Issuu

AUGUST 2026

Manufacturing

Engineering

Process

Control

Automation

P 31 - Hörmann UK has introduced the HTL2 ISO thermally efficient telescopic dock leveller, which delivers up to 55% improved thermal insulation compared to standard dock levellers.

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©2026 Zebra Technologies Corporation and/or its affiliates. Zebra and the stylized Zebra head are trademarks of Zebra Technologies Corporation, registered in many jurisdictions worldwide All rights reserved. All other trademarks are the property of their respective owners. 28/06/26

EDITOR’S NOTE Editor Oliver Batt oliver@cimltd.co.uk Publication Manager James Burke jb@mepca.com 01795 509105 Head of Brand Development Jim Bearden jim@mepca.com 01795 509105 Design & Production Grant Waters grant@cimltd.co.uk James Taylor james@cimltd.co.uk Administration Manager Natalie Woollin admin@cimltd.co.uk 01795 509103 Credit Facilities Manager Gwen Lee creditcontrol@cimltd.co.uk 01795 509103 Head of Digital Xhulio Bishtaja digital@cimltd.co.uk Marketing Manager Lucas Payne lucas@cimltd.co.uk Director Tom Woollin tom@cimltd.co.uk Managing Director John Denning © 2026 Cogent Multimedia 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 Cogent Multimedia 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 nonpublication of any advertisement.

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AUGUST 2026

elcome to the August issue of MEPCA magazine. This month, we navigate the racks and aisles of warehouses and address the challenges that face the complex global circularity system that is logistics in our Warehouse & Logistics focus. As our long-term readers may spot, we’ve previously focused on Warehouse Automation, but have opted for a broader brush stroke this time to do the topic justice. I believe the quality and variety of content we’ve received as a result speaks for itself. Dexory leads the section with an examination of warehouse transformation at scale. On page 22, I report on Exotec’s ambitions to disrupt logistics. As can be expected, automation and robotic technologies, such as AMRs and palletisers, dominate the solutions covered in the focus. However, as argued by Thorworld (p.38) and several other contributors, fundamental operations should not be overlooked, with the importance of insulation, temperature monitoring and loading bay safety and efficiency highlighted. Returning to our cover this month is Bosch Rexroth, discussing why simplicity is the future of machine automation (p. 14-15). Elsewhere in the issue, Lloyds’ Dave Atkinson shares advice on getting into the defence sector (p.10); our Manufacturing Champion cuts through the BS of machine vision (p.12); and Gallagher discusses how manufacturers can improve resilience (p.50). This year’s industry events continue to deliver. We share our coverage of SMW 2026 (p.56), one of our top events of the year so far. As the UK braces for a third heatwave, enjoy this issue in the shade, and be sure to stay hydrated.

Oliver Batt, Editor @Mepca-magazine

To subscribe to MEPCA visit our website www.mepca.com or scan the QR code.

CONTENTS Industry Partners:

FEATURES 8 INDUSTRY NEWS 10 OPINION 12 MANUFACTURING CHAMPION 14 COVER STORY 17 WAREHOUSE & LOGISTICS

46 DRIVES, MOTORS & CONTROLS 48 PROCESS CONTROL 50 BUSINESS OPERATIONS 54 DIGITALISATION 56 EVENTS 66 COMING UP

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INDUSTRY NEWS

THE WORLD’S FIRST COLOURING BOOK FOR FUTURE MOTOR ENGINEERS

enzel Elektromotoren makes its case for a career in electric motor engineering even to the youngest generation. The Berlinbased company takes an original approach and is the first industrial manufacturer to publish a colouring book about its work. Children of preschool and elementary-school age can explore how large industrial motors are built. “The colouring book is meant to bring children joy and spark curiosity about technology along the way,” says Anja Leipold, head of marketing at Menzel. “We already partner with schools in our region to raise awareness of motor technology and attract young people to apprenticeship programs. Our industry is vital to every branch of manufacturing and the economy. It’s never too early to get the next generation interested in what we do. Who better than a motor manufacturer to show what goes into building, testing, servicing and repairing electric motors?” The colouring book portrays a varied line of work at the intersection of skilled trades, electrical and mechanical engineering and industrial production. The illustrations are based on photographs from the shopfloor and depict the manufacture of large electric motors in precise detail.

Menzel takes talent development seriously. The familyrun business, now in the third generation and approaching its centennial in 2027, trains young people as electrical machine and drive systems technicians every year. menzel-motors.com

ENDOLINE AUTOMATION WINS EXPORTER OF THE YEAR GOLD AND REACHES NATIONAL FINALS

ndoline Automation has been named Gold Winner in the Exporter of the Year category at the Bedfordshire Chamber of Commerce SME Bedfordshire Business Awards 2026 and has subsequently secured a place in the SME National Business Awards finals later this year. The achievement recognises the Bedfordshirebased manufacturer’s continued international growth, engineering innovation and commitment to supporting customers worldwide. Exporting now represents a significant proportion of Endoline’s business, with its end-of-line packaging automation systems installed in more than 30 countries through a combination of direct customer relationships, distributor partnerships and OEM collaborations. Founded in 1981, Endoline has grown from a small packaging machinery manufacturer into a global supplier of advanced end-of-line automation systems. Today, the company designs, manufactures and installs bespoke packaging solutions for manufacturers across the food, beverage, pharmaceutical and consumer goods sectors. Andrew Yates, Managing Director of Endoline Automation, said: “We are delighted to have been named Gold Winner in the Exporter of the Year category and to have secured a place in the national finals. Exporting has

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been a key part of Endoline’s growth for many years, and this recognition reflects the dedication of our employees, distributors, partners and customers around the world.” Winners of the SME National Business Awards will be announced later this year. endoline-automation.com

INDUSTRY NEWS

NEXT-GEN HUMAN–ROBOT SAFETY TECHNOLOGY

Oxford Technology has announced an investment in BeyondFence, a robotics company developing ISO compliant technology designed to allow humans and industrial robots to work safely together without the need for traditional physical safety barriers.

