their automation investment.” They also launched CoMig, their first cobots branded dynamic welding solution accessory for the Universal Robot. Cobots.ie formed a new partnership with Asyril SA and is proud to introduce their series of high- performance flexible feeding solutions for parts and components to the Irish market. In March of this year the company announced their new Leasing
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program in collaboration with Universal Robots for the UR line of collaborative robots. “In the current climate, we are aware that companies are being more cautious in terms of capital investment. Our latest service option lowers the financial barriers for manufacturers to invest in automation,” states Dan Buckley, Managing Director at Cobots.ie. The new financial leasing options are a response to the growing need for flexible automation implementations and allows companies to remain competitive in spite of economic pressures. J
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ROBOTICS & AUTOMATION
Robotics and Resilience – Futureproof your business with Universal Robots From a global labour shortage to the unexpected challenge of the Covid-19 crisis, automation has never been more relevant to the survival of manufacturing businesses. niversal Robots, the global leader U in automation, boasts a ten-year legacy in developing and providing
But how easy is it to integrate a cobot and what real benefits can they offer businesses? Irish Development Lead at Universal Robots, Samantha Cummins-Byrne, explains. “Bettering business efficiency, increasing profitability and improving employee safety are the primary concerns manufacturing businesses are facing and actively trouble-shooting. We know from our experience with manufacturers that issues such as labour shortages, employee safety and even floor-space can prevent them from competing in this highly-challenging market. “Having entered the Irish market in 2015 we’ve made a significant impact in terms of changing the perception of automation and educating businesses here, along with the support of our distribution partners, Reliance Automation and Cobots.ie, and the opening of the first UR cobot training centre in Cork. “Our cobots have resolved issues for thousands of manufacturers and the work we’ve done
in the last couple of years has brought about hugely positive impacts to the profitability, efficiency and culture of Irish businesses. These results are now the focal or talking point industry-wide. “Our cobots are the very peak of innovation but also accessible, and it’s this powerful combination that allows businesses of all sizes to be part of the new revolution and build resilience. With current crisis in mind, we’d urge businesses, regardless of size, to get in touch and discover how our tech can give you a competitive edge and safeguard operations for the future. “Our cobots are extremely cost-effective. Customers experience the financial benefits of their investment in just a couple of months. We offer a leasing programme too to combat cash flow and seasonal fluctuations which is great for SMEs. “One of the main attractions to our cobots is how easy they can be programmed. With just basic training, our cobots can be programmed to perform any task in just a couple to hours. Our cobots have. been programmed to complete just about everything – from stacking boxes to slicing pizza to polishing steel. Interestingly, the ease of programming also means that our cobots can be redeployed to different areas as required, supporting peak production times or unexpected staff shortages. “Consistency is a real draw for businesses who use our cobots. For example, tightening screws or sanding a piece of wood will always be done with the same tension and pressure, removing the risk of human error. “Our cobots can be situated in small spaces and are intentionally built to interact or collaborate with humans. In-fact, our customers tell us regularly that their human workforce feels motivated and rewarded by the arrival of a cobot as it means they are given. The opportunity to upskill in automation programming, while also no longer having to complete harmful or repetitive tasks.” For more information visit universalrobots.com or Universal Robots A/S on LinkedIn. J
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collaborative robots and has a strong footprint in manufacturing across Ireland and the UK. In response to immediate challenges caused by the Covid-19 pandemic, Universal Robots has created a free online suite of educational tools that can be accessed from home or the office and will support Irish businesses to discover how automation can transform its operations. Free Online Suite
The free online suite includes: • Online meetings Avail of a 45-minute, one-on-one online meeting with a local member of the Universal Robots team to discuss how collaborative robots could become part of your business. • Online Academy Complete easy-to-follow modules to upskill in automation and receive an official certification on completion. • Webinars Experience how Universal Robots cobots perform various functions and how your business can benefit. • LinkedIn Stay in the loop by following Universal Robots A/S on LinkedIn • Case Studies Discover the real-life impact cobots are having on businesses across the world. Following a seismic shift in the percep-
