MEPCA Magazine January 2024

January 2024 www.mepca-engineering.com

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CONTENTS Editor Chris Callander chrisc@cimltd.co.uk Publication Manager James Davies jamesd@cimltd.co.uk 01795 509105 Account Manager Hannah Moody hannah@cimltd.co.uk 01795 509115 James Burke jb@cimltd.co.uk 01795 509115 Design & Production Grant Waters grant@cimltd.co.uk James Taylor james@cimltd.co.uk Administration Manager Natalie Murray admin@cimltd.co.uk 01795 509103 Credit Facilities Manager Gwen Lee creditcontrol@cimltd.co.uk 01795 509103 Marketing Manager Lucas Payne lucas@cimltd.co.uk Sales Director Tom Woollin tom@cimltd.co.uk Chief Executive John Denning © 2023 TGM Publishing Limited,1st Floor, Saphir House, 5 Jubilee Way, Faversham, Kent, ME13 8GD. No part of this magazine may be reproduced or stored in a retrieval system or transmitted in any form – electronic, mechanical or physical – without express prior permission and written consent of the publisher. Contributions are invited and when not accepted will be returned only if accompanied by a fully stamped and addressed envelope. Manuscripts should be typewritten. No responsibility can be taken for drawings, photographs or literary contributions during transmission or in the editor’s hands. In the absence of an agreement the copyright of all contributions, literary, photographic or artistic, belongs to TGM Publishing Limited. The publisher accepts no responsibility in respect of advertisements appearing in the magazine and the opinions expressed do not necessarily represent the views of the publisher. The publisher cannot accept liability for any loss arising from the late appearance or non-publication of any advertisement.

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January 2024

s a new year dawns, what does 2024 hold in store for the manufacturing sector?

News of optimism, as reported by Make UK in this issue of MEPCA, is very welcome. However, as I am writing this, an unexpected fall in GDP for the month of October 2023 has been announced, with one economic consultancy warning that the UK may be in “the mildest of mild recessions”.

Elsewhere, many organisations are reporting a marked improvement in lead times as supply chain issues are overcome. And energy prices have eased somewhat, although they remain significantly higher than around two years ago. But the war in Ukraine, which triggered many of the recent supply chain issues and the spike in energy prices, continues. And further conflict in the Middle East is already having a global impact, and should there be an escalation the implications could be significant.

The one certain thing is that the outlook for the manufacturing sector over the next 12 months, and beyond, is uncertain.

It is, therefore, important for manufacturers to do what they can to build resilience into their organisations. Alongside diversifying supply chains, having robust inventory management and financial health monitoring, a key approach for building resilience is adopting digital technologies. Implementing the Industrial Internet of Things, AI, and machine learning can enhance predictive maintenance, improve supply chain visibility, and enable more efficient operations. It can also enable flexibility, through manufacturing systems that allow for easy reconfiguration, allowing manufacturers to quickly adapt to changing demands.

So, if you haven’t already, help your organisation tackle the uncertain months and years ahead and make 2024 the year you bring automation to your business.

Enjoy the issue.

Chris Callander, Editor

@Mepca-magazine To subscribe to MEPCA visit our website www.mepca-engineering.com or scan the QR code.

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CONTENTS Industry Partners:

FEATURES 16 COVER STORY Silverson Machines

18 ROBOTICS ABB, Yaskawa and OMRON

24 CABLES & CONNECTORS PEI Genesis

25 FOOD PROCESSING FOCUS

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Oakley Food Projects, Fortress Technology and Russell Finex

32 PUMPS & PUMPING SYSTEMS Verder

34 SENSORS & SENSING SYSTEMS ESI Technology

36 MACHINE SAFETY ABB, Pilz and Euchner

www.mepca-engineering.com

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INDUSTRY NEWS

Campaign aims to accelerate global sustainability

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BB has launched a new global sustainability initiative, showcasing the power of technology and expertise to accelerate sustainability while enhancing productivity. ABB’s Real Progress campaign is a rallying call to customers, partners, and suppliers, inspiring them to harness technology leadership and the solutions that exist today to amplify their own impact across process industries such as mining, metals, pulp, and paper.

For more than 130 years, the company has been embedded in industries where emissions are hard to abate and where alternative solutions are either unavailable or difficult to practically implement. Today, ABB is combatting many changes happening in the world, such as rising emissions, water and energy scarcity, and workforce skills challenges. The decarbonisation challenge unites the mining, pulp, paper and metals industries with leadership teams striving to meet increasing market demand with a more rapid increase in energy and resource efficiency to reach their committed sustainability targets such as more carbon-neutral operations. Across these vital process industries, there is a growing recognition that automation, electrification and digitalisation are essential components

of their journey towards meeting climate targets set out by businesses, legislation, governments and international agreements over the next 25 years and beyond.

In the mining industry, Real Progress means helping customers through their energy transition, with electrification combined with world-class technologies for hoisting and grinding. The ABB eMine solution is one example, empowering them to convert fossil fuel reliant mines to all-electric. By automating all electrification solutions, customers can now monitor, control, and then reduce their energy consumption and greenhouse gas emissions in real time.

ABB is also supporting customers in the transformation of the pulp and paper industry, helping to reduce waste and accelerate towards circularity. Solutions include the ABB Quality Control System (QCS), which is deployed to provide paper makers with visibility into the sheet as it is formed to reduce waste and improve runnability. Automation combined with advanced process control (APC) can support consistent operations, improved production, energy savings and reduced

costs. Meanwhile, modern drives and motors ensure reliable operations, energy efficiency and process performance.

In the metals industries, ABB is committed to enabling customers to use less energy and raw materials when producing steel and aluminium through advanced automation and electrification systems, combined with industry-specific equipment and digitalisation, across plants.

While the digital solution ABB Ability Smart Melt Shop helps bring autonomous plants to life by connecting and automating crane and ladle movement to reduce thermal losses, ABB ArcSave electromagnetic stirrer (EMS) makes electric arc furnace (EAF) operations more productive and resource efficient. For the entire metals enterprise, ABB Ability Energy Management System monitors and optimises energy consumption, supporting manufacturers to meet their sustainability goals.

Manufacturing & Engineering week gets smart for 2024

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ollowing the success of the 2023 Manufacturing & Engineering Week, the event is set to become Smart Manufacturing & Engineering Week in 2024.

According to the event’s organisers, the small adjustment reflects the forward-looking nature of the event and focuses on the new technologies, tools, and solutions that are driving the sector forward.

Commenting on the change, Verity Noon, Marketing Director at Nineteen Group, said: “The week is all about cutting-edge innovations in hardware and software and

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solutions to the current challenges being faced around industry 4.0, sustainability and supply chain shortages, to name a few.

Manufacturers and engineers are constantly looking for ways to work smarter, become more efficient, stay ahead of the competitive curve and explore new business models and practices, and Smart Manufacturing & Engineering Week will help them do just that.

With more than 10,000 manufacturers, designers, engineers and maintenance professionals attending in 2023, the event will expand way beyond 450 exhibitors with the addition of Drives & Controls in Hall

5. Laura Parris, Event Director for Drives & Controls at Nineteen Group, said of the addition: “Drives & Controls is one of the great brand names in the UK industrial exhibitions sector. It has such a long history from the days when it overflowed from its original home in Telford to where it now finds its natural place as part of Smart Manufacturing & Engineering Week”.

Drives & Controls complements the other exhibitions, Design & Engineering Expo, Smart Factory Expo and Maintec perfectly.

In addition, Air-Tech and Fluid Power & Systems will also be returning.

INDUSTRY NEWS

Made Smarter national roll-out to turbocharge digital transformation for SME manufacturers

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ade Smarter, a programme helping SME manufacturers access technology and digital skills, is to be rolled out

nationally.

The Government has committed to expanding the Made Smarter Adoption Programme to all nine English regions in 202526 before working with Scotland, Wales, and Northern Ireland from 2026-27.

The announcement means hundreds of thousands more SME manufacturers will get access to technology advice, leadership, and skills training, as well as grant funding for digital internships and technology projects.

The commitment, alongside plans for £4.5 billion in funding for British manufacturing, will also boost productivity, growth, and decarbonisation for SME manufacturers across the country.

Launched in the North West in 2019, the Made Smarter has engaged with 2,500 manufacturers and funded 334 technology projects, which are forecast to create 1,550 jobs, upskill 2,772 existing roles, and increase North West GVA by £242m.

The successful blueprint has since inspired Made Smarter adoption programmes in the North East, Yorkshire and the Humber, the West Midlands, East Midlands, and West of England.

The announcement coincides with the publication of a new report by Made Smarter.

‘Delivering Impact: How Made Smarter Inspires Digital Transformation’ outlines the impact of the adoption model and proposes ways to make it even better.

Brian Holliday, Co-Chair of the Made Smarter Commission and MD of Siemens Digital Industries, said: “This announcement by the Treasury clearly demonstrates that UK manufacturing matters. It represents a tremendous investment boost for our makers that will enable the confidence to invest in innovation, productivity, and sustainability.

“Key sectors benefit, but so does the long tail of small and medium firms, which is really important to directly address our recent challenges of weak overall productivity and investment.

“I believe the business benefits of digitalisation are now clear while being an enabler for industrial decarbonisation too – the

Brian Holliday, Co-Chair of the Made Smarter Commission and MD of Siemens Digital Industries.

package of measures announced in bolstering Made Smarter, targeted regulatory reform and sector support, along with our world-class Catapults and Universities now makes the UK one of the best countries on the planet to sustainably design, make and export goods.”

Mitsubishi Electric and Visual Components form joint venture for 3D simulators

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itsubishi Electric Corporation has recently announced that it has partnered with Visual Components, headquartered in Espoo, Finland, in a joint venture company named ME Industrial Simulation Software Corporation, to develop and sell 3D simulators for manufacturing applications. Mitsubishi Electric and Visual Components hold 70% and 30% stakes respectively in the company, which began operating on November 1.

Through the new company, Mitsubishi Electric plans to enhance its digital twin

platform for circular digital-engineering business solutions. Visual Components’ software is compatible with Mitsubishi Electric’s factory automation (FA) products thanks to standard functions for connecting with PLCs and robots as well as interfaces for expanding the functionality of 3D simulators.

By combining Mitsubishi Electric’s advanced control technology and manufacturing expertise with Visual Components’ technology, the JV is expected to further strengthen the functionality and services of Mitsubishi Electric’s “MELSOFT Gemini”* 3D simulator, which customers use to overcome labour shortages, improve productivity and

upgrade the quality of their manufacturing.

The JV’s development base in Finland will enable it to fully leverage Visual Components’ development expertise in order to verify device control using 3D simulators, upgrade design efficiencies through control-logic generation, and improve productivity through the utilisation of extensive manufacturing data. Furthermore, the customised-solution capabilities of Visual Components’ sales engineers will enable Mitsubishi Electric’s FA Systems business to better meet the diverse manufacturing needs of customers, particularly in Japan and other Asian markets where Mitsubishi Electric’s presence is particularly strong.

www.mepca-engineering.com

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SOLUTIONS FOCUS

Evolution of networked communications

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ith the evolution of advanced digital technologies, it can be challenging for engineers to integrate Ethernet technology into devices and systems that don’t always fit conveniently in cabinets or DIN rail enclosures. To tackle these issues, Brainboxes has developed the Pure Embedded Ethernet Switch (PE-505).