n modern manufacturing, robots and humans are typically separated by extensive safety fencing. Current safety standards require barriers to extend to the maximum possible reach of a robotic arm, with systems designed to instantly shut down the robot if any object or person touches the fence. While effective for safety, these arrangements consume significant factory floor space, increase installation costs, and reduce operational flexibility. BeyondFence solves this challenge by replacing the safety perimeter with certified intelligence built around the robot’s surface. By seamlessly incorporating this advanced touch-detection technology, BeyondFence empowers robots to instantly freeze movement upon physical contact, such as with a human hand or torso. In March 2026, Siemens Cre8Ventures announced that BeyondFence had joined the Siemens Cre8Ventures Digital Twin Marketplace. “The collaboration begins with a focus on fenceless robot automation and will expand into Autonomous Mobile Robots (AMR) and other autonomous systems. Together, Siemens Cre8Ventures and BeyondFence will explore how digital twins can accelerate the validation, deployment, and scaling of next-generation robotics solutions across European industry.” BeyondFence’s founders are Luc Yao and Dr. Camus Su, both of whom bring extensive experience in robotics and industrial technology. The company is headquartered in Oxford while maintaining deep technology partnerships globally. The investment from Oxford Technology, whose latest funds take advantage of SEIS (Seed Enterprise Investment Scheme) and EIS (Enterprise Investment Scheme) tax reliefs, will support the company’s initial operating costs as it progresses toward securing its first commercial sale. BeyondFence is already in discussions with several prospective customers. One early deployment may involve a major European company specialising in packing fruit for supermarket distribution, where enabling people and robots to work more closely together could deliver substantial operational and cost efficiencies. Commenting on the investment, Lucius Cary, founder of Oxford Technology said: “BeyondFence is addressing a major industrial challenge with a highly practical,

compliant, technology solution. As robotics adoption accelerates at pace globally, enabling safe and efficient human-robot collaboration will be paramount. We believe the company has the potential to significantly improve factory productivity while maintaining the highest safety standards.” Luc Yao added: “Industrial 5.0 puts human judgement and creativity back at the centre of production. BeyondFence is the infrastructure that makes that possible, safely, and at industrial scale.” Dr. Camus Su said: “Achieving this level of certification for fenceless human co-presence is genuinely new territory in industrial safety standards. As AI evolves toward Physical AI and Agentic AI, creating a human-centric, fenceless environment is no longer just a safety preference; it is the foundational infrastructure that allows robotic AI to safely expand its application skills. We are at the beginning of what that makes possible.” oxfordtechnology.com beyondfence.eu

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OPINION

A PRACTICAL PATHWAY INTO DEFENCE As Make UK Defence and Lloyds launch a new practical guide to help SME manufacturers in defence supply chains, Dave Atkinson, UK Head of Manufacturing, SME & Mid‑Corporates at Lloyds, reflects on a new era for the industry.

n June, the government published its long-awaited Defence Investment Plan, which builds on 2025’s Strategic Defence Review, setting out a 10-year vision for defence spending with small and medium-sized businesses at the centre. You don’t need existing defence credentials to be considered. Indeed, new entrants are valued for bringing fresh thinking to longstanding challenges. But supplying the defence sector presents particular challenges, from extra accreditations to elevated security requirements, which can be tricky to navigate. In response, Lloyds has joined forces with Make UK Defence – the manufacturers’ organisation that champions the UK’s defence supply chain – to create A Practical Guide to Working in Defence1, which includes real life insights from businesses that have successfully established themselves in the defence supply chain. It’s a great starting point, but there are also many well-established organisations that are working to create practical routes for capable manufacturers to access this expanding market. Joining relevant trade bodies and attending industry events can help build industry knowledge and create valuable connections.

FINANCIAL SUPPORT

And it’s important to approach this opportunity with your eyes wide open. You don’t need a perfect, finished plan; what matters is showing you understand the strategy you’re trying to execute and the implications it carries. The right finance partner should then be able to help structure the most appropriate support around your specific needs. That might mean working capital facilities to help manage increased cash flow requirements. Products like Asset Finance, Hire Purchase and our Capital Import Finance proposition can also work when investing in new machinery before contracts are fully executed. It’s also worth exploring the British Business Bank’s Growth Guarantee Scheme and UK Export Finance (UKEF), which can provide additional support for businesses pursuing defence opportunities overseas. As my colleague Ralph Edwards, Head of Trade Commercialisation, Business & Commercial Banking at Lloyds, notes, turning export opportunity into sustainable growth depends on having the right financial support in

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place, and Lloyds is focused on supporting UK businesses with connected trade finance, international payments and FX risk management to help manage risk, protect working capital and trade internationally with greater confidence.

THE NEXT STEP

A fundamental question for any manufacturing business considering defence work must be whether this opportunity aligns with your capabilities and strategic direction. What’s required is thorough preparation, appropriate resourcing, realistic timescales and commitment to building the relationships that underpin success in this sector. That can translate into real opportunities for SME manufacturers. See how Lloyds is supporting UK manufacturers to innovate, grow, and lead at: lloydsbank.com/manufacturing All lending is subject to status. Eligibility criteria applies. Lloyds and Lloyds Bank are trading names of Lloyds Bank plc. Registered Office: 25 Gresham Street, London EC2V 7HN. Registered in England and Wales no. 2065. Telephone: 0207 626 1500. Authorised by the Prudential Regulation Authority and regulated by the Financial Conduct Authority and the Prudential Regulation Authority under Registration Number 119278. Lloyds Bank Asset Finance, part of Lloyds Banking Group, is a member of the Finance & Leasing Association (FLA) and complies with the FLA Business Code of Practice. Further information is available from the FLA at www.fla.org.uk

1. lloydsbank.com/business/resource-centre/insight/defence-practical-guide.html

OPINION

SLOW ADOPTION, FASTER ACCELERATION Nikesh Mistry, Sector Head of Industrial Automation & Test and Measurement, GAMBICA, argues that the UK’s slow adoption of robotics might prove to be an advantage in disguise.

he UK has the lowest robot density in the G7. The most recent official figures, published by the International Federation of Robotics in its World Robotics 2025 report, put Western Europe at 267 robots per 10,000 employees and the EU-27 average at 231, against a global average of 132. The UK does not trouble that top table. Industrial robot installations here actually fell 35 per cent in 2024, and the pattern into 2025 has stayed cyclical rather than transformative. Read as a scoreboard, that is a losing position. However, if we see it as a starting condition for the next phase of manufacturing, it could be closer to an opening. The reason is timing. Germany’s 449 robots per 10,000 employees and Korea’s extraordinary 1,220 were built up over decades of fixed, hard-tooled automation, largely serving automotive and electronics lines. That installed base now must be upgraded or retrained to communicate to modern AI systems, and it is not necessarily quick nor cheap. The UK has far less of that legacy stock to work around. Where the story now sits, into 2025 and Q1 2026, is not really about robot density at all; it is about what happens next, and there the picture looks considerably more competitive. North American robot orders held broadly flat in the first quarter of 2026, but collaborative robot orders rose 55.6 per cent in units and 78.2 per cent in revenue year on year, with the strongest growth outside automotive entirely, in life sciences, electronics and food. That is a market shifting away from the fixed, highvolume automation the UK never fully built, and toward the flexible, software-defined systems a less burdened manufacturing base can adopt without a retrofit bill first. On AI specifically, Make UK’s most recent research, published this June, found that only 2 per cent of UK manufacturers describe AI as widely embedded in their operations, with just under 40 per cent using it in pockets and one in five not using it at all. Over half claim skills shortages, not cost or infrastructure, as the primary barrier. That is a genuine problem, and no amount of positive framing changes it. But it also means the constraint sitting between the UK and a more automated manufacturing base is a workforce and adoption confidence problem rather than a cost issue. This is definitely something we can rapidly influence and

ties in with the government’s new industrial AI adoption plan. The comparison with Europe and Asia should not be seen as a problem. Germany and Korea now have to retrofit their way toward the next generation of manufacturing. The UK, for once, gets to build straight into it. The UK’s slow start on automation was never the disadvantage it appeared to be. Because we skipped the decades long build out of rigid, hard tooled robotics, we’re not carrying the downtime, cost and resource burden of upgrading legacy systems to talk to modern AI. That gap becomes a genuine head start, provided we accelerate hard from here. UK manufacturers can put that same time and capital straight into AI-native, software-defined production. Slow first, fast now, is a perfectly good position to be in, as long as we treat it as a springboard rather than an excuse. gambica.org.uk