tion of automation in the workplace, manufacturing businesses in various sectors such as pharma, electronics, food and construction have transformed their operations by turning to Universal Robots cobots to fulfil dispensing, welding, screwdriving, inspection, finishing and other assembly line tasks. Benefits of Cobots
PROCESSING & MANUFACTURING I PNEUMATIC TUBE SYSTEMS
Advanced Pneumatic Technology designing solutions to meet every customer’s unique requirements neumatic tube systems have been P around for almost over one hundred years. The aim has always been efficiency, to save time in not having people hand carry items from one part of a building to the next. Advanced Pneumatic Technology (APT) have adopted, designed, adapted, and developed Pneumatic tube systems for host of different facilities. Most people will be familiar with the cash tube system in retail stores. Going back to the mid-20th Century, we would still have people recall: “I remember seeing these in Clearys, zipping along the wire.” As they did in many grocery and general stores in Ireland and UK. Our SafelinK System is now considered by many retailers as being as necessary as air conditioning and alarms. People are also accustomed to seeing Pneumatic Tube Systems in hospitals where there are used to send patient samples from Wards or clinics directly to the Lab. APT now have our Aerocom AC3000 system in 40 Irish Hospitals and 95 in UK. It saves time, makes staff working hours more efficient (as they are carrying out other tasks) and patients can often get a quicker turnaround time on their results. This is the benefit we
want to transfer to the manufacturing industry!! Quality Control
One element that almost all manufacturing companies have in common is testing. Quality control is an integral part of any company to ensure standards are maintained. Biscuits, Flour, Alcohol, Soft drinks, Hardware goods, Tinned Goods, Factory parts, Pharmaceutical, Dairy, Assembly lines they all test samples! Aerocom AC3000 Pneumatic Tube Systems can transport these samples directly from production/assembly lines directly to the laboratory or quality control room. This process can save 1,000’s of hours of walking!! Case Study: Milk powder production
A prominent producer of milk powder has 3 main bagging lines and one central testing laboratory. And the raw material liquid milk is taken in, liquid sample is taken from the tanker and carried to the lab (4minute walk). Once the tanker is pumped out and production begins, there are several testing points through the production process as well as at the bagging lines. The main issue is that the production area (like all in food, drink and pharmaceutical production) is critical care or clean room standards of hygiene meaning staff wear protective clothing. When samples 42
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were being removed from the bagging lines, the staff would have to de-gown to bring the samples to the lab, and re-gown when going back in. 5 minutes changing time, twice as well as 5 minute walk to the lab. 15 minutes to bring a sample to the lab. This was done every 30 minutes!! The company installed an Aerocom AC3000 System with a station at each of the production lines and each of the bagging lines, and now samples can be taken, bagged, placed in a transport carrier, into the sending station and they are in the lab in around 3 minutes!! This is just one example in one type of Industry!! APT is 30 years in business and specialize in designing solutions to meet every customer’s unique requirements. The question is, if you or your staff spend any amount of time hand carrying items from one part of your premises to another (even outside or separate buildings) then APT have a solution for you. It will save you time, save you money, increase efficiency and the investment in a Pneumatic Tube System will pay for itself in a very short time. Call us today, and we can survey your premises in person or review via drawings remotely and design a system to meet your requirements. J
I ENGINEERING
Combilift raises the bar Currently the largest global manufacturer of multi-directional forklifts and an acknowledged leader in long load handling solutions, Combilift is continuing to innovate and to extend its international reach. ased in County Monaghan, Ireland, the company has sold more than 50,000 units in over 85 countries since being established in 1998. Central to Combilift’s success has been constant investment in R&D and in the latest manufacturing technology. Combilift invested Eur50 million in constructing a new Global Headquarters and highly advanced manufacturing facility in 2018 to consolidate its global leadership position. Having produced 6,500 units last year, the new facility has the capacity and flexibility to increase this number according to
ations and enable them to make the best possible use of one of their most valuable commodities – space.” He adds: “Any company that wants to improve its handling and storage procedures will find a solution from our product range.”
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tion based, niche specialist products – all of which are designed to allow very safe, space saving and productive handling of diverse loads,” says Martin McVicar. “Our models in general can replace a number of other types of forklifts and handling equipment and this versatility also reduces costs for customers whilst increasing efficiency.”