Brainboxes supported a leading Tier 1 supplier to go from prototype into full scale production by having all the options for design engineers to integrate Ethernet functionality into their systems.

To create an early prototype, engineers have the option of using DIN rail mounted devices such as Brainboxes Industrial 5 port Ethernet Switch (SW-505). With its familiar interface and low design-in time, this off-the-shelf module is perfect for proving out the supplier’s original concept. After proving that the system

works with the SW-505, the supplier was eager to integrate the same functionality inside of a small form factor device. An embedded ethernet switch, such as Brainboxes Embeddable 5 port Ethernet Switch (SW-105), is smaller and cheaper than the DIN rail mounted option. However, it’s still challenging to fit all this connectivity into a small space.

Consequently, the supplier designed its own custom module with an Ethernet chip into its fully embedded system. While a chip is the smallest option, it still takes a lot of resources to design in. Another issue with using a chip is ensuring that the design passes all the tests, from reliable power cycling to EMC. The Pure Embedded 5 port Industrial Ethernet Switch (PE-505) was rigorously tested by the suppliers. The device was rapidly power cycled over 100,000 times

(across thousands of hours) and compared to the supplier’s own custom module. The Brainboxes Pure Embedded was found to be significantly more reliable than the supplier’s in-house custom design. With its mega compact form and seamless integration with design software, and ultrareliability, the supplier could easily deploy the PE-505 into the production of its gas monitoring systems. www.brainboxes.com

Space saving solution for monitoring speed

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he new DI1600-series of speed monitors from ifm electronic offer a spacesaving yet versatile solution for monitoring the speed of rotating shafts in a wide range of applications from conveyor systems to centrifuges. DI1600 monitors combine a pulse-generating inductive sensor with speed evaluation circuitry in the same compact M18 housing, which, thanks to its robust metal construction, requires no additional impact protection.

As well as standard versions that will suit most industrial applications, the new speed monitors are also available in ATEX versions approved for use in hazardous environments. Both the standard and ATEX versions can be supplied for flush mounting or non-flush mounting installation, with all types having an IP67 ingress protection rating.

All of the speed monitors in ifm’s innovative DI1600 range feature an IO-Link interface together with conventional pulse

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and switching outputs. Users can configure the switching outputs to provide singlepoint under- or over-speed indication, for two-point operation or for window-mode operation. The speed setting range is 3 to 24,000 impulses per minute, and the monitors incorporate a user-programmable start-up delay to prevent spurious operation while equipment is running up to speed.

Parameterisation can be performed via

the IO-Link connection, which also provides access to speed values and allows current settings to be checked. Alternatively, the monitor can be configured locally using the integrated setting ring. Sensing ranges for the integrated inductive sensor are 12mm and 8mm, respectively, for non-flush and flush versions of the standard monitors, while for the ATEX versions, the corresponding ranges are 8mm and 5mm. www.ifm.com

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SOLUTIONS FOCUS

Third generation Mantis stereo microscope on show at Southern Manufacturing

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ision Engineering, the worldleading provider of innovative inspection, metrology, and digital 3D visualisation solutions, will be promoting iMantis 3rd Gen, the latest addition to its best-selling and award-winning range of ergonomic optical stereo microscopes at Southern Manufacturing for the first time in February 2024.

Mantis is in use in tens of thousands of R&D, manufacturing and analytical sites around the world. Mantis 3rd Gen incorporates the latest developments in optics, digital cameras and fully adjustable LED lighting, to keep Mantis at the forefront of stereo imaging.

Mantis is designed for precision engineering, electronic engineering, medical device manufacture, and a wide range of other applications that require high-quality

images and superior ergonomics. It features a unique, patented, eyepieceless design that delivers a large, highquality optical stereo image directly into the user’s eyes, making it more comfortable and easier to view than traditional microscopes.

Manipulative, rework and restoration tasks need stereo images, to allow easy hand-to-eye coordination and depth perception. Mantis 3rd Gen combines stereo optical images with highresolution camera options for manipulation and recording.

Mantis 3rd Gen features long working distance and excellent depth perception, now with a choice of 3 magnifications, making it ideal for a wide range of applications. It also now comes as standard with five different ways to illuminate your subject, giving you the flexibility to adjust

the lighting to get the perfect image for your needs.

In addition to its outstanding image quality and ergonomics, Mantis also features a powerful digital imaging system that allows users to capture, review, and share highresolution images. This makes it easy to share your work with colleagues, document your findings, and train new employees. bit.ly/VEMantis

A flexible and precise smart conveyor solution for higher payloads

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ncredibly flexible, the Beckhoff XTS drive uses unique linear motor technology to independently drive and control movers around a track, enabling the seamless combination of work processes of varying durations, on-the-fly product changes, and the addition or removal of workstations as needed.

Hepco’s GFX serves as the transport path, mechanically guiding the movers along the motor modules. It absorbs the substantial forces acting on the movers, ensuring precise alignment and resistance to deflection with great precision.

Smart transportation systems are undergoing strong growth, marked by a noticeable increase in higher-load applications. Responding to this market demand, HepcoMotion is expanding its range of guidance solutions for Beckhoff’s XTS with the new GFX-r, a system that provides movement in rectangular paths.

Based on the existing GFX design and incorporating the inherent flexibility and

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precision of GFX/XTS technology, the curved segments have been removed, enabling transportation of payloads up to 40kg.

GFX-r is the integration of Beckhoff and Hepco’s TMS (Track Management System) and the increased drive capacity of XTS 7 & 10 pole magnet arrays.

By removing the curved sections, a larger mover, powered by Beckhoff’s longer magnet arrays, can be used. TMS completes the rectangular path, transitioning movers between tracks.

With an impressive load-bearing capability, GFX-r is ready to make a significant impact across many industries, including automotive and EV, aerospace, and logistics. GFX-r is ideally suited for machine cells incorporating robots, power tools and sensors, as well as for automated assembly and inspection systems. The possibilities are endless; indeed, any application with loads up to 40kg, significant moment loads, and

heightened in-process stresses, stands to gain immensely.

The absence of curved motor sections allows movers to be stronger, more powerful and with a larger mounting platform, while maintaining accuracy, durability, and agility.

Mover speeds of 4m/s, payloads up to 40kg and press loads up to 1500N are possible.

Additionally, movers with longer magnet arrays also reduce heating losses by up to 60%.

GFX-r is available in both 4 & 6 bearing versions for increased strength and stability. www.hepcomotion.com

Revolutionise your warehouse master efficiency with cobot palletising solutions The KUKA LBR iisy cobot excels in precision, speed, and dexterity for various industries. Its low weight, high speed, compact design, and integrated sensors make it impressive. KUKA now provides a turnkey cobot palletising solution with the LBR iisy 11kg cobot, lifter, and vacuum gripper.

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OPINION

Manufacturing is in an optimistic mood Make UK CEO, Stephen Phipson, explains that while there is welcome optimism in the manufacturing sector, helped in part by the recent introduction of supportive political policy, there are still challenges which need to be overcome.

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t’s fair to say that the last few years have been a rollercoaster ride for manufacturers who have had to deal with the pandemic, the shock to energy prices from the Russian invasion of Ukraine, not to mention the continued challenges posed by new trade arrangements with the EU and the ongoing skills shortage. That’s before you factor in the domestic political chaos.

But there may finally be signs of optimism according to the findings of Make UK’s annual survey of over two hundred senior executives, which was conducted with PwC. The overarching message is that Britain’s manufacturers are viewing the UK as a more competitive place to locate their activities compared to twelve months ago, with an increasing number believing they are moving ahead of their European rivals. However, the report also shows they remain wary of the huge threat to their competitiveness posed by the economic behemoths of the US, India and China.

The report also shows that at company level they are more bullish about the prospects for the manufacturing sector in 2024 with the vast majority of companies seeing opportunities outweighing the risks to their business.

Manufacturers are backing up this belief with investment in new products, expansion into new markets, and taking advantage of the accelerating use of new digital technologies to improve their business.

These commitments should be boosted by the recent positive announcements from the Government on full expensing, the extension of the Made Smarter scheme and, the creation of an Advanced Manufacturing Plan which puts the sector firmly front and centre of efforts to boost growth in the UK. However, the survey also shows that manufacturers are wary of the prospects

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for both the UK and global economies, while significant challenges remain in the faces of increased energy and employment costs, as well as access to domestic skills.

In particular, the survey shows that digital technologies have the potential to boost productivity, with almost three-quarters of companies believing digitising operations will boost their operational efficiency. In addition, more than half of companies see generative AI as a means to increase the productivity of their workforce, while a similar number will be leveraging cloud and emerging technologies to reduce their carbon emissions and support their transition to net zero.

However, not everything in the garden is rosy as, despite more optimistic prospects for the year, more than half of companies still see risks in increased energy costs, closely followed by the impact of political instability, which is probably now the new normal. More than two-thirds are still seeing problems associated with supply chain disruption, while a similar number see lack of access to domestic skills as a risk.

And it is this issue with access to skills which is leading to employment ‘creep’ as nine in ten companies say the biggest challenge they face is controlling their employment costs, given they have to pay above the odds to attract and retain talent.

The overall picture, however, is far more positive than it has been for some time.

Having for so long been told that the UK

economy doesn’t need a manufacturing sector we now have ‘advanced manufacturing’ listed as one of the Government’s key growth sectors and a very much more supportive policy environment.

As well as the recent Autumn Statement announcement on full expensing, there has been the expansion of the Made Smarter scheme to boost digital adoption by SMEs as well as the Advanced Manufacturing Plan. Ideally, we would like to see all this brought together under an overall formal Industrial Strategy which would include skills, energy and infrastructure but the focus on manufacturing is long overdue and very welcome as we start 2024.

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OPINION

Rebrand puts automation at the heart of manufacturing In December 2023, the PPMA Group of Associations announced that it has rebranded to AutomateUK. George Thompson, Chairman of BARA, explains what this means for the associations, their members and the sectors they serve.

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irstly, I should say don’t worry, PPMA (the Processing and Packaging Machinery Association), BARA (the British Automation & Robot Association), and UKIVA (the UK Industrial Vision Association) will continue to be important divisions of the new AutomateUK. Each association will be represented, BARA and UKIVA by their committees, and PPMA by a newly formed innovation panel, providing sector-specific insight to our group leadership.

PPMA was established in 1987 as the UK’s trade association for suppliers of processing and packaging machinery to both the domestic and overseas markets.

BARA and UKIVA joined forces with PPMA in 2009.

For those who aren’t aware, UKIVA promotes the use of image processing technology throughout UK industry. In a nutshell, it helps Automation to be able to see. Each of us plays an essential role in representing our members and providing essential information to those who are looking to start their journeys within those respective fields. The trouble is there are huge areas of overlap between the three organisations’ areas of expertise. There

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are times when end users will need advice from within each organisation, so where do you start? I am biased and always suggest that BARA would be a good starting point, which, of course, would be highly contested by both PPMA and UKIVA. As a group of Associations, we have recognised this issue and, well, we have a plan.