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MANUFACTURING CHAMPION

MANUFACTURING CHAMPION OF THE MONTH We’re delighted to spotlight Peter Jelf, founder and CEO of Visicon, as our August Manufacturing Champion. Peter’s known for his “no BS” approach to machine vision. Speaking with our editor, Peter reveals how he fell into this niche field and why it’s prone to overcomplication.

he field of machine vision was in its infancy when Peter began to specialise in it. “I wasn’t quite there for the birth of machine vision, but I was there when it went mainstream,” he recalls. While machine vision hadn’t been covered during Peter’s multi-skilled apprenticeship with Ford Motor Co., he gained experience of it in the pharmaceutical industry at a contract packer. He’d started as an electrical engineer before becoming a project engineer. It was then that he became responsible for projects involving machine vision, including pharmacode reading and blister inspection, which provided his first real exposure to the field. At just 23, Peter set up a consultancy firm after taking voluntary redundancy when the contract packer closed the facility. At first, he offered whatever service he could – project engineering, CAD drawing, controls engineering – but through a contact at Omron, he was given the opportunity to use its new vision system, which people were struggling to implement. At the time, he had no choice but to learn by doing. “It was a steep learning curve,” he admits, as few others were working in that space. But it allowed him establish a niche in machine vision as it transitioned from the laboratory into industrial automation. Visicon was born and has since become a trusted voice in machine vision. Indeed, Peter is known as the “no BS machine vision expert”, a moniker that came from customer feedback. “I think the problem with machine vision is that the industry is populated by nerds,” he says, and he counts himself among them, but the difference is that, having done his time on production lines as an engineer, he can explain it in more practical terms. Whereas those with a computer science background and no practical experience tend to overcomplicate things. And there are, of course, those who benefit from keeping it as a “black art” when illumination, both figuratively and literally, is crucial. As he puts it, “If you break it down, cameras do nothing more than capture light. So, once you understand that, and you understand how light behaves, then it makes it all a lot simpler.” The most important piece of advice Peter has for organisations considering a machine vision solution is talk to someone about it. People working in machine vision

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are knowledgeable and happy to share that knowledge, he says. Most machine vision projects are achievable; it is really a matter of how to approach it. “So, save yourself the headspace and just talk to someone.” As with all automation projects, there’s a benefit to taking “baby steps” with machine vision implementation over rushing into a huge site-wide transformation project. “Get the quick win in first, get people on board, see the return on investment, and then take the next step. You don’t have to do it all in one go.” For further practical, no-nonsense advice on machine vision, visit Visicon’s website or follow Peter on LinkedIn, where he posts regular video content. visicon.co.uk bit.ly/4vGM6om

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COVER STORY

WHY SIMPLICITY WILL DEFINE AUTOMATION

A shift in what manufacturers expect from automation is forcing machine builders to reconsider machine design. Here, leading provider of automation solutions Bosch Rexroth describes why simplicity will define the next generation of machine automation.

or decades, machine builders have been judged on what their machines can do: faster cycle times, tighter tolerances and higher throughput. Those performance metrics remain important, but today’s manufacturing landscape has fundamentally changed. Customers are no longer simply buying machinery; they are investing in flexibility, resilience and future-proof production. As manufacturers across the UK continue to face rising labour costs, skills shortages, increasing energy prices and pressure to improve sustainability, the conversation around automation is changing. The challenge is no longer whether to automate, but how to automate in a way that delivers value quickly while remaining adaptable to tomorrow’s requirements. This shift is forcing machine builders to rethink not only the machines they design, but also the technologies they choose.

COMPLEXITY HAS BECOME THE HIDDEN COST Modern automation systems have evolved significantly over the last decade. While technological capability has expanded rapidly, so too has system complexity. A typical machine may incorporate linear motion systems, servo drives, robotics, vision systems, safety technology, sensors and multiple software platforms. While each technology is highly capable, together they can increase engineering effort, extend commissioning times and make ongoing maintenance more difficult. For many OEMs, engineering hours have become one of the most valuable

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resources. Skilled automation engineers are increasingly difficult to recruit, while customers continue to expect shorter lead times and quicker returns on investment. This has created a new priority within machine design: reducing engineering complexity. Rather than focusing solely on component performance, manufacturers are increasingly asking different questions: • How quickly can this machine be engineered? • How simple is commissioning? • Can operators easily modify production? • Is the system scalable? • How easily can it integrate with future digital technologies? These questions are reshaping automation strategy across almost every manufacturing sector.

THINKING IN SYSTEMS RATHER THAN COMPONENTS

Historically, automation projects have often been assembled from individual products selected independently throughout the design process. Today’s leading manufacturers are taking a different approach by defining the complete motion requirement first, and then configuring integrated subsystems that combine mechanics, drives, motors and software within a single engineering environment. This systemsbased approach offers several advantages. Engineering effort can be reduced because many components are already designed to work together. Digital configuration tools minimise specification errors, while pre-engineered software shortens commissioning. Instead of spending valuable engineering hours integrating technologies from multiple suppliers, engineers can focus on optimising machine performance. Just as importantly, this approach reduces project risk. In an environment where delivery schedules

COVER STORY continue to tighten, predictable implementation has become just as valuable as technical performance.

FLEXIBILITY IS REPLACING FIXED PRODUCTION

Manufacturing is becoming increasingly dynamic. Production runs are becoming shorter, product variants continue to increase, and customers expect rapid changeovers with minimal downtime. Machines designed for a single product over many years are becoming less common. Instead, manufacturers require equipment capable of adapting quickly to changing market demands. Linear motion technology has evolved alongside this trend. Intelligent axes, configurable multi-axis systems and integrated mechatronic solutions enable machines to be reconfigured faster while maintaining high levels of precision. This flexibility is particularly valuable in sectors such as packaging, electronics, battery manufacturing, medical technology and food production, where production agility directly impacts competitiveness.

DIGITAL ENGINEERING IS BECOMING THE COMPETITIVE ADVANTAGE

Digitalisation is often associated with factory data and predictive maintenance, but one of its biggest impacts occurs much earlier during machine development. Modern engineering software allows designers to configure, size, simulate and commission complete motion systems digitally before hardware is assembled. Automated parameter generation and visual programming reduce manual engineering while helping avoid costly commissioning errors. The benefits extend beyond faster machine development. Digital engineering improves consistency, supports collaboration, standardises successful designs and enables engineering teams to deliver more projects with limited resources.