Free Design and Layout Service Combilift also offers a free design and layout service, which serves as a tool for resolving problems for customers and enabling them to maximise space. This service was previously carried out by personal visits to customers’ sites but due to the coronavirus has now been replaced with a remote system. Martin McVicar explains: “Using inhouse developed technology as well as A key feature of all Combilift pedestrian trucks is the WhatsApp calls with site owners whilst unique, patented multi-position tiller arm, which can be they walk around the premises and turned to the left or right of the truck. take shots of specific areas, Combilift design engineers can get a good customer demand. Indeed, it is capable of overview of requirements. Using additional producing a finished machine every fifteen measurements supplied, they can provide minutes. 3-D designs and animations with a turnIn 2019, Combilift achieved a turnover around of just 24 hours. This helps in the region of Eur250 million and cur- Combilift to bring extra value to their operrently employs approximately 650 people at its site in Monaghan with a further 100 staff in other locations around the world. Combilift is co-owned by CEO and cofounder Martin McVicar and Technical Director Robert Moffett. Handling Solutions Combilift develops and manufactures handling solutions in the form of multi-directional forklifts (the company was the first in the world to launch the all-wheel drive engine powered multidirectional C-Series truck), sideloaders, narrow aisle articulated trucks, pedestrian operated stackers as well as straddle carriers and mobile gantries for handling extreme loads. “We are not in the business of manufacturing conventional forklifts, but offer solu-
Evolution Combilift’s initial multi-directional forklifts were designed for the safe and space saving handling of long loads in confined spaces – sideways travel made this a possibility compared to other less manoeuvrable forklifts. This was of course very attractive to industries handling, for example, long packs of steel, timber, plastics, and metals. As the company’s customer base has increased, the product range has evolved – very often on the basis of customer feedback. Combilift has developed a large range of warehousing products such as the Aisle Master articulated truck for narrow aisle operation and the pedestrian range, for handling pallets as well as longer loads. Since the introduction of the Combi-SC straddle carriers, Combilift has made strong inroads into industries such as freight, containerisation and multimodal as well as those that handle extreme loads such as the oil and gas and offshore sectors. €50 Million Investment The advanced nature of Combilift’s new Eur50 million Global Headquarters and manufacturing facility is indicative of the
Pictured at the launch of the Combi-Ventilate are (left to right): Antonio Patacho, Combilift Engineer; Martin McVicar, co-founder & CEO of Combilift; Dr Michael Power, National Clinical Lead, Critical Care Programme, Irish Health Service; and Christopher Carragher of Combilift.
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company’s expertise in engineering and design. In planning its new factory complex Combilift drew upon its extensive experience in designing warehouse and logistic facilities for international clients. The facility was planned from the inside out by two dedicated in-house engineers using 3D Solid Works and Google Sketch-Up for 3D visualisation. Many factories are constructed in a linear design, but Combilift’s management wanted the design engineers to have quick and easy access to the production floor. The central position of the engineers’ offices within the L-shaped layout means that all the various assembly areas are within easy reach to clarify any questions and remove any potential barriers for communication. Martin McVicar comments: “Traditionally production plants are set up to produce volume products with standard configuration or to produce tailored customised products in low volume. Combilift has built a production plant which allows both to take place. There is a significant amount of space between each of the
assembly lines to allow the customised items to be positioned on the line as required.” Combilift implements a Lean Six Sigma approach to help it achieve its goals incorporating Kanban on the assembly lines for the high volume items. Combilift has also invested in state-of-the-art equipment such as a $1 million Peddinghaus multi-function plasma cutting machine. Environment-friendly and Energy Efficient The new factory incorporates a number of environment-friendly and energy efficiency features. For example, 23% of the roof space is fitted with skylights with large floor to ceiling windows increasing the overall natural light inside the building to 84%, more than that required under building regulations, enabling staff to work in a comfortable natural daylight environment. When artificial lighting is required, it is supplied by 1,100 LED lights with individual PIR sensors. Solar panels supply 185 kW of energy, while a 1 Mw biomass boiler provides heating for the spray ovens and assembly lines.
The biomass is fuelled by supplier pallets, and 40 acres of willow have been planted on Combilift land to ensure sufficient ongoing supplies. A 110,000 litre rain harvest tank collects and stores rainwater, which is used for jet washing and bathroom facilities. The new factory is certified to globally recognised ISO standards - Quality Management ISO 9001:2015, Environmental Management ISO 14001:2015 and Health and Safety OHSAS 18001:2007. “The new facility has allowed us to increase output significantly over the past two years. In the current climate it has also made it easier to implement social distancing and to increase efficiency,” he points out. Constant Innovation Combilift has grown its range of pedestrian trucks significantly since introducing its first pedestrian stacker in 2013. This is in response to the growing demand for pedestrian operated trucks, as many companies are looking to use these rather than ride-on forklifts when possible, particularly in areas where other personnel may be present, in busy production plants for example, as they enhance health and safety procedures. A key feature of all these models is the unique, patented multi-position tiller arm, which can be turned to the left or right of the truck and enables push button rotation of the rear wheel parallel to the chassis and back again. It allows the operator to remain in the safest possible position when working in narrow aisles - at the side of the truck rather than at the rear as is the case with other pedestrian trucks. This reduces the risk of the operator being crushed or trapped between the truck and the racking. The company’s latest innovation, the Combilift Container Slip-Sheet (CombiCSS) is designed for mechanised loading of products into containers. It is a much less labour intensive system than using multiple forklifts and reduces physical strain and risk to personnel and also minimises product damage. Loads weighing up to 30,000kg can be assembled on the slip-sheet platform outside the container and guided into the container by a hydraulic pulling mecha-