This plan has enabled us to take direct action and change to AutomateUK. Simply put, Automation is at the heart of everything that we do and at the heart of everything that our members do as well. That is why we have put automation front and centre in our new branding.

The PPMA Show will continue at the NEC on 24 – 26 September 2024, just with a bit of a facelift. The new branding of AutomateUK instead of PPMA being the obvious change.

AutomationUK and the Machine Vision Conference, which are co-located events at the Coventry Building Society Arena in Coventry on 18 - 19 June 2024, will also continue; however, they will be reflecting the updated branding of BARA and UKIVA, respectively.

So, what else will be changing, I hear you ask? Well, we are busy working on our new website and improving our social

media presence to help end users find the information they need faster and easier, as well as directing them towards solutions that will help them solve the issues they are facing. We will also be lobbying and discussing issues that affect our industry with policymakers and influencers, highlighting the challenges that face our members and end-users. We’ll advise on strategies that the government and other regulatory bodies can utilise to help overcome these challenges, helping to guide regulatory and technical issues for the benefit of everyone.

We will make our voice louder by using our existing channels, having a greater presence throughout traditional media platforms as well as social media and through new innovations such as the UK Automation Forum. Rest assured that AutomateUK will continue to be a defining voice, not only for our members but for the automation and manufacturing industries as a whole.

If you would like to start your automation journey but don’t know where to start, I would highly recommend visiting the AutomateUK website, which will be able to guide you and give you some initial information.

Remember, to automate is to innovate.

Contact YASKAWA For more information go to: www.Yaskawa.co.uk Tel: 0330 678 1990

COVER STORY

High shear mixing for food applications For over 75 years, Silverson Machines has been supplying customers large and small across the world with high-shear mixing equipment. In our cover story this month, we explore some of the mixing tasks Silverson mixers can be used for and how this can be advantageous to manufacturers in the food industry.

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ith its extensive knowledge and expertise of applications in the food industry, as well as the versatility of Silverson mixing equipment and the size of the product range, the company has supplied mixers for hundreds of food applications.

Many of the most common applications that Silverson provides mixing solutions for now have their own ‘how to’ video on the Silverson website. These videos demonstrate how a Silverson high-shear mixer can be beneficial in applications as diverse as preparing samples for aflatoxin testing, manufacturing agglomerate-free batter mixes, or effectively dispersing gums and thickening agents, such as pectin or xanthan gum, for better quality products.

Deagglomerating gums and thickeners One of the most common problems when dispersing powders, such as gums and thickeners, into liquid is the formation of agglomerates. If not dispersed correctly, these agglomerates can affect the appearance, texture and quality of a finished product.

When agglomerates remain in a mix, this results in a low yield of the powdered ingredients, leading to increased processing costs, and often, a filtration stage is needed to remove the agglomerate, adding extra time to the process.

By using high shear when mixing powdered ingredients into water, agglomerates are instantaneously broken down as they pass through the rotor/stator workhead, resulting in an agglomerate-free mix with maximum yield.

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One food manufacturer got in touch with Silverson for help revitalising its mixing process after their previous mixing set-up became too expensive due to the high percentage of pectin in its formulation. The customer had been using a conventional agitator to try and disperse the pectin, but agglomerates kept forming in the mix.

Because of this, the customer had to incorporate much more pectin than they needed to obtain their desired results.

After seeing the Silverson’ how to’ video on dispersing pectin, they got in touch, and a trial was run using a Flashmix powder/ liquid mixer. Using the Flashmix, 5% pectin was quickly incorporated into the liquid stream via the powder hopper. After a short recirculation period, hydration was complete, and the customer got the results it wanted with no need to add excess amounts of powder.

Incorporating 5% pectin quickly and effectively meant a 20% reduction in pectin compared to the previous process. The cost implications of this were huge, so much so that the mixer would pay for itself many times over with the savings made on the raw material. In addition, further money would be saved due to the shorter processing time, and because it eliminated the problems with partially hydrated pectin in the vessel, greatly improved process hygiene.

Reclaiming waste High shear mixing has long been used for the reclamation of confectionery, with the high cost of raw materials such as sugar and cocoa encouraging manufacturers to reclaim and rework ‘off-spec’ product. But now, this is expanding into other areas of the food production industry with cheaper processing costs, for example bakery products and waste pasta, as manufacturers aim to become more sustainable in their processes.

The reclamation of these products works in a similar way to reclaiming confectionery; the product for rework is incorporated into a liquid, usually water, and reduced down into a slurry. This slurry can then be used in subsequent batches of the product. For this process to be effective, the mixing equipment must be capable of disintegrating solid material down into a homogeneous mixture, which can be forwarded on for further processing.

The clarification and recycling of vegetable oil waste is another innovative way in which the food industry is trying to combat excessive wastage. In a recent case, a Silverson customer wanted to manage the amount of oil it was using by prolonging the usable life of vegetable oil, with the goal of eventually reducing the wastage to zero.

The vegetable oil, which was being used in the batch frying process for a snack product, could be reused by incorporating a foodgrade powder, which would reduce the free fatty acid levels to below a threshold where it would then be suitable for reuse.

An impeller was unable to prevent a thick

COVER STORY residue from building up in the vessel due to the limited movement it was creating in the tank, and this was affecting the ‘cleaning’ of the oil. The in-tank movement created using a high-shear mixer kept the product recirculating throughout the entire vessel while incorporating the powder. Once a high-shear mixer was incorporated into its process line, the amount of new oil being purchased by the company was reduced from 30,000 litres every week to 30,000 litres every two weeks, cutting their processing costs by 50%.

Homogenisation A Silverson high-shear mixer/homogeniser can achieve a globule or droplet size of 2 – 5 microns. In some cases, depending on the formulation, finer results down to 0.5 microns can also be obtained, eliminating the need for expensive homogenisation equipment in the manufacturing process.

This is what happened recently when a flavouring manufacturer purchased a Silverson Batch mixer after successful trial results at a laboratory scale. Before contacting Silverson, the company was using a process that relied on mixing ingredients for a long time using a conventional agitator to form a pre-mix. This pre-mix was then fed through a high-pressure homogeniser several times to obtain a uniform particle size of 5 microns.

After seeing the Silverson Mixing Science ‘What is homogenisation’ animation on the Silverson website, the company got in touch to find out what particle size it could achieve using a Silverson High Shear mixer. A trial was arranged to test the company’s application at a laboratory scale.

For the trial, a Silverson Laboratory mixer fitted with a General Purpose Disintegrating Head was used. Keeping the ingredients and formulation the same as its current process,

when using the Silverson Laboratory mixer, the company was able to achieve a uniform particle size of around 1.5 microns after only five minutes of mixing. This was a huge reduction in processing time compared to the previous mixer, and the particle size had been reduced finely and uniformly enough that they could completely eliminate the high-pressure homogenising step.

The company immediately scaled up and purchased a Batch mixer, which has been added to the process line and has been able to produce high-quality flavouring for them in a much quicker time. In most cases, the company now bypasses the high-pressure homogenisation stage, but when used, the pre-mix created with the Batch mixer means it passes through at a much faster rate and in a single pass.

Forming stable emulsions In order to form a stable emulsion, whether you are producing an oil-in-water or water-

in-oil emulsion, you need to obtain the finest possible droplet size. The mixing equipment needs to impart a large amount of energy into the mix; the more shear energy introduced into the mix, the smaller the suspended droplets will become, creating a fine, stable emulsion with both phases completely and uniformly dispersed into one another.

Conventional mixers and agitators, which are suitable for basic liquid/liquid blending, are unable to form a stable emulsion because they do not have the necessary means to impart large amounts of energy into the mix. This type of mixing equipment simply moves the two liquid phases around the vessel, so although it may appear as though the phases have blended, the droplet size hasn’t been significantly reduced, so once the agitation stops, the emulsion will soon separate into the two distinct phases once more.

High shear mixing subjects the liquids to intense high energy, which reduces the droplet size sufficiently and allows the two phases to combine, resulting in a stable emulsion that will not separate once the shear energy has been removed.

As well as the above mixing tasks, a single Silverson high shear mixer is also able to perform a wide range of other mixing processes, such as dissolving, reducing particle size and blending liquids of varying viscosities, with speed, consistency and substantially reduced mixing times compared to conventional mixing equipment. www.silverson.co.uk

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ROBOTICS

Robotic automation supports food industry ambitions Julian Ware, UK & Ireland Sales Manager for ABB Robotics, explains why he expects to see the mass adoption of automation across food and beverage businesses over the next five years.

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he biggest names in the food and beverage industry have already embraced automation, with automated equipment helping them to realise new levels of flexibility, productivity and profitability.

Now, these technologies are increasingly within the reach of smaller players, which is crucial in an industry that is skewed heavily towards small and medium enterprises (SMEs). Across the EU, for instance, SMEs account for 99% of the industry, according to trade body Food Drink Europe.

There are several other industry-specific characteristics that make food businesses ripe for automation. The ever-shifting pattern of consumer tastes makes it important for food and beverage companies to be able to adapt quickly and keep pace with changing market demands. Meanwhile, recent supplyside disruptions have added to the pressure to respond rapidly in an unpredictable business environment. All this makes it essential that food companies ensure they have the most flexible systems in place that can readily adapt to evolving circumstances.

Meanwhile, some of the biggest barriers that have previously deterred food industry operators from investing in robotic solutions have effectively been torn down, resulting in a 76% increase in robot adoption in the food and beverage industry between 2021 and 2022 (source: 2022 World Robotics report, International Federation of Robotics (IFR)).

The first is affordability. The price of today’s systems is much lower than 20 years ago.

For many cost-conscious companies – and for SMEs in particular – the increased affordability of automation technologies has recently brought them within reach for the first time.

Of course, affordability is about more than upfront costs. Food and beverage is typically a low-margin industry, and that was historically cited as a reason that the

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sector was slow to invest in automation.

However, the decision to automate – whether that’s a single robot or a complete solution – can unlock new levels of productivity and competitiveness.

In other words, it delivers a timely return on investment, protecting tight margins and helping to ensure that companies can meet demand from their customers to deliver on time and in the right quantities.

The spiralling cost of energy impacts the affordability equation, too. Uncertainty around energy prices means that companies are seeking ever more inventive ways to cut their bills. Advances in robot technology, including energy-saving robot controllers that can achieve energy savings of up to 20% through the inclusion of features such as power regeneration and brake energy recovery, offer scope for improved energy efficiency that can help to reduce energy costs whilst optimising performance.

Ease of use is the other traditional barrier to take a tumble. Recently there has been a step change in the ease with which operators can interact with technology.

Today’s robots, for example, require comparatively little training to program and operate, thanks to innovations such as intuitive, drag-and-drop-type programming tools. These are opening new application opportunities among users who might previously have been deterred by a lack of in-house expertise.

A combination of artificial intelligence (AI) and machine vision is also helping robots to operate more autonomously and with far greater flexibility in applications such

as product picking and intralogistics. AIenabled robots can see, act and reason in the world around them, completing tasks too varied and complicated for traditional programmed robots. These robots engage in reinforcement learning, effectively adapting to new tasks on their own.