SUSTAINABILITY STARTS WITH SMARTER ENGINEERING

Sustainability increasingly begins during machine design rather than solely through lower energy consumption during operation. Reducing unnecessary engineering iterations, simplifying commissioning, selecting modular technologies that can be upgraded rather than replaced and improving serviceability all contribute to lowering the overall lifecycle impact of industrial equipment. Modular automation architectures also allow manufacturers to modernise production incrementally, extending equipment life while reducing capital expenditure. For many organisations, sustainability and operational efficiency are now closely linked.

PREPARING FOR THE NEXT DECADE OF AUTOMATION

Technologies such as AI-assisted engineering, collaborative robotics and increasingly connected production systems will continue transforming manufacturing. However, success will not necessarily belong to companies adopting every new technology first. It will belong to organisations that build automation on open, scalable foundations capable of evolving alongside changing business needs. Machine builders that embrace integrated engineering, modular architectures and simplified commissioning will be better positioned to respond quickly to customer requirements while controlling development costs. Ultimately, the future of automation is not about adding more technology; it is about making sophisticated technology easier to implement. As manufacturers navigate economic uncertainty, supply chain disruption and increasing competitive pressure, simplicity may become one of the industry’s greatest competitive advantages. The companies that succeed will be those able to engineer, deploy and adapt automation quickly, giving customers the flexibility they need for the future. boschrexroth.co.uk

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Sumitomo EMEIA 2026 Gears.Motors.Drives MEPCA A4 6mm Bleed.indd 1

06/01/2026 11:03:26

FOCUS ON:

WAREHOUSE & LOGISTICS

Sponsored By

WAREHOUSE & LOGISTICS

SPEED, DATA AND GROUND TRUTH Modern manufacturing logistics must transform to handle the heightened demand being placed upon it. Here, Dexory, the warehouse intelligence and automation specialist, demonstrates what the transformation of a logistics operation looks like at scale with a leading automotive manufacturer.

peed and accuracy are the lifeblood of modern manufacturing logistics. Manufacturers face mounting pressure to deliver on tighter schedules, adapt to fluctuating demand and navigate global disruptions. With the rise of e-commerce and just-in-time production, and compounded by customer expectations for near-instant delivery, the industry is shifting to prioritise agility and precision like never before. Manufacturers need logistics operations to be robust enough to withstand these pressures while maintaining efficiency. Rapid, data-driven decision-making has become essential to ensure that raw materials, components and finished goods move seamlessly through the supply chain.

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Timely insight, enabled by real-time data and advanced analytics, sits at the heart of that transformation.

FROM DATA TO INTELLIGENCE: TURNING INSIGHT INTO ACTION

Collecting data is only part of the challenge. The true value of that data lies in turning it into actionable intelligence; a continuous, real-time picture of what is actually happening on the warehouse floor, rather than a periodic snapshot. The gap between data and actionable intelligence has left many manufacturers exposed. Traditional cycle counts, manual stock checks and infrequent audits meant that, for most of the year, operations were making decisions based

WAREHOUSE & LOGISTICS on data that was hours, days, or even weeks out of date. In just-in-time environments, that gap is where production delays begin, where expedited shipments are triggered, and where confidence in replenishment decisions quietly erodes. Digital twins, AI-powered decision-making and predictive analytics are now closing that gap. Rather than reacting to problems once they surface, manufacturers can anticipate disruptions, optimise inventory levels and act on real-time operational context before issues ever reach the production line.

GROUND TRUTH IN PRACTICE: THE STELLANTIS STORY

The experience of Stellantis, one of the world’s leading automotive manufacturers, shows what this transformation looks like at scale. Operating highly sophisticated production environments across multiple global facilities, Stellantis sought to strengthen inventory integrity and unlock greater efficiency across its warehouse operations. At its Sterling Heights Assembly Plant, Stellantis partnered with Dexory to deploy DexoryView, bringing continuous, real-time warehouse intelligence into daily operations. By combining autonomous, aisle-by-aisle robotic scanning with seamless WMS integration, Stellantis gained full visibility across their warehouse space, with wall-to-wall, floor-to-ceiling stock checks performed every day. Real-time inventory accuracy reached 99 per cent plus, supported by AI-powered insights that enabled proactive decision-making, which was all achieved with no infrastructure changes, no aisle closures, no disruption to production, and no upfront capital investment. The results followed quickly. Stellantis saw a 26 per cent increase in warehouse integrity, reaching 99 per cent within two weeks of deployment. Inventory errors and warnings fell by 98 per cent, directly supporting uninterrupted production and confident replenishment decisions. Manual stocktake effort dropped by 95 per cent, freeing 47 hours per week to be reinvested into highervalue, performance-driven tasks. A single scan identified 37,800 previously unrecorded pallets, while expedited shipments and scrap loss fell by 77 per cent, a direct result of proactive verification replacing reactive correction. The investment itself was recovered within two weeks, simply through identifying misplaced stock that had previously gone undetected. As one Senior Supply Chain Manager at Stellantis put it: “With DexoryView, we’ve moved from reactive firefighting to proactive planning. We now see exactly what’s in the warehouse and where it is, without delays, guesswork or manual rework.” The results were significant enough that Stellantis is now expanding DexoryView to five additional North American facilities through 2026, following full signoff from plant and process engineering leadership.

ROBOTICS AS A STRATEGIC ADVANTAGE

Stellantis’s experience reflects a broader shift already underway across manufacturing logistics. Robotics now achieve accuracy rates exceeding 99.9 per cent, minimising the errors in inventory tracking that can disrupt production

in precision-dependent industries like automotive and electronics. Subscription-based adoption models mean manufacturers no longer need heavy upfront investment to benefit. Deployment can happen within days, not months, delivering immediate reductions in waste, error and labour cost. Beyond physical tasks, robotics now double as data collection tools, offering manufacturers an always-on view of production efficiency and inventory levels. That realtime visibility allows teams to reduce downtime through immediate alerts on equipment or inventory issues, enhance accuracy by ensuring components arrive exactly where and when they’re needed, and optimise operations by pinpointing inefficiencies before they compound into costly disruption.

THE SHIFT FROM REACTIVE TO PROACTIVE

The throughline across both the broader industry trend and the Stellantis case study is the same: speed and certainty in decision-making are no longer differentiators, they are baseline requirements for competitive manufacturing. Operations still relying on periodic checks and manual processes are, by definition, managing reactively, i.e., responding to problems after they’ve already affected production. Manufacturers who have closed the gap between assumption and reality are operating differently. Replenishment decisions are made with confidence rather than buffer stock. Production schedules hold because the components behind them are exactly where the system says they are. Audits no longer require halting operations, because the data has already been continuously verified.

CONCLUSION

Manufacturing logistics is undergoing a profound transformation, driven by the dual imperatives of speed and data intelligence. Stellantis’s results demonstrate what’s achievable when warehouse intelligence moves from concept to daily operation: faster decisions, fewer errors, and production lines that keep moving because the data behind them is finally trustworthy. For manufacturers still operating on assumption, the gap between that and reality is no longer a minor inefficiency, but a widening competitive disadvantage. dexory.com

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WAREHOUSE & LOGISTICS

5 SIGNS OF AN ASSUMPTIVE OPERATION For most warehouse operations, the gap between what the system says and what is physically on the floor is invisible … until it’s a problem. By the time a production line stops or an expedited shipment is triggered, it has already cost the business. Here are five signs a warehouse may be running on assumption rather than reality.

1. THE LAST FULL STOCK CHECK WAS WEEKS AGO.

Periodic audits create a false sense of control. Between counts, the operation is running on data that grows less accurate by the hour. If the team can’t tell the current state of every location right now, the operation is operating on assumption.

2. WMS AND PHYSICAL STOCK REGULARLY DISAGREE. Discrepancies between system records and physical inventory are more than an inconvenience; they are a red flag. Every mismatch is a decision waiting to go wrong, whether that’s a replenishment call, a production schedule, or a shipment commitment.

3. THE TEAM SPENDS SIGNIFICANT TIME ON MANUAL STOCK CHECKS. If skilled warehouse staff are walking aisles with clipboards, the operation is consuming resources to generate data that is already out of date by the time it’s recorded. That time has a cost, and so does the inaccuracy.

4. UNEXPECTED LINE STOPPAGES OR EXPEDITED SHIPMENTS.

These are the most visible symptoms of an assumption-

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led warehouse. When parts aren’t where the system says they are, production pays the price. If this is a recurring pattern, the root cause is almost always a data gap.

5. REPLENISHMENT DECISIONS ARE BASED ON INSTINCT RATHER THAN OPERATIONAL CONTEXT.

When buyers and planners can’t trust inventory data, they compensate with buffers, over-ordering, and gut feel. The result is higher carrying costs, wasted space and a supply chain built around uncertainty rather than ground truth. The good news is that none of these are permanent. A continuous warehouse intelligence layer (one that delivers real-time ground truth across every location, every shift) closes each of these gaps without disrupting the operation. The warehouses pulling ahead aren’t auditing more frequently, they’re operating on reality, all the time. DexoryView is the warehouse intelligence platform giving manufacturing operations the real-time ground truth to make faster, more confident decisions- every shift, without disruption. Find out more: dexory.com

Dexory.com

Your WMS holds a version of your warehouse. DexoryView holds the reality. DexoryView gives manufacturing operations the ground truth to act with confidence- a continuous intelligence layer delivering 99%+ inventory accuracy, every shift. Automated cycle counting processes over 10,000 location scans per hour, closing the gap between what your WMS says and what is physically on the floor. The result is real-time operational context, predictive decision support, and the clarity to keep parts flowing and lines running- before problems surface.

Learn more about DexoryView solution

WAREHOUSE & LOGISTICS

EXOTEC: TRANSFORMING GLOBAL LOGISTICS

Earlier this year, French robotics company Exotec opened its new strategic headquarters, Imaginarium, in Lille. It marked the occasion with the first edition of the Exosummit, an event gathering the company’s partners, customers and industry leaders. MEPCA’s editor attended to report on Exotec’s mission to transform global logistics.

ince 2015, robotics company Exotec has been at the forefront of robotic warehouse solutions. It began with the Skypod® robot, Exotec’s renowned AMR (autonomous mobile robot), a flexible and highly modular, goods-to-person automated storage and automated retrieval system (AS/AR). The Skypod® has full 3D movement, enabling it to scale vertical storage racks up to 14 metres. It is also highly agile and travels at an impressive 4 metres per second. In 2025, Exotec released a new generation of the robot with an even more compact design. While innovation remains at the heart of what Exotec do, it is now focusing on the bigger picture. No longer satisfied with simply building robotic systems for warehouses, Exotec wants to provide end-to-end warehouse solutions, as an integrator. Key to this transition is the company’s new headquarters: Imaginarium.

IMAGINARIUM

The building is a surprisingly elegant amalgam of architectural styles. Modern glass and steel meet industrial red brick walls and pillars. Imaginarium is designed so that anyone entering the building must pass through the “village square”, a welcoming space that invites people from across departments to meet, connect and collaborate. The building also accommodates a 8,560-square-metre production site, where Exotec’s technology is manufactured, tested and validated, and where the Skypod® system can be seen in action. The R&D office has purposely been situated close by for swiftly testing and deploying ideas. In an intimate press briefing, Exotec’s co-founders Romain Moulin (CEO) and Renaud Heitz (CTO) explained the building’s strategic importance. Exotec was founded in Paris in 2015, but soon moved to Lille. As Renaud Heitz explained: “Lille is at the centre of European logistics. You are close to the UK, Belgium, Netherlands, Germany, close to the seaports with Rotterdam, with Dunkirk […] the most advanced logistics comes from the seaports.” From Lille, Exotec first established itself in Europe; in 2019 Exotec gained success in Japan; in 2020 it expanded

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Renuad Heitz, Co-founder and CTO (left); Romain Moulin Co-founder and CEO (right) into North America, and its US operation now accounts for 50 per cent of the company’s growth; and this year, Exotec introduced the next generation of Skypod® to South Korea. Alongside this international and operational expansion, Exotec continues to expand its technology, improving the Skypod® system and developing technologies around this, including palletisers. However, four years ago, the company realised its current facility would not support its ambitions in either respect. Imaginarium was designed to rectify this. The building spans 25,000 square metres and every aspect of its design has been carefully selected. The brickwork respects the architecture of Northern France’s industrial heritage, while its more modern features maximise light and space. As described above, collaboration and connection are emphasised at a design level. It is built to be Exotec’s hub; a place where staff from across its global operation can converge for seminars, training and collaboration. Exotec’s co-founders insisted that innovation remains crucial to their strategy. Indeed, 10% of the company’s

WAREHOUSE & LOGISTICS

revenue is invested back into R&D, and as Romain Moulin explained, “This building is key to accelerating the innovation loop.” The focus of that innovation has now shifted, as Exotic alters course from robot manufacturer to full warehouse integrator.

THE EXOSUMMIT

The inaugural Exosummit reinforced the company’s mission through the testimonials of its customers and discourse with industry leaders from across Exotec’s broad ecosystem. The key note speech was delivered by Xavier Lhors, AfterSales Supply Chain Director, Renault Group, who described the company’s “high impact” partnership with Exotec, which has seen its Skypod® robots do the equivalent of 50 laps around the world. Renault required an industrialgrade, high-capacity system to handle the automated fulfilment of over 3 million parts. Exotec delivered a system that consisted of 85 robots, picking 7,000 lines a day, and managing 25,000 SKUs (50 per cent of the company’s total). Lhors joked that Exotec also being French didn’t secure them Renault’s business. But one thing that made Exotec stand out from the competition was change management. Exotec helped with this often-difficult transition, ensuring there was clarity of purpose and this was communicated clearly with stakeholders. The biggest surprise, he said, was the acceptance of the system by Renault’s staff.