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nism. So it is stress free and quick and easy – a 40’ container can be fully loaded in as little as 6 minutes. Rising to the Challenge In April 2020, drawing on its expertise in engineering and software design, the company launched the Combi-Ventilate, a splitter device which turns one ventilator into multiple ventilation stations. Designed to address the requirements of medical professionals in the current Covid-19 emergency, the Combi-Ventilate was developed by a team of mechatronic and software engineers in Combilift. “We have made Combi-Ventilate under the same ethos and with the same objective as we do with all our the Combilift products - which is all about doing more with less,” comments Martin McVicar. “We have undertaken this non-profit endeavour in order to meet and facilitate the demands of the global crisis for health services around the world, the lack or shortage of ventilators. The medical device sector is not our core business but making critical equipment which keeps people safe and alive has always been our focus and this latest project, driven by our desire to help during these difficult times, mirrors what our research and development has done for the last 20 years. If our product can save lives, if we can make a difference during these hard times then we are making the world a better place for everyone.” Development Strategy Combilift is continuing to reinvest in innovation as the company expands its international presence. “We invest 7% of our turnover in R&D and ongoing product development is key to our continuing success in breaking into new markets and gaining new customers,” says the Combilift CEO. “This combined with listening to our customers means we can develop customised solutions to meet their needs. The free warehouse and site design service that we offer to potential customers demonstrates our strong belief in delivering a solution that benefits our customers.” He concludes: “As we continue to scale the business we are putting more of our own personnel on the ground in overseas markets with currently over 100 based overseas today.” J 47
INFORMATION TECHNOLOGY
Solid Solutions Supporting Excellence By David Crane, Solid Solutions istory will tell us what the medium and H long term implications of the COVID19 pandemic on business have been. We have all seen changes to everyday working. As a service provider delivering engineering design solutions to thousands of design and engineering companies, at Solid Solutions, we were uncertain about the impact our customers would experience.
Like everyone else, we had to jettison our business plan overnight and come up with a new strategy to maintain our communication and service levels. The challenge was not insignificant. Our main engagement with customers has always been heavily based on face-to-face activities. We have scaled this up over the past few years to deliver a huge calendar of live activities with events, training classes and seminars taking place every working day of the year, across Ireland and the UK. Naturally, all of this stopped in the space of an unprecedented 24 hours and we suddenly found ourselves cut off from all forms of direct interaction. No Playbook
There was no playbook for us to refer to but one thing was immediately apparent, everything would have to go digital. We have run webinars in the past, of course, our Webcast Wednesday live webinars ran for several years, but customer attitudes had
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moved towards video-on-demand so we had built a library of video content for customers to use, but this was going to need to be different. The strange nature of what we were all experiencing presented a new opportunity though. We quickly recognised the determination in many people to make use of the free time offered up through working from home, furlough, or reduced working hours. Customers had more time to talk about topics and technologies that a busy schedule would have previously hampered. We set about delivering a schedule of daily live broadcasts. Initially, we focused on the technological challenges of working at home and using design software but once everyone had settled into a routine, we shifted our attention to exploring personal development and upskilling.
Under normal circumstances, this kind of material would only be delivered to customers paying a subscription fee. The pandemic and its consequences, however, have changed the attitude and approach of many service providers. The prevailing sentiment has been that we are all in this together. At Solid Solutions, we chose to unlock our registrations to anyone wanting to join us and we provided the certifications free of charge.
The ‘Recovery Race’
We started to see customers looking ahead to what comes next. The ‘Recovery Race’. As businesses go back up through the gears they will need to find new efficiencies and take every advantage on offer from the technology and services they use. We started getting requests for topics on our productivity tools such as data management and collaboration. Useful, of course, during this time of remote working but we can see how businesses are looking at making sure they never get caught short again, when it comes to file access and sharing when needing to work remotely. Our audience started to build quickly and we have been delivering live content to over 1,000 engineers and designers every week. We have started to change up the formats to encourage interaction, questions, and live engagement. In week three we were able to host a live certification event for SOLIDWORKS software users to over 800 designers, of which 93% passed and became Certified SOLIDWORKS Associates. This turned out to be the largest SOLIDWORKS certification event that’s ever been held and certainly isn’t something we would have ever expected before lockdown began. MANUFACTURING & SUPPLY CHAIN, VOL 1 ISSUE 1
In time this will all return to normal we hope, but for now we will continue to broadcast free live events to share knowledge and provide education. At some point, the recovery race will begin in earnest and engineering companies will take themselves back into the market having hopefully gained some new skills and insights into the software they have available to them so that they can compete and get back up to speed as quickly as possible. J