Inside Industry E76 by ProactivePublications

IN76

JUL/AUG 2022

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INDUSTRY

CONNECTING INDUSTRIES WORLDWIDE

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BARIL COATINGS

A company as durable as its coatings

FRAGOL

German oils and lubricants company blending a strong sense of ethics

MORELO REISEMOBILE The driving force in luxury motorhomes

John White Managing Director

IT’S SHOW TIME! Managing Director John White welcomes events back onto our calendars. Our editorial, sales and marketing teams are certainly glad to be in contact with the event planners. Likewise, the events teams seem overjoyed to be able to discuss media partnerships with us once more. As an international media company specialising in business-to-business publications, we naturally must conduct much of our work over the telephone and by email. However, the chance to meet many of you face-to-face is always a pleasure. Events, of course, allow us all to not only promote our products and services but also network on a more personal level. I know that the teams I often send out to these events enjoy the experience… I suspect, in part, due to some of the post-event restaurants and bars that some of you apparently ‘force’ them to frequent with you! We have been working closely again over the last few months with event organisers to help promote these popular events and with many of the event exhibitors to help drive traffic toward their stands. Therefore, be sure to spend some time browsing that section of the magazine and our website if you are planning to attend any events this year. Unfortunately, I cannot always send a team out as there is simply too much to do back at headquarters with our new look website, online company profiles, social

media activity and general digital marketing plans. However, if you are lucky enough to be attending any events, please search out our printed or online magazine presence in our usual place within the press booths. I shall sign off now and let you enjoy this edition. If you would like to take advantage of the talents of my various teams to help promote your company or event, then I suggest that now is as good a time as any, especially whilst they are all so excited and energised! n

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elcome, dear reader, to your latest edition of Inside Industry. There is a certain buzz and energy in our office – there is always, of course, because clearly my team all love their job and their boss – however, I mean a little more of a buzz than normal. Each edition is, as always, full of all sorts of company profiles, advertisements, news and views. However, what has been noticeably absent for a good 18 months or so is the focus on upcoming international events, shows, fairs and exhibitions. We have always prided ourselves on being an official media partner for these prestigious events for well over a decade now and, much like you I am sure, we have missed the excitement of promoting, and in many cases attending, these events due to Covid-19 lockdowns. Therefore, I must give some of the credit for my increased staff energy to the fact that international shows, fairs, events and exhibitions seem to be firmly back on our calendars. As many of our regular readers already know, we enjoy being partners with some major events within many industry sectors and after the forced sabbatical due to Covid19, I am sure that you are as happy as we are to be able to exhibit, visit or even simply read about these events again.

INDUSTRY

Send us your news Have your latest news published in our next edition of Inside Industry. news@insideindustry.com Inside Industry

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Managing Director John White Editorial Manager Daniel Barnes Feature Writers Jordan Yallop Phil Nicholls Filomena Nardi Colin Chinery Andy Probert Romana Moares Laura Watling Richard Hagan Events Manager Adam White Business Development Manager Darren Foiret Editorial Development Managers Jasmine Lodge Jeff Johnson Ginelle Lorenzo Clare Bishop Kain McBarron

Director’s comment It’s show time!

Sales & Marketing Director Richard Brightmore Sales Manager Helen Leisi Project Managers Kym Hamilton Tony Ingrouille Chris Renicar Becky Scrivens David Earl Callum Robb Callum Smith Dane Coady

Webmaster Michael Stamp

Industry events Upcoming events in the industry

Company Reg No: 06783092 Company VAT No: 167 6757 57

Inside Industry

ACHEMA 2022 Inside Industry looks ahead to the much anticipated return of ACHEMA

Special report 16

Country focus 8

Designers Daniel O’Malley Sarah Jones Georgina Harris Telephone: +44 (0)1493 445121 +44 (0)1502 566216 Email: news@insideindustry.com Website: www.insideindustry.com

Events 6

Art Director Ian Spencer Art Editor Philip White

Event preview

Introduction 3

USA Dematic accelerates supply chain innovation with Google Cloud United Kingdom Siemens renews major contract with Brammer Buck & Hickman Brazil AkzoNobel launches mosquito-repellent coating in Brazil to help combat disease Germany Volkswagen-led research team set up to advance battery-recycling technology

Are robotics set to play a starring role in the next ten years of British manufacturing? Steve Ellis, Managing Director at FPE Seals details the potential impact robotics can play in British manufacturing

News 20

Industry news in brief The latest company and industryrelated developments from around the world

Matter of fact 26

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Did you know? Interesting and unusual industry facts from around the world

What’s new in the industry? 28

From simple ideas to engineering feats The latest innovations, ideas and product launches

Contents

Featured in this issue 32

The driving force in luxury motorhomes MORELO Reisemobile Always one step ahead Friulforgia Pushing into tubular expansion tech Enventure Global Technology Vertical ascent Manospack Loading up a storm SAMSON Materials Handling Certified ethical oils FRAGOL 2,000 Swiss FLIRTs worldwide Stadler Dedusting the world NESTRO Lufttechnik

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Composites and compassion deBotech Prepped to pounce on new opportunities SmartLynx Airlines Landing the cargo Menzies Macau Airport Services Innovative halal food production hub thrives Gallant Venture Multi-skilled, safety conscious operator Sparks Maintenance Contracting

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A company as durable as its coatings Baril Coatings Colour is a language that continues to evolve Lechler P66

Inside Industry

Industry Events Upcoming events in the industry

upcoming events

ACHEMA – 22-26 August 2022 With manufacturers and service providers from over 50 countries presenting their products for chemical, pharmaceutical and biotech research and manufacturing as well as energy and environmental services, ACHEMA is the driving force and groundbreaker for the international process industries and their suppliers. ACHEMA attracts 150,000 attendees from 150 countries who make a difference in the process industries and plan to take their business to a new level. There is no other event in the calendar that offers such a comprehensive mix of pioneering technology and global networking – an up-close experience that appeals to all the senses and inspires sustainable connections. www.achema.de

PACK EXPO International – 23-28 October 2022 PACK EXPO International offers a comprehensive selection of packaging and processing solutions for industry, educational sessions and networking opportunities. Packaging and processing technologies and equipment on show will include: automation and robotics, printing and labelling, materials and containers, remote operation, processing equipment, supply chain, and track & trace technology. Held in Chicago, attendees come from the world’s biggest companies, as well as small start-ups looking to scale up production, and mid-sized companies that are launching products, growing their brands, expanding e-commerce, working on sustainability and more. www.packexpointernational.com

FABTECH – 8-10 November 2022 FABTECH returns to Georgia World Congress Center November 8-10, 2022 and provides a convenient ‘one-stop shop’ venue where you can meet with world-class suppliers, see the latest industry products and developments, find the tools to improve productivity, and increase profits. Experience the power of in-person events to discover, educate, and motivate the metal fabrication industry.

www.fabtechexpo.com

Inside Industry

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HARD

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Intermodal Europe – 8-10 November 2022 For over four decades, Intermodal Europe has been the most targeted annual meeting point in Europe for companies associated with container shipping and intermodal transport across road, rail, and sea. The event facilitates the opportunity to meet and do business with 140+ leading global suppliers, discover the latest container innovations and technology, network with senior-level peers, and hear about the challenges and opportunities facing the container shipping market today from field experts.

www.intermodal-events.com

MEDICA Connected Healthcare Forum – 14-17 November 2022 MEDICA is the world’s largest event for the medical sector. Seven main product categories will be included in the exhibition halls this year: electromedicine / medical technology, laboratory equipment, diagnostics, physiotherapy / orthopaedic technology, commodities and consumer goods, information and communication technology, medical service and publications. Each year, leading individuals from the fields of business, research, and politics grace this top-class event with their presence – naturally alongside tens of thousands of national and international experts and decision-makers from the sector. www.medica-tradefair.com

London Build Expo – 16-17 November 2022 Hosted at Olympia London, the UK’s biggest festival of construction features a jam-packed two days of incredible content across six conference stages with a 50% representation of female speakers, hundreds of exhibitors, live music, entertainment and networking events including Meet the Buyer sessions, Women in Construction and much more.

www.londonbuildexpo.com

Inside Industry

Country Focus Reporting on the latest developments from the USA’s industry

USA Dematic accelerates supply chain innovation with Google Cloud Dematic – American-headquartered intelligent automated solutions company and subsidiary of the global intralogistics provider KION Group – has announced a partnership to transform the supply chain industry through accelerated cloud innovation.

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said Kirsten Kliphouse, President, North America, Google Cloud. “We’re pleased to partner with Dematic to provide customers with innovative solutions and technologies that will help them quickly address changes across the industry and that support their digital transformation goals.” With Google Cloud, Dematic customers will be able to create a more sustainable supply chain by leveraging data to understand efficiencies to be gained in areas such as operations, planning, labour and inventory.

About Dematic Dematic designs, builds, and supports intelligent automated solutions empowering and sustaining the future of commerce for its customers in manufacturing, warehousing, and distribution. With research and development engineering centres, manufacturing facilities, and service centres located in more than 35 countries, the Dematic global network of over 11,000 employees has helped achieve approximately 8,000 worldwide customer installations for some of the world’s leading brands. Headquartered in Atlanta, Dematic is a member of KION Group, one of the world’s leading suppliers of industrial trucks and supply chain solutions.

About The KION Group The KION Group is among the world’s leading suppliers of industrial trucks and supply chain solutions. Its portfolio encompasses industrial trucks such as forklift trucks and warehouse trucks, as well as integrated automation technology and software solutions for the optimisation of

supply chains, including all related services. Across more than 100 countries worldwide, the KION Group’s solutions improve the flow of material and information within factories, warehouses, and distribution centres. The group, which is included in the MDAX, is the largest manufacturer of industrial trucks in Europe in terms of units sold in 2021. In China, it is the leading foreign manufacturer (as measured by revenue in 2020) and number three overall. The KION Group is also one of the world’s leading providers of warehouse automation (as measured by revenue in 2020). At the end of 2021, more than 1.6 million of the KION Group’s industrial trucks and more than 8,000 of its installed systems were in use by customers of various sizes and in numerous industries on six continents. The group currently has around 40,000 employees and generated revenue of around €10.3 billion in 2021. n

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ematic aims to bolster supply chain resiliency and deliver go-to-market solutions by combining Dematic’s supply chain expertise with Google Cloud’s cutting-edge cloud, Artificial Intelligence (AI) and Machine Learning (ML) technologies. The partners will join forces to leverage shared learnings that will drive rapid cloud innovation. By migrating Dematic’s offerings to the cloud and introducing AI and ML, Dematic said it is expecting to improve customers’ supply chain execution. “This partnership is a continuation of our invaluable collaboration with the Google Cloud team, whose keen interest in helping us build and test the next generation of warehouse management solutions makes this alliance a perfect match for our growth strategy. Through this partnership we are helping our customers advance their positions in the industry,” said Dematic Chief Technology Officer Dee Cusack. “We value Google Cloud’s drive for innovation and commitment to reimagining our customer solutions as we make our own transition to the cloud. We’re excited to start the next chapter of our business together.” The partnership will allow Dematic to develop and deploy a range of solutions, including eCommerce and omnichannel fulfilment, and control tower applications for key vertical markets including general merchandise, grocery, apparel, and food and beverage. “Google Cloud is committed to helping organisations across the supply chain address the rapidly-evolving needs and expectations of customers, suppliers, and fulfilment centres with cloud technology,”

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Country Focus Reporting on the latest developments from the UK industry

United

Kingdom Airbus increases its UK innovation footprint to develop new hydrogen technologies Airbus is strengthening its presence in the UK with the launch of a Zero Emission Development Centre (ZEDC) for hydrogen technologies.

eronautics giant Airbus has launched a Zero Emission Development Centre (ZEDC) for hydrogen technologies. According to the company, priority for the UK ZEDC will be the development of a costcompetitive cryogenic fuel system required for the successful entry-into-service of Airbus’ ZEROe passenger aircraft by 2035 and to accelerate UK skills and know-how on hydrogen-propulsion technologies. The UK ZEDC will benefit from the recent commitment by the UK Government to guarantee £685 million of funding to the Aerospace Technology Institute (ATI) over the next three years to support the development of zero-carbon and ultra-low-emission aircraft technologies. “Establishing the ZEDC in the UK expands Airbus’ in-house industrial capabilities to design, develop, test and manufacture cryogenic hydrogen storage tanks and related systems for the ZEROe project across Airbus’ four home countries. This, coupled with our partnership with ATI, will allow us to leverage our respective expertise to realise the potential of hydrogen technology to support the decarbonisation of the aviation industry,” said Sabine Klauke, Airbus Chief Technical Officer. Technology development at the new UK ZEDC, to be based in Filton, Bristol, has already started and will cover the full product capabilities from components up to whole system and cryogenic testing. End-toend fuel systems development, a speciality of Airbus in the UK, is one of the most complex technologies crucial to the performance of a future hydrogen aircraft.

The ZEDC complements Airbus’ existing Research and Technology footprint in the UK, as well as the work on cryogenic liquid hydrogen tanks being done at Airbus’ existing ZEDCs in Madrid, Spain and Stade, Germany (composite structure technologies) and in Nantes, France and Bremen, Germany (metallic structural technologies). All Airbus ZEDCs are expected to be fully operational and ready for ground testing with the first fully functional cryogenic hydrogen tank during 2023, and with flight testing starting in 2026.

The next frontier in alternative propulsion technology Hydrogen is a high-potential technology with a specific energy-per-unit mass that is three times higher than traditional jet fuel. If generated from renewable energy through electrolysis, it emits no CO2 emissions, thereby enabling renewable energy to potentially power large aircraft over long distances but without the undesirable by-product of CO2 emissions. Because hydrogen has a lower volumetric energy density, the visual appearance of future aircraft, according to Airbus, will likely change. This is to better accommodate hydrogen storage solutions that will be bulkier than existing jet fuel storage tanks.

Two primary uses for hydrogen in aviation Hydrogen has been safely used in the aerospace and automobile industries for decades. The aviation industry’s challenge now is to take this zero-emission energy

carrier and adapt it to commercial aviation’s needs. At Airbus two primary uses for hydrogen are being worked on: hydrogen propulsion and synthetic fuels. On the topic of hydrogen propulsion, hydrogen can be combusted through modified gas-turbine engines or converted into electrical power that complements the gas turbine via fuel cells. The combination of both creates a highly efficient hybrid-electric propulsion chain powered entirely by hydrogen. When it comes to synthetic fuels, Airbus’ engineers are looking at how hydrogen can be used to create e-fuels, which are generated exclusively through renewable energy. Hydrogen produced using renewable electricity is combined with carbon dioxide to form a carbon fuel with net-zero greenhouse gas emissions. Airbus confirmed it expects to make the necessary decisions on the best combination of hydrogen technologies by 2025. With this new Filton facility, Airbus said it is reaffirming its long-term commitment to remain a major player in Britain’s worldleading aerospace ecosystem, working with the Jet Zero Council to drive forward research in the sector, supporting green jobs and helping the UK meet its ambitious net zero targets. The launch of the UK ZEDC follows the opening of the £40 million AIRTeC research and testing facility in Filton in June 2021, jointly funded by the ATI and Airbus, to deliver the next generation of aircraft wing, landing-gear systems and fuel system designs. n Inside Industry

Country Focus Reporting on the latest developments from the Brazilian industry

Brazil AkzoNobel launches mosquito-repellent coating in Brazil to help combat disease AkzoNobel’s Coral brand in Brazil has launched a new product designed to combat the Aedes aegypti mosquito, which spreads dengue fever.

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Concerns about health and safety at home have greatly increased in recent years

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When a mosquito lands on the new transparent topcoat, the permethrin is absorbed through its feet and over-excites the insect’s nervous system, causing it to disengage or fall off. Permethrin is a well-known repellent and is commonly used in fabrics for mosquito nets and protective clothing. “Concerns about health and safety at home have greatly increased in recent years,” explained Daniel Campos, AkzoNobel’s Director of Decorative Paints in Latin America. “This new coating – the first of its kind in the region – is a clear matt varnish which can be applied over any painted wall. 10

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Public health is a major issue in countries across the world. In Brazil, dengue is a particular problem. We want to help people look after their families by offering a breakthrough product which has been proven to give continuous protection against the Aedes aegypti mosquito, 24 hours a day, for up to two years

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eople in Brazil have a new ally in the fight against an invasive carrier of dengue fever – a powerful mosquitorepellent coating developed by AkzoNobel’s Coral brand. Known as Well-being Protection AntiMosquito, the colourless matt varnish contains an active ingredient called permethrin. Its repellent action is specifically designed to combat the Aedes aegypti mosquito, which was largely responsible for dengue cases in Brazil surging 165% during the first few months of 2022 – according to figures from the Brazilian Ministry of Health. As well as spreading dengue, Aedes aegypti can also transmit the zika and chikungunya virus.

“It’s a great example of ‘People. Planet. Paint.’ in action and shows how our pioneering approach to product development can help make a genuine and lasting difference, including to people’s health and well-being.”

Breakthrough product Mr Campos continued: “Public health is a major issue in countries across the world. In Brazil, dengue is a particular problem. We want to help people look after their families by offering a breakthrough product which has been proven to give continuous protection against the Aedes aegypti mosquito, 24 hours a day, for up to two years.” The effectiveness of Well-being Protection Anti-Mosquito was tested in an independent external laboratory, certified by the Brazilian Network of Analytical Laboratories in Health. All the tests took place on painted walls and ceilings in a life-size house environment and successfully proved that mosquitoes were repelled from the room after contact, with the active ingredient being retained in the varnish matrix.

Dengue is a viral infection transmitted to humans through the bite of infected mosquitoes. According to the World Health Organization, the global incidence of dengue has grown dramatically, with around half the world’s population at risk. Up until May 14th this year, there were 855,910 reports of probable infection of dengue in Brazil, with an incidence of 401.2 per 100,000 inhabitants. The extent of the public health problem is underlined by the fact that dengue, zika and chikungunya don’t have a specific treatment. So prevention is regarded as the best strategy.

AkzoNobel Brazil Currently only available in Brazil, there are plans to make the new product available in other countries and regions. AkzoNobel is active in more than 150 countries and has set its sights on becoming the global industry leader. Brazil is a key market in South America, a region responsible for 9% of the company’s revenue globally, where the company operates with a portfolio of leading brands such as Coral, Sparlack, Alabastine, Wanda, Sikkens, International and Interpon. In 2019, Coral became the official national paint of CASACOR, the largest and most complete exhibition of architecture, interior design and landscaping in the Americas. Throughout the country, AkzoNobel has six units located in strategic locations, where it produces and distributes essential products to make people’s lives more pleasant and inspiring. n

Country Focus Reporting on the latest developments from the German industry

Germany Volkswagen-led research team set up to advance battery-recycling technology The HVBatCycle research consortium aims to permanently manage cathode metals, electrolyte and graphite in a closed material cycle.

eading German names from business and science have teamed up to jointly prove that the most valuable components of drive batteries can be recovered and reused several times in succession through recycling. The HVBatCycle research consortium is funded by Germany’s Federal Ministry for Economic Affairs and Climate Action. Under the leadership of the Volkswagen Group, TANIOBIS GmbH, J. Schmalz GmbH and Viscom AG, have been working together with researchers from RWTH Aachen University, TU Braunschweig and the Fraunhofer Institute for Surface Engineering and Thin Films for the past three years on researching and developing the required processes for the project. Michael Kellner, Parliamentary State Secretary, said: “European battery production can only be successful if it focuses on sustainability in as many areas as possible. Sustainable batteries are crucial for an energy and transport transition that is guided by high environmental and social standards.”

materials for hydrometallurgical manufacturing processes including solvent extraction. As a subsidiary of JX Nippon Mining & Metals, the company has in-depth knowledge of hydrometallurgical recycling of lithium-ion batteries that are to be applied in the project. Kazuhiko Iida, CEO of TANIOBIS, added: “Through this partnership between industry, government, and academia, JX Metals group aims at early commercialisation of LiB recycling.” According to Dr Shizuo Sugawara, Deputy CEO of JX Nippon Mining and Metals, with this project, the JX Metal group is taking a further step to develop the early commercialisation in the EU region, where industry, government, and academia are proactively accelerating an electric vehicle shift. “JX Metals group has been working on the development of recycling technology to establish closed-loop recycling, the circular process to recycle valuable metals from used LiBs to the raw materials for new ones, and our group has already developed the technology that can extract metallic salts for raw materials of LiBs,” explained Dr Sugawara.