THE FUTURE OF INTRALOGISTICS

Further into the summit, Marie-Axelle Loustalot-Forest, retail automation specialist, and Vineta Bajaj, Group CFO, Holland & Barrett, discussed the retail sector and the future of intralogistics. They described how the growth of online shopping seemed unstoppable during covid in 2018 before later plateauing due to inflation. Shopping habits have since become more irregular and harder to predict. People now vary where, when and by what means

they shop. This has resulted in business volatility and an imperative for fulfilment systems to be more dynamic and flexible, and, of course, automated. AI adoption and autonomous deliveries were discussed as the next logical steps for the sector. However, this comes with the challenge of overcoming negative perceptions. A subject that was addressed in the following segment, when Peter Mohnen, CEO of Messer SE & Co. KGaA (former CEO of KUKA) and Nicolas Hunsinger, Head of ESG at Exotec, joined discussions. How can the perception of robots and automation be changed from a threat to an asset? The panel looked at a number of examples of the positive impact of automation, including the fact that countries with higher robotic densities actually have lower unemployment rates, and, interestingly, that women are more likely to work in an automated warehouse. They concluded that responsible automation was crucial, and this means deploying tech with the full awareness of its cultural impact.

FROM SELLING ROBOTS TO SELLING WAREHOUSES

With the first Exosummit, Exotec perfectly articulated the pressures facing global logistics and why dynamic and flexible automation-based approaches will be the future. Towards the end of the Exosummit, Exotec’s co-founders shared that the transition from selling robots to selling warehouses had not been an easy one. They explained that one of their early warehouse projects failed because they didn’t fully understand the warehouse’s fulfilment process and were too focused on the robots. Their solution has been to hire people who know the intricacies of warehouse fulfilment and absorb that knowledge into the company. With Imaginarium, Exotec has created an innovation hub, from which it can take new insights and swiftly turn them into real-world solutions for its global customers. Exotec.com

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WAREHOUSE & LOGISTICS

ROBOTS ACCELERATE PRODUCTION LOGISTICS Leading factory automation provider B&R recently automated its logistics processes in partnership with KNAPP.

Roman Seitweger, Head of Production for B&R

&R Industrial Automation GmbH, a member of the ABB Group, is a leading supplier of robotics, control systems and software. With highly dynamic logistics requirements at its headquarters in Eggelsberg, Austria, the company decided to automate its transport, storage and order-picking processes. B&R chose KNAPP to provide the intralogistics solution. By combining an automated store, computer-guided picking stations and autonomous mobile robots (AMRs), KNAPP was able to ensure a seamless material flow at the facility, from goods-in to dispatch. Roman Seitweger, Head of Production for B&R, comments: “The KNAPP solution was particularly convincing because it wasn’t a standard solution, but one that was tailored to our specific logistics processes.”

HIGH-DENSITY STORAGE

KNAPP’s Evo Shuttle store is the heart of the automated solution, providing 91,622 storage locations, with 80 shuttles zipping back and forth on 40 levels. Three different heights are available in the racks, with containers stored double deep. Some containers are even stacked for storage automatically by a special stacker/destacker station with integrated measurement technology. In this way, the Evo Shuttle system ensures maximum storage density. Combined with faster access times, this has increased warehouse throughput at Eggelsberg by 35 per cent.

ORDER PICKING UP BY 50 PER CENT

Previously, order picking at the warehouse was a totally manual process, which was physically challenging and resulted in a relatively high error rate. Now the Evo Shuttle

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supplies four of KNAPP’s ergonomically designed Pick-itEasy workstations, where picking for either manufacturing or shipping is guided by user-friendly screens for high levels of accuracy. There are also Kanban racks equipped with pick-to-light displays for fast-moving components. The workstations have increased picking throughput by 50 per cent, with up to 6,000 order lines processed per day.

MOBILE ROBOTS

A fleet of KNAPP’s Open Shuttle autonomous mobile robots, along with existing tugger trains, connect the Evo Shuttle store with B&R’s manufacturing lines, delivering components to the production stations and taking completed parts or empty containers away. They operate through halls that are separated by rapid-action doors, which the Open Shuttles are able to control. The AMR system is adaptable, with new paths and processes being added as required, and integrated scanners ensure safety around employees.

INTELLIGENT SOFTWARE

The control solution for the automation was also supplied by KNAPP, using its own KiSoft software platform, which covers all hierarchy levels and is connected seamlessly to B&R’s SAP® system.

LIFETIME SUPPORT

KNAPP also provides Customer Service for its solution at B&R, ensuring maximum system availability through reactive and preventative maintenance. knapp.com

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rise to new dimensions

Our Open Shuttle range of autonomous mobile robots includes models for handling containers, trays, cartons and pallets. AMRs provide an efficient, safe and dynamic transport solution, with rapid implementation and layout changes at the click of a mouse.

knapp.com

WAREHOUSE & LOGISTICS

WAREHOUSE SAFETY, RE-IMAGINED Keeping warehouse operatives safe from the many physical hazards present on the shopfloor requires a company to see risks before they escalate and proactively manage them. Verkada’s integrated, AI-powered physical security platform is designed to support this.

arehouse and manufacturing environments are fast-paced, high-throughput environments where forklifts, loading docks and constant foot traffic create real safety risks. For safety and operations teams, staying ahead of incidents rather than simply reacting to them is critical to protecting employees and maintaining compliance. Verkada’s integrated physical security platform gives manufacturers the tools to move from reactive investigations to proactive prevention, all while simplifying day-to-day operations.

PROACTIVE, AI-POWERED ALERTS

REDUCED INVESTIGATION TIMES

ENSURING GREATER OVERSIGHT IN LINE WITH REGULATIONS

When an incident does occur on the warehouse floor or at the loading dock, speed matters. Verkada’s natural language search allows teams to quickly locate relevant footage without scrubbing through hours of video, simply by describing what they’re looking for. Unified timelines make it easy to build a complete sequence of events by pulling together footage across multiple cameras and floorplans, from receiving to racking to the dock itself. For dock-related incidents specifically, Helix integration lets teams link freight numbers or third-party data directly to time-stamped video, making it fast to audit exactly what happened during a loading or unloading incident. And once the right clip is found, sharing it is simple: footage can be sent directly to colleagues via email or text, eliminating the need to download files to a hard drive. The result: less time spent manually reviewing footage and more time focused on keeping people and product moving safely.

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Rather than waiting to find out what happened after the fact, Verkada helps teams understand what’s happening on-site in real time. Slip-and fall-detection can automatically notify safety teams the moment an accident occurs, enabling a faster response. Line-crossing alerts can detect when workers enter hazardous or restricted areas, helping prevent incidents before they escalate. Together, these AI-powered alerts shift safety management from a reactive “what happened” mindset to a proactive “what’s happening now” approach.

Compliance is an ongoing responsibility, and Verkada helps organisations stay ahead of it. PPE compliance alerts can identify when employees are missing safety vests, hardhats, or goggles, not as a tool for correction, but as an opportunity for use in training that reinforces a culture of safety. Beyond visual monitoring, air quality sensors can track health hazards like dust particle exposure, elevated noise levels, and heat index, giving teams greater visibility into environmental risks. The goal is simple: empower safer practices across every level of the facility. With Verkada, distribution centres gain the tools to protect their people, streamline investigations, and stay ahead of risk, building a safer, more proactive workplace from the ground up. Interested to learn more? Book a demo: verkada.com/uk/demo/

WAREHOUSE & LOGISTICS

THE ROLE OF LOADING AUTOMATION From short run promotions to new packaging compliance and supply chain upheaval¸ Wouter Satijn, Chief Revenue Officer, Joloda Hydraroll, discusses the role of loading automation in operational agility.

ero-touch production lines and slick warehouse operations enable manufacturers to quickly ramp up for major event promotions, like the recent World Cup, and other timely opportunities to tap into massive global demand. Yet behind the scenes, the continued reliance on manual loading and unloading processes is creating a huge operational overhead. The management of short run promotions, for example, requires dedicated and expensive co-packing partners. It also demands additional staff, including forklift drivers, which are now scarce. And of course, event-led marketing is just one expression of a far broader requirement for more agile operations. New packaging demands, such as the EU Packaging and Packaging Waste Regulation (PPWR), will inevitably lead to more SKUs and product complexity that will place a significant burden on existing loading and unloading processes. Companies are also adapting in response to geopolitical uncertainty, with shipping delays, fast rising costs, even the creation of completely new supply chain routes, which demand new levels of agility and responsiveness. Against this backdrop, it is a priority to create a seamless, automated unloading and loading process that removes current constraints and optimises processes in both manufacturing and logistics. Replacing manual loading and unloading, which relies heavily on forklift trucks, with automated systems such as slipchain, moving floor, trailerskate and other automated container loading solutions, fundamentally transforms the

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way loading is managed within the end-to-end production and distribution model. Cutting load times from 45 minutes to less than ten provides the scalability required to seamlessly respond to peaks in production, such as those driven by event-led product marketing campaigns. It reduces the number of people required to handle the load process, allowing the manufacturer to more effectively manage dedicated packaging requirements internally. Plus, it plugs the black hole that manual processes create in end-to-end visibility, providing the information required to support a far more effective response to supply chain upheaval. Ultimately, automation within loading and unloading provides the foundation for a more agile business model, while also unlocking additional potential. End-to-end operational visibility enables real-time allocation of goods to specific loading bays to improve truck fill rates. It provides the scalability required to respond to new sustainability demands. And it enables product marketing to embrace creative innovation without facing a production stand-off or reliance on expensive third-party co-packing providers. With an agile production and logistics model, including automated loading and unloading, manufacturer marketing teams can confidently embrace short-run promotional innovation and maximise the global customer engagement opportunity. joloda.com

WAREHOUSE & LOGISTICS

MULTI-MILLION-POUND SUPPLY CHAIN SAVING In this case study, management consultant Baringa identifies multi-million-pound pharma supply chain savings in just six weeks with Kallikor, a supply chain design platform, demonstrating the benefit of simulation-led analysis in warehousing and logistics operations.

n 2025, Baringa engaged with a pharmaceutical services provider whose European warehouse network was operating with latent capacity. While volumes were expected to grow significantly, parts of the network were constrained in ways that static analysis could not fully explain. Baringa’s client needed to understand the cost and service implications of reconfiguring its European network to increase capacity utilisation and support future growth safely – and what structural changes might be required – without relying on assumptions or committing capital prematurely. James Moffatt, Director, Baringa, says, “Existing analysis was insufficient as the company was unable to digitally recreate warehouse setups in enough detail to assess future scenarios. To help meet the firm’s diligence requirements, we engaged Kallikor to build a model of the operations.”

THE SOLUTION

Baringa partnered with Kallikor to create a simulation digital twin that allowed a range of possible growth scenarios to be tested safely before decisions were made. Using Kallikor’s Warehouse DesignLab, the team built a detailed operational model of the client’s European warehousing operations, capturing storage, throughput, labour and constraints across four temperature-controlled chambers. Kallikor enabled Baringa to: analyse current utilisation levels across storage and throughput and test the feasibility of consolidation; develop a range of growth scenarios to model business growth in line with the client’s three-year sales forecast; and devise storage and throughput volume projections across four temperature channels over three-year periods. Furthermore, Baringa used the advanced technology to run 72 different consolidation scenarios to compare structural options and the client’s operational, financial and service impacts. Further opportunities for improvement were also discovered, including greater throughput and tightly defined CAPEX investments for expanding storage. Ultimately, Baringa was able to provide a board-ready

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proposal showing an 18-month payback period within six weeks. With Kallikor’s simulation-led analysis, Baringa was able to confidently recommend the reconfiguration of the European network. This promised a clear path to achieving operational efficiency and profitability in line with projected growth estimates. The fully costed and executable business case was delivered in six weeks, recommending targeted CAPEX investment, with the client achieving a multi-millionpound EBITDA uplift and payback in less than 2 years. James Moffatt, continues, “Thanks to Kallikor’s technology and expertise, we were able to quickly move from first engagement to board-ready business case at unprecedented speed; half the time a project of this nature would normally take. We’re looking forward to working with our client on further projects.” Jonathan Barrett, Founder, Kallikor, concludes, “This engagement shows how simulation-led experimentation helps organisations unlock growth without flying blind. By testing how systems behave as demand scales, teams can align stakeholders and commit to decisions with confidence.” kallikor.ai

WAREHOUSE & AUTOMATION

HÖRMANN IMPROVES THERMAL INSULATION Hörmann UK has introduced the HTL2 ISO thermally efficient telescopic dock leveller, which delivers up to 55% improved thermal insulation compared to standard dock levellers in both closed and loading positions.

esigned to minimise heat loss at the loading bay, the HTL2 ISO supports facilities managers and operators in improving energy efficiency while maintaining reliable and efficient loading operations. Well established as a leading provider of comprehensive loading bay solutions, Hörmann designs systems to suit a wide range of operational requirements and site conditions. Building on this expertise, the HTL2 ISO dock leveller, when used in conjunction with Hörmann’s sectional door, delivers what is claimed to be the most energy-efficient dock leveller and door combination currently available. The integrated solution is particularly well suited to cold stores, food distribution centres and other facilities where maintaining consistent internal temperatures is critical. The HTL2 ISO dock leveller is supplied fully preassembled and incorporates a 50 mm insulation panel beneath the platform, alongside a unique, patent-pending insulated panel beneath the moving lip. A 390 mm lip overlap ensures reliable bridging between the leveller and vehicle, providing flexible loading options while helping to maintain consistent internal temperatures. To further minimise heat loss, all grooves, gap seals and vertical edges are optimally sealed to prevent thermal transference at critical points. The HTL2 ISO is available in standard sizes up to 3000

mm in length and features a standard rated load of 60 kN, making it suitable for demanding industrial applications. Installation and servicing are straightforward, thanks to the fully pre-assembled insulation panels and seals. The hydraulic components are located beneath the insulation panels, ensuring they remain easily accessible for maintenance at all times. Completing the system, Hörmann’s sectional door is equipped with a suspended bottom section, allowing door operation in front of the dock leveller. When closed, the bottom seal rests directly on the insulated dock leveller panel, maintaining continuous thermal insulation. Optimum sealing is achieved through a guide channel system and a central sealing unit, ensuring consistent performance during daily operations. Phil Thorpe, Industrial Division Manager at Hörmann UK, comments: “The development of the HTL2 ISO dock leveller, along with the sectional door, means we can offer developers and operators a market-beating combination of Hörmann quality and reliability, together with excellent thermal insulation properties. Once again, Hörmann has responded to changing operational needs and developed products that are unique to the market.” To view information of Hörmann loading technology visit the company’s website. hormann.co.uk

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WAREHOUSE & LOGISTICS

DOING MORE WITH EXISTING SPACE As land costs continue to rise, making better use of existing warehouse facilities is vital. Optimising existing warehouse space requires rethinking equipment, aisle width and storage layouts, as leading forklift manufacturer Combilift explains here.

ather than investing in costly and disruptive expansion or relocation, many businesses are embracing the “improving, not moving” approach: a smarter and more cost-effective solution, enabling businesses to maximise capacity within their existing facilities and support growth without major investment or operational downtime.

RETHINKING EQUIPMENT

A good starting point is to evaluate a facility’s current materials handling equipment. Traditional forklifts often require wide aisles and large manoeuvring areas, creating significant volumes of non-productive space and reducing storage capacity. By contrast, narrow aisle operations allow businesses to store more product within the same footprint, improving efficiency while reducing energy consumption and increasing throughput. With nearly three decades of experience, Irish manufacturer Combilift combines versatile material handling solutions with intelligent warehouse design, helping businesses handle and store more products without expanding their facilities.

MULTIDIRECTIONAL OPERATION

Handling long and bulky loads such as timber and steel presents unique challenges. Combilift’s multidirectional forklifts enable operators to transport these loads efficiently in confined areas, both indoors and outdoors. The multidirectional range operates like a conventional forklift, moving forwards and backwards, but with the ability to change the direction of the wheels and travel sideways at the flick of a switch. This capability improves manoeuvrability in tight spaces and allows sideways navigation, eliminating the need for elevated loads when manoeuvring around machinery, obstacles, or parked vehicles in restricted areas. The result is a safer operation, a more efficient handling process and a better use of available space.

OPTIMISING NARROW AISLE OPERATIONS While multidirectional forklifts maximise efficiency and space when handling long loads, warehouses storing palletised goods can also boost storage density by

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adopting narrow aisle operations. Designed to operate in aisles as narrow as 1.6 metres and lift loads to heights of 15 metres, the Aisle Master articulated forklift maximises both floor and vertical space. Its “truck-to-rack” capability streamlines loading, unloading and storage, while its ability to work seamlessly indoors and outdoors eliminates the need for separate reach and counterbalance trucks. For applications where pedestrian-operated trucks are more suitable, Combilift’s electric pedestrian range combines compact manoeuvrability with enhanced operator safety. Its patented multi-position tiller arm allows the operator to work safely from the side of the truck rather than behind it, improving visibility, eliminating crush-zone risks and enabling precise load placement. The innovative design also allows aisle widths to be reduced to as little as 2.1 metres.

BEYOND MANUFACTURING

Combilift’s skilled design engineers also provide a complimentary warehouse and yard planning service, creating layouts tailored to each customer’s operational requirements. By optimising aisle widths, storage layouts and equipment selection, businesses can create additional storage capacity without expanding their footprint. In many cases, storage capacity can be increased by up to 50 per cent without expanding their premises. For more information on how Combilift helps businesses increase capacity, improve safety and prepare their facilities for future growth, visit the company’s website. combilift.com

Enhancing Gas Analysis: The Role of Quantum Cascade Lasers in Advanced Process Monitoring Scan the QR-code to learn about the applications and advantages of optical gas sensing technologies www.hamamatsu.com

WAREHOUSE & LOGISTICS

TECHNOLOGY ROOTED IN REALITY The future of forkifts and material handling technologies is being shaped by the experiences and demands of end users, explains Ron Farr, Head of Dealer Warehouse Sales & VNA, EMEA, Yale Lift Truck Technologies.

s the needs of warehouses evolve, material handling equipment must keep up. Operations that are bound to manufacturers that sell off-the-shelf solutions risk falling behind their customers’ fast-changing demands, as standardised equipment is less able to adapt to changing workflows. As such, many successful material handling products and technologies now emerge from an end user-driven design approach, a structured process of understanding customers’ unique, real-world challenges and converting feedback into features that improve safety, productivity, operator comfort, and value. Although many warehouses share common challenges, such as labour shortages, increased SKU variety, and tighter delivery windows, the solutions required can vary widely by operation. When purchasing lift trucks, operations must consider how they’ll be used to enhance operational efficiency. For example, a truck’s lift and lower speeds may be among the best available, but a lack of stability at height could prevent those equipment-focused metrics from translating to a meaningful difference in key operational metrics. Designing trucks based on this approach is not just about listening to what customers say. It requires expert guidance to observe how customers work and collaboration to refine their requests into solutions they need. This means working closely with stakeholders throughout the operation, studying customer workflows, and validating concepts with real users throughout development. This enables the designer and the customer to work together, uncovering potential problems and addressing those concerns without adding unnecessary costs. A foundation of this approach is learning about and understanding every aspect of a customer’s operation. This is accomplished through interviews across roles. Operators, purchasing agents, safety managers, technicians, and dealers all interact with equipment differently. Every pointof-view helps increase the understanding of what works and what doesn’t. Site visits and observation also allow manufacturers to see your operation firsthand, giving them insight into workflows and uncovering opportunities. Trend and usage analysis, cataloguing industry developments and emerging

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use cases can also help anticipate needs and adapt solutions. This feedback keeps solutions rooted in reality. It also helps keep trade-offs between cost, performance, and usability grounded in operational priorities, such as total cost of ownership.

OPERATOR COMFORT AND AWARENESS

Forklift operators spend long hours handling repetitive tasks under pressure. Poor ergonomics can lead to fatigue and injuries. Ergonomic risk factors include prolonged repetitive motion