It’s worth mentioning one more key driver for automation that will impact food and beverage companies, as well as other key industries: While many of the challenges coming down the track over the next 20 years remain unpredictable, the impact of an ageing population is a looming challenge that companies can already see coming.

With fewer young people joining the workforce as older people retire, automation is an ideal insurance policy against the impact that this will have on the availability of skills and resources.

It is almost certain that the rate of adoption of automation in general, and robots in particular, will grow dramatically in future. The benefits of improved product quality and consistency, coupled with enhanced profitability and product throughput, provide a strong case for implementing these technologies.

Meanwhile, any lingering concerns around cost or ease of use are being rapidly eroded. new.abb.com

CONNECTING PEI-Genesis is a leader in the design of custom interconnect solutions with a best in class product portfolio that supports the harsh environments of the aviation, energy, military, industrial, rail, and medical sectors worldwide. With sales offices throughout North America, EMEA, and APAC, PEI has a robust distribution network.

In addition, PEI-Genesis has years of strong, established relationships with industry leading companies & corporations within this network.

GLOBALLY

As a designer and manufacturer in the ever-growing electrical interconnect industry, partnering with PEI-Genesis means everlasting growth potential and an esteemed service level to customers that is unmatched in the industry.

LET’S CONNECT: +44 (0) 23 8062 1260

www.peigenesis.com

Dec23_EMEA_MEPCA_Full_page_advert.indd 1

01/12/2023 14:31:03

ROBOTICS

Larger self-contained robot systems extend benefits With strong demand for robot welding solutions across the manufacturing sector, YASKAWA has introduced a new larger capacity turnkey solution to complement its already popular range of welding stations.

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ompact, self-contained robot welding stations that are easy to install, operate, and move around to suit production changes are helping users exploit the benefits of using robotic systems across a wider range of manufacturing applications. A good example of this is the range of self-contained robotic systems from YASKAWA, which has recently been extended following the introduction of the ArcWorld CS cell, a larger model added to the existing smaller HS Micro and RS Mini systems.

Based on a platform, the ArcWorld CS robotic welding station is designed with a host of user-friendly features which help to deliver the best performance in the smallest possible space, featuring a separate working area for the robot and operator, respectively.

The design means the robot, positioner, controller and power supply are all mounted on a self-contained common platform, which also allows space for two welding robots

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without the need to increase floor space.

The scope of delivery includes the MOTOMAN welding robot (or robots), the platform, metal walls, a fume hood with outlets for ventilation and exhaust, a positioner or fixed table, start panel and CE-marking. The user-friendly design of the CS system gives operators their own separate working area in a bright workplace with curved sliding plexi doors and the required materials close at hand.

Connection of the CS system is easy; simply plug in the main power to the power distribution box located on the back of the platform while internal connection to the robot controller and interior lighting are already in place. In addition to the outlet for the welding power source, the power distribution box also has extra sockets for

230VAC and 400VAC that can be used for other equipment, while sockets for connecting pressurised air are located nearby.

With over 650,000 units installed worldwide, Yaskawa is the largest manufacturer of industrial welding robots worldwide.

The extensive ArcWorld range now covers nearly all options of robotic welding applications, such as MIG, TIG, Plasma, spot and laser welding. The corresponding drive and control technology, along with turnkey automated welding systems, from standard cells to more complex customised systems combined with market-leading expertise, underpins the success of the Motoman ArcWorld range of robotic welding systems. bit.ly/3vgbEKI

CONTROL SOLUTIONS

IT/OT convergence in industrial automation Henry Claussnitzer, Business Engagement Manager at OMRON Europe, explores how the evolution of eco-systems is supporting the integration of information technology and operational technology in industrial settings.

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uture-focused manufacturers are edging closer to their ideals of flexible, efficient and sustainable production by exploring digital transformation in earnest. However, as interest in digitalisation builds, it is becoming apparent that a huge gulf exists between the worlds of OT (Operational Technology) and IT (Information Technology). This divide needs to be bridged if today’s visions for factories of the future are to become tomorrow’s reality.

IT, OT and IoT are three similar acronyms that have very different meanings. In short, OT is focused on machine behaviour and outcomes, whereas IT relates to information and communication. OT covers those systems that interface with the real world, such as controls, actuators and sensors; IT covers the computer, data storage, networking infrastructure, software and processes that are used to produce all forms of electronic data. OT monitors events, processes and physical devices and generates information that is then processed

by IT systems. IoT is the data flow between the two worlds – without data, there is no IoT.

From stand-alone solutions to eco-systems Historically, OT and IT have existed as two distinct worlds, with companies specialised in one or the other. The simple reason for this is that no individual company can straddle both spheres. The problem with this siloed approach is that IT/OT connectivity is needed if both IT and OT are to be exploited to their full potential.

This realisation is driving the evolution of so-called ‘eco-systems’. Companies with different areas of expertise are coming together to form clusters that

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drive innovation on a higher plane and bring integrated IT/OT solutions to the marketplace.

One example of this synergistic approach is OMRON’s partnership with Dassault Systèmes. Dassault brings the IT element (virtual twinning), whilst OMRON brings OT (industrial automation). Together, these two companies form the core of an eco-system that can be adapted to different applications and markets by adding extended partners with specialist skills in areas such as wireless networking, system integration, robotics and machine building. The eco-system model provides a fast and flexible alternative to gaining in-house IT/OT capabilities via acquisition.

Whilst this explains how IT/OT convergence can be achieved, it doesn’t explain why it is necessary. Here is an anecdote that illustrates the need for IT/OT

connectivity: one of my two boys spends much of his spare time playing on a flight simulator. In the virtual world, his pilot skills are second to none, but I wouldn’t trust him to fly an actual plane because he has no real-world experience.

The same is true in the world of industrial automation. The IT provider might have the capabilities to create a virtual twin of a factory, a system or a production line, but what it lacks is real-world knowledge of processes and equipment behaviour.

Therefore, if a change is made in the virtual twin to optimise the process, the IT specialist does not know whether this is feasible in the real-life production environment. This is where the OT provider adds value – by giving data to the twin that will enable it to understand how the system will behave in real life. In this way, IT and OT work together, translating the insights gleaned from both

CONTROL SOLUTIONS worlds in a two-way street that leads to tangible improvements, whether accelerated time to market for a new product or more efficient use of labour and resources.

It’s important to emphasise that this is not the same as creating a one-time simulation of a process or a machine. The virtual twin mirrors the physical system in real time and can be run over the lifetime of a system or product, so there is always an opportunity to check – in a safe parallel digital environment – how new materials, new ingredients or new tools will behave. The continuous monitoring of the machine or process can also be channelled for preventative maintenance and energy management purposes.

IT/OT connectivity in action

mistakes are made in the virtual world. This is beneficial to any manufacturing industry, but in particular the automation industry, where there is huge pressure to accelerate time to market and minimise the risk of failure for new products.

Another example of IT/OT convergence is where SCADA systems (IT) visualise what is happening on the production line through the capture of real-time data via connection to OT line elements. Edge control (OT) is then deployed to deliver fast feedback to the process, enabling immediate adjustments to be made.

There are numerous examples of how IT/OT connectivity can bring benefits to industries such as e-mobility, pharmaceutical manufacturing and intralogistics. By creating a virtual model of a new machine or line, Collaboration is key projects can be de-risked, and the time Interactive, integrated, autonomous and it takes to build and test the installation intelligent automation have16:06 the can be dramatically reduced as costly VisionEngineering Mantis ad 180 x 126mm 2024 copy.pdf 1 solutions 11/12/2023

potential to transform manufacturing, but to deliver true value, these solutions need to seamlessly integrate IT and OT. Thankfully, the creation of eco-systems is making this happen, with exciting implications for designing flexible and future-proof production systems. industrial.omron.co.uk

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CABLE & CONNECTORS

Connecting smart agriculture Smart agriculture, or farming 4.0, leverages technology and data analysis to track critical parameters related to crop health. This new approach to farming has the potential to deliver long-term cost savings, higher yields, minimal environmental impact, and increased productivity. However, achieving these smart-farming technology goals requires the right interconnects, as PEI Genesis explains.

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mart farming is defined as using advanced technology — the Internet of Things (IoT), the cloud, artificial intelligence, and big data — to empower farmers to monitor, track, analyse, and automate their operations more effectively.

In the face of challenges such as population growth, climate change, and soil degradation, more farmers are turning to smart farming as an innovative way to boost global agricultural productivity. With the current global population at 8.1 billion and a projected surge to 9.7 billion by 2050, the demand for global agriculture production is projected to increase by 69%. This growth underscores the urgency for effective farming techniques to support the expanding population.

Smart agriculture combines sensor technology and data analysis to track soil quality, weather conditions, and crop health.

Farmers can make data-driven decisions for planting, fertilisation, irrigation, and harvesting using data analysis. As a result, farmers can increase agricultural precision, gaining control of individual field metrics such as seed count, fertiliser usage, pesticide quantity, and water consumption.

For indoor agriculture, smart sensors can enable automated climate control by monitoring and adjusting temperature, humidity, and lighting, among other environmental factors. In livestock operations, smart sensors can monitor animal health, noting activity levels and nutritional status.

In addition, smart agriculture allows farmers to adjust growing conditions remotely from any location using tablets or phones. This feature simplifies delivering optimal conditions for each step of a plant’s growth cycle, increasing accessibility. Smart agriculture technology is continuously evolving, having already significantly impacted diverse areas of farming.

To better understand the potential of smart agriculture and the specific needs related to interconnect solutions, let’s explore

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three product solutions that work exceptionally well for smart farming applications.

The Ecomate series from Amphenol is a family of circular, multiway connectors that is highly versatile and offers excellent performance.

The Ecomate RM (Rugged Metal) Series includes IP67-69K rated indoor/outdoor circular connectors with a maximum current rating of 300A, ideal for high-current applications where exposure to humidity, moisture, water, and chemicals is expected. These are well-suited to harvesting equipment and greenhouses.

The Ecomate Aquarius Series also offers IP67/69K rated connectors but with a bayonet style based on MIL-DTL-26482.

Their UV and corrosion resistance is critical for farming applications exposed to sunlight and potentially corrosive chemicals.

The Ecomate Plastic Series features IP67 rated, high-impact circular thermoplastic bayonet connectors that combine light weight and lower cost. These connectors work well for shock and impact-loading applications, such as agricultural drones and harvesting equipment.

The Trim Trio connector series from Eaton is engineered to provide outstanding performance in the harsh environments within agriculture.

The UTS connectors are plastic sealed with a waterproof IP68/69K rating and a quick-mating 1/3 twist turn bayonet coupling system. The UTG variant is lightweight with a plastic connector and metal locking for added protection from aggressive environments in fields. While the UTO option is built using zinc and aluminium alloy for full EMI shielding. And the final option, the UTL, is a range of power

and control supply connectors.

These highly versatile connectors offer a high mating cycle and an extremely reliable quick-mating 1/3 twist-turn bayonet coupling system. They are available with three types of contacts (machined, stamped and formed, and high-speed) and are interchangeable and intermateable. The series suits applications where vibration, shock, and other issues may otherwise cause disconnections. While the UTO line’s EMI shielding is ideal for transmitting critical data or control signals.