Holistic view of recycling Sebastian Wolf, Chief Operating Officer Battery Volkswagen AG, explained: “Recycling batteries and production rejects play a crucial role in securing the supply of raw materials for our planned factories. Through the HVBatCycle project, a holistic view of recycling processes and thereby the implementation of the closed loop of battery materials is being prepared.” TANIOBIS is a leading global producer of high-quality tantalum and niobium-based

Closed raw material cycle and multiple recycling In order to use less materials from primary sources such as mines, essential raw materials should not only be recovered once, but several times. For this purpose, battery cells made from recycled material are recycled again in order to prove that even multiple recycling runs have no impact on the material quality. Closing the cycle requires complex interdisciplinary processes.

For efficient, ecologically and economically useful recycling, all processes must be coordinated with one another to produce single-variety, high-quality secondary materials with the highest safety requirements. In particular, this involves scalability and cost-effectiveness. The consortium project focuses on the mechanical-hydrometallurgical recycling route, which is characterised by low energy requirements. The HVBatCycle project is intended to show efficient processes and innovative solutions that ensure the development of an end-to-end value chain with high profitability and at the same time the highest possible recycling and energy efficiency and minimal environmental pollution. To sum up the importance of the collaboration, Dr Kazuyuki Marukawa, Vice Chairman of TANIOBIS GmbH and CEO of JX Metals Circular Solutions Europe GmbH, added: “We unitedly contribute to the success of the project. We will newly establish a hydrometallurgical plant for the upcoming R&D based upon our technologies in Goslar, where TANIOBIS operates its main facility. “In this project, we play a key role to optimise the recycling processes to recover the high-quality materials with high yields, inputting black mass (pulverized batteries) provided by Volkswagen AG. Starting up with EU and Germany together with Volkswagen-led research team, JX Metals group will globally contribute to the early spread of EVs which are indispensable for the realisation of a carbon-free society and the realisation of a resource-recycling society through the foregoing efforts.” n Inside Industry

Event Preview Inside Industry looks ahead to the much anticipated return of ACHEMA

Inspiring sustainable connections at ACHEMA 2022

Having endured Covid-related cancellations and postponements since the event was last held back in 2018, ACEMA 2022 is back with a bang! This August will see manufacturers and service providers from over 50 countries presenting their products for chemical, pharmaceutical and biotech research and manufacturing as well as energy and environmental services. Björn Mathes, Managing Director at DECHEMA Exhibitions, explained why ACHEMA is the driving force and ground-breaker for the international process industries and their suppliers. Questions by Daniel Barnes. ACHEMA 2022 has been rescheduled to August (from its previous April dates). How confident are you of the new event taking place this summer, and how appreciative are you, as organisers, to the understanding exhibitors and visitors have offered you during these challenging times? We are very confident of this year’s ACHEMA. No matter how the pandemic will evolve, end of August will be a perfect timing for a secure and light-hearted gathering of our industry. When ACHEMA opens its doors on August 22nd it will be over four years since the last in-person show took place. The enthusiasm is really heightened by the long absence. So much has happened since ACHEMA 2018: from lab to production, from C-suite to company culture, and above all, the sustainable shift and smart solutions that have arrived at the core of our industry. 12

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So we have really put our heart and soul into realising the first real big industry gathering since the pandemic hit us, and of course we appreciate all industry players who share this vision with us. The slogan for this year’s event is ‘Inspiring Sustainable Connections’. Please can you talk us through the meaning behind the wording? As said, we are organising ACHEMA from the heart, for more than a hundred years now. But ACHEMA is not just a normal tradeshow, it brings together the whole chemical and pharmaceutical process industry, from the lab to plant and apparatus engineering up to packaging and storage technologies, from solution providers to owneroperators, from young professionals to C-suite.

We connect people with innovative ideas and technologies. And we do this for a higher purpose: the sustainable development of our industry in particular as well as the planet and our society in general. Thus, our mission at ACHEMA is inspiring sustainable connections. And of course, the double meaning behind sustainable is on purpose. Since two years we see that in-person connections are much more intensive and long-lasting than pure digital connections. ACHEMA has identified three key focal topics for 2022: The Digital Lab, Product and Process Security, and Modular and Connected Production. Why were these topics chosen and how do you plan to promote/discuss them?

from lab to production, we see some backlog demand. On an activity area we will show a total of six use-cases for the connected and digitalised laboratory: the smart lab of tomorrow to experience, touch and try out. Modular and connected production focuses for example on Module Type Package, Ethernet APL and OPC UA. Modularisation for flexible production will be the future of our industry. Just think about the container facilities of BioNTech. For our industry, safety was always a top priority, but now with increasing connectivity, security has become the same priority level. That’s why we have chosen it as our third focal topic. All topics will have a home in our congress and the exhibition and will be featured with extended communication activities.

The industry is still under an enormous digital transformation with loads of activities going on and new challenges coming up. The lab is the place where it all starts, but in terms of digitalisation and data exchange between different hardware as well as

Covid-19 has completely decimated the trade show industry throughout the past two years. What actions has ACHEMA taken to ensure guests who physically visit the event will remain safe?

Inside Industry

Event Preview Inside Industry looks ahead to the much anticipated return of ACHEMA

We have a fully professional health and safety concept in place, which is, together with the health authorities, continuously monitored and will be adapted according to the current pandemic situation. The general setup of the Frankfurt Fairgrounds with a loosened, relaxed hall layout, a sophisticated fully fresh-air ventilation system, optimised visitor flow management, safe catering concepts, and many measures now familiar to us in everyday life will create the framework for a safe yet comfortable exhibition environment. Guaranteed! What visitor and exhibitor numbers are you targeting for this year? Is there room to grow, especially in the number of exhibitors? We expect that we will further grow in the number of exhibitors in the next weeks. We are already seeing an increasing interest in ACHEMA from all over the world due to the fact that immunisation rates are increasing, and the pandemic might come to an end. With our August date and the easing of the Corona situation planning certainty comes back to the agenda. What’s new for 2022? We are introducing a new exhibition group, the so-called Digital Hub. It will be the central meeting place for digital experts and participants who are interested in or actively involved in the digital transformation of the process industry or who are actively involved in shaping it. At the same time, the Green Innovation Zone will act as a meeting and discussion point with several showcases for the sustainability 14

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challenge of the process industry, by far the largest challenge the industry has ever faced. For the first time, ACHEMA 2022 has also fully integrated the congress into the exhibition. All lecture sessions will take place either on stages directly in the exhibition halls or in the immediate vicinity of the exhibition groups. With so many global exhibitions available to companies, what USPs do you feel give ACHEMA an advantage over other similar shows? ACHEMA is not a typical specialised fair. It is a world forum, a global industry gathering place. There is no other event in the calendar that offers such a comprehensive mix of pioneering technology and global networking – an up-close experience that appeals to all the senses. This has made ACHEMA the driving force and groundbreaker for the international process industries and their suppliers for more than a hundred years. It is the only trade show that covers the full range of technology and services, from laboratory equipment, plant engineering and apparatus construction to packaging and storage technology, all in one place. Due to this we not only bring chemists, engineers, and process technicians together but also biotechnologists, energy and environmental experts, IT specialists and skilled experts from many other disciplines. What do you consider to be the main industry challenges for 2022 and the upcoming years, and how far do events such as ACHEMA go in helping companies overcome such difficulties?

22-26 August 2022

Frankfurt am Main, Germany – www.achema.de –

Even if the current geopolitical crises overshadow everything else, the biggest challenge of this decade is climate-neutral production. To achieve this, we need interdisciplinary cooperation and exchange across competitive and sectoral boundaries. This is exactly what ACHEMA stands for.

perspectives in laboratory and analytics, digitalisation, new bioprocesses and technologies. The challenges for the process industry are complex. That is why thought leaders, users and technology providers discuss in five highlight sessions where we are today and what the process industry can expect from the future.

For those who may be new to the event this year, and may be visiting for the first time, what advice could you give? What can they expect from their trip to Frankfurt and the trade show?

Looking at what ACHEMA has planned for 2022, on a personal level, what are you looking forward to the most?

Let me describe my first ACHEMA experience several years ago as an exhibitor at that time. The experience was overwhelming – the sheer size of ACHEMA, the global character and of course the fact that it brings together so many international experts from all areas of process industries. In addition to specific leads, this also resulted in valuable discussions with stand visitors who had completely different fields of expertise. This is exactly what you can expect from this year’s ACHEMA, a true melting pot of our industry. And there is one piece of advice I can offer: bring comfortable shoes! ACHEMA is large and you will have to walk a lot to see all the innovations on display. Please can you tell me more about your ACHEMA Congress – who do you have lined up to speak and what topics are high on the agenda? With five theme days, the congress underlines its integral part of ACHEMA. With several C-suite speakers as well as technical experts, none of the topics that are of concern to the process industry are left out. Daily highlight sessions on the respective topics set additional accents, and include: hydrogen economy, fossil-free production,

Well, after this long dry spell of more than four years since ACHEMA 2018, I am eagerly awaiting the moment when ACHEMA opens its doors to the attendees and the fairgrounds start vibrating with that unique ACHEMA spirit you shouldn’t miss out. Given the fact that this show will be also the last one of our long-serving CEO, Thomas Scheuring, it will be a very emotional one for all of us at DECHEMA. How do you envisage ACHEMA developing; what is your vision of the future for the brand? The trade show concept of ACHEMA has been adapted time and again, and in some ways, we have reinvented the show during the last century. In times of constant change and changing markets, this will continue to be the case in the future. At present, there is a general trend – trade fairs are increasingly becoming happenings and events. Emotions play a far greater role than they did in the past. The expectations of visitors and exhibitors regarding the flexibility and efficiency of a trade show are also changing rapidly. We will address this in the further development of the ACHEMA concept. Personally, I really want to take every action possible to take the multisensory experience of our attendees to a new level. n

Special Report Steve Ellis, Managing Director at FPE Seals, details the potential impact robotics can play in British manufacturing

Are robotics set to play a starring role

in the next ten years of British manufacturing?

In order to keep up with the demand British manufacturing faces, more businesses are adopting robotics as a solution. Steve Ellis, Managing Director at FPE Seals, discusses the ways your business could benefit.

echnology is constantly changing our day-to-day lives and has had a particular impact on the working world. Automation is fast becoming a key conversation within multiple industries in Great Britain, including manufacturing with robotics emerging as the solution. Over the past few years, a need to move towards more automation in the manufacturing industry has been seen. In fact, a survey done by ABB Robotics found that of 250 SME and manufacturing companies, 81.2% were considering incorporating robotics into their processes to combat issues with workforce shortages and supply chain disruptions. In this article, we’ll look at how, in order to keep up with the demand British manufacturing faces, more businesses are adopting robotics as a solution. We’ll also dive into what they can do for your business.

What can robots do for you? A big question from businesses still on the fence about bringing in robots is what can they do to improve processes. By automating sections of your manufacturing processes with robots, you’re given an opportunity to stay competitive within a constantly evolving industry. 16

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Substituting traditional labour with robots within your processes can help to provide added efficiency. Robots don’t require breaks, and they’re programmed to carry out specific practices with much smaller margins for error than humans. This results in a more cost-effective output from your business, which could see greater revenue for less paid labour. Robotics can also be useful when it comes to tasks that require a steadiness that can’t always reliably come from humans. Whether it’s handling or removing materials that can be harmful or dangerous, welding, or separating materials from one another, robotics makes those tasks much easier to carry out.

They work among us… The UK’s manufacturing industry has leant into a ‘quality over quantity’ mentality, focusing on top value from each product made, and robotics are now being incorporated into processes. Between 2020 and 2021, the UK became one of the top 15 for sales of industrial robots globally. The International Federation of Robotics (IFR) found that 2,205 industrial robots were installed throughout 2020, which brought the total in the country to around 23,000.

Steve Ellis, Managing Director

These robots are primarily found in the automotive manufacturing industry in the UK with around 875, making up 16% of those that were installed in 2020. Several sectors are seeing a benefit in robot application due to a lack of workers, including the food and beverage sector, which already uses industrial machinery and hydraulic cylinders, has seen an increase to 304 robots in 2020. This is a 96% increase in volume since the previous year.

Looking to the future Though these numbers continue to rise, the IFR still ranked the UK outside of the top 20 countries with robot density within manufacturing. We can take from this that there is still room for robotics presence in manufacturing to grow on our shores. The government itself outlined how much growth was possible in a Business, Energy and Industrial Strategy (BEIS), estimating that there

was a potential 40% annual growth for robotics and autonomous systems in the UK between 2020 and 2030. This could in turn mean an extra £6.4 billion in value for the UK economy by 2035. And if our creation and sale of autonomous robots is set to increase, our use of them across a number of industries may be set to increase alongside it. Automating your business process with robotics is not something to be scared of. The myth that robotics steals jobs has long since been debunked, and there is plenty of room for improvements within the manufacturing industry that they can help solve. Implementing robotics can help keep your business competitive in the global market, as well as provide an efficiency that is impossible to achieve with manual labour. There are currently a record number of robots installed; however, there is still room for growth, and the amount of revenue that could stimulate the UK economy if more is installed is staggering. n Inside Industry

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Industry News The latest company and industry related developments from around the world

AkzoNobel protects world’s biggest offshore wind farm

he world’s largest offshore wind farm is about to become operational off the UK coast, with all 165 of its giant 8MW turbines being protected from the ravages of the North Sea by coatings supplied by AkzoNobel. Located around 89km off the east coast of England, Hornsea 2 is due to be up and running by mid-2022. It has the capacity to produce more than 1.3 gigawatts of energy – enough to power over 1.3 million homes. The foundations of all the turbines (which tower 204m above sea level) have been coated with Interzone 954 from the company’s International brand. Originally designed for the demanding protection of offshore oil and gas structures, the product has now also become the go-to solution for offshore wind farms. “It’s fantastic to be involved in such an ambitious project with this kind of size and scale,” said Simon Parker, Director of AkzoNobel’s Marine and Protective Coatings business. “As the world moves to a greener and more sustainable future, it’s essential that vital infrastructure isn’t just fit for purpose, but is equipped for the long term as well. “That’s where Interzone 954 plays such a vital role. It’s one of the industry’s most trusted products for protecting structures operating in the harshest environments. It has more than 30 years of proven performance and has now protected over 2,000 offshore wind assets worldwide.” The splash zone of each wind turbine – which is intermittently wet and dry due to tides and waves – is the most prone to corro-

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sion. Interzone 954 has a unique blend of properties, including excellent barrier protection, exceptional abrasion resistance and high film build. It’s also resistant to a wide range of chemicals. Four years in the planning, the 462 sqkm Hornsea 2 project follows on from the successful 2021 completion of Hornsea 1 – previous holder of the world’s biggest offshore wind farm title. Its 174 7MW turbines, also coated by AkzoNobel, already supply power to around a million homes in the UK.

ArcelorMittal publishes concept for global low-carbon emissions physical steel standard

rcelorMittal has published a concept for a low-carbon emissions steel standard to help incentivise the decarbonisation of steelmaking globally and support the creation of market demand for physical steel products which would be classified as lower, and ultimately near-zero, carbon emissions steel. According to ArcelorMittal, the creation of clear definitions for low-carbon emissions physical steel is an important component of ‘demand pull’ and ‘supply push’ mechanisms that are required to support the steel industry in its transition to net zero by 2050. Clear definitions will also help inform targeted policy to support the scale-up and commercialisation of these near-zero technologies. At the heart of the concept are three core principles. Firstly, it must include a dual score system comprising a LCA value for finished products (EPD for construction products) alongside a decarbonisation rating system which categorises low and near-zero carbon emissions per tonne of hot rolled steel and rewards producers as they decarbonise from their starting point.

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We must have a system that defines what constitutes physical low-carbon steel during the transition to near and ultimately net zero. This will help support a return on the investment required to transition to low-carbon steelmaking which will be more costly than the technologies used today

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Secondly, it must be designed in such a way that incentivises the decarbonisation of all methods of steel production through technology shifts, rather than simply through increasing scrap rates using existing technology. This can be done by using a sliding scale based on the percentage of scrap used in production, a system which is also at the heart of the ResponsibleSteel™ and International Energy Agency (‘IEA’) low-carbon emissions steel models. And finally, it must include a clearly defined boundary from which carbon emissions are counted for the decarbonisation rating system.

The concept is designed to be complementary to methods for rewarding virtual low-carbon steel, at least until significant amounts of physical low-carbon steel are available. “We have spent a lot of time thinking about how to do this in a fair way that incentivises all steelmakers to reduce emissions and ultimately achieve net zero,”said Brad Davey, Executive Vice President, ArcelorMittal, and chair of the company’s climate committee. “We know that there are many organisations giving this question a lot of thought. We are in close discussion with several of these organisations and have welcomed the opportunity to share our expertise of steelmaking with them as they develop their recommendations. We believe these principles will help incentivise the industry and will also prove intrinsic in providing transparency and clarity to steel consumers, guiding their purchasing decisions and helping to develop green steel lead markets.” Any standard must incorporate a dual score consisting of: a LCA value for finished products so that customers can clearly see the embodied carbon emissions of the steel they purchase; and a decarbonisation rating system akin to the labelling system already used in the EU for white goods, which measures the level of steel producers’ decarbonisation progress. Recognising the importance of a consistent boundary in order to enable a like-for-like comparison between steel producers for the decarbonisation rating system, ArcelorMittal’s concept proposes a core steel system boundary that can be readily measured today, based on the Net-Zero Steel Pathway Methodology Project. This counts all Scope 1 and 2 emissions as well as selected Scope 3 emissions from ironmaking, steelmaking, casting and rolling. Geert van Poelvoorde, Executive Vice President and CEO of ArcelorMittal Europe, added: “We must have a system that defines what constitutes physical low-carbon steel during the transition to near and ultimately net zero. This will help support a return on the investment required to transition to low-carbon steelmaking which will be more costly than the technologies used today. “We believe it is important that any standard has a dual approach that clearly states the LCA value of the product as well as a rating to show decarbonisation progress. This makes the embodied carbon content of the product clear to customers but also the progress that producer is making towards near zero – a vital component of ensuring every company contributes to achieving the Paris Agreement.” Inside Industry

Industry News The latest company and industry related developments from around the world

Johnson Controls appoints Rodney Clark as Vice President and Chief Commercial Officer J ohnson Controls, the global leader for smart, healthy and sustainable buildings, has named Rodney Clark as Vice President and Chief Commercial Officer, effective June 1st, 2022. In this role, Mr Clark will lead global sales excellence efforts across the company, replacing Chief Commercial Officer, Brian Young who retired at the end of last year. Mr Clark will also take on a portion of the role being transitioned from Michael Ellis, Executive Vice President, Chief Customer and Digital Officer, who will retire at the end of the year. “I am excited to welcome a proven, strategic leader such as Rodney to Johnson Controls,” said George Oliver, Chairman and CEO of Johnson Controls. “As we deliver on growth platforms such as decarbonisation in smart, healthy buildings, Rodney will build on our progress, collaborating with customers on outcome-based solutions and service offerings through OpenBlue, while expanding our market, building scale, capacity and capability.” Rodney Clark most recently held the role of Corporate Vice President of Global Partner Sales and Channel Chief at Microsoft. In this role, he led a team responsible for customer and partner relationships, accelerating growth through the Microsoft partner ecosystem, as well as cross-partner strategy and outcomes through the Microsoft partner network. Prior to this, he served as the Corporate Vice President of the Internet of Things (IoT) and Mixed Reality Sales, responsible for building

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intelligent systems and mixed reality capability, through sales and go-to-market execution. “I’m delighted to be joining Johnson Controls, they have an incredible team that is driving innovative technology that transforms ordinary buildings into dynamic, healthier, safer spaces for all of us to enjoy,” said Mr Clark. “Adding intelligent cloud and intelligent edge solutions to their traditional offerings creates an enormous opportunity and will help customers address their most critical challenges – including the achievement of sustainability targets with agile, flexible and scalable solutions.” Johnson Controls announced its digital transformation nearly two years ago with the introduction of OpenBlue, a complete suite of connected solutions that delivers impactful sustainability, new healthy occupant experiences, and safety and security. These emerging and disruptive technologies such as cloud, Edge AI and machine learning address climate change by helping companies achieve their net zero and renewable energy goals. Further fortifying Johnson Controls as a leader in the industry, the company acquired FogHorn, a provider of Edge AI software earlier this year. As the number of sensors and amount of data in buildings continues to grow exponentially, the value of processing data and applying intelligence at the edge, without having to send data to the cloud, becomes increasingly pronounced. This further creates value for customers by enabling real-time, secure and actionable insights.

His Excellency Sharif Al Olama, Under-Secretary, Ministry of Energy and Infrastructure UAE; Right: Helmut von Struve, CEO Siemens Middle East

UAE Ministry of Energy and Infrastructure selects Siemens tech to power nation’s electric vehicle charging corridor T he United Arab Emirates’ Ministry of Energy and Infrastructure selected Siemens technology for a nationwide network of ultrafast electric vehicle (EV) chargers which will help reduce carbon emissions, boost adoption of EVs by addressing so-called range anxiety, and lay the groundwork for a more connected and sustainable transportation system. Ten Siemens Sicharge D 160 kW ultra-fast chargers will be installed on the highways in Ras Al Khaimah, Ajman, Umm Al Quwain and Fujairah. To meet the changing market demands, the chargers have a scalable power up to 300 kW and can be expanded with additional external dispensers for up to two additional charging cables. All are cloud-connected devices which allows operators to monitor and manage the chargers remotely. “The UAE is committed and working with confidence to reduce the nationwide carbon footprint, by working on the demand side, supply-side and working on our different energies and future technologies to reduce our carbon footprint,” said Sharif Salim Al Olama, Under-Secretary of the Ministry of Energy and Industry. “Electric vehicles are integral to this effort, and providing this fast, efficient and convenient EV corridor is a crucial step in the energy transition.” Siemens will provide the charging infrastructure equipment, control and monitoring software, as well as training and commis-

sioning support for the new network. The command-and-control system allows full monitoring and control of all units and provides the foundation for the next phase of the project, which is to build an app for drivers to access and book chargers. “We are proud to support the sustainability program in the United Arab Emirates with our EV charging solution,” said Birgit Dargel, Vice President Sales eMobility at Siemens Smart Infrastructure. “This project in the UAE continues the success story of our public fast charger Sicharge D. “With a peak efficiency of 96%, it is one of the most efficient highpower DC chargers currently available. Its communication ability with the cloud provides operators with real-time information and flexibility to manage their charging network. Its intuitive, height adjustable 24” touch screen display as well as its elegant appearance guarantees a great user experience.” The Ministry of Energy and Infrastructure and Siemens signed a memorandum of understanding in October 2021 to establish a long-term partnership that will aid the ministry’s sustainability and digitalisation targets. In addition to transportation, the discussions include smart building technologies, microgrid and industrial energy management and intelligent substations on the grid edge. The national EV Charging Corridor is the first project that will be delivered under the MOU framework. Inside Industry

Industry News The latest company and industry related developments from around the world

BASF to build commercial scale battery recycling black mass plant in Schwarzheide, Germany

lithium-ion batteries, as well as material recovery and recycled content targets for nickel, cobalt and lithium. BASF’s Catalysts division is the world’s leading supplier of environmental and process catalysts, ensuring the efficient production of a wide variety of chemicals, plastics and other products, including advanced battery materials. BASF Schwarzheide GmbH has been part of the BASF group since 1990. More than 2,000 employees produce specialised chemicals at the production site in Lusatia. The product portfolio ranges from polyurethane based products and systems, crop-protection agents and water-based coatings to engineering plastics, foams, dispersions, Laromer brands and from 2022 also battery materials.

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ASF will build a commercial scale battery recycling black mass plant in Schwarzheide, Germany. This investment strengthens BASF’s cathode active materials (CAM) production and recycling hub in Schwarzheide. The site is an ideal location for the build-up of battery recycling activities given the presence of many EV car manufacturers and cell producers in Central Europe. This investment is expected to create about 30 new production jobs, with start-up planned for early 2024. Black mass production is the first step in the battery recycling process and is based on mechanical treatment of the batteries. The produced black mass contains high amounts of the key metals used to produce CAM: lithium, nickel, cobalt and manganese. It will be the feedstock for the commercial hydrometallurgical refinery for battery recycling that BASF plans to build mid of this decade. “With this investment in a commercial scale battery recycling black mass plant, we take the next step to establish the full battery recycling value chain at BASF. This allows us to optimise the end-toend recycling process and reduce the CO2 footprint,” said Dr Peter Schuhmacher, President, Catalysts division at BASF. “The closed loop from end-of-life batteries to CAM for new batteries, supports our customers along the entire battery value chain, reduces the dependency from mined raw materials and enables a circular economy.” Battery recycling is an important lever to reduce the CO2 footprint of battery electric vehicles, and is key to meet ambitious, circularity-driven policy requirements, expected under the proposed EU Battery Regulation. These will cover recycling efficiency of

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DHL Supply Chain Australia agrees to acquire The Glen Cameron Group

HL Supply Chain, part of the Deutsche Post Group (DPDHL), is acquiring 100% of the Glen Cameron Group, an Australian logistics company specialising in road freight and contract logistics. The Glen Cameron Group operates a fleet of 1,000 trucks and trailers, and has more than 820 employees around Australia. The strategic combination of the Glen Cameron Group with DHL Supply Chain will strengthen DHL’s position in the evolving Australian road freight market and create one of the largest logistics companies in the country with combined revenue of over AU$1 billion (€670 million). “Given DHL Supply Chain’s continued outstanding performance, we strategically invest to further facilitate our accelerated growth, meeting our customers’ current and emerging needs. Therefore, I am delighted that we are acquiring this market leading transportation business in Australia, making us the clear provider of choice in a significant logistics market,” said Oscar de Bok, CEO, DHL Supply Chain. “This acquisition signifies our commitment to grow the business in Australia, enhancing our service offering to provide the best solution to our customers. The supply chain is evolving quickly and with significant transport operational capability, we will be more agile, respond faster to changing demands, and continue to deliver on our promises,” said Terry Ryan, CEO, DHL Supply Chain, Asia Pacific. “This is a unique opportunity for DHL Supply Chain to add additional high-quality transport services to our warehouse and transport solutions in Australia. We look forward to offering a fuller range of transport services to existing and new customers. DHL is well recognised for having a strong warehouse base and with this acquisition,

we will be strengthening our offer with four services; Domestic Nationwide General Freight, Domestic Nationwide Express Freight, Specialised Services and Contract Logistics transport – with dedicated solutions for customers,” said Steve Thompsett, CEO, DHL Supply Chain Australia and New Zealand. The Glen Cameron Group is recognised as a leader in freight and contract logistics and DHL will benefit from the expertise of the Cameron Logistics’ team in the consumer and grocery sectors. Glen Cameron, Founder and Executive Chairman of the Glen Cameron Group said: “Since founding the Glen Cameron Group 47 years ago we have built a successful, diverse, and resilient business. What began as one 8-tonne truck in 1975 has evolved to be one of Australia’s largest transport and logistic business. Together with DHL, we can take our business to the next level.” The Glen Cameron Group will benefit from DHL’s large-scale network in over 220 countries and global forwarding expertise in air, ocean and road freight to ensure strong development opportunities for the business, its customers, and its employees. “I’m excited to see the Glen Cameron Group join with DHL. Together, we can increase our footprint and become one of the largest transport and logistics businesses in this country,” said Mr Cameron. “With the backing of a highly successful global corporate business, we have an opportunity to invest in growth and open new opportunities for our employees, and this marks an important milestone to continue an important legacy in the Australian transportation industry.” In Australia, DHL Supply Chain employs some 4,000 logistics professionals at its warehouses and transport operations. Inside Industry

Matter of fact Interesting and unusual industry facts from around the world

matterof fact Germany has the longest rail network in Europe, with over 39,000 km of track carrying over 12 million passengers per day to 5,400 stations.

One of the world’s first production motorhomes was the 1929 REO Speed Wagon Camper. Built on a 12-passenger bus chassis, it featured a fold-out sofa bed and a pull-out “grooming” sink with a pressurised water system.

In 2020, Cairo International Airport knocked Johannesburg’s OR Tambo International Airport off the top spot as Africa’s busiest airport. Cairo maintained its hold into 2021 with 58.8% passenger growth to over 11.3 million.

Titin, a contraction of Titan protein, is encoded in the human TTN gene. This giant-sized protein has a chemical name to match, consisting of 189,819 letters when written in full.

Wind turbine blades from Dutch Wind farm Irene Vorrink will be the first to enter the recycling process and be turned into skis, snowboards and construction materials for solar farms.

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“

Every problem is a gift

“

without problems we would not grow – Anthony Robbins –

Barra Airport in the Outer Hebrides of Scotland is unique, being the only airport with scheduled flights using a tidal beach as a runway. The triangle of runways marked with permanent wooden poles ensures that the DHC-6 Twin Otters serving the airport can always land into the wind. The 40ft EleMMent Palazzo motorhome from Austrian manufacturer Marchi Mobile sold for around $3 million. EleMMent Palazzo is the world’s most expensive motorhome and features a pop-up roof terrace, two floors, a cocktail lounge and underfloor heating.

Engineering is accepted to consist of four main branches, each with numerous sub-disciplines: chemical, civil, electrical and mechanical.

The Pantone Colour of the Year for 2022 is Pantone 17-3938 Very Peri, a shade of purple combining “beloved blue” with “violet red” undertones.

The original Ferris wheel was built by George Washington Gale Ferris Jr in 1893 for the World’s Columbian Exposition in Chicago. At a total height of 80.4m, the rotating wheel weighed 40 tonnes on a 13.8m axle. The first Ferris wheel was the largest constructed steel object at the time. Inside Industry

What’s new in the industry? The latest innovations, ideas and product launches

what’s

new

in the industry ?

World’s first certified label material to fight ocean bound plastic pollution

Volta Trucks reveals its fullelectric 7.5 - and 12-tonne Volta Zero variants Electric commercial vehicle manufacturer Volta Trucks has revealed the forthcoming 7.5- and 12tonne Volta Zero variants – the second product family in its full-electric vehicle range. The 7.5- and 12-tonne Volta Zeros have been designed by Volta Trucks’ partner, Astheimer Design in Warwick, UK alongside Volta Trucks’ own engineering teams. The vehicles will be visually identical at the front, with the 12-tonne vehicle having a longer chassis and body, and a second set of rear wheels and tyres, to accommodate the increased vehicle payload. Having confirmed the start of the project in December 2021, a Pilot Fleet of vehicles is expected to be launched for customer trials in 2024, with series production due to commence in early 2025.

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UPM Raflatac is the first company in the world to invest in ocean bound plastics waste as label raw material in its new Ocean Action labels. Ocean bound plastic is abandoned plastic waste recovered from areas up to 50km inland from waterways, defined as “at risk of ending up in the ocean” by OBPCert. The new innovative label material is made possible by close collaboration with multiple partners in the product’s value chain. The Ocean Action label material is available as White and Clear Top Coated PP films with RP37, RF37, and RP74 adhesives and PET 23 PCR and glassine liners. These label materials are a perfect fit for fast-moving consumer goods (FMCG), such as household goods, personal care, packaged foods, and beverages.

DOBOT launches collaborative Robot CR3L Intelligent robots manufacturer DOBOT has unveiled the CR3L Collaborative Robot. The DOBOT CR3L is an ultra-long cobot with a reach of 1,700mm, an increase of 11.5% in comparison to the previous version of the DOBOT CR Series. The robotic body of the CR3L enables performing in small spaces, perfect for applications requiring extended reach for robots, such as loading and unloading, sorting, and wide-range inspection of small parts in consumer electronics and semiconductor industries. Along with the DOBOT CR3L robotic arm, there are six different versions of the DOBOT CR Collaborative Robot Series products with diverse payload types: 3kg, 5kg, 7kg, 10kg, 12kg, and 16kg.

NAS® Mantis™ - revolutionary robotic trim press handler BMG has unveiled the Mantis Robotic Trim Press Handler from NAS Nalle Automation Systems. The Mantis™ is a robotic trim press handling system being labelled as the next generation in thermoformed product handling, compatible with all trim presses but specifically designed for both non-servo- and long-eject models. This compact and configurable system fits within a client’s facility and interfaces with any trim press make or model. Product containment throughout the process dramatically reduces jams and product loss. Highlights include: compact trim press receiver (TPR) – patent pending, VeriTool™ RFID tool verification – patent pending, no product contamination, simple intuitive controls, product isolation and reject through HMI, plus quick and easy changeover.

Mondi and EW Technology’s new machine for paper pallet wrapping

OnRobot’s new material handling palletizer OnRobot, the world leader in hardware and software solutions for collaborative applications, has launched OnRobot Palletizer, a complete collaborative palletizing solution designed to take the physical and financial pain out of palletizing processes. OnRobot Palletizer allows users to choose a palletizing system that works for their specific application needs thanks to its space saving footprint, and ability to handle many different types of boxes, packages, patterns, pallets and stacking heights. Compatible with collaborative robot and light industrial robots from the Doosan, Fanuc, Omron, Techman and Universal Robots brands, the OnRobot Palletizer is available as a complete out-of-the-box system or as individual components to create a mix-andmatch solution.

Packaging and paper company Mondi has collaborated with Austrian mechanical engineering company EW Technology to launch a new machine for paper pallet wrapping on small-to-medium production lines. Offering two settings, the machine can be fully automated to wrap up to 60 pallets every hour or semi-automated to wrap 10-15 pallets per hour. The machine takes a full reel of Mondi’s Advantage StretchWrap paper, allowing customers to replace the multi-layer plastic which is currently the industry standard for pallet wrapping. Advantage StretchWrap is 100% virgin paper, created with renewable materials and fully recyclable in existing paper waste streams across Europe.

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FEATURED IN THIS ISSUE morelo reisemobile manospack

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MORELO

PROFILE

While most of us know what it’s like to embark on an epic road trip, only a select few know what it’s like to do so in a luxurious motorhome such as those produced by MORELO Reisemobile. Beginning with nothing more than a prototype, a drawing, and a dream to be the last word in luxurious motorhomes, MORELO has, in only a dozen years, fought its way up from plucky upstart to becoming the undisputed European market leader in luxury motorhome production. Sales Director Sven Stadthalter spoke to Richard Hagan about the company’s amazing journey. 32

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he scene is Germany, in early 2010. It’s nearing the end of a typically cold European winter. Somewhere in an even colder sheet metal factory space without any heating, six skilled artisans are busy building a prototype motorhome. The factory is so cold that the glue the men are using is frozen and has to be thawed with boiling water. When summer arrives in June, the factory feels like an oven and it makes the already hard work even harder. Sales Director Sven Stadthalter summarised the conditions in a typically understated German fashion: “It was the most complicated situation.” All of that discomfort and hard work paid off in August that same year, however, when the team displayed their prototype vehicle at Caravan Salon, the world’s largest trade fair for motorhomes and caravans. Attendees loved the MORELO Reisemobile prototype so much that eight orders were placed right then and there.

Revving up production With those orders in hand, it was time for MORELO to build a production facility, so construction of the new MORELO factory duly began in August 2010. It was finished in February 2011. Since then, the company has enjoyed strong demand for its vehicles. “Within two years, in 2012, we were already producing 180 motorhomes per year,” Mr Stadthalter revealed. “In 2015 we produced 260 vehicles and by our tenth anniversary in 2020, we were producing over 400 per year. As of 2022, we are still growing. Yet despite constant increases in capacity, we still can’t meet demand.” In 2021, after 11 years in business, MORELO recorded a very substantial €120 million turnover. “That’s been especially impressive to us given the short time frame in which we’ve been in business,” he remarked. “But still, we are in the fortunate position of being able to sell more than we can produce.” Inside Industry

SUPER B SUPER B is a Dutch manufacturer of high-end lithium iron phosphate batteries (LiFePO4) established in 2007. We are proud to have MORELO as one of our key partners in the RV market for several years. MORELO stands for first-class motorhomes that are among the best in the world. A MORELO is always a statement of wanderlust, excellent comfort and superior quality. We also embrace this philosophy in the development of our batteries. Every Super B battery is produced with 100% focus on quality. We select and match all our A-grade battery cells upfront. Not one single battery will leave the factory before it has been thoroughly tested: intermediate and end of line. Only this way we can guarantee the lithium batteries we produce for MORELO are reliable, safe and durable. In the end, MORELO owners need first-class batteries to enjoy freedom and optimal comfort during their holidays.

editorial mention

TEN HAAFT The name MORELO, like the name ten Haaft, stands for quality consciousness, reliability and pan-European expert service. Over the past 30 years, we at ten Haaft have featured numerous new and further developments and have become the foremost manufacturer of premium mobile satellite technology systems. MORELO is a long-standing partner. We appreciate not only the extraordinarily good cooperation, but also the professional and friendly way with which we can meet every employee at MORELO. editorial mention

SKA SITZE GMBH In recent years, SKA Sitze GmbH has developed into one of the leading international seat manufacturers for premium class motorhomes. We owe this success to the excellent cooperation with our customers such as MORELO Reisemobile, for whom we have been supplying the seats since their very first vehicle. Last but not least, our customers and developers set the standard for our outstanding products. editorial mention

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MORELO

PROFILE

Sales Director Sven Stadthalter

Naturally, the company has firmed up plans to further improve its production capacity and has set aside a €40 million budget for the process, beginning with its staff count. From only six employees back in 2010, by 2022 MORELO employed 425 staff with plans to add another 100 in the near future. In June 2021, the company completed a 3,500 sqm expansion to its production facility. An additional 1,000 sqm expansion to its exhibition hall/showroom is in the pipeline and furthermore, the company was reviewing improvements to its production management, efficiencies and general processes to improve throughput on its production line.

Luxury for every occasion MORELO produces a range of six luxury motorhomes catering to a broad range of budgets and customer needs. The range is topped by the Grand Empire – an 18 tonne, 530 horsepower, 12m-long luxury estate on wheels – which MORELO refers to as the ‘benchmark’ in luxury motorhomes. The Grand Empire is a machine for the most discerning traveller and offers a vast range of luxurious optional extras and customisation. At MORELO, no customisation request is too much effort. Mr Stadthalter eagerly 38

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highlighted a particular project that really showcased the company’s ability to accommodate even the most challenging customer requests. “For one of our most difficult projects, the customer required that we incorporate a garage at the back of the motorhome to accommodate either his Maserati or Porsche supercars. His requirement was clear: they have their home with them and they want to take their garage with them; they wanted us to make it possible to put their supercar in their MORELO.” MORELO’s flexibility doesn’t stop there. Mr Stadthalter stressed that customer interaction and feedback is something they take so seriously that it has even resulted in the birth of a whole new, more affordable motorhome product. “At the 2021 Caravan Salon, we introduced the MORELO Alcove directly as a result of customer requests,” he confirmed. “We’re very close to our customers and had received requests for this kind of vehicle many times in the past, but we’d always turned it down due to the difficulty of producing this kind of vehicle at the same time as our other motorhomes. The fact that we’ve introduced it now, proves how important customer feedback and market demands are to us.”

Driving away from the competition Since its inception, MORELO has pursued an aggressive growth and expansion strategy. In 2019, the company overtook its competitors to become the European market leader. “We’re putting more and more distance between us and them every year now,” added Mr Stadthalter. He explained that the company’s growth is fuelled by two main factors: passion and enthusiasm for what it does, and its hightech, custom-built production facility in Schlüsselfeld, Germany. On the first point, Mr Stadthalter was adamant: “You have to understand our attitude,” he said. “We produce luxury motorhomes because it’s the only thing that we want to do. Of course, we have to make a profit, but the focus of our management is that we love what we do, it’s our passion, and we constantly try to impart that enthusiasm to all of our employees. It’s what makes our product so special, so we have to maintain the right mindset.” That mindset is made immediately apparent in the second factor – MORELO’s advanced, custom-built production facility. 19,000 sqm worth of buildings includes a 900 sqm storage hall, and a new 5,500 sqm customer vehicle service centre.

MORELO’s production line is extremely modern and had the substantial benefit of being custom-built right from the start, to suit the company’s particular needs. “We started from zero, on a green field,” Mr Stadthalter recalled. “From the beginning, we had the opportunity to build according to our own vision and to design our buildings ourselves. Therefore, unlike our competitors, we aren’t stuck with old, inefficient buildings and production layouts.” MORELO’s production line is one process on a single, straight 220m-long line that is supplied with material from either side by its various pre-mount departments. The production line is even able to cope with the production of right-hand side drive vehicles – something for which MORELO is uniquely capable of doing, Mr Stadthalter proudly revealed. “The UK market is quite important to us and one of my favourite projects was making it possible for us to produce righthand drive vehicles in our production line,” he said. “With our passion and love for what we do, we developed a solution that involves sending right hand-drive cars through the line, backwards. MORELO is now the only manufacturer in Europe, producing a righthand drive luxury motorhome.”

Reinhard Lo ̈hner, Robert Crispens, Managing Directors

As of 2022, MORELO boasts an impressive 3,500 motorhomes on the road. Its factory comfortably adds to that number as it completes a new MORELO motorhome – from the smallest in its range to the largest – every ten working days.

The customer is always closest At the end of May 2022, MORELO hosted its annual MORELO Open – the first one in two years as a result of Covid. The event was attended by more than 700 motorhomes and their owners which filled up MORELO’s 130,000 sqm company site. “This was a very special event and one that we’re very proud of,” said Mr Stadthalter. “We enjoyed live music and other events and just generally had

a good time. We shared ideas and of course, we did what Bavarians do and drank a lot of beer!” he added with a chuckle. In closing, he reiterated the company’s passion for its customers: “Some manufacturers only focus on their business-to-business relationships and forget about the end customer. We understand, however, that the end customer is the most important part of the whole game. “We see ourselves and our customers as a big family; we try to be familiar with and close to them whenever we can, talking to them and listening to what they say about our products, how they use them, and what they want from them. And of course, we love what we do. That’s what makes us special and interesting.” n Inside Industry

FRIULFORGIA SRL

PROFILE

Always one step

ahead The latest round of investment at Friulforgia Srl, the Italian forging company, expanded the scope of its marine products. Mosè Molaro, Sales Manager, outlined these new opportunities to Phil Nicholls and Daniel Barnes. 40

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F Mosè Molaro Sales Manager

Francesco Rizzani Plant Manager at Friulforgia

riulforgia is part of the TTN Group founded by Ernesto Pirovano in 1978, providing thermochemical surface heat treatments to the Italian forging industry. TTN Group steadily expanded, serving a growing number of forges with a range of speciality treatment services. A regular expansion of equipment allowed TTN Group to handle progressively larger projects, such as deep bore drilling equipment up to 16m. In 2008, Mr Pirovano decided it was time to become a vertically integrated production company and founded his own forging shop. This project became Friulforgia, built from scratch at a facility outside Sedegliano in the Province of Udine in the northeast of Italy, opening in February 2009. Friulforgia began with just 12 members of staff but has now grown to 70 employees carrying out a range of heat treatments, rough machining, and final machining. Friulforgia remains part of TTN Group’s seven companies spread across three countries: Italy, Spain, and the USA. The group employs 500 people and has an overall turnover of €70 million – €20 million of which is attributed to the success of Friulforgia. The throughput of Friulforgia guarantees a capacity of 800 tonnes per month. To sustain this growth, the company has kept a continued program of investment in both equipment and personnel. A new

press in 2018 increased Friulforgia’s capacity from 25 MN to 38 MN. The machining workshop was doubled in size in 2019, with Friulforgia installing additional mills and lathes for final machining during 2020 and 2021. The key investment for 2021 was a new multi-tasking turning machine. The latest addition allows Friulforgia to produce machined shafts up to 20m long, via turning, boring, milling and grinding. “This major investment was specifically planned in order to provide an even more complete service to our customers in the marine industry, where propeller and intermediate shafts can be very long and challenging,” explained Friulforgia’s Sales Manager, Mosè Molaro.

Marine forging Friulforgia’s new lathe can work in conjunction with the assorted bore drilling machines operated by TTN Group. This combination enables the group to drill and hone holes up to 20m long. Friulforgia now has the capability to deliver to clients fully machined forgings, ready to mount on ships. Friulforgia is equipped to produce a diverse range of products in a broad range of markets including offshore, subsea and hydro power. Friulforgia also supplies clients in the marine, metallurgy, power generation and power transmission industries. Inside Industry

TACCHI GIACOMO E FIGLI SPA Tacchi Giacomo e Figli SpA is a leading company in the production of lathes and large deep hole drilling machines used in the processing of propeller shafts for the naval industry, amongst other applications. We have recently supplied and installed a drilling machine capable of machining a boring depth of up to 22m and an internal diameter of 800mm. As for external machining, we have recently supplied and installed machines the for turning, milling and grinding of shafts with external diameters up to 2,100mm and length of 22m. In addition, for applications in other sectors of the heavy precision mechanical industry, we have supplied machines to produce workpieces with larger diameters and lengths, weighing up to 320 tons, for both lathes and drilling machines. Our organisation, for sales, service and spare parts, covers the whole world, from Europe to North and South America, India, the Far East and Australia. For more information, visit our website www.tacchi.it. editorial mention

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FRIULFORGIA SRL

PROFILE

“We are well-known in several different markets thanks to the diversity our product range, as we can forge any shape with our open-die presses, and we can do it with any kind of steel grade,” said Mr Molaro. “We forge long products such as shafts, rods, pinions, pipes, as well as massive cylinders, bushings, wheels, valves, clamps, sockets and many other shapes.” Friulforgia has been active in the marine industry since the beginning of the company. Initially, the company delivered premachined propeller and intermediate shafts to one of the major European manufacturers of marine thrusters. The customer quickly accepted supply of additional Friulforgia final machined items. This relationship steadily expanded into the provision of a range of steering and propulsion components every year. Friulforgia has since expanded its client base to several other thruster and rudder manufacturers. Marine products include shafts, crank pin discs, hubs, flanged pipes, and other propulsion-related components for any kind of thruster. All these items are certified by third-party accredited registers directly in Friulforgia. 46

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Simplified procurement Mr Molaro acknowledged that competition within the forging industry is tough, especially in Italy. However, Friulforgia benefits from being part of the wider TTN Group as it can work with metallurgists and machining specialists within the organisation. The client benefits from this simplified procurement structure where a single point of contact provides access to so many specialised processes. “There is no other company in Italy that can provide such a wide range of services altogether, and by investing in our 20 metre-long multitasking lathe, Friulforgia is now ahead in the marine competition.” Friulforgia enjoys a close relationship with suppliers too. “We buy hundreds of ingots to be forged every year,” Mr Molaro said, “And there are no compromises on quality.” The company buys many varieties of steel – from carbon to stainless steel, including tool steels, Duplex, and super Duplex – choosing suppliers very carefully, following strict qualification and monitoring procedures. Most ingots are bought from Italian mills, but Friulforgia also sources from mills in Austria and Germany.

Friulforgia carefully matches the ingot to the product, as each supplier performs better on some steel grades than others. By knowing its suppliers so well, Friulforgia selects the best solution to maximise the final performance of its products to the benefit of its customers. “In the past decade,” Mr Molaro explained, “We have witnessed a strong tendency of centralisation in the scope of components procurement, as our customers prefer to buy comprehensive solutions from the manufacturers instead of dividing the orders between different suppliers, where each performs a different activity.” Friulforgia is perfectly positioned to capitalise on this trend. A continual program of investment in final machining and testing equipment maintains Friulforgia’s strategy of vertical integration.

Green investment Francesco Rizzani, Plant Manager at Friulforgia, outlined the importance of sustainability at the company. The company has ISO 14001 certification and strictly monitors its impact on the environment. “We plan on achieving yearly improvements in energy consumption and waste

production,” Mr Rizzani said. “We are now evaluating the implementation of a photovoltaic installation on our roofs to cover more than 30% of our electricity needs. “Our commitment to respect nature, environment and safety is sustained by major investments to contain furnace emissions and to have scrap material properly disposed of. We believe any business activity should promote the health of the local community; this is possible only if you respect who and what is around you.” Addressing the wider industry, Mr Molaro considered the challenges facing Friulforgia: “With the energy crisis and the war in Ukraine obstructing the supply of primary elements for steel production, we can consider ourselves lucky as our Italian suppliers of ingots managed to absorb the blow and keep working, allowing us to produce continuously with no setbacks.” The biggest challenge facing Friulforgia is competing with the Asian market where manufacturing costs are lower. Some customers transferred into Asia, shifting their procurement to local suppliers. However, the outlook for Friulforgia remains buoyant due to its diverse market portfolio. The ongoing investment strategy means “a constant development and improvement of our customer base,” asserted Mr Molaro.

Onwards to trade shows During the pandemic, the company explored innovative ways to connect with customers. “We found alternative solutions to promote our activities,” Mr Molaro revealed. “This included renewing our website and

creating a virtual tour of our production premises. These choices were successful and greatly appreciated by both new clients and well-established customers.” Moving forward, Mr Molaro is enthusiastic for the return of trade shows. “This year we will finally be able to attend at least three separate shows: OTC in Houston as ForgeTTN; Euroguss in Nuremberg as TTN Group; and SMM in Hamburg as Friulforgia. In each of these shows we will have our own booth and we are very optimistic about the outcome, as we think that after two years of restrictions the attendance will be very rewarding.” This positive outlook also applies to the future of Friulforgia. “The verticalisation of our activities has always been one of our priorities,” Mr Molaro said. “We will maintain this trend in the future, with further investments in final machining and the other activities directly related to it.” The next planned investments at Friulforgia are related to the heat treatment capacity which will be doubled by 2023. The current growth in renewable energy will offer Friulforgia new opportunities within hydropower generation, offshore platforms and associated marine industries. Friulforgia’s business model maintains complete control of the manufacturing process. To this end, Mr Molaro concluded: “We believe the best way to serve our customers is to provide them with the most complete solutions possible in order to simplify their procurement activity, and to do it with no need of sub-suppliers.” n Inside Industry

ENVENTURE GLOBAL TECHNOLOGY

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PROFILE

First established in 1999, Enventure Global Technology has over 20 years of experience engineering industry-leading expandable liner innovations for the downhole environment. Now, with over 2 million feet of its revolutionary solid expandable liner technology installed worldwide, Matt Meiners, Director of Technology & Product Development, sat down with Richard Hagan to talk about how this technology is saving operators huge amounts of money, time and even the wells, of over 250 operators in 39 countries around the world.

ell-site oil and gas operations, regardless of location, are complex and fraught with risks and technical difficulties that must constantly be assessed and overcome to ensure the successful drilling, completion, and production of a well. Enventure Global Technology, based in Houston in the US, manufactures and supplies a range of products and services designed to enhance the entire lifecycle of a well, including exploration, development, production and remediation.

Expanding possibilities with SET® Enventure’s signature product offering, the SET® Openhole Liner, was first introduced in 1999 and is based on the use of solid expandable liner technology. The SET Openhole Liner involves the controlled expansion of a solid steel tubular in the downhole environment. For those unfamiliar with this technology, the use of expandable tubulars involves enlarging the

inner diameter (ID) of a downhole tubular and its threaded connections using Enventure’s proprietary steel metallurgies, expandable premium connections and solid or segmented expansion cones. The expansion cone is pushed axially through the tubular using hydraulic force provided from the surface. As it travels through the tubular, it radially expands and plastically deforms the tubular, with a gain of up to 20% of its inner diameter. According to Matt Meiners, Technology and Product Development, expandable tubulars have several advantages when used for the oil and gas industry. Enventure was established out of the necessity in deepwater Gulf of Mexico to alleviate the problem of frequent reductions of inner diameter due to having to set extra casing strings to manage openhole trouble zones whilst drilling. Whenever extra traditional casing string must be used, the subsequent string must be smaller, thereby creating a telescopic effect that can lead to prematurely running

out of available string sizes and compromising the well. “When using expandable liners, you can optimise the inner diameter of your casing once total depth has been reached,” Mr Meiners added. “Another disadvantage of reducing ID as extra casing strings are set is that the operator may sometimes have to lay down their conventional drilling assemblies and pick up smaller, less commonly used drilling assemblies. These actions all add risk and cost to the well design.” Enventure’s expandable liners are a comprehensively proven solution and an effective alternative to traditional casing strings. The company boasts two million feet (over 375 miles) of its tubulars installed worldwide, on behalf of over 250 drilling operators in 39 countries and nearly 2,500 installations. These installations represent “far more successful installations than any other expandable provider,” as Mr Meiners noted. Its tubulars range in size from 3½” to 16”.

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ENVENTURE GLOBAL TECHNOLOGY

Expanding into intervention solutions The majority of the company’s installations in the early 2000’s were in deepwater open-hole drilling applications, but since the mid 2010’s, the majority of its installations have been on intervention and remediation projects. Expandable tubulars have applications in cased-hole applications as well. “Expandable liners can be used to repair damaged casing and casing connections, to cover unwanted perforations or used as a mechanical diverter to improve recovery during refracturing operations,” said Mr Meiners. A widely used intervention solution offered by Enventure is its ESeal Cased-hole Patches and Liners – another of the company’s very popular solutions. ESeal has been successfully used in both existing and re-entry wells to seal off leaks and/or perforations, thus reinforcing the casing, improving the integrity of the well’s architecture, and allowing full pressure pumping capability into the reservoir. A particularly interesting, trending development that Enventure is currently involved in is cavern storage wells, for which its ESeal Liners have proven to be a winning solution in the industry. “Using an expandable liner offers a regulatory compliant and economically feasible solution when sealing the casing of a cavern well,” Mr Meiners explained. “This solution is accomplished by repairing and sealing a corroded or damaged section of casing when it occurs over the life of the well. By repairing existing storage wells with this technology,

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PROFILE

the resulting inner diameter is larger compared to conventional repairs, which then maximises the well’s throughput capacity.

Assurance vs insurance Customer perception of expandable liners has historically been a stumbling block for wider-scale adoption of Enventure’s technology. But as Mr Meiners pointed out, it’s an issue the company has been working hard to change, and their efforts are slowly paying off. “We are often viewed as a planned contingency service or a form of ‘insurance’ for drilling operations. We are called out when the client runs into problems,” he commented. “Some major operators are now using us as a planned service, or as ‘assurance’. After repeatedly fighting trouble formations well after well, with other means like cement squeezes, and getting inconsistent results, they recognise the value of investing in a reliable solution, and they plan us into their operations from the start. “Much of our competition isn’t direct competitors, but indirect competitors,” he continued. “These are mainly technologies that can be used in lieu of expandable liners. Cement squeezes, chemical diverters and ‘pump and pray’ methods are effective when they work but are sometimes unreliable. Meanwhile, more reliable, and less-traditional methods, like managed pressure drilling, are effective but far more costly.” The company is optimistic that it can continue raising awareness of the value of using expandable liners to its cus-

tomer base and growing it even further, through ongoing awareness campaigns and through constant exploration and development of new solutions using expandable tubulars.

An expanding global footprint Enventure employs around 100 people globally with its headquarters based in Houston, Texas. Its manufacturing, assembly, R&D, and machine shop are all located at its second facility in Katy, Texas. In addition to the above, its Katy facility has the ability to build, assemble and test both prototype and commercial equipment, with a capacity to safely conduct live test expansions of any size in excess of 200 ft. Beyond Texas, Enventure has assembly operations in Saudi Arabia, Canada, and Norway. Further afield, it has operational centres in Aberdeen, Dubai, and Kuala Lumpur. With such a large footprint, Enventure has been at the forefront of using video communications to meet and collaborate with internal staff and external partners. Mr Meiners highlighted the company’s recent and very successful use of video tools to connect its clients to witness development and live testing of bespoke tools and connect with third party inspections when required by the client. “Before the Covid-19 pandemic, clients would typically oversee development operations or testing in person to ensure that their purchased equipment performs as expected, will meet their installation

requirements, that the machinery has been serviced correctly and that we have all of the right industry procedures and processes in place,” he affirmed. “We’ve managed to transition to the use of video to connect the client to these processes instead. By not having to get everyone involved in this process to one physical location, it’s made the process much safer and more efficient with fewer distractions, and it’s saved clients from having to travel internationally, all while still delivering the same results.” Since the early 2000’s in particular, Enventure has racked up a number of impressive milestones. In 2007, it celebrated its first monodiameter installation, and only a year later it reached its onemillionth foot of pipe expansion. By 2014,

it had established its refracturing liners into US land-based operations. A year later, it introduced its high torque rotating liners. Between 2018 and 2019, Enventure launched its strongest expandable premium connection for refracturing applications, and it made its commercial monodiameter systems available in multiple sizes.

Awards in the pipeline In early March 2022, Enventure was awarded the prestigious API Q2: Specification 1 certification. This certification is the leading standard for oil and gas service providers and has been awarded to fewer than 200 companies. This coveted certification is only given to companies that can demonstrate robust procedures to ensure personnel com-

petency, proper risk assessment, contingency planning, and service quality. In addition, Enventure boasts an ISO 9001:2015 certification. This certification is awarded to companies that meet certain quality management system standards and which demonstrate the ability to consistently provide products and services that meet customer and regulatory requirements. In closing, Mr Meiners reflected on the company’s position in light of these awards. “They truly reflect the success of our processes, the competencies of our personnel, and our perseverance towards safe and flawless services to our customers,” he noted. “With these certifications, our customers can be assured of receiving the most outstanding solid expandable technologies.” n

Inside Industry

MANOSPACK

Inside Industry

PROFILE

Flexibility and highly focused customer service have seen Manospack grow to become one of the leading manufacturers and suppliers of folding cartons in Greece. “Together with the customer, we look at what is the most efficient and complete solution for their needs,” said CEO Thanasis Manos. Report from Colin Chinery.

ith an agility to meet the most demanding requirements while offering high-scale production capabilities, Manospack has grown to become one of the leading manufacturers and suppliers of folding cartons in Greece. “Our flexibility means we can not only meet today’s demands but also anticipate tomorrows with complete product packaging and design solutions for the food and drink industry,” said CEO Thanasis Manos. Based in the north of the country near Thessaloniki, Manospack designs and manufactures high quality cartons at competitive prices. Cosmetics, clothing, and electronic industries are other end users. The business was founded in 1976, but it was nearly 30 years later in 2004 that the rapid expansion to today’s prominence began, said Mr Manos. It was a quantum leap powered by the continuous investment in technology and human resources – typically €1 million a year since 2015 – that is now a company trademark. A pivotal point was the completion of a €3 million vertical integration programme in 2017. This gave Manospack the total in-house capacity and capability to deliver the flexibility and a customer-centric focus that distinguishes it from its multinational rivals.

Complete solutions

“Customers are used to having big lead times, and we answer this by having high stocks of raw materials in bulk. It’s a buffer every customer needs, and this is the way we work.”

Exports grow Vertical integration has also been the key for the company’s increased presence in both the local and European markets, said Mr Manos. Exports currently account for a third of an €8.5 million turnover, with Belgium and the Netherlands the major markets, followed by Germany and the Balkan countries. Powering everything is an impressive and inclusive portfolio of applications and services. “We work with the customer so we can find solution he actually needs, with a range of finishing characteristics; innovative cartons that are essential for product differentiation,” stated Mr Manos.

“We are a true one stop shop,” detailed Mr Manos. “Nothing is outsourced, and together with the customer we look at what is the most efficient and complete solution for their needs.” Across the packaging industry, 2021 has seen rising raw material costs and massive availability issues. “At the same time, the market is growing, and we have the resources to meet this,” commented Mr Manos. And in a competitive domestic market where multinationals are its rivals, flexibility is the ace in Manospack’s hand. “The multinational companies are not very flexible, with different production facilities all around Europe. But with us, the customer can find everything under one roof, giving us a flexibility that is the direct result of vertical integration. “For example, given the market upheaval we are going through, it is very important that the company has all the production in its hands and can make everything easier and straightforward for the customer. Inside Industry

MANOSPACK

PROFILE

High quality five colour offset printing and advanced finishing techniques with inline acrylic varnish, UV, plastic film lamination, embossing and hot foil printing, are readily obtainable at Manospack. Cartons suitable for direct contact with frozen or non-frozen-food are sourced from around the world with special extrusions, polyethylene, polyethylene terephthalate (a form of polyester) and aluminium.

Great offset printing With ovenable and microwaveable paper trays widely used by frozen meals and a lucrative fast-food market, Manospack delivers the advantages of this type of packaging with great offset printing results in three-ply clay coated cartons with custom made inside extrusions. Manospack also manufactures paper trays up to 75mm deep on substances such as virgin fibre board, recycled carton, and corrugated board, serving specific customer needs for crispy baking, seal ability, production efficiency, packaging functionality and promotion. Packaging for the beverage industry is crucial for promoting and differentiating among similar beverages and spirits.

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“We provide our customers with various varnish coating combinations offering cost effective quality packaging,” asserted Mr Manos. “We offer a special window patching application, pick and place, that along with hot foil and embossing techniques, creates an eye catching and innovative carton.”

Visual appeal Mr Manos continued: “Visual appeal is a main factor in packaging. Customers spend on competitive designs which we develop for them with structures and shapes, while following the advertising company’s design instructions.” Display stands are an advertising and merchandising tool with a direct impact on product sales, and here Manospack provides market specific solutions to create and produce an innovative and attention-grabbing display. “We communicate and cooperate with our customers to provide them solutions and a combination of materials including carton board, corrugate board, PVC and corrugated plastic. “Our large size printing format and converting ability allows us to develop a cost effective and functional display carton, by

Sustainably – a top priority Sustainability, and carbon reduction, form an integral part of the Manospack strategy, improving operational performance and reducing potentially harmful emissions. Supplier locations are already short-distanced, with wood and paper sourced from forests with the highest environmental and social standards, and the company became only the second in Greece to be awarded FSC (Forest Stewardship Council) certification. “Certification was a pioneering decision we took. We are able to provide customers with this certification when requested. Pricing is the same both for FSC and non-FSC, and that’s another advantage for the customer,” underlined Mr Manos. “Customers, and especially their buyers, such as Marks and Spencer for example, are becoming increasingly demanding on

C buying packages that are FSC o s, an M s certified, and we are seeing si it being requested more and more. “Customers are also becoming more sensitive regarding the weight of waste, and more positive and receptive towards new packaging solutions that use less paper.” Waste elimination is a feature of the company’s €7 million investment programme scheduled to come online next year, that will see a 70% spend on new machinery and 30% on new manufacturing floor space. “Looking ahead this is set to double our turnover, with the same number of staff, and increase our market presence against multinational competition,” revealed Mr Manos. “And this will be achieved by what Manospack actually sells – flexibility and service. n Th an a

combining most of our advanced finishing techniques such as UV lacquer, hot foil printing or embossing.” Functionality, cost-effectiveness, compatibility of the packaging with the contemporary packaging methods and techniques, are all taken into account before Manospack provides a new packaging proposal, said Mr Manos. “Cartons must stand out on the shelf, but it is also very important for the product to be functional and stay as long as possible in a customer’s hands, so we continuously research and develop ways to develop cartons that have increased sustainability.”

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SAMSON MATERIALS HANDLING

PROFILE

SAMSON Materials Handling Ltd designs and manufactures an extensive range of mobile loading and unloading systems for handling bulk materials in various applications globally. Petar Karaivanov, Marketing & Communication Manager, related the company’s history, strengths and future plans to Phil Nicholls. 56

Inside Industry

gantry with a variable angle decline conveyor which formed the basis of the Samson Material Feeder, featuring an intake hopper that received the crop directly from the farm’s tipping trailers. In turn, this fed to the link conveyors and along to a radial boom elevator which was later developed into the Stormajor. Through the 1980s, the company diversified extensively into the current range of industries. A fully mobile shiploader was built for the Kings Lynn port, featuring twin feeder conveyors which could receive cereals from two trucks simultaneously. B&W diversified into multiple industrial sectors including agriculture, mining, metallurgy, cement and power. The company developed solutions to effectively handle a huge variety of materials for different applications worldwide. In 2002, B&W Mechanical Handling Ltd was acquired by the AUMUND Group, a German-based machinery and equipment specialist. This union gave AUMUND access to complementary technologies and products, along with greatly expanding B&W’s global reach. In 2013, B&W Mechanical Handling Ltd rebranded as SAMSON Materials Handling Ltd, named after the iconic Samson material feeder that launched the company’s success.

Local materials

AMSON Materials Handling grew from the rich fields of the Fens in East Anglia in the UK to reaching out into multiple industries around the world. The company began in 1966 when Tom Brown and Raymond Woodbine formed a partnership called B&W Engineering. Initially repairing agricultural machinery,

the partners spotted a gap in the market and applied their engineering skills to build a Potato Bulker, featuring a belt discharge system. Registering as a limited company in 1975, Tom and Ray rebranded as B&W Mechanical Handling Ltd. Further development in collaboration with a local farmer in 1976 lead to an overhead

Even as a global company, SAMSON Materials Handling Ltd has a strong sense of its origins. “While we strive to be a global company,” explained Petar Karaivanov, Marketing and Communication Manager, “it’s extremely important to have a local presence and local footprint.” SAMSON’s headquarters are in Ely, in Cambridgeshire, still in the heart of the Fens where its story began. The company has about 30 employees designing and producing an extensive portfolio of machinery. Since its beginning, SAMSON has sold over 700 material feeders, over 100 Stormajor units, ,140 shiploaders and more than 50 eco hoppers. Mr Karaivanov explained how the small team at SAMSON works closely with the Inside Industry

SAMSON MATERIALS HANDLING

PROFILE

customer: “We liaise with our clients to understand their specific needs, offering our own extensive knowledge and experience in bulk materials handling to ensure we accommodate their requirements both technically and commercially. “Our equipment is tailor-made to match the clients demands for functionality and where they want to deploy the machine. Also, we are dedicated to providing the most comprehensive range of mobile solutions for bulk materials handling in several industries including ports and terminals, mining, cement, foodstuffs, as well as agriculture and power.” Mr Karaivanov is clear on the benefits of working within the small, dedicated team at SAMSON: “The team is great, with lots of positive energy. Everyone’s extremely keen on improving the business; you can definitely sense the very positive and high standard of energy in the office.” Alongside the provision of bespoke machinery to customers, SAMSON offers

Inside Industry

an after-sales service running 24/7, with the support of field services. This is another aspect of SAMSON’s dedication towards customers. “We maintain a solid relationship with clients,” said Mr Karaivanov. “Each of our Sales Managers is a specialist in their field, and at the end of the day, they are people’s people, because they’re salespeople, so they form strong connections. It’s not only a sales relationship, but also a personal relationship. “We focus on our customers technical and commercial needs, providing high quality and reliable solutions that give our customers peace of mind. Those customers who experience this go from ‘new customer’ to a ‘returning customer’, which is an important aspect of our business in both the capital and after-sales arena.”

The strength of Samson The Samson Material Feeder that gave its name to the company remains SAMSON’s most popular machine, especially for use

in ports when combined with the company’s shiploaders. “Our machines are really specialised in delivering flexibility,” Mr Karaivanov explained. “Operating on different quay layouts, narrow or wide, the shiploader delivers independent performance. What highlights our shiploader’s flexibility is its mobility. The equipment can be stored away from the quayside, until it is needed for operation. This means the quayside can be kept clear, free from obstruction to allow other operations to take place on the same quay space. “The shiploader has state-of-the-art mobility options included, which improves the machine’s manoeuvrability, thereby reducing the overall loading times of a vessel.” This increase in performance is due to a fully mobile chassis with different design options to match every type of vessel from barges to Post-Panamax size. Loading reaches up to 3,000 tonnes per hour, depending on the material being handled.

As a company with engineering expertise at its heart, SAMSON is especially proud of the Eco Hopper. “The fundamentals of flexibility, adaptability and lower environmental impact apply to the Eco Hopper as well,” Mr Karaivanov said. The Eco Hopper is an ecologically sensitive solution for the efficient import of dry bulk cargoes. The hoppers are designed to accommodate the characteristics and flow properties of virtually any bulk material. Rates of up to 5,000 tonnes per hour may be achieved, subject to grab crane performance. SAMSON is also equipped to deal with larger projects, such as the recent refit of the Hanson cement capital works plant in nearby Leicestershire, UK. “The scope of the project was substantial,” Mr Karaivanov explained. “We helped Hanson replace the complete chain, lower rollers, drive units and a full set of trails.”

engineering teams, including the group’s focus on innovation.” The Stormajor opens up new possibilities for stockpiling, barge loading and rail car loading. As well as featuring a radial outloading boom on a single chassis, it has the unique benefit of total mobility, providing universal applications and ultra-high performance. It has the flexibility to receive a wide range of materials directly from tipping trucks, shovels, articulated dump trucks or even crane grabs. The upgrade to the SAMSON Stormajor won the 2021 Project of the Year Award from the Materials Handling Engineering Association. At the same MHEA event, the Harold Wright Award was given to Barry Woodbine, co-founder of B&W Engineering and current consultant at SAMSON.

An eco-paper A storm of awards The SAMSON Stormajor, which featured in the development of the company, has recently been upgraded to a new version. “Together with AUMUND Group we engineered a Stormajor 2.0, which is a more robust machine, offering up-to-date technology and the ability to handle more material. This is something SAMSON and AUMUND are proud of as it highlights the engineering capabilities and vision of our

As a company with deep roots in an agricultural setting, SAMSON has a strong sense of environmental responsibility. A member of the Port Equipment Manufacturers Association (PEMA), SAMSON was invited to share its expertise by leading the writing of the paper Dry Bulk Cargoes and the Impact on Air Pollution in Ports. This paper was led by Dan Birkett, SAMSON Materials Handling Sales Manager for Asia, Middle East, and Southern Africa.

The PEMA paper explored the issues associated with the handling of dry bulk materials in port environments in terms of the pollution generated and what technologies and solutions are available to port operators to improve the situation. “In order to make sure that we provide sustainability for the client,” said Mr Karaivanov, “we have a research and development team that constantly reviews project specifications and tries to tailor our equipment to be even more effective in various industries for different clients.” The sheer flexibility of SAMSON machines allows customers to save on capital costs and maximise the efficiency of their operations. As a global company, SAMSON has been impacted by supply issues, especially during the Covid-19 pandemic, confirmed Mr Karaivanov. “We observe global phenomenon such as the current problems with the global supply chain. Sometimes, yes, issues arise, but thankfully, nothing too major has happened to us as our team always manages to solve any problem.” The future looks promising at SAMSON Materials Handling. Mr Karaivanov sees “the prospect of continuous growth, because SAMSON is such an innovative company. We began in the Fens serving potato growers and now we work with diamond mines, and everything in between.” n

Inside Industry

FRAGOL

PROFILE

FRAGOL AG is a specialist supplier of heat transfer fluids, high quality compressor and vacuum pump oils, and lubricants for the food industry celebrating its 60-year anniversary in 2022. Iris Zerfass, CEO, outlined her business principles to Jordan Yallop and Phil Nicholls. 60

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erman oils and lubricants company FRAGOL blends a strong sense of ethics into its business model. Owned and run by a family with a long-term interest in the firm, paired with personal morality and a published code of conduct have created a friendly and principled company. The 60-year history of FRAGOL began in 1962 with the establishment of the company Brenntag Kraft und Schmierstoff, a joint venture between Brenntag and Total. Dr Heiner Mueske was appointed Managing Director in 1985 and conducted a management buyout in 2004, by which time the company name had changed to FRAGOL Schmierstoff. Further changes followed, culminating in adopting the name FRAGOL AG in 2017. In 2020, Dr Mueske retired from the board of FRAGOL, but remains closely associated with the company as a strategic advisor. Iris Zerfass, who joined the FRAGOL management team in 2014, took the role of CEO in the family company. FRAGOL is based in Mülheim an der Ruhr in western Germany with 30 employees. Growth is steady at FRAGOL, with sales figures increasing consistently over the past few years. Driving this growth are the broad range of fluids and lubricants at FRAGOL. Ms Zerfass was clear about FRAGOL’s best-selling line: “It’s the H1 lubricants, which are used in the foodstuff production.” All FRAGOL H1 lubricants are manufactured according to DIN ISO 21469, meaning that these oils are safe for incidental contact with food products. Alongside the stringent manufacturing requirements necessary to achieve the safety certification, FRAGOL sought religious approval of its products. “Our H1 lubricants are kosher and halal certified,” Ms Zerfass explained. “This is very important, especially for Asia and North

Africa, so these lubricants can be used for both kosher and halal food production. We actually have a rabbi and an imam coming into the factory and auditing our production before issuing a certificate.”

FRAGOL rocks oil The FRAGOL portfolio consists of a broad range of products. Its synthetic lubricants are suited to specialised applications including hydraulics, gears, compressors and vacuum pumps. The lubricants are applied to those areas of the machine under increased stress due to the demanding operating conditions. The portfolio of heat transfer fluids at FRAGOL is the largest in Europe. The company has a specialised team of engineers and chemists presiding over a range of 60 different fluids. As well as its own FRAGOLTHERM® brand products, FRAGOL also has other high-quality fluids from renowned manufacturers. Heat transfer with thermal oils is part of many industrial processes, or simply for heat recovery. FRAGOL products cope with temperatures ranging from -115°C to 430°C. Raw materials used include aromatic compounds, HT oils, mineral oils, silicone oils and polyglycols. FRAGOL offers an analysis service to clients for heat transfer fluids, helping the customer understand the condition of the fluid and making recommendations for future action. In its industrial lubricants business unit FRAGOL offer customers more bespoke options beyond the standard portfolio. The ‘Tailor-Made Products’ service is available for special applications not covered by the standard range of products. Here, FRAGOL partners with the customer to develop bespoke solutions for a specific problem. Another special option is the Private Label Service, where FRAGOL offers to supply items from its full range of high-quality products but Inside Industry

Inside Industry

FRAGOL

PROFILE

Iris Zerfass, Fragol CEO

labelled and marketed under the private label of the customer. These fluids are blended to the usual FRAGOL standard, with next-generation base oils and additives from its constantly expanding portfolio.

Friendly and agile Despite the vast range of products available from FRAGOL, the company remains small and agile in the market. Ms Zerfass sees this as a clear advantage. “If the customer is not happy with one product, but another one works for them, then we can sell that. I don’t have to worry about filling my production quotas because we work with small blenders. We have no issue with making less of product A to create more of product B. We’re really flexible.” The small working atmosphere at FRAGOL is another distinctive feature. “We’re a very friendly company because FRAGOL is family owned,” explained Ms Zerfass. The friendliness within the company is supported by the official Code of Conduct. The code supports FRAGOL’s corporate values and supports the team in their daily work. FRAGOL’s friendly team are excited to return to trade fairs this year, particularly ACHEMA which had previously been cancelled due to the pandemic. ACHEMA is the world’s leading trade fair for 64

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the process industries, held in Frankfurt am Main in August. FRAGOL plans to take a booth at the fair but faces a new set of decisions as business adjusts to a post-Covid world. “We are discussing whether we wear masks in the booth or not,” Ms Zerfass said. “Because if we do, then people can’t see our faces. However, if we don’t wear masks, then people might not feel safe to come into our booth. It’s all these little things that we never had to think about before.”

FRAGOLTHERM innovation Innovation is a key aspect of FRAGOL’s business model. A seven-member team of engineers focuses on heat transfer fluids, pushing forward R&D within the company and advising clients on the latest developments in the field. By deploying this expertise, FRAGOL ensures that customers use the best solution available for their applications. One recent solution was the FRAGOL-lead replacement of cooling fluids with environmentally friendly alternatives. A technical consultation with the customer lead to the replacement of a system using approximately 20 cbm of diethylbenzene-based cooling fluid with the more environment-friendly FRAGOLTHERM F-12. The FRAGOLTHERM F-12 is a synthetic heat transfer fluid that can be used in a temperature range between -85°C and 230°C. The drive towards sustainability is a strategic focus at FRAGOL. Expert advice from FRAGOL ensures clients use products perfectly suited to the application, resulting in a longer working life for the fluids, thereby reducing consumption. “We try as a business to make our office climate neutral,” Ms Zerfass explained, “But more importantly, we try to build an ecofriendly and non-toxic product line. We invest heavily in R&D for products with sustainable applications.” The growing awareness of sustainable issues within the industry can be seen in the shift in customer enquiries at FRAGOL. “For example, heat recovery is always quite interesting, because when the cost of energy is low, nobody’s interested in heat recovery,” Ms Zerfass said. “Now, of course, everybody’s very interested again in heat recovery applications.” FRAGOL has a close relationship with key blending and warehousing partners who are instrumental to ongoing production. Ms Zerfass emphasised that FRAGOL’s reliability as a supplier during difficult times within the supply chain was a keystone of building a long-term relationship with business partners. “We were always able to supply,” she said, “And that is something I tell my people and my customers; that this is unique: we were always able to supply what is a very specific product. We believe it’s important that both parties have a win, and it’s only if both parties are healthy businesses, that we can work together long-term.” Recent issues with the global supply chain have been a challenge for FRAGOL. The company works hard to overcome problems with sourcing raw materials. Yet, FRAGOL has weathered these issues. “We have a very stable business,” concluded Ms Zerfass. “We have sustainable growth; it’s important for a business to be sustainable, not only environmentally, but by building slowly, carefully and reasonably. “Our strategy is to focus on what we are best at, which is developing the best product and delivering the best solutions for our customers’ applications.” n Inside Industry

STADLER

PROFILE

Swiss company, Stadler, has built rail vehicle construction solutions for 80 years. Ralf Warwel, Sales Director, related the journey to Phil Nicholls.

he Stadler story began in 1942, when Ernst Stadler founded the Ingenieurbüro Stadler engineering office in Zurich. The company began producing battery- and diesel-powered locomotives in 1945. 31 years later, in 1976, the business changed its name to Stadler Fahrzeuge AG on becoming a public limited company. It went public, with its shares listed on the SIX Swiss Exchange for the first time in 2019. By 1984, Stadler produced its first passenger vehicle, while its core business was custom manufacturing for Swiss private railway companies. In 1989, the chairman of the board of directors and acting CEO, Peter Spuhler, bought the small Stadler company, consisting of only 18 employees. Peter laid the foundations for the company expansion with the successful development of Stadler’s first modular rail vehicle. In the years that followed, Stadler grew steadily, establishing partnerships and subsidiaries across Europe. Stadler maintains its headquarters in Bussnang in eastern Switzerland. Today, it has a workforce of more than 13,000 at its various production and engineering facilities in Europe and beyond. It also provides after-sales service in more than 70 locations around the world. 66

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2021 was a successful year for Stadler with record annual orders worth CHF 5.6 billion (approximately €5.4 million) up 28% on 2020. Despite a “tense supply chain situation” Stadler revenues increased by 18% to CHF 3.6 billion (€3.5 billion) and delivered group profits of CHF 134.5 million (€129 million). Ralf Warwel, Sales Director, summed up the appeal of Stadler’s product lines: “Stadler trains are economical, rely on state-of-theart technology, and ensure maximum comfort for passengers. We produce high-speed and intercity trains, suburban and regional transport trains, light rail vehicles and trams offer ground-breaking performance, reliability and safety. “Our product portfolio includes modular vehicle concepts, tailormade vehicles and a full range of signalling solutions and services, worldwide, around the clock.” Ralf pointed out that Stadler also provides an after-sales package to clients: “Most of our rolling stock projects are supported by a service/maintenance contract, many lasting 35 years.” Ralf discussed Stadler’s best-selling train, the FLIRT, which stands for Fast Light Intercity and Regional Train. Alongside this product, Stadler’s regional train line includes the double-decker

Inside Industry

STADLER

PROFILE

KISS and the WINK, a low-floor, convertible, innovative short train for local transport. Stadler produces the FLIRT 200, a high-speed version with a maximum speed of 200 km/h. However, its mainstay is the FLIRT 160, with a maximum speed of 160 km/h. This single-decker regional train was launched in 2004 and has sold 2,000 units in 21 countries. The FLIRT operates in a range of climates, from Africa to the Arctic Circle. Ralf noted the appeal to clients of the highly customisable FLIRT package: “They can be easily adapted to battery technology, which can be accommodated in a separated power-pack or distributed underfloor and on the roof. The typical Stadler power-pack is an intermediate module that can be inserted between two cars to accommodate a range of different energy sources. This way, the FLIRT can also be powered by electric, diesel or hybrid, as well as by using batteries and hydrogen. Its lightweight construction is made of aluminium, and features maintenance-friendly devices and components to keep operating, energy, and maintenance costs low.”

Signalling the future Stadler has many projects underway at any one time. Ralf referred to the recent acquisition of the German signalling specialist company BBR Verkehrstechnik GmbH as a project which best illustrates Stadler’s capabilities. This addition will enhance its position as a provider of state-of-the-art signalling solutions to drive forward and shape the digitalisation of the rail industry. Before this acquisition, Stadler’s focus for signalling activities had been the on-board equipment of rail-bound vehicles. The company had already strengthened its position in this area with the acquisition of the Swiss company Bär Bahnsicherung AG in November 2021. At the beginning of this year, Stadler created a new division for its entire signalling portfolio. BBR brings infrastructure-related solutions such as electronic interlockings, train detection systems and points operating equipment to Stadler. Existing BBR product lines also include on-board equipment for rolling stock manufacturers and development work, particularly in the areas of interlockings, train protection and component retrofits. BBR employs around 270 people at its headquarters in Braunschweig, central Germany, and at its factory in Vufflens-laVille near Lausanne in western Switzerland, which will be maintained by Stadler. Now, more than 500 people work within Stadler’s signalling division. The acquisitions of BBR and Bär Bahnsicherung demonstrate Stadler’s ambitions in the field of signalling, strengthening its portfolio with another strategic pillar. Rail digitalisation promotes sustainable mobility, supporting 2050 climate targets. The new signalling portfolio enables Stadler to actively shape the digitalisation of the rail industry, positioning it at the forefront of innovation within this field.

Investing in people Ralf was very clear about what sets Stadler apart from the competition: “Stadler prides itself on its attention to detail, customer-focused approach, innovation, and the value for money our products represent. Above all, we are proud of our ability to listen, ensuring that clients receive the vehicles and services that exactly meet their requirements.” 68

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As well as close partnerships with clients, Stadler has a similar collaborative approach with suppliers. “Stadler invests in its relationships with suppliers and works hard to build long-lasting links with them,” Ralf explained. “The nature of our work means that we can be working with a particular supplier on a certain project for several years, so it makes sense for everyone – not least our clients – that these relationships are highly effective.”

Green rail The trend within the rail industry towards sustainability is clear to Ralf: “As the demand for more environmentally-friendly products goes up, and in light of more stringent carbon emission targets, Stadler is committed to working with clients to de-carbonise rail networks around the world. With a keen focus on innovation, we aim to go beyond regulatory requirements, ensuring that our products have the lowest carbon footprint that today’s green technology allows. “Stadler has a two-pronged approach to de-carbonising the railway. First, we make electric trains more attractive and efficient, and second, we develop efficient solutions for railways that are not electrified yet.” An example alternate solution is the hydrogen-powered FLIRT H2 sold to the San Bernardino County Transportation Authority (SBCTA) in southern California. The FLIRT H2 can operate at up to 130km/h with 108 seated passengers. The trains are scheduled for delivery in 2024 to run on the Redlands Passenger Rail Project, a nine-mile connector between Redlands and San Bernardino’s Metrolink station.

“Electrification is still the greenest way of operating a railway,” Ralf said. “However for lines with low patronage, it makes economic sense to operate battery trains or trains with other types of energy storage.” Stadler has sold over 300 battery trains to nine different countries. In December last year, Stadler set a new world record with its FLIRT Akku, which travelled more than 220km in battery-only mode, the longest distance on record and covered in the Guinness World Records book. “Battery trains produce lower carbon emissions than diesel trains,” Ralf continued, “They are more energy efficient and provide a very attractive alternative to diesel. Battery power enables the operator to run trains on an extended network and offer a fantastic solution for non-electrified lines, avoiding costly infrastructure upgrades for transport organisations and governments.”

Like all international organisations, Stadler is influenced by global events. “The pandemic affected businesses and institutions in every country,” said Ralf, “and segued into the current volatile geopolitical situation. Stadler is trying hard to mitigate some of the global supply chain problems, finding workarounds where possible and working closely with clients to achieve this.” Ralf concluded by offering a positive outlook on the company’s future: “At Stadler, we maintain close relationships with both suppliers and clients, and have a policy of openness and transparency. Nearly all of our customers are regular or repeat customers, indicating the effective, trustworthy and durable nature of Stadler’s relationships. “Stadler wants to maintain its position to provide sustainable rolling stock solutions, enabling our customers to decarbonise the railway and achieve their climate targets.” n Inside Industry

NESTRO LUFTTECHNIK

PROFILE

NESTRO Lufttechnik GmbH has specialised in extraction and filter systems for the past 45 years. Till Uhle, Director Marketing and Sales, shared details of the company’s innovative range with Phil Nicholls. 70

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one of the first suppliers in the field of filter technology for the wood industry, NESTRO Lufttechnik GmbH was an early developer of clean air systems. NESTRO technology features the fan located downstream of the filter and thus only charged with clean gas. This arrangement increases fan energy efficiency by up to 30%. The story of NESTRO began in 1977, founded by Paulus Nettelnstroth, with the first production facility opened in 1978 at Kirch-Brombach in Hesse, central Germany. In 1980, NESTRO relocated to Röllbach in Bavaria, where it developed reverse air filter technology with additional flushing air fans, enabling highly efficient, energy-saving cleaning of filter bags. During the 1990s, NESTRO was a pioneer in the Eastern European markets, building a strong sales network in a relatively short period. In 1993, the company finally inaugurated its production and office building

on a 44,000 sqm site at its current headquarters in Schkölen, Thuringia. NESTRO today has three production sites, located in Germany, Poland, and Hungary with 300 employees in total. Each site focuses on a strategically defined sub-set of NESTRO’s range, typically with an output tailored to the respective national market. The NESTRO Group posted impressive sales of over €40 million last year, with customers across five continents and in many different industries. Till Uhle, Director Marketing & Sales, outlined the broad appeal of NESTRO products: “Our solutions are needed wherever dust, chips, cuttings, punching waste, smoke or paint mist are produced during material treatment or processing, and wherever material can be separated using air flow, such as in the waste disposal and recycling industry.” Mr Uhle was keen to maintain customer confidentiality with regards to current projects but remained clear about the reasons behind the steady growth.

“We serve small and large customers alike,” he said. “NESTRO has small sales orders and large project businesses. This broad positioning in many sectors and in many international markets makes us significantly less dependent on market fluctuations than some of the other market players. “We are currently experiencing a crossindustry boom in orders, despite significantly higher prices, arising from a necessary surcharge due to the situation in the supply market. Even price-adjusted, the first quarter of 2022 showed the highest order intake in the company’s history.” The USP of NESTRO products is clear to Mr Uhle: “Setting up, standing and maintenance times, energy efficiency or recycling rates/qualities are all increasingly becoming matters for the focus of managerial attention. NESTRO provides personal support for customers to face-up to these new challenges in providing optimum working conditions.

Inside Industry

NESTRO LUFTTECHNIK

PROFILE

“Our systems extract material that is hazardous to health or process-impairing in an energy-efficient manner and thus help clients implement perfect quality air with reduced downtimes. NESTRO systems also convey, shred, separate, store or compact the residual material according to the requests of our customers.”

Deduster upgrades Innovation continues to drive NESTRO’s performance. Back in 2014, NESTRO launched the first deduster with an air volume of over 7,000 cbm/h approved for indoor installation. Now in 2022, development of this technology has led to a range of dedusters equipped with IE5 synchronous reluctance motors and matching frequency converters. IE5 packages can save operators up to 22% of the energy costs compared to those using IE3 motors. Mr Uhle shared the features of the next generation dedusters: “The development of the mobile NESTRO deduster series type NE J for indoor installation in the established performance classes is based on the company’s decades of experience in woodworking, in device technology and in the construction of high-efficiency fans. “The use of clean air dedusters for material extraction is perfect for small and medium-sized companies from many different industries, and always worthwhile for cost reasons.” 72

Inside Industry

NE J dedusters offer multiple savings for customers. Short pipeline routes reduce investment costs and ensure overall low line resistances. The mobile plug-and-play nature of the NE J range that only requires power, a compressedair connection and junction of the pipeline further reduces installation costs. The frequency controlled IE5 reluctance motor achieves an operating efficiency above 90% and thereby reduces running costs. The filter material guarantees a residual dust content of < 0.1 mg/m³ with the return air; cleaner than outdoor air. As the deduster circulates air without heat loss, customers can significantly reduce heating costs. The addition of an intelligent, certified automatic fire extinguishing system without the use of water or dry chemicals cuts the NE J’s maintenance costs.

Cutting edge investments Development at NESTRO, confirmed Mr Uhle, is an ongoing process. “NESTRO is constantly investing in buildings and machines at all three locations,” he explained. “Last year, for example, a new cutting / shearing / bending system from Prima Power was put into operation in Germany connected to the automatic high rack stocking area. This has given us clear advantages in terms of productivity, economy, precision, and flexibility. “An automatic loading unit for the supply of raw sheet metal as well as

a system-integrated load/batch robot between the cutting/shearing segment and the bending segment guarantee automatic, multi-shift operations if required. Now for the first-time metal sheets with a length of up to 4 m can now be tooled.” Additionally, pre-cut parts with a length of up to 3m can be bent in a highly adaptive manner. The bending segment can carry out positive as well as negative bends, even with complicated geometry, without turning the sheet while the tools are automatically adapted to part and material. With much less manual work, it is now possible to produce very demanding parts – using a manufacturing specific design – which leads to significant cost savings in the downstream working process.” Competition in the field is strong, but Mr Uhle is confident of NESTRO’s position. “Our employees, our distributors and our specialist retail partners are all excellently established on the market and have a lot of experience and extensive knowhow in air technology. We not only offer a product, but always a systemic solution, possibly with extensive government funding opportunities, to completely satisfy each customer.” The route to a satisfied client begins with NESTRO’s relationships with suppliers. “In these difficult times,” Mr Uhle explained, “our long-standing supplier relationships are crucial to being able to survive

on the market. Quality has always been an important factor for us here. “Now our partners are helping us, especially in the current critical areas of delivery capability and reliability. I think each of your readers knows how challenging these two issues are today, which had otherwise always been taken for granted. These solid partnerships with our suppliers are the key factor for every project in 2022. Conversely, our suppliers can also rely on us as customers.”

Sustainable growth Moving into 2022, Mr Uhle identified two main trends: energy efficiency and intelligent control technology. He explained: “In several countries there are subsidy programs for replacing old, more energy-intensive system technology with new ones. For this, energy efficiency criteria must be met. We believe that these requirements will become even more stringent due to climate change.” In 2020, NESTRO received the REC Sustainability Award. “Our group of companies has positioned itself completely sustainably,” Mr Uhle said. “NESTRO generates its own electricity at two locations

“The use of clean air dedusters for material extraction is perfect for small and medium-sized companies from many different industries, and always worthwhile for cost reasons” using polycrystalline photovoltaic modules with a total output of 530 kWp. We also generate heat at all three locations. “At NESTRO, we believe that filter and extraction technology is a sustainably growing business, as the requirements for clean air in production facilities are becoming more demanding, and not just because of occupational health and safety laws.” Yet, challenges remain for NESTRO. Supply bottlenecks – especially of electrotechnical vendor parts – have impacted production and delivery times. The rural locations of NESTRO plants exacerbate the

growing challenge of employing skilled workers, as young people are drawn to metropolitan areas. Despite these challenges, Mr Uhle maintained a positive mindset: “We want to continue to grow internationally and defend our consulting leadership in the market. To this end, NESTRO will continue to expand production in terms of space and technology at all our locations in the upcoming years. We are continuously revising our product portfolio to be able to offer customers simple, comprehensive, and energy-efficient system solutions.” NESTRO’s team spirit carrying it into the future is evident to Mr Uhle: “It is of course great to accompany NESTRO with its motivated team on a sustainable growth course and to permanently establish it on the market as a high-quality supplier. In addition, it is absolutely satisfying to work for a company whose products ensure a cleaner and therefore more liveable environment.” He concluded: “The flat hierarchies in our family business facilitate exchange and enable quick decisions. It is said that the fast eat up the slow: we’ll keep our appetites.” n

Inside Industry

DEBOTECH

PROFILE

Composites and A pioneering company manufacturing carbon fibre and composite parts, deBotech has over 20 years’ experience in delivering advanced solutions to industry leaders, sportspeople, and specialist applications. Utilising advanced manufacturing techniques and a state-of-the-art production facility, deBotech is poised to continue its meteoric rises in this sector. Jordan Yallop caught up with CEO Hans deBot, or ‘Carbon Hans’ as he’s known by his peers. 74

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the late 1990s, Hans deBot would spend many nights in his small garage, toiling away until the early hours manufacturing and finessing carbon fiber components and refining his ambitions. Today from his office in Mooresville, North Carolina, Mr deBot, CEO of deBotech remains exceptionally humble about a career that has quite literally flashed before his eyes. Those ambitions, he admits, have paid him back big time. At the core of these life-changing moments, with his beloved wife, Jamye, together with his daughter and son by his side, is carbon fibre, whether as components for NASCAR teams or providing for such industries as aerospace, aviation, maritime, and the military.

Land, sea, and air

The demand for deBotech’s expertise is simple: the desire for a lighter material compared to traditional heavier ones for all kinds of applications. Carbon fibre is king whether it be for land, sea, or air. More than 20 years back, Hans deBot worked for a sailboat mast manufacturer in Charlotte, North Carolina. During this time, the company, which mainly used aluminium to build sailboat spars, began a carbon fibre division. “The company brought someone in, and he failed. So, I was asked to have a shot at it and I helped develop a process to build a one-piece continuous fibre hollow sailboat spar for Americas Cup boats and race boats all over the world,” recalled Mr deBot.

Having anchored his expertise, and running the company’s engineering division, Mr deBot generated interest from NASCAR racing teams in his local area of Mooresville – Race City USA – to build carbon fibre parts for their vehicles. It was in the offcuts or scraps generated from the carbon fibre during his daytime job, that he spotted an opportunity to reuse for other applications and race car parts. So in 1998, deBotech was formed. “My old employers thought it was a good idea, but two weeks later, the owners split, and that interest died. So, I decided to do it on my own. I worked in the day job till 9pm and worked diligently in the garage of my house till the early hours, developing carbon fibre parts for racing cars,” he affirmed. Mr deBot said his side business kept growing, still predominantly within automotive until he was challenged to build a bobsled for one of the US teams for the Salt Lake City Olympics in 2002. “I’d never built a bobsled in my life, but it was a new challenge. I built a bobsled and made it to Salt Lake City. The Technical Director from USA bobsled, Bob Cuneo, called and said: ‘Hans, that’s a work of art, let’s get working with you.’” Since that day, Mr deBot has worked with the US bobsled team, even seeing the team claim the gold medal in 2010. He has been building the full bobsleds and skeletons since 2012.

Inside Industry

DEBOTECH

PROFILE

On the automotive side, deBotech has been heavily involved with General Motors since 2014 and produces carbon fibre components for its vehicles. On the 2019 ZR1, deBotech built the majority of the carbon fibre products and is now working on the new mid-engine C8 Corvette, and other multi-level products for future Corvette models. “Our state-of-the-art production facility and advanced manufacturing techniques ensure each part we produce is held to aerospace tolerances,” asserted Mr deBot. “We utilise a total systems approach, encompassing design support through production to ensure customers are satisfied.” He added: “We are currently in expansion mode and want to ramp back up to not only two full production shifts, but a third. It is an open invitation to anyone in the UK and Europe who wants a great career to look us up and consider coming out here.” Such is the demand for deBotech’s products that 75% of output is dedicated to automotive.

Untapped potential Mr deBot pinpointed one challenge in general that is potentially stopping the sector from showing its true potential: skilled manpower. “Finding self-motivated, self-driven and focused individuals is becoming 76

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more difficult,” he said. “We have 12 million unemployed in the USA, but deBotech has difficulty finding 75 people who want a rewarding career and to help us expand further.” He added: “The automotive OEM world is very challenging, but we have the rigours, resilience, and tenacity to succeed. What sets us apart is the level of technology and to build better, provide the best customer service, and enjoy the journey. That’s why we have close relationships and support suppliers and clients alike. Ultimately, we are committed to being the number-one carbon fibre and advanced composite parts manufacturer in the world. “This industry has one of the greatest potential growths wrapped around smart vehicles, energy, conservation, safety: all these avenues carbon fibre has input into.” Mr deBot explained that automation is being used for certain aspects of the manufacturing process currently. “We’ve introduced quite a bit of automation in one of the stages, which is preparation for coatings and paint; we have a lot of automation associated with any bonded components. When you are bonding any structures together, it’s all done with automation robots. “That’s the one thing about unique building, they’re still artistic and style prod-

A composite business Mr deBot revealed the company was currently engaged in research work for an American doctor working in the UAE to develop a donor heart transport unit. But the medical applications for the company’s products is not limited to humans. “We’re also working with a vet, Bill Bickley, of PALS, from Texas, who approached us wanting to make carbon fibre prosthetic limbs for dogs. I looked at the product, believed in it, and we undertook the R&D ourselves and got to a level where it now works. There’s nothing like seeing the joy in an owner’s face or the happiness in the dog giving them their mobility back. It is truly inspirational.”

He added: “Carbon is growing in levels of excitement and energy conservation all over the world. People want to build lighter cars, but in motor racing, vehicle weight has always been critical.” Growth and volume have continued a substantial upward trajectory for the company, while expertise and technology have combined to build parts better, lighter and more complex. It is the experience of the company that sets itself apart from the competition and Mr deBot is of the firm opinion that this is not an industry anyone can walk into. “We can provide more technologically advanced products that others simply can’t manufacture,” stated Mr deBot. “I understand carbon fibre, plus I am not afraid to have the backbone to take risks. I have challenged myself many times, told clients to give me a shot at what they want, and I can build their products.” Mr deBot was keen to stress that if you’re willing to work with passion, then

Mr deBot, CEO of deBotech

ucts, and it still takes an artisan to do it, which is what I love about it, as a person can feel very self-rewarding to know that it’s an artist building the product rather than just some guy standing in a spot pushing a button every day.”

he will welcome anyone from anywhere because deBotech is ready to continue its growth. “Even though we see challenges every day, you’ve just got to figure out how to work the challenges and make the positives shine well above the negatives that we’re all dealing with currently,” he concluded. n

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SMARTLYNX AIRLINES

PROFILE

SmartLynx Airlines continues to go from strength to strength as it plots a path across the skies. To meet growing demand from European and overseas markets, the company has recently announced a fleet expansion, including two Boeing 737 MAX 8 aircraft. CEO Zygimantas Surintas outlined to Andy Probert how the company is setting out for new horizons.

martLynx Airlines is bucking the trend in a global airline industry that is struggling to find its feet, wrought mainly by the impact of Covid-19. An expanded fleet, new business wins, a new cargo division and line maintenance centre clearly indicate the airline continues to be a soaraway success in this highly competitive market. 30 years since it was founded, the Latvian headquartered airline, with subsidiaries in Estonia and Malta, specialises in offering full lease aircraft-crew-maintenance-insurance (ACMI) services. In 2019, its fleet stood at 24, with A320s and A321s covering mainly tourist flight operations in Europe, Asia,

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and Africa. Since then, SmartLynx CEO Zygimantas Surintas and his team have remained laser-focused on advancing the business. “In 2021, the company decided on a very aggressive stance on growth,” confirmed Mr Surintas. “We began the year with just 12 airplanes, but grew the fleet to 36 by the end of 2021, and most were flying during that period. Our anticipation is to double our fleet strength, culminating with 65 leased planes by the end of 2022. “Our strategy is that we believe in the market, and we believed business would recover, particularly in Europe where it has responded extremely well.”

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SMARTLYNX AIRLINES

PROFILE

Expanded, diversified portfolio He elaborated: “As a result of the pandemic, we have diversified from one business line to three: passenger narrow-body, passenger long-haul, and cargo narrow-body/long-haul fleets. “The crisis has also given us an opportunity to introduce a new type of airplane in the narrow-body fleet, with the addition of our first Boeing 737 MAX. For me, the company direction was ‘Let’s not waste this crisis, let’s use it’, and I believe my team did this very well.” The company’s fleet now includes six long-haul modified planes flying for the cargo division and two Airbus A321 freighters, while the rest are narrow-body Airbus 320/21s on passenger operations. “Within 2022, we may consider further additions to the fleet with the new generation A330 freighters,” Mr Surintas revealed. In 2021, SmartLynx took on an extra five Airbus A330 Zero LOPA aircraft to meet the growing market demand for long-haul cargo ops. With these modified aircraft, the airline can transport cargo shipments such as vaccines and medical supplies. Earlier in 2021, SmartLynx Malta began supporting the Express Division of Deutsche Post DHL Group with two Airbus A321 freighters, aiding them to meet the increasing demand for express cargo transportation worldwide. Bases in Saarbrücken, Germany, and Basel, Switzerland, were opened. The company operated on behalf of TUI Deutschland, providing full-charter flights to tourist destinations around the Mediterranean and Canary Islands.

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Technical additions “We were delighted to partner with the likes of DHL, Volotea, and Royal Air Maroc and provide them with exceptional passenger and cargo ACMI services,” acknowledged Mr Surintas. “The fact that such esteemed companies choose to work with us proves that our professionalism and expertise are valued and respected.” In October 2021, SmartLynx partnered with FTI GROUP, the third-largest tour operator in Europe, for an exciting non-stop connection from Berlin to Dubai.

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SMARTLYNX AIRLINES

PROFILE

Besides improving its fleet and services, SmartLynx has grown in size, recruiting over 80 people for office teams in Riga, Tallinn, and Malta. It recently introduced a new Maintenance Control Centre in Malta with EASA Licensed Type rated A320/A330 engineers. The company is also on the way to beginning operations with SmartLynx Technik. “Initial works to make this new Part 145 SLX Line Maintenance Organisation a reality has begun,” said Mr Surintas. “We foresee having a total of ten SmartLynx Technik stations across Europe within the next two years.” Expansion has continued into 2022, with SmartLynx increasing its cargo fleet strength, adding two more A321Fs with plans for further additions. Both A321Fs are leased to SmartLynx by entities managed by Cross Ocean Partners. Precision Conversions undertook the passenger to freighter conversions. Both will support DHL’s European network, and come in tandem with further reducing DHL’s CO2 emissions with the introduction of the most fuel-efficient narrowbody freighter aircraft in its class. The new technically advanced narrow-body A321F offers additional capacity with the lower deck automated cargo loading system to meet the increasing demand for express cargo transportation. It also delivers the lightest airframe and has been designed and configured for optimised freight operations, maximum revenue load, increased profitability, and maximum fuel efficiency. Mr Surintas commented: “The additional A321Fs underline our commitment to the future, focused on cleaner, environmentally conscious and sustainable air freight transport. We have the A321Fs for five years and expect to have an extra 20 A321Fs by the end of 2023. It is a critical strategic element for the company.”

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With close to 300 office-based people and over 1,800 crew personnel, representing more than 40 nationalities, Mr Surintas said SmartLynx would be among Europe’s top 10 flight operators by the end of 2022. SmartLynx was founded as Latcharter Airlines in 1992: commencing operations with two leased TU-134B aircraft, it was the first airline to undertake package holidays from Riga. Lofleidir Icelandic acquired the airline in 2006. The SmartLynx brand was adopted in 2008 before a management buyout in 2012. Four years later, a Netherlands-based investment fund became the owner with aims to enlarge the fleet and expand its operations worldwide. SmartLynx is a family member of Avia Solutions Group – a leading global aerospace services group with 100 offices and production stations providing aviation services and solutions globally. SmartLynx’s passenger numbers have grown from 1.9 million in 2016 to 3.5 million by the end of 2019. Mr Surintas predicted 2022’s figure would hit about 5% below that peak figure. Under Mr Surintas’ guidance the company has continued a steady global expansion, which in 2022 saw SmartLynx announce the procurement of a new client, Nigerian airline, Air Peace – Nigeria and West Africa’s largest airline. Initially damp leasing two A320s based in Lagos until May 2022, SmartLynx is now flying five aircraft for Air Peace. The partnership also confirms SmartLynx’s return to Africa where it has operated since 2007. He added: “Another important commitment for us, and one which is backed up by our signing of the EASA Covid Charter, is to maintain and continuously improve safer flying methods.”

This has since followed with the opening of a new competence and innovation centre in Vilnius, Lithuania. The addition of the new location will enable the company to better manage its growing operations.

New opportunities Mr Surintas continued: “As we are becoming the largest airline in the Baltics. Our strategy is to grow our investments and extend our business into different continents in the next two years, strengthen our long-haul division, reach all our key milestones, and increase market share. “We believe the European and Asian markets will show strong recovery, and we expect up to 900 airplanes will leave the longhaul markets. ACMI will certainly become a very important solution in this kind of market.” In confirming its aggressive approach, SmartLynx has agreed with SMBC Aviation Capital to lease its first two Boeing 737 MAX 8 aircraft, to meet growing demand from European and overseas markets. He said: “The most exciting part for our customers will certainly be the new destinations that are now in range. However,

cutting fuel consumption, lowering noise and CO2 emissions is no less important. The additions of the latest generation aircraft mean significant service improvements and unmatched technical reliability across all markets. “As SmartLynx continues to modernise its fleet, there’s no doubt the Boeing 737 MAX 8 is the right aircraft for us, and we were pleased to work with SMBC to make it happen. These aircraft will allow us to ensure even better-quality service and unmatched technical reliability.” Mr Surintas commented: “The past five years of success have enabled SmartLynx to navigate the pandemic. Our reputation, safety, reliability, as well as our transparency and loyalty to clients has stood us in good stead for the long-term.” As much as SmartLynx will by its nature pounce on any new opportunities, Mr Surintas ominously warned: “While the aviation industry will remain intensely competitive and tough, especially the European market where there have not been many bankruptcies yet, I expect there to be a lot of blood spilt in the next 24 months.” n

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MENZIES MACAU AIRPORT

PROFILE

E H T

O G R A C N A L

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Menzies Macau Airport Services Ltd has over 25 years’ experience providing a full portfolio of aircraft ground services for passenger and cargo aircraft at Macau Airport. Managing Director Raymond Lo outlined the company’s plans for growth in conversation with Phil Nicholls. 84

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acau Airport qualifies as one of the world’s most unusual airports. Based in the densely populated special administration region of China, the small size of the Macau peninsular means that land is in great demand. Thus, the runway is built on reclaimed land in the Pearl River estuary. Surrounded by water, the Macau runway is large enough for 747s to land, with two narrow causeways allowing the aircraft to reach the shore. Managing the services at this unique airport is Menzies Macau Airport Services Ltd, a joint venture between Menzies Aviation, Air Macau, EVA Air, CNAC and local business leaders. Menzies Macau was established in 1994 as a full-service aircraft handling provider, offering a broad portfolio of passenger, cargo and aircraft services. The Passenger Service Department employs an advanced computerised checkin system and supervises the arrival, boarding and transfer of passengers. The multi-lingual team also provide specialist services like VIP-escort, wheelchair assistance and the supervision of unaccompanied minors. Menzies Macau is proud of the AHS1000 certification achieved by the Department; an IATA-recognised award for consistent performance. At the Macau International Airport Cargo Terminal, Menzies Macau provides loading/ unloading, warehousing, screening and onward logistics services. Its 7,800sqm warehouses are equipped with the latest

equipment to securely store high-value goods or maintain temperature-sensitive items in suitable conditions. The facilities at Macau include a live animal room and a suite of X-ray machines. To support cargo operations at the airport, Menzies Macau owns two remote cargo warehouses in mainland China. Both external warehouses are located close to the Guangzhou Baiyun International Airport, about 100km away from Macau. Guangzhou Airport is the fourth-largest cargo airport in China, handling 2 million tonnes of freight annually. These Guangzhou warehouses enable Menzies Macau to offer end-to-end cargo transit services and feature prominently in the company’s plans. Menzies Macau Airport Services operates ground handling operations, delivering excellence from touchdown to take-off. It handles every commercial flight that arrives and departs from Macau International Airport with an exemplary record for safety and punctuality. These services include check-in, boarding and arrivals, aircraft loading and unloading, along with towing aircraft around the distinct airport layout. Menzies Macau deploys 1,200 pieces of equipment, both motorised and non-motorised. Finally, Menzies Macau offers a suite of aircraft line maintenance services with a team of qualified mechanics with CAA, CAAC and FAA licences. The team provides routine line inspection services, pre-flight Inside Industry

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MENZIES MACAU AIRPORT

PROFILE

checks and fuelling supervision. Menzies Macau mechanics are also capable of additional services such as rectifying defects and reporting technical irregularities.

Hit by Covid To provide these diverse services, Menzies Macau Airport Services currently employs about 490 people. This is down from the preCovid levels of 800 employees. The ongoing impact of the pandemic is still affecting Macau airport and thus Menzies Macau. Managing Director Raymond Lo highlighted the cause: “Passengers will come back gradually, but not until the Macau government or Chinese government changes it’s Covid Zero policy. Right now, we are still under this policy, which is greatly affecting tourism and the airport.” Pre-Covid, Menzies Macau handled an average of 100 flights per day. In contrast, during the pandemic this has fallen to 20 flights per day. Mr Lo was confident that the passenger numbers will bounce back at Macau, but it may take until 2025 before the average number of flights will build up to between 70 and 80 flights per day. “The future depends upon China’s Covid policies,” he said, “Because Macau is a tourist destination, and a lot of our tourists come from China.”

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Fortunately for Menzies Macau Airport Services, the company also processes cargo. In 2019, Menzies Macau handled 41,705 tonnes of cargo, falling to less than 33,153 tonnes in 2020. Despite the impact of Covid, the volume of cargo bounced back in 2021 to 48,636 tonnes. Mr Lo recently returned to the role of Managing Director this year, having previously worked for the company between 2009 and 2019, before moving to Canada. Today, he sees the future of Menzies Macau in cargo services.

Forwarding cargo “My focus nowadays, from when I came back to the company, is how to build our cargo market,” Mr Lo explained. “How to attract cargo to Macau Airport, instead of going through Hong Kong, Shenzhen Bao’an or Guangzhou Baiyun.” Mr Lo is overseeing the rearrangement of warehouse space at Macau airport, increasing the area available for freight. Menzies Macau is also exploring the options for subcontracting some of the cargo forwarding services to help with any surge in demand. The bulk of cargo flying out of China is controlled by powerful cargo forwarders in Guangzhou, Shenzhen and Hong Kong.

This situation can help boost Macau airport, because there is a closed border between China and Hong Kong. As no such border exists for Macau, Mr Lo regularly visits the cargo forwarders in Guangzhou and Shenzhen to build those vital personal relationships that help drive new business. Hong Kong handles 5 million tonnes of cargo annually, while Macau takes less than 1% of this volume. Mr Lo is certain there is scope for cargo expansion at Macau. “We can have growth of 10 to 20%, if we find a suitable cargo forwarder partner who uses Macau as their international airport instead of Hong Kong.” Menzies Macau is expanding its external warehouse network with additional facilities in Zhuhai, 9km up the Pearl River from Macau. The plan is to begin processing cargo at Zhuhai, before then shipping it onwards to Macau. In conjunction with the existing warehouses at Guangzhou, the growing network of cargo facilities is geared up towards processing more cargo through Macau. Mr Lo’s monthly visits to the cargo forwarders in Guangzhou and Shenzhen is steadily building up the reputation of Macau airport and laying the foundation for the expanded cargo services. These face-to-face contacts are vital to building

personal relationships. Forming these close connections is easier for a smaller airport like Macau, in comparison to somewhere much larger.

Building a runway success With the pieces falling into place for an expansion of cargo services at Macau, there are still challenges facing Mr Lo and his colleagues. Away from Covid, the greatest of these is the foreign worker quota operating in Macau. “The problem is that we rely heavily on manual workers,” Mr Lo said. “If we don’t have sufficient manual workers, then we have limits on our growth.” The unemployment rate in Macau is steadily growing, which makes the government reluctant to approve the hiring of foreign workers. However, Menzies Macau struggles to fill vacancies for the manual workers required to operate many of its services. This is especially true of the cargo handling roles. Mr Lo is eager

for the Macau government to understand the special circumstances operating at the airport and duly approve additional foreign manual workers to facilitate further growth. To mitigate these employment challenges, Menzies Macau launched a vocational training school to build up a pool of up to 100 trained staff. The availability of this trained workforce available at short notice will allow Menzies Macau Airport Services to respond swiftly to new opportunities. The local Covid restrictions will end at some point, so the company is prepared to respond to any sudden growth in flights at Macau airport. It is challenges like this which brought Mr Lo back to this unusual airport in the role of Managing Director at Menzies Macau. “I like the job; I like facing different challenges every day. I like to drive the business forward and see the changes as we push towards success,” he concluded. n

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GALLANT VENTURE

PROFILE

W Indonesia has taken firm strides to seize the opportunity to tap into the multitrillion-dollar global halal market by allocating four designated industrial zones to develop goods for the Muslim market. One of these – the Gallant Venture-owned Bintan Industrial Estate – is quickly proving to be one of the nation’s first halal food hubs. Andy Probert takes a closer look. 90

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ith a population of 260 million people, of which 90% are Muslim, it is surprising that up until 2018, Indonesia did not have any dedicated halal industrial parks to speak of. Even more so, given that Indonesia is the world’s top consumer of halal food. Predictions suggest the global halal food industry is estimated at $2.5 trillion, and with the world’s Muslim population set to reach 2.2 billion by 2030 – effectively more than a quarter of the world population – Indonesia resolved to transition from being a mere consumer of halal products to being a primary driver of the Islamic economy. In a bid to bridge the gap between demand and fulfilment of halal products, Indonesia’s government resolved to identify four pilot

Mr Edmund Lai (right) and Mr Jeremy Chen (left) from Riau Investment Marketing Team of Gallant Venture Ltd (Gallant Venture Ltd is the owner of Bintan Industrial Estate and Bintan Halal Hub)

locations to become halal parks. These would be for the development of food, beverages and pharmaceuticals compliant to Islamic standards. One of these key sites is on the existing Bintan Industrial Estate (BIE), a 4,000-hectare rare sea-fronting integrated site located in the southern part of Bintan Island, Indonesia. Bintan, along with Batamindo Industrial Park in Batam, (which has also been allocated as a halal hub), are owned by Singaporebased, Indonesia-focused investment holding company Gallant Venture. “Our business is well-positioned to leverage the strategic alliance between Singapore and Indonesia governments and is in close proximity to Singapore,” commented Edmund Lai, Head of Gallant Venture’s Riau Investment Marketing. Gallant’s core business is as a utility provider, master planner and developer of industrial parks, property development and resort operations. With a total asset value of $1 billion, the group also has a foothold in the automotive and offshore marine industry through its associated companies.

ters in Singapore and manufacturing at BIE, said Mr Lai. “BIE has free-trade zone (FTZ) status, is strategically located to tap into Singapore’s financial and transportation network, and its overall cost-competitiveness is complimentary to international companies looking to manufacture for the export markets.” Being a self-contained development, BIE offers a complete lifestyle accommodation through Bintan Inti Executive Village, an exclusive enclave for tenants. Housing options include well-appointed bungalows, studio apartments, modern condominiums, clubhouse facilities, tennis courts, and other amenities. Workers’ dormitories are available onsite, and the site has a professionally managed infrastructure, amenities and total customer care solutions. “BIE, since 1994, has been the manufacturing location of choice for some of the world’s leading companies. Target industries include electronics, electrical and general manufacturing, food processing, aviation MRO, maritime and offshore marine engineering,” emphasised Mr Lai.

Bintan free trade zone status With Singapore just an hour’s ferry ride away, investors can tap into the advantages of the Singapore-Bintan twinning model by setting up regional headquar-

Bintan Halal Hub Following its special status allocation, BIE has zoned up a cluster of 22 ready-built factories to kick off the Bintan Halal Hub

and is now home to some growing food processing companies. Mr Lai said: “BIE envisions creating a leading multi-user halal manufacturing supply chain for the global and domestic markets. We have earmarked around 100 hectares of land to realise this potential.” Bintan Halal Hub will be supported by a dedicated halal management team and an ecosystem of supporting facilities. BIE is strategically positioned to capitalise on the halal market in Indonesia and to access the rest of the halal market through Singapore. “As one of Indonesia’s first halal food hubs, approved by the government, the park offers a one-stop halal manufacturing location dedicated to food and halal-certified products. “We have a team of professionals and Halal certification authority onsite to assist with every operational need. Our halal ecosystem will be the platform and differentiator for their growth into the halal market,” Mr Lai asserted. As a value-added service and depending on the type of products, Gallant Venture Inside Industry

GALLANT VENTURE

PROFILE

could be leveraged to distribute products through the group’s chain of retail stores in Indonesia’s domestic market, creating quick go-tomarket opportunities. Operating in an FTZ allows import duty exemption on raw materials and equipment, as well as Value-Added Tax exemptions for exporting industries. Mr Lai said foreign companies could work within a conducive investment climate as 100% foreign investment is allowed, and the government had a double taxation avoidance agreement with 59 countries. Under the Generalized System of Preferences, eligible products with Indonesia’s Certificate of Origin are entitled to preferential duty-free entry to member countries. The industrial estate has available readybuilt factories for immediate occupancy, abundant land for scalability and sustainability in operation, and an onsite liaison team that provides business license and consultancy services. Accommodation is available, and infrastructure, such as halal-certified water. Additionally, partnerships with halal laboratories and the Halal Audit Agency are established to assist investors with quick access and fuss-free testing, traceability audits and certification. 94

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Halal products: Indonesia and globally “Indonesia’s Halal Product Assurance Law has made halal certification mandatory for the sale of all food, beverages, drugs, cosmetics and other products commonly used,” commented Jeremy Chen, Manager of Gallant Venture’s Riau Investment Marketing. Implemented on October 17th, 2019, the Halal Law requires consumer products and related services in the country to be Halalcertified and has given a five year phase-in period starting from the mandatory certification of food, beverages and slaughter process. Halal certification and labelling requirements will become mandatory for food and beverages products starting on October 17th, 2024. Mr Chen added: “We want to develop a dedicated food and halal processing zone to allow manufacturers to produce safe, halal-compliant products through our integrated facilities. Knowing they are made in the Bintan zone, local and global consumers and distributors can confidently buy the products.” With around 60% of the world’s Muslims living in the Asia Pacific region, Bintan has all the elements to thrive. “Indonesia’s population of 264 million, includes 42% aged between 25 to 54 years

who are the biggest spending age group,” outlined Mr Lai. “There is still a massive gap between demand and fulfilment of halal products that we can meet.” Due to its strong halal market potential, Indonesia is well-positioned to be the leading market for halal products and services, becoming a significant global player. In 2020, domestic spending on halal products and services stood at around $184 billion and is expected to grow 14.96% to around $282 billion by 2025. “This makes Indonesia one of the biggest spenders in halal food globally, creating a vast market opportunity for businesses to seize,” he emphasised.

Case study: Bionesia BIE is home to Bionesia Organic Foods, an organic coconut producer that exports to the USA, Europe, and the Asia Pacific region. Bionesia is a joint venture between a German company and Salim Group, one of the largest conglomerates in Indonesia.

To meet the growing worldwide demand for coconut products, including rising sales within Indonesia and the rest of South East Asia, Bionesia leverages BIE’s “closeness to Riau’s plantations and trade connectivity and ASEAN’s network of free trade agreements”, explained Bionesia’s Chief Marketing Officer Gerd Waldkircher. Susanto Kusnadi, Chief Operating Officer emphasised that “Bintan’s low tectonic activity compared to other parts of Indonesia and links to Singapore’s logistics capabilities ensure supply chain reliability and competitive prices.” Singapore’s port is critical in exporting Bionesia’s finished goods to foreign markets, such as China, Germany, India, and the USA. To ensure consumer trust, Singapore-based laboratories, including SGS and Eurofins, certify Bionesia’s organic products are free from pesticides and plastic phthalates. “Sending samples to Germany could take us a month. Working with Singapore laboratories recognised in the USA and Europe helps us reach our customers faster,” elaborated Chief Executive Officer Olaf Tobin.

international airport in Bintan. Situated next to Bintan Industrial Estate, the airport is expected to make the estate even more attractive for investors to base their factory operations there. “This will allow faster shipment of raw materials from sources and quicker access for finished products to intended markets,” he said. “Bintan Halal Food Hub is more than ready to address the world’s growing demand for halal products.” n

Bintan Halal Food Hub is more than ready to address the world’s growing demand for halal products

Future plans With a solid base to grow upon, Bionesia has a five-year master plan to establish 12 factories and expand its operations by 75% to capture more overseas markets, including emerging regions such as the Middle East. Mr Lai said Gallant Venture’s future proposals would include the construction of an Inside Industry

SPARKS MAINTENANCE CONTRACTING

PROFILE

Award-winning Missouri-based Sparks Maintenance Contracting offers a multi-level approach to industrial contracting for many high-grade clients in the US. With safety at its core, the company has continued to grow apace in a highly competitive environment because of its can-do attitude. Andy Probert reports. 96

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stablished by Brad Sparks in 2000, Sparks Maintenance Contracting (SMC) is a multi-faceted company that handles a range of contracted industrial projects across industry. Bryce Sparks, Justin Edmond and Josh Edmond all joined the business in 2015, helping to accelerate the company’s growth. From industrial maintenance, installations, fabrication and welding to machining and rigging – and everything in between – the company is a specialist in many different trades. SMC, operating out of Bowling Green, Missouri, has a 75,000 sqft production facility capable of any size fabrication job. It is specialised in tool and die, builds, maintenance, production machining and contract assembly. “We are often called to act on large scale industrial projects from extracting a production line and putting a new one in, to the installation and removal of all types of paint, blast, and wash booths,” detailed Ryan Niemeyer, Director of Operations.

Unique capabilities The company, which employs around 100 people, has experienced 25% growth year-onyear for the last five years, due to its unique offering of being able to go that much further on a job. “Often, we are called in to do one job for a client, and often that then leads into another,” said Mr Niemeyer. “Our unique

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SPARKS MAINTENANCE CONTRACTING

capability is that seemingly disparate services that we offer often fit well together to provide the customer the total package to meet their needs. SMC’s crews are regularly on the road working for clients in a multitude of industries, such as oil and gas and industrial, as well as being experts in industrial power distribution, energy management systems, fabrication, welding, pipefitting, PLC and blast booths. The company’s mechanical contractors also oversee mechanical projects for organisations, and these responsibilities run to industrial heating or cooling systems, refrigeration, piping, and plumbing of a building. SMC also offers top-of-the-line epoxy flooring to restore and transform floors to meet clients’ standards, while it is also

PROFILE

capable of being a contractor to fabricate steel structures such as buildings, platforms and mezzanines. At its facility, SMC makes use of many different tools for each project. CAE programs and CAD programs allow employees to design and fabricate what their clients require. These can include production lines, ventilation systems, suspension systems, pipefitting, and HVAC projects. Offering a full range of commercial and industrial fabrication, modularisation and pre-assembly work, SMC’s projects range from in-house to on-site installations, repairs and removal. SMC also has CNC fabrication equipment, including a shear, press brake, plasma table, machining centres, lathes and a new laser table to complete any given project.

When it comes to rigging materials and crane operations, the company has employees certified in that core area, enabling them to set machinery, heavy equipment, or install entire production lines. And when it comes to crane work, the company utilises its rigging workhorses – the Traksporter and Hoist 40-60 Forklift – to carry out jobs. Mr Niemeyer emphasised that no matter what the workforce was engaged in, safety was at the core of everything. “Safety is not only a practice that we train and perform on; it is a culture that our workforce lives by,” he added. “This culture is formed by shared values at every level, perception and competencies that ensure each employee has the determination never to give safety a day off. This means at work or home, our culture never stops. We are dedicated to having a progressive safety culture.” This involves employee participation, auditing, and program evaluations to ensure they constantly follow the industry’s best safety practices.

Innovative and reliable Given the demand for services, SMC is currently engaged in investing in a new facility in Bowling Green, which will be eight times as big as the existing headquarters. Mr Niemeyer commented: “It is an exciting phase in the company’s development, and the new facility, which is due to open by mid2022, will be able to offer even more industrial capabilities for clients, such as our new laser cutting technology.”

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The business’ dedication to clients recently earned SMC an award from Toyota for outstanding performance on projects in Toyota Motor North America Inc. And in line with its innovative approach, the company has developed tension monitoring anchor bolts and studs for use in any industry requiring the anchoring of heavy machinery. The Acura Monitor Bolt permits the ‘wrench-less’ checking of the tension of the anchor bolt. The repeatable accuracy of the Acura Bolt tension indicator makes the use of a torque wrench obsolete. The bolt is repeatable under operating conditions to a plus or minus 5% of the desired tension, considerably better than plus or minus 25% commonly attained with a torque wrench. SMC also supplies steel soleplates and two-piece shim able dyno chocks. According to Mike Smith, Director of Sales, it helps insulate epoxy grout for longer life and better bond strength to soleplates. The company also allows shimming up or down to correct the ‘hot alignment’ with a two-piece chock design. The soleplates are also factory sandblasted and coated. Mr Niemeyer said that while the company has adopted successfully pandemic measures and restrictions enabling teams to continue working out in the field, the biggest challenges were being felt with supply chain issues and the availability of critical materials. He said that the main differentiator between SMC and other companies in the industry was not only its facility capabilities but the staff’s work ethic to provide options and solutions on jobs in the field. “We are always communicating with the client and ensuring that the job we do is of high quality. When we come across an issue, we don’t plough on but communicate and cooperate with the client to find a solution. “We always retain a can-do attitude, and given the industrial contracting sector that we are in, we maintain transparent and honest relations with customers that help foster long-term partnerships.” Mr Niemeyer concluded: “SMC has built a reputation over the past 22 years as being a highly reliable contractor, no matter how complex the job. We have built a client base built on word of mouth, recommendation and return business, and these are the foundations to our success.” n

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BARIL COATINGS

PROFILE

as its

A company as durable

coatings

Celebrating its 40th anniversary this year, world-renowned paint and coatings manufacturer Baril Coatings has been championing sustainable bio-based products for over two decades. This family run business has been working on its sustainability goals for much longer than the recent worldwide push. Made up of a tight-knit group of committed employees, the company makes products for sectors ranging from industrial, maritime and construction, to maintenance. A report by Jordan Yallop. 100

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aril Coatings is an industry recognised, global player in the paint and coatings sector. The company has a rich family history dating back to its founding in 1982 and is currently enjoying its 40th anniversary this year. From a small-scale paint maker operating out of a shed, Baril now distributes its products globally and have been used in high profile constructions, such as the Stadionul Ion Oblemenco ,a football stadium in Craiova, Romania. Starting in the small Dutch town of Moerkapelle, the company’s highly skilled and committed employees have been its beating heart since day one; now 40 years later, Baril is capable of producing 6 million litres of product a year. Captained by the entrepreneurial Duijghuisen family, corporate social responsibility has always been very important to the company. “We’re very much into sustainability and it’s not just in the recent years that we started to think about it. It’s already been that way for over 20 years,” stated Joost Broeders, Technical Director. “This is the way we want to go; all our actions and activities should be based on sustainable thinking and corporate social responsibility. We like to say that it is in our veins.” Baril is actively working on cleaner factories and is leading the charge with bio-based coatings. The company actively admits that its greatest asset is its committed and driven team, around 80 strong, who are experts in their field and can keep up with the changes within the industry. Baril has production facilities in the Netherlands, USA and in Poland, and with local distributors across Europe and

North America, the company has built up a great deal of trust from its customers. The company’s brands of durable protective coatings are used in over 20 countries and can even be tailored to the specific requirements of the customer to cater to every situation.

Coating the market Baril Coatings is active in a number of markets, explained Hans Jansen, Export and Sales Manager. “We develop, produce and sell our own coatings at a high quality, mainly for industrial applications, in addition to a small amount of work in the DIY sector. We are also very active in the construction and infrastructure markets and machinery equipment, marine and offshore sectors. Our coatings are meant for all kinds of substrates, steel, aluminium, concrete, wood and various other substrates.” When it comes to coatings for the construction and infrastructure sectors, steelwork exposed to the open air needs cost-effective and sustainable protection against corrosion (up to C5). The DualCure and SteelKote coatings from Baril stand out because of their sustainability, flexibility, adhesion, ease of application, resistance against corrosion and chemical and mechanical resistance. This is all the result of the company’s great competence in coating chemistry in combination with extensive attention to the necessities and wishes of its clients. Baril tailors products towards the engineering and the industry, providing a sustainable finish. Baril’s products allow the customer to reduce their Volatile Organic Compounds (VOCs) emissions, offering more environmentally friendly solutions for the metal processing industry. These Inside Industry

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products optimally protect machines and devices against damage and wear; the quick drying characteristics mean a lot of time can be won in the production process. Joost Broeders said: “Our DualCure products are a technology that we have patented, it has a fast cure performance, and this specific product has a very high durability. Outdoor durability is more and more important in all kinds of special market requests. This is because protection is one very important characteristic but so is the speed of application and cure time.” The maritime and offshore sector is another key market for Baril. The broad range of products Baril supplies to these harsh environments protect steel under heavy stress. All of the products are qualified for immersion under NORSOK, IM 13 and are considered ‘ocean proof’. Coupled with long maintenance intervals, reduced maintenance costs and maximal corrosion protection, Baril’s products are tailored to meet all marine needs. Finally, Baril also makes environmentally friendly biobased paints for the home and maintenance sector. The company’s Copperant brand allows the customer to protect surfaces while also

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reducing their carbon footprint; while the Roboton solvent-free and water-based floor coatings protect concrete floors, walls, staircases and wooden floors in a sustainable way. These coatings are also made solely using energy sourced from Baril’s solar panels. Mr Jansen said: “50% of our business is export and a small, but rapidly growing percentage is the DIY market. The most important market we serve in the Dutch segment is structural steel. “Our products for this market are excellent if you want to apply multiple layers in one day and it has to be transported tomorrow. With the DualCure products, these solutions can be given to both the customer and the final user.

20 years of bio-based solutions Baril Coatings designs, develops and produces coatings that are as sustainable as possible, with the aim of allowing its customers to both protect their assets and reduce their carbon footprint. The company actively invests in sustainability, and seeks out new avenues of research to achieve this goal without sacrificing quality and utility. Baril is taking a proactive approach to complying with

the Sustainable Development Goals of the United Nations. Mr Jansen said: “It’s a relentless challenge getting more and more biobased material in our products; it’s an ongoing adventure. We see our customers getting increasingly excited for these kinds of products because they are also faced with environmental issues in their own sectors. So, if you have a supplier that’s a front runner in bio-based solutions, you’re already halfway there. “To be honest, 20 years ago, we didn’t even tell them that it already was partially biobased.” Joost Broeders added: “Components that we used at that time were already bio based for the most part, but at the time there was no market specifically for biobased; so, it simply wasn’t marketed that way. Now we see customers are actively asking for it.”

Uncompromised performance The creativity and innovation that Baril Coatings has been able to

achieve is, in no small part, accredited to the highly skilled and motivated team. Another factor is the ownership; as a family-owned company, the employees are able to take an active role in the development of the company’s vision. As a result of its close-knit approach, Baril has risen to challenges and is committed to finding the most interesting

and innovative solutions to the sustainability conundrum. According to Joost Broeders, the company is showing no sign of slowing down the mission. “Bio-based products will be more and more important, not only to the DIY market but also for the industrial market. The most important thing at that point is quality.”

He concluded: “When we exchange the raw material to biobased, there should be no discussion about diminished performance of the product. I’m positive that these kinds of solutions will help us to grow and hopefully in three years’ time, most of our products will at least have 50% biobased content; that is really our goal.” n

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For over 150 years, millions of customers have trusted Lechler’s various paints and coatings for applications ranging from home decor to marine and industrial uses. From humble beginnings to a company employing nearly 600 industry specialists, Lechler now has a global reach exporting to over 65 countries worldwide. As Jordan Yallop discovered, the company has got to where it is today through an emphasis on technology and innovation.

echler, founded in Stuttgart, Germany in 1858, paints the picture of a company that has perfectly blended history and heritage with modern technology and a forward-thinking mentality – much to the benefit of the countless customers the world over who have applied, painted, dipped, rolled or sprayed Lechler products onto all manner of things. Following the company’s continued growth in the early years, a subsidiary was opened close to Lake Como, Italy. The Italian branch became independent in 1910, after which three brave executives took over the branch after its closure. However, it could be argued that it was the entry of Dr Onnik Manoukian in 1924 that was the inception of the company’s modern ethos of research and development. A family company still owned by the Manoukian family today, this almost-century-old dedication to R&D has since enabled

the brand to stand out from the crowd and differentiate itself on the market. “I believe that the story of Lechler and its continuous evolution is what characterises the company’s depth,” stated Mannik Manoukian, Corporate Communications Specialist. “From that day till today, the Manoukian family has always believed in the values transmitted by the grandfather of the current generation. “These values are what is leading the brand to export to 65 countries and to diversify. We entered the nautical sector with the purchase of the Stoppani brand in 2007 and following the purchase of the IVE brand in 2013, Lechler is also growing in the habitat sector.

A world of colour Today, Lechler, employing approximately 600 members of staff, operates across five sectors – Industry, Refinish, Decorative, Yachting and Habitat.

“Lechler's business has always been focused on and characterised by constant technological development,” stated Ms Manoukian. “The company is based on research, innovation and the consequent formulation of new painting products.” The company is headquartered and operates three production sites in Italy – Foligno, Seregno and Como. The 120,000 sqm Como plant is solely dedicated to the production of all Lechler’s solvent-based paints with a production capacity measuring 20 million litres a year. The Foligno facility is dedicated to the manufacture of the company’s water-based paints. Spanning 60,000 sqm, the site has a production capacity of 6 million litres a year. Finally, the 21,000 sqm Seregno plant produces the products for Lechler’s Habitat sector and has a production capacity of 4 million litres a year. The company has four other European branches – in the UK, France, Spain and Inside Industry

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Germany – and also has four further locations in Brazil, the largest of which is a production site in Rio Grande Do Sul which is spread over 30,000 sqm with a production capacity of 4 million litres a year. “Each business has its most successful products that mark its history,” said Ms Manoukian. “In every sector we are careful to respond to the sudden changes in the market and in European legislation that push towards the formulation of sustainable and low-VOC products. Our core business is certainly allocated between Refinish and Industry. “For Refinish we have just proposed new air, water and UV painting processes composed of innovative high-tech products that allow users to combine low emissions and significant energy savings. In line with the times, we have also formulated specific antibacterial additives based on innovative substances, designed 106

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for the release of highly functional silver ions for all artifacts and environments that require specific prevention and resistance to bacterial proliferation.”

Colourful ideas Two of Lechler’s ongoing stand-out projects are The Bodyshop of Everything and Natural Value. The Bodyshop of Everything, so far launched in Italy and France, and soon to be in Spain, is described as a movement to get bodyshop painters out of their comfort zone. Recognising that the auto repair and bodyshop sector was not experiencing a very prosperous time even before the advent of Covid-19, Lechler promptly readjusted its programs and approach to the market. “This is to convince the sector to enhance their importance and unique professionalism (which is represented by the ability to give maximum value to any sur-

face), through a high-quality painting process. Not limiting this professionalism only to the painting of cars, but also extending it to all those objects that need to be restored,” said Ms Manoukian. Lechler has structured this into a uniquely branded program that is intended to support bodyshop painters from a commercial, marketing and colour consultancy perspective. The other project, Natural Value, centres on the ability to use technological innovation with the ability to create what Lechler calls a “Culture of Colour”. Falling under the umbrella of the company’s Tech brand, Natural Value is a collection that uses nature as its inspiration by recalling its chromatic material schemes. The collection is divided into three categories: Simplemat, offering one-coat matt enamels with low visual impact; Soft Grain, a selection of gloss and textured enamels for a subtle finish; and Perfect Lacquer.

“Perfect Lacquer is a finish obtained by overlapping transparent and coloured layers interacting with each other. Manufactured items painted with Perfect Lacquer show supreme gloss and deep, iridescent and enigmatic gloss – saturated, appealing and seductive finishes,” said Ms Manoukian.

A greener future One of Lechler’s most recent and noteworthy investments is the Lechler Village renovation project. This is the planned renovation of the company’s Como headquarters, which will see its expansion, as well as the existing buildings being overhauled to increase sustainability and safety. The company is also starting a project to digitise many of the company’s operations to ensure the integration of human resources, processes and technologies are in line with corporate strategies and objectives. Adding to this, Lechler has always ensured a steady stream of investments through its Inside Industry

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Operations Department to help with sustainability goals. These investments are aimed at the improvement of safety standards, environmental protection and responsible resource consumption. “Sustainability is certainly the trend the market must necessarily follow, both from a legislative and a moral standpoint,” said Ms Manoukian. “Lechler has always followed this path with projects aimed at lowering emissions, as well as reducing waste in all the sectors in which it operates. Water-based systems and products have been included in all businesses and today represent a valid and technologically competitive proposal.” The company actively seeks to collaborate with customers and partners who believe in sustainability. An example of which is Enessere, an Italian wind turbines manufacturer with whom a relationship was established due to mutual love for what Ms Manoukian described as “the highly technological, and beautiful to show.” The company cited one of the biggest future challenges being the continued transition to a new model of sustainable development. As for the here and now, 108

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the company is still addressing the disastrous effects Covid had on the supply chain and the diminished availability of products due to world events. As such Lechler’s main objective was to guarantee the flow of supplies and shipment to customers – which was achieved with excellent results.

Concluding with a positive point on how the company has worked together to get through the tough times, Ms Manoukian said: “All the people threw their hearts over the obstacle demonstrating closeness and attachment to the company even in difficult times.” n

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