Our third example, the Amphenol SurLok Plus field-installable over-moulded compression lugs, are an excellent option for power management and distribution interconnect solutions. The Surlok Plus represents a compact, quick-mating, robust product line with plug-and-play flexibility.

They are IP67-rated, touch-proof, and feature Amphenol’s RADSOK contact technology.

Applications where these are ideally suited range from rugged outdoor farm equipment to indoor greenhouses. Their compact size also makes them suitable for drones.

The RADSOK socket and contact construction results in an ideal pressure over a more significant portion of the mating surface.

This creates low contact resistance, resulting in a higher current rating and ampacity in a smaller package than standard bolt-on compression lugs. www.peigenesis.com

Focus On: Food Processing

MEPCA explores a range of topics for the food processing sector P26 – The importance of a comprehensive design phase when planning your food factory

FOOD PROCESSING FOCUS

New food factory?

Where to start Oakley Food Projects, a specialist in the design and fit-out of food-production facilities, outlines the importance of a comprehensive design phase when planning your food factory.

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ne question that always arises when considering an expansion project is how much will the project cost? Taking time with a thorough design phase means that you can discuss the necessary specifics to ensure you understand what is included and costed within the scope. This reduces the risk of complications later in the project and can mean both you and the contractor know exactly what has been allowed for.

With a comprehensive design phase, you can ensure that every area of your expansion project is discussed and thrashed out down to every detail. Taking time over these details will mean that you have included everything down to the last minutiae and also enables your chosen partner to quote the build and fit-out phase of the project more accurately.

This will mean your quote will be an accurate representation of what your expansion project is going to cost.

Unforeseen costs Something you don’t want when moving into a new factory facility is regrets. Not being presented with detailed design options could result in fundamental design flaws. You don’t want to be later discovering better ways you could have built your new facilities and wondering why you didn’t consider or do them.

Choosing to carry out a design phase with an experienced food industry partner will mean all the options will be laid out to ensure that your new factory is built specifically for your business’s manufacturing needs. This means you can choose the best option and have one fixed cost to go by, saving cost in the long run as last-minute changes/ additions can add significant expense to your project.

A typical starting place is deciding how much space you need in your new factory

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facility to allow your business to cope with the growth you’re experiencing. If you skip the design phase, how can you determine the building size you require or the amount of production space you need? Discussing the must-haves of your new factory with a turnkey fit-out partner like Oakley means you can be given guidance on the cost base the design team based on previous experience.

This will give you an idea of how large your project is going to be and enable you to have a realistic cost in mind rather than pulling a number out of the air.

Safety knowledge Food safety certifications are often overlooked when planning an expansion project. Without knowledge of certain accreditations such as BRC or SALSA, you may find yourself in a difficult position when realising these haven’t

been considered due to the design phase being avoided. This can severely impact the project’s cost due to unforeseen additions/ changes being made to ensure you comply with accreditation requirements.

Working with a knowledgeable food industry design partner will mean these accreditations are considered throughout the design process. This is not only important for your brand’s reputation but also saves you a lot of extra cost in the long run due to lastminute additions being made to the project, ensuring the new factory facility meets food safety requirements.

Oakley’s strong reputation is built on solid food factory design experience coupled with a unique turnkey approach that removes the stress and risks from food factory expansion. oakleyfoodprojects.com

Feeling overwhelmed with your factory expansion plans?

Oakley are the UK’s leading design, build and fit out partner for growing SME food manufacturers.

Oakley’s turnkey approach to factory design, build and fit out means that, as the business owner, you can focus on growing your business, without the stress, distraction and risk that often accompanies an expansion project.

Your factory expansion plans… delivered Visit and find out more at www.oakleyfoodprojects.com

FOOD PROCESSING FOCUS

Global cheesemaker invests in combi system A family cheesemaker and dairy giant is benefitting from a game-changing food safety inspection solution custom-engineered by Fortress Technology.

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ombining metal detection and checkweighing into a streamlined twin-lane configuration, the spacesaving inspection system manufactured by Fortress Technology is assisting a household cheese favourite to maintain its authenticity and consumer food safety promise. At the same time, the small-footprint machine is helping to optimise resources, reduce dairy waste and maintain the cheesemakers premium global brand integrity.

Several of the cheesemaker’s flagship processing plants now deploy the latest inspection and checkweighing technology from Fortress. The machines are helping to ensure products are delivered to consumers and food service enterprises free of contaminants, as well as adhering to the latest international weights and measures regulations.

Being premium products, the ability to isolate each contamination event and reduce good product wastage was an attractive feature. Currently, five customised twin-lane Raptor ‘Combination’ systems are located between the upstream packaging area and the secondary case loading section in two of the company’s cheese processing plants. The innovative design has solved the immediate challenge of inspecting cheese products tightly spaced together.

Receiving sliced, blocked, shredded and soft cheeses directly from the upstream dualhead bagger and flow wrapping packaging machines, the integrated Fortress system starts with a cleverly engineered and compact curving conveyor. Designed to ensure optimal spacing between lanes, the conveyor also helps to avoid congestion by spacing product lanes out evenly as they are fed into the individual, lane-specific metal detector aperture and checkweighing belt.

Constructed to the highest food grade standards, the metal detector and

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Metrological Compliance

ppm per line – are fed into the Raptor digital checkweighing system. To comply with global weights and measures regulations, in just milliseconds the in-motion, three-belt checkweigher weighs, analyses, captures and reports data simultaneously.

Replicating the reject motion of the metal detectors, air nozzles blast out-oftolerance products off the line into lockable bins, requiring minimal intervention from operators. Sophisticated software adds full transparency, with an average weight mode making instant reject decisions and combining the batch statistical data from across both lanes.

Products that pass both inspection tests then move onto a merging conveyor, aligning and presenting the packs to an automated downstream case packing system.

For optimal reporting efficiency and to assist with transparency, the combi system features data logging and can also be connected to Fortress Technology’s Contact 4.0 software. Auditor-friendly data reports can be exported as either PDF or Excel files covering a specific production line and/or time period.

After inspecting the cheese packs for metal contaminants, good cheese packs – at 140

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checkweigher conveyor decks and belts are all designed to be easily removed from the machine for rapid deep sanitation and maintenance. In seconds, and without using tools, plant operators can unclip and disconnect the conveyor motor, sanitise it, and instantly restore tracking once the conveyor is clipped back into place.

Half The Waste The inspection machine consolidates a single metal detector uniquely divided into two compact apertures, plus two independent weight verification checkweighers. Each technology and lane have individual air blast reject mechanisms to isolate metal contaminants and weight rejects. This helps to reduce and minimise quality cheese products being wasted by over 50%.

As each lane, metal detector aperture, checkweigher and reject is programmed to run independently, interruptions are minimised during product switchovers or maintenance.

Additionally, it is possible to run two different product lines, pack sizes or SKUs simultaneously on the adjacent conveyors.

Global Sieving & Filtration Specialists

Ensure the quality of your food and beverage products

Discover our full range of high-quality equipment Compact screeners Designed for high-volume screening of powders and liquid slurries, our vibrating sieves will enable you to double your throughput capacity, without increasing floor space.

High capacity graders Improve your product quality and streamline your production processes by accurately grading fractions in a single pass.

Self-cleaning filters Our self-cleaning filters remove contamination from liquids, down to 15 microns without the need for replacement bags or cartridges.

What makes us specialists?

Customized solutions

Applying innovation to meet your requirements

Comprehensive customer service Technical support and global stocking

Specialized testing facilities

Trial your products for total peace of mind

Liquid solid separators Ideal for removing high-load suspended solids from liquid slurries, our versatile centrifugal separator will increase your productivity and reduce costs with flow rates up to 1000 l/hr.

Call us on +44 (0) 20 8818 2000 Or visit our website www.russellfinex.com MEPCA Ad Artwork - Food and Beverage.indd 1

12/12/2023 08:57:12

FOOD PROCESSING FOCUS

Self-cleaning filter delivers ROI in one year Russell Finex offers a wide range of sieving and filtration solutions to the food and beverage industry, supplying well-known brands including Nestlé, Mondelez and Warburtons. MEPCA found out how the company’s Self-Cleaning Russell Eco Filter helped to improve productivity for Windsor & Eton Brewery.

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indsor & Eton Brewery opened in 2010, almost 80 years since the last brewery in Windsor closed. The U.K. company now brews over 1.4 million pints of beer across a wide range of styles each year and packages it into casks, kegs, bottles, and cans. The beverages have won over 90 major international, national, and regional awards.

The brewing, fermentation, conditioning, and packaging stages of production are carried out on-site at the brewery. After the conditioning stage, all the keg, can, and bottle products are filtered and packaged either on-site or taken off-site for bottling at a contract bottler.

For most products, coarse filtration at 100 microns is necessary to remove hop material and yeast slurry, for which the brewery used a small 30-centimeter cylindrical metal in-line filter. However, the main limitation of this metal filter was its low capacity and short time before blockage occurred.

As a result, the brewery had to frequently stop the beer transfer operation and clean the material build-up from the filter before continuing. The impact of repeated cleaning of the filter during a filling operation was as much as 15 minutes of downtime each hour.

The brewery would occasionally bypass this coarse filtration stage and go straight to the 5-micron fine filtration stage, causing the operational life of the cartridges used to be significantly reduced.

A Windsor & Eton Brewery employee, who previously worked for Russell Finex, noticed how long the filling process took due to the filter blockages. He suggested that the brewery use a self-cleaning filter to avoid this problem. After investigating this alternative solution, the brewery purchased a modified

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Self-Cleaning Russell Eco Filter.

The Russell Finex machine has eliminated all downtime for filter cleaning during a transfer operation due to its larger filter screen size and the self-cleaning mechanism. The solids waste valve allows operators to continuously remove waste without stopping. As a result, filling operations using the Self-Cleaning Russell Eco Filter are more consistent and reliable.

Matt Stead, Head Brewer at Windsor & Eaton, said: “At all stages of the process, through trialling of a test unit to designing and fabricating our machine, the team at Russell Finex has endeavoured to really understand our processes and needs.

The team has actively supported us with the testing and trialling of various filtration options. We have ended up with a bespoke build that suits our needs particularly well.”

Windsor & Eton Brewery now passes approximately 420,000 litres through the machine annually. The brewery has

estimated that using the Russell Finex filter will avoid about 40 hours of non-productive downtime for filter cleaning each year.

A further benefit is that the operational life of the filter cartridges at the fine filtration stage has been extended from 6-9 months to 18-24 months, giving the brewery a potential saving of £2k per year.

The brewery also plans to look into using the Self-Cleaning Russell Eco Filter to help clarify the beer. Placing the filter underneath the fermentation vessel will remove more hop and yeast sediment while the product is chilled compared to what would settle out naturally over time.

As a result, a beer that would take 11 days to be ready for bottling can instead be ready in 8 days. By freeing up the fermentation vessel sooner for the next batch, the brewery has the opportunity to expand its capacity by 25%. bit.ly/RFBrew

Flexibility to help manufacturing flow Create personalised products for your customers with flexible industrial automation solutions that adapt to your changing needs. #MakeitFlexible

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PUMPS & PUMPING SYSTEMS

Peristaltic pump range gains industry recognition Verder, the manufacturer of the Verderflex range of peristaltic pumps, recently claimed the coveted Industrial Product of the Year Award in the Industrial Plant and Equipment Awards 2023 for its Verderflex iDURA 45-80 range. This accolade marks not only a significant achievement for Verder Liquids but also signifies a leap forward for industries seeking top-tier pumping solutions.

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n the dynamic world of industrial machinery, it is innovation that keeps businesses moving with efficiency and success. The iDURA 45-80, an integral part of Verderflex’s full DURA range, stands out for its exceptional features that redefine the capabilities of peristaltic pumps.

The inclusion of a factory-fitted IP66 integrated inverter and hose burst detection, coupled with Internet of Things (IoT) connectivity, sets the iDURA series apart in the landscape of industrial pumps.

One standout feature of the DURA range is the integrated inverter, which is enabled with IoT. This addition allows for precise control of the pump’s speed, empowering operators with the flexibility to take advantage of the 99.99% volumetric efficiency associated with a Verderflex iDURA pump. The result is increased accuracy, enhanced energy efficiency, reduced operational costs, and improved overall performance. This intelligent inverter technology showcases Verder’s commitment to sustainability and aligns with the global push toward greener industrial practices.

The inclusion of hose burst detection is a game changer in terms of operational safety. This advanced technology swiftly

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identifies hose failures, triggering an immediate pump ‘trip’ response to prevent extended downtime and costly repairs. In an industry where reliability is paramount, the iDURA series provides peace of mind to operators, ensuring uninterrupted processes and safeguarding both equipment and personnel.

The IoT connectivity of the full iDURA range opens up a new realm of possibilities. By enabling remote monitoring, Verder empowers businesses to optimise their operations, minimise downtime, and make data-driven decisions. The inverter connectivity extends the iDURA from a standalone pump into a fully integrated process control system to provide IoT functionality in line with any 4-20mA device. The pump can provide everything from a simple ‘is it running?’ message to information such as absorbed power, flow rate and current. Real-time data analytics not only enhance efficiency but also contribute to predictive maintenance, prolonging the lifespan of the equipment and reducing overall operational costs.

The versatility of the iDURA series makes it a valuable asset across various markets. The wide choice of hose materials means the pump can be easily slotted into a range of process plants in many industries. The iDURA series is well suited to the water treatment sector, where reliability and efficiency are critical. It can also be used for precise dosing requirements or the transfer of sheer

sensitive fluids such as flocculation products or carbon crystals, as the gentle pumping action ensures damage to the media as low as 1%. The pump’s robust design and advanced features also make it well-suited for handling challenging fluids in diverse industrial processes.

Verder’s success in winning this award with the iDURA 45-80, and the value of the full iDURA range, is not just a triumph for the company but a testament to the industry’s ongoing pursuit of excellence. As businesses evolve to meet the demands of a rapidly changing landscape, innovative solutions like the iDURA series pave the way for increased efficiency, reduced environmental impact, and improved safety standards.

Verder’s Industrial Product of the Year Award for the iDURA 45-80 is a recognition of the company’s commitment to pushing the boundaries of what is possible in pumping technology. As industries continue to evolve, Verder stands at the forefront, providing cutting-edge solutions that not only meet but exceed the expectations of a dynamic and demanding market. The iDURA series is not just a pump; it’s a testament to the power of innovation in shaping the future of industrial processes. www.verderliquids.co.uk

More knowledge.

More safety.

Become a CMSE – Certified Machinery Safety Expert! ®

Knowledge and competence in the field of machinery safety.

With internationally recognised TÜV certificate.

More content. More competence.

• Extensive knowledge relating to the machine’s lifecycle • Information on current standards and legal practice • Details on the risk assessment procedure • Functional safety: Safety control systems, pneumatic and hydraulic systems • Actual implementation of compliance strategies

Courses now available to book at Pilz HQ in Corby, at your premises or - NEW for 2024 - at locations throughout the UK!

Scan the QR code for more information, dates and to apply for courses.

The international machinery safety qualification.

CMSE

AD_CMSE_210x297_EN_2023_11_v1.indd 1

Pilz Automation Technology ◆ Corby NN18 8TJ 01536 460766 ◆ training@pilz.co.uk ◆ www.pilz.co.uk 05/12/2023 15:33:55

SENSORS & SENSING SYSTEMS

Pressure precision in hydrogen applications ESI Technology outlines the transformative role its pressure transmitters play in the hydrogen revolution.

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s the world collectively shifts towards cleaner and more sustainable energy solutions, hydrogen has emerged as a frontrunner in the race to decarbonise industries and power generation.

In this pursuit, the effective and reliable monitoring of hydrogen processes becomes paramount. ESI Technology’s pressure transmitters have positioned themselves as indispensable tools in ensuring the safety, efficiency, and success of hydrogen applications.

Hydrogen, often heralded as the fuel of the future, holds immense potential to revolutionise the energy landscape. As a clean and versatile energy carrier, hydrogen offers a solution to mitigate carbon emissions across various sectors, from transportation to industrial processes. However, harnessing the full potential of hydrogen requires advanced technologies to monitor and control its production, storage, and utilisation. ESI Technology has emerged as a key player in this endeavour with its state-of-the-art pressure transmitters.

Safety is paramount One of the primary considerations in hydrogen applications is safety. Hydrogen’s unique properties, including its flammability and potential for embrittlement of materials, necessitate precise monitoring and control.

ESI’s pressure transmitters are designed with safety in mind. These devices provide accurate and real-time pressure readings, enabling operators to maintain optimal conditions within hydrogen systems.

Accidents and leaks can be swiftly detected and addressed, ensuring a secure operating environment for both personnel and equipment. ATEX & IECEx certification is available across ESI’s intrinsically safe range of hydrogen pressure transmitters.

Hydrogen environments can be harsh, posing challenges to traditional

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instrumentation. ESI’s pressure transmitters are engineered with a robust titanium structure that provides excellent resistance to hydrogen embrittlement, enabling them to thrive in such conditions.

This durability not only enhances the longevity of the instruments but also contributes to the overall reliability of hydrogen applications.

Efficiency optimisation Hydrogen processes demand a high degree of precision to achieve optimal efficiency.

Pressure fluctuations can significantly impact the performance of these systems. ESI’s pressure transmitters excel in providing precise and reliable pressure measurements, allowing operators to fine-tune processes for maximum efficiency. The unique Siliconon-Sapphire sensor technology provides outstanding performance and gives excellent stability over a wide temperature range.

Excellent measurement accuracy provides high resolution with a precision greater than one in 10,000, even at high pressure.

Whether it’s hydrogen production, storage, or transportation, the ability to maintain consistent pressure levels is crucial for minimising energy losses and maximising overall system performance.

Real-time monitoring In the dynamic landscape of hydrogen processes, real-time monitoring is indispensable. The GD4200HUSB digital pressure transmitter provides instant and accurate pressure readings, via the ESIUSB software, empowering operators with the information needed to make timely and informed decisions. The software has many features, including leak testing, the ability to

measure, record, and view up to 16 sensors at the same time, virtual differential pressure measurement, automatic test start and stop time controls, and alarm levels for each individual sensor. Whether adjusting process parameters, responding to anomalies, or optimising system performance, the ability to access real-time data is a game-changer in the world of hydrogen applications.

Environmental Impact The global transition to hydrogen is not only about meeting energy demands but also about reducing our environmental footprint.

ESI’s commitment to sustainability extends beyond the benefits of hydrogen itself. By enabling precise control and monitoring, the company’s pressure transmitters contribute to minimising waste, energy consumption, and emissions associated with inefficient processes. In this way, ESI Technology aligns with the broader goals of a greener and more sustainable future.

By prioritising safety, optimising efficiency, and offering compatibility with the demanding hydrogen environment, ESI has positioned itself as a key enabler of the hydrogen revolution. As the world looks to hydrogen to drive a sustainable future, the role of reliable and advanced instrumentation cannot be overstated, and ESI’s pressure transmitters stand at the forefront of this transformative journey. esi-tec.com

MACHINE SAFETY

Take integrated safety a step further Integrated functional safety in variable speed drives is nothing new, but now new developments in drive technology can allow safety features to be integrated more seamlessly with wider process architecture, as Liam Blackshaw, UK Product Manager – LV Drives at ABB, explains.

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f a process or procedure suddenly goes wrong in an industrial setting, you want it to stop as quickly and as safely as possible. Most modern variable speed drives (VSDs) are already equipped with multiple safety features. A number of the more familiar safety features are relatively basic. For instance, safe torque off carries out the function of a mechanical safety contactor in bringing a machine to a complete stop when activated. Not only can it react faster than a mechanical contactor, but it also takes up less cabinet space. As applications have grown more complex over time, an increasing variety of types of motor stops and slowdowns are required for different types of machines. Many of these can be carried out by the drive itself, enhancing safety while reducing the need for additional cabinet devices.

Stopping and slowing down a motor are in theory relatively simple tasks. Recent developments in drive technology are enabling more sophisticated integration of safety within process systems. ABB’s FSPS21, enables safety functions to be integrated on certain ABB drives at a much lower cost. This is achieved by using PROFIsafe and PROFINET communication protocol standards to integrate PLC function with drive function. This can be performed with any safety PLC which supports PROFIsafe and PROFINET, and ultimately means that fewer components are required, decreasing the complexity of an installation without compromising on safety.

Drives equipped with the FSPS-21 module are well-suited to situations where only a small number of I/Os are required, as the in-built communication protocols can carry out of the majority of the most essential safety functions. Moreover, because the VSD’s safety functionality is governed by the PLC, STO and SS1 (Safe Stop 1) can be

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immediately – and safely – activated when called upon to perform an emergency stop, manual shutdown, or a wide range of other parameters such as detected overspeed.

Some applications already use a safety PLC, so ABB’s FSPS-1-equipped VSDs save duplicating programming safety functions programming because PROFIsafe and PROFINET communication are integral to the drive and can be programmed predominantly within the PLC. The result is that, when required anywhere across the system, drive-based safety functions can be activated by the PLC, and not just rely on detection by an individual drive. The FSPS21 module complies with SIL 3 and PLe safety levels.

ABB’s FSPS-21 module removes the need to wire and connect drive logic with safety relays and contactors, as the safety functions are already predesigned within the module to make commissioning easy. It also enables safety functions for multiple drives and machines to be maintained from a single controller. The module also allows drives to be grouped according to an application’s

applicable safety zones. For instance, when a conveyor line drive’s overspeed may require all associated drives to stop, this can be done by simply activating the integrated STO once for the whole group.

Automation systems traditionally required many external add-on devices to ensure their safety, but purchasing, installing and programming those additional devices is no longer a necessity. This is a benefit to many because it not only simplifies the provision of critical safety functions within a system, but it also avoids having to deal with the increasing complexity of installing such features after the fact.

Many industrial environments have long been fraught with potential danger, so integrated functional safety in drives is not a wholly new concept. However, combining safety functionality with a PLC system can better ensure that safety features are triggered exactly where and when they’re needed without compromising on productivity or the longevity of the machines. t.ly/ABBfunsa

SCHMERSAL | Enigma Business Park Malvern, Worcestershire, WR14 1GL

www.schmersal.co.uk uksupport@schmersal.com

MACHINE SAFETY

Machinery Directive becomes Machinery Regulation With publication in the Official Journal of the European Union in 2023, it is now binding that the new EU Machinery Regulation will replace the Machinery Directive as the most important legal provision for machinery safety. Machine safety specialist Pilz explains what this will mean to companies that design, build and sell machinery.

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ew approaches and issues, such as digitisation, required the ongoing development of the Machinery Directive.

After a transition period, the new Machinery Regulation will apply to all companies in the European Economic Area that design, build and sell machinery.

Machines that are imported into the area of European jurisdiction also have to meet the requirements.

The EU Machinery Regulation came into force in all EU member states 20 days after it was published in the Official Journal.

As a machine manufacturer you then have 42 months to comply with the new requirements for plant and machinery. Thus, the Machinery Regulation (MR) will become mandatory in 2027.

Key changes The Machinery Regulation gives machine manufacturers more precise specifications for how to handle substantial modifications on a machine, as well as machines subject to inspection. What’s more, it also takes into account the growing importance of digitisation and Industrial Security: It describes requirements for the cybersecurity of products as well as digital instructions.

The MR covers machinery, as before, and now also ‘related products’.

• Machines subject to inspection: The list of machines subject to inspection, which was previously in Annex IV of the Machinery Directive 2006/42/EC, has moved to Annex I. In Section A it contains a list of high-risk machines, for which mandatory inspection and certification through a third party are required. In future, six machine categories will be subject to inspection; application of a harmonised standard does not remove the inspection obligation. This is due to the current developments in artificial intelligence.

For the six listed product groups, machine

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manufacturers can no longer selfdeclare compliance in conjunction with a harmonised standard, as previously. Instead, a named accreditation body must be involved.

• Substantial modification: The regulation has been extended to include the definition of a substantial modification of machinery and the legal consequences of such a modification. A conformity assessment procedure is required for machinery safety if a machine undergoes major modifications or when changes are made that affect the machine’s compliance with the statutory provisions for CE marking. If a substantial modification has taken place, the user becomes the manufacturer – with all the obligations that entails.

• Safety components: The definition of safety components now includes not only physical, digital and/or mixed-type components, but also software.

• The emergence of new digital technologies such as artificial intelligence, the Internet of Things and robotics present new challenges for product safety. The regulation covers the safety risks arising from new digital technologies.

• In a new section entitled ‘Protection against corruption’, the Machinery Regulation now also establishes requirements for the cybersecurity of machinery. Cybersecurity threats must not be allowed to compromise the machine’s safety functions.

Manufacturers will need to review their existing safety concepts in this regard.

• Digital instructions: Manufacturers shall be allowed to supply instructions in digital

form. Should the customer request it, the manufacturer must supply the instructions in paper format. The EU declaration of conformity may be provided in digital form, and partly completed machinery may be delivered with digital assembly instructions and with a digital declaration of incorporation.

Harmonised standards It is still unclear how the process will run with the existing harmonised standards under the Machinery Directive. As it currently stands, these will need to be relisted. With over 750 directly listed standards alone, that means a significant effort over several years. With a defined transition period of 42 months, the standards committees now have a lot of work ahead of them. It will be interesting to see whether the relevant standards will be available as harmonised standards by the time the EU Machinery Regulation comes into force in 2027.

As a machinery safety expert, Pilz is actively involved in the creation of new legislation and is always informed on the latest developments.

The latest updates on the Machinery Regulation and a downloadable whitepaper on the topic, are available on the company’s website. pilz.com/mr

MACHINE SAFETY

Keeping pace with growing automation complexity The escalating use of intricate automation solutions in modern factories has created a pressing need for advanced safety measures. These solutions must be adept at averting accidents while facilitating seamless interaction between operators and machines, as Euchner explains.

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nitiating the machine design process requires equipment designers to conduct a comprehensive risk assessment in accordance with BS EN ISO 12100:2010. This standard mandates the identification of potential hazards associated with machinery, encompassing normal operation, maintenance, and equipment setup.

Adherence to the BS EN ISO 13849-1:2023 standard is crucial for designing safety-related control systems that meet required safety levels, avoiding safety-related failures that could result in injuries or fatalities.

The rising prevalence of collaborative robots (COBOTS) is a good example of the complexity of the safety challenge. In the case of COBOTS, which are designed to work alongside humans, a thorough risk assessment is imperative before deployment.

Assumptions regarding the inherent safety of COBOTS can overlook potential hazards such as collisions, entanglement, or crushing.

Assessments should consider factors like the specific tasks performed by COBOTS, the working environment, and potential interactions with human workers.

Complexity is Growing Addressing safety challenges in modern equipment requires more than simply shutting down machinery. Operators often need to interact with machines for programming, teaching, setup, and maintenance tasks.

Unfortunately, this interaction is sometimes overlooked during the design phase, leading to makeshift solutions or operators attempting to bypass safety devices. Industrial safety solution provider Euchner has developed technology to enhance safety and efficiency when interacting with complex machinery.

The Euchner Multi-Functional Gate Box (MGB2) modular solution emerges as an innovative safety system catering to complex machinery across various industries, including palletisers and robot cells. This system

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prioritises the safety of both operators and equipment while simultaneously improving efficiency and minimising downtime.

Noteworthy is its flexible modular construction, allowing users to tailor the safety system using off-the-shelf modules, making it a costeffective solution.

Comprising handles, locking units, escape releases, fieldbus connections, and various function modules, the MGB2 modular solution offers versatility to meet diverse application needs. With options for both classically wired OSSD versions and industry-leading fieldbus connectivity, integration is seamless.

This eliminates the need for expensive remote safety IO points, reducing wiring and installation time. Moreover, the MGB2 modular seamlessly integrates the CKS2 RFID key system, offering a sub-module version of the popular ‘key-in-pocket’ solution, enhancing safety in complex automated systems.

Data and Information The benefits of Industry 4.0 are numerous, including improved efficiency, reduced costs, increased flexibility, and better quality control. It is changing the way that factories operate and is bringing about a new era of industrial production that is more connected, intelligent, and responsive to customer needs.

Considering the interaction of the operator with the machine can be instrumental in determining the overall performance of equipment at any given time, it makes sense to include the technology in the door interlocks themselves. Euchner leads the way in this field and includes Industry 4.0 technology in many of its products, including the new Euchner CTS Interlock with the innovative FlexFunction, to give insight into the way the systems are operating and ensuring production issues are highlighted promptly but also helping to prevent manipulation of the safeguards themselves. Information, including the status of the interlocks, the number of times the devices have been locked/unlocked, as well as product identification information, is all readily available to the factory automation platform. Engineers can use this information to highlight areas of unreliability in the process and put corrective actions in place.

The integration of cutting-edge safety technology is crucial in designing and operating complex machinery that involves human interaction. With the growing demand for efficient machinery, prioritising safety during the design phase is essential to ensure the well-being of all stakeholders. www.euchner.co.uk

Live Events 4-6 June 2024 | NEC Birmingham

9 events

12,500+ visitors

450+ exhibitors

Incorporating:

Learn more at www.mandeweek.co.uk or scan this code

8 content theatres

EVENT REVIEW

LiftEx 2023 brought the lifting industry to Liverpool LiftEx 2023, sponsored by CoreRFID, attracted the crowds to the exhibition centre located among the vibrant docks on the banks of the Mersey in Liverpool on 21-22 November 2023.

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ver 1000 visitors across two days came to see the lifting products and services from more than 80 global exhibitors at LiftEx 2023.

This included all the latest lifting products, including hoists, mobile and overhead cranes, steel chains, wire rope, winches, shackles, web slings, rigging, spreader beams, height safety and load monitoring equipment, IT solutions and more. It was clear to see from the busy aisles that this was a popular event.

It was great to see the industry getting together and spending time with each other, sharing ideas and talking about business.

LEEA welcomed many visitors to its stand – the first thing they saw as they walked through the entrance. Representatives from the Regional Council for Australia and New Zealand also had a stand where they discussed their ongoing work in that region along, including the successful first LiftEx in Sydney last May. The LiftEx Accredited Training Scheme Seminar, which took place on day one, provided a series of lifting training sessions and presentations delivered by the LEEA Accredited Training Scheme (ATS) members.

They proved to be very popular, with all the sessions well attended.

The seminar kicked off with a look at Deterioration of Crane Ropes from Tensology, which covered factors causing wire rope deterioration and the modes of deterioration of crane ropes as well as the key points of wire rope discard. Load Weight Estimation from Mentor Training detailed how to use mathematical equations to calculate a load’s volume and the material

weight in kg per metre cubed. In Centre Onsite – Online from GGR Group discussed the range of courses offered as part of its e-learning approach. Wire Rope Socketing was demonstrated by Certex (UK). The final presentation of the day was on Sling Mode Factors, which saw Elevation Training and Development run through mode factor calculations, different types of working load limits, and sling angles and lengths.

It was not all work across the two days.

On the eve of LiftEx opening its doors, LEEA hosted a pre-event social at Anfield Stadium, home of Liverpool FC, handing out scarfs in LEEA’s colours. Liverpool legends such as Bruce Grobbelaar joined the great networking event, making it a night to remember as was, of course, the 5th Annual LEEA Awards – the lifting industry’s party of the year with comedian, presenter, actor and singer Jason Manford as special guest.

The organisers offered a big thank you to all those who attended LiftEx 2023, as well as to the exhibitors and sponsors. LiftEx 2024 will be held on 16 & 17 October at London Olympia West. www.leeaint.com

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EVENT REVIEW

Advanced Engineering 2023 declared the best yet The UK’s largest annual gathering of engineering and manufacturing professionals, Advanced Engineering, opened its doors once again on November 1 and 2, 2023 at the NEC, Birmingham. Across the two days, 8,943 attendees witnessed the latest innovations that the UK has to offer at Advanced Engineering, making it an extremely busy and energetic event.

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ver 400 companies exhibited at Advanced Engineering, along with a further 202 at its co-located show, Lab Innovations. Visitors, which included representatives from Airbus, Rolls-Royce, IBM, Boeing, McLaren, BAE Systems, Catapult HVM, Department for International Trade, Jaguar Land Rover and many more, could access both shows with one badge, giving the opportunity to explore an even wider range of products and services. The co-located attendee number of over 13,000 professionals translated to a successful event for our exhibitors.

This year, the distinguished composites zone, in partnership with Composites UK, attracted high-quality visitors and exhibitors, proving itself to be the go-to place for the UK’s leading composites sector. Here, highquality visitors and exhibitors were actively seeking the latest innovations in composite materials. Elsewhere, Advanced Engineering visitors were treated to a fresh look thanks to the recent rebrand. This was coupled with a new cross-industry floor layout, which allowed for a more diverse range of exhibitors from various industries, including newly added sectors such as marine, motorsport, construction, medical, rail and sport.

For companies targeting the aerospace and defence sectors, ADS returned with its Meet the Buyer programme, during which 90 brands participated in 105 supplier engagements, which was a 132 per cent increase on last year and will no doubt go on to become partnerships that enable huge engineering breakthroughs in the sector.

Attendees also had access to over 150 industry-leading speakers across its forums. Because of Advanced Engineering’s partnership with The CPD Group, all of the

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talks counted towards visitors’ CPD. This year, Advanced Engineering introduced a main stage, which was sponsored by Lloyds Bank and supported by Make UK, where speakers such as Richard Noble OBE, former holder of the world land speed record and serial innovator at ThrustWSH and Stephen Phipson CBE, Chief Executive of Make UK took to the stage. There were also several panel discussions, including one on women in manufacturing, which was led by Dr Megan Ronayne and supported by some of the leading female figures in the industry.

Across the exhibition’s four other forums, automotive, aerospace, composites and advanced materials and technologies, visitors could hear from industry experts on topics ranging from supply chain management, digitalisation and the skills gap.

All of the above led to this year’s edition of Advanced Engineering being labelled as the best event to date, with an increased net promotor score that illustrates the improved quality of visitors, making it attractive to leading manufacturing and engineering professionals.

At the show, Stephen Phipson commented: “There is a great buzz at the show. It’s very

active, and we’ve had lots of interest from people. Shows like this are absolutely vital because they are opportunities to network and learn from each other. It is an opportunity to think of something or see something you never thought would happen. It is the sense of community and collaboration that is very important for our industry.”

Enabling Innovation returned for another year, where ten start-ups competed to win £2,000 towards the establishment of their business. OxDrive, a provider of rugged, high-torque electric drivelines, was the winner, with Christopher Horton, Managing Director, accepting the award. “This is the first time that OxDrive has been recognised with an award, and we’re over the moon to win it,” Horton commented. “We manufacture a lot of our products externally, so we plan on using the prize money to take us further on the R&D and production road.”

More than 80% of exhibitor space has already been sold for 2024, which will take place on October 30 and 31 at the NEC, Birmingham. www.advancedengineeringuk.com

EVENT PREVIEW

Showcasing cutting-edge silicone, adhesive, tape and functional film solutions With just over a month to go until the 2024 Silicone Expo Europe, co-located with Tape & Functional Film Expo Europe, the events’ potential delegates are encouraged to register now ahead of the event, which promises to shape the future of engineering.

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ark your calendars for February 28-29, 2024, as the RAI Amsterdam transforms into the epicentre of innovation and expertise at Silicone Expo Europe, co-located with Tape & Functional Film Expo Europe. All engineers, innovators, and industry leaders are invited to a remarkable event that brings together top exhibitors, industry pioneers, and thought leaders. Visitors can discover the latest advancements, gain insights from influential speakers, and forge invaluable connections.

Join the industry in shaping the future of engineering.

Among the distinguished exhibitors at Silicone Expo Europe and Tape & Functional Film Expo Europe, Elkem, TESA, Wacker, and UTH stand at the forefront of innovation. These industry giants will showcase their cutting-edge silicone applications, adhesive solutions, and functional films. Delegates at the show can explore their booths to witness first-hand the transformative technologies that are reshaping various sectors, from automotive and electronics to healthcare and beyond.

Knowledge will be unleashed, and ideas ignited at the Technical Conference, where visionaries from renowned companies will share their expertise. The event boasts a keynote address from Dow, with other sessions delivered by Momentive, HÜBNER, and Sigmasoft, offering profound insights into the latest developments in the industry. Additionally, visitors are encouraged not to miss the engaging panel discussion focusing on the future of 3D printing – a session sure to spark innovative ideas and collaborative discussions.

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Forge connections, fuel collaborations Silicone Expo Europe and Tape & Functional Film Expo Europe offer more than just a platform for learning; they provide unparalleled networking opportunities. Visitors can engage with fellow attendees, industry experts, and exhibitors to exchange ideas, establish partnerships, and explore potential collaborations. The event’s interactive atmosphere fosters connections that can propel projects and initiatives to new heights.

“The quality of the conversations on our booth was on a high level, and the organisation of the show was outstanding.

Putting the hat of a visitor on, you got the

complete Silicone competence within a manageable size. The Expo exceeded our expectations, and we are more than happy to participate in 2024,” Said Rico Group’s Markus Landl following the 2023 Expo.

Anyone with an interest in the silicone, tape and functional film sectors is urged to take this opportunity to be a part of the future of engineering, and visitors can register now to attend Silicone Expo Europe and Tape & Functional Film Expo Europe 2024. Those who do visit the show can embrace the chance to explore groundbreaking technologies, gain insights from industry leaders, and network with likeminded professionals. www.silicone-expoeurope.com

INDUSTRY UPDATES

How standardisation for data centres can reduce costs

The NORDAC ON decentralised frequency inverter

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Join experts from the HARTING Technology Group, Delta Energy Systems and ZVK GmbH on Wednesday, 17 January 2024, for an informative live webinar looking at how standardisation for data centres can reduce costs and speed up time-to-market against this backdrop.

During the webinar, the panel will discuss how standardisation based on the Open Compute Project (OCP) can help to reduce the total costs of ownership (TCO). You’ll learn how standardisation helps reduce complexity and speeds up time-to-market. In addition, you’ll discover that space-saving components can open up more IT space for computer equipment and how employing energy-efficient connectors improves energy efficiency by up to 50%. bit.ly/HARTweb

The drives can be used over a speed range of 0 to 2600rpm, and with the IE5+ motor, constant torque down to standstill without any need for motor forced cooling.

The communication protocols, for example Profinet, EtherNet/IP or EtherCAT, are selected via parameters, making the device perfectly suited for integration into IIoT environments.

As with all NORD frequency inverters, the NORDAC ON is equipped with a powerful PLC for functions close to the drive.

Optional extensions include STO, internal braking resistors and an integrated brake control, which controls the motor holding brake without wear and ensures reliable holding of the stop position at standstill, for example in inclined conveyors. www.nord.com

he worldwide data centre market is experiencing explosive yearon-year growth as our reliance on remote working, computer apps, and the Internet of Things increases at a staggering rate.

Motion controller optimises multi-axis motion coordination

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rio Motion Technology has launched a new motion controller based on Intel multicore processors, running Microsoft Windows alongside Trio’s Advanced Motion-iX core. The PC-MCAT-2 will give OEM machine builders a control solution that allows easy integration of Windows applications together with advanced motion functionality.

Based on Trio’s Motion First Automation approach to machine control, the PC-MCAT-2 starts with motion.

The motion controller runs Microsoft Windows 10 with a choice of four processors, from Celeron through to a Core i7, as well as up to 256GB solid-state drive memory. To increase machine functionality, PC-MCAT-2 can integrate and control virtually any peripheral device, such as camera vision systems or sensors, via its extensive communication port array. Ports include HDMI, USB, serial ports, and general-purpose digital I/O. The motion controller also enables IoT connectivity, providing a high-speed link from the host machine to a wider factory network, thanks to three Ethernet ports. To enhance network segmentation and bandwidth, each Ethernet port has a separate IP address. triomotion.com.

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he NORDAC ON frequency inverters are part of the NORD modular system and can be optimally combined with the company’s IE3 or IE5+ motor ranges to provide the ultimate in drive flexibility and efficiency.

New sensors for easier, more economical positioning and inspection

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he latest class of sensors introduced by sensor specialists BAUMER continues to push the boundaries of performance by combining outstanding measurement precision of up to 5µm in an ultra-compact package. Using profile analysis, the ‘smart’ 2D OX series sensors are now able to solve a variety of challenging positioning and inspection tasks more efficiently and economically across a wide range of assembly and handling applications.

These 2D profile sensors are ideal for manufacturing applications wherever OK/NOK inspections or positioning tasks are possible via the evaluation of height information. They enable measuring ranges of up to 500mm with a field view of up to 300mm, ensuring design freedom for numerous applications. A comprehensive set of integrated tools can be parameterised directly via an intuitive web interface to ensure complete processing of the profile data directly in the smart sensor.

The new OX sensors are compact and lightweight and can be simply connected with a single cable thanks to Power-over-Ethernet. www.baumer.com/OXM200

CONNECTIONS 3D Print Manufacturing

Machine Safety

Midlands 3D Printing T: 01785 594389 E: sales@midlands3d.com W: www.midlands3d.com

Anti Vibration Products, Mounts & Bushes

Schmersal UK Ltd T: 01684 571980 E: uksupport@schmersal.com W: www.schmersal.co.uk

Marking Solutions

Fibet Rubber Bonding (UK) Ltd T: 01282 878200 E: sales@fibet.co.uk W: www.fibet.co.uk

Connectors & Cabling Solutions

T-Mark T: 0870 803 1877 E: sales@t-mark.co.uk W: www.t-mark.co.uk

Pipework Systems

CEMBRE Ltd T: 01675 470 440 E: sales@cembre.co.uk W: www.cembre.com/en

Control Systems

Jacob UK Ltd T: 01694 722841 E: sales@jacob-uk.com W: www.jacob-group.com/uk

Pressure Measurement Specialists

Beckhoff Automation Ltd T: + 44 (0)1491 410539 E: info@beckhoff.co.uk W: www.beckhoff.co.uk

Drives, Motors & Gears

ESI Technology Ltd T: +44 (0)1978262255 E: sales@esi-tec.com W: www.esi-tec.com

Robotics & Automation

Nord T: 01235 534404 E: GB-sales@nord.com W: www.nord.com

Dust & Fume Solutions Impact Technical Services T: 0116 244 8855 E: enquiries@impactts.co.uk W: www.impacttechnicalservices.co.uk

Flow Meters Titan Enterprises Ltd T: +44 (0)1935 812790 E: sales@flowmeters.co.uk W: www.flowmeters.co.uk

High Shear Mixing Equipment Silverson Machines Ltd T: +44 (0)1494 786331 E: sales@silverson.co.uk W: www.silverson.co.uk

Industrial Communications Brainboxes T: + 44 (0) 151 220 2500 E: sales@brainboxes.com W: www.brainboxes.com

Industrial Fans Axair Fans UK Limited T: 01782 349 430 E: aj@axair-fans.co.uk W: www.axair-fans.co.uk

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KUKA Robotics UK Ltd T: 0121 505 9970 E: sales.uk@kuka.com W: www.kuka.com

Sensors Carlo Gavazzi UK Ltd T: 01276 854110 W: www.carlogavazzi.co.uk IFM Electronic T: 020 8213-0000 E: enquiry.gb@ifm.com W: www.ifm.com PLUS Automation Ltd T: 0121 58 222 58 E: Sales@PLUSAutomation.co.uk W: www.PLUSAutomation.co.uk

Storage Solutions BITO Storage Systems Ltd. T: 02476 388 852 E: Info.uk@bito.com W: www.bito.com

Test & Inspection AMETEK Land (Land Instruments International) T: +44 1246 417691 E: land.enquiry@ametek.com W: www.ametek-land.com Cupio Services Ltd T: 01256 262800 E: info@cupioservices.co.uk W: www.cupioservices.co.uk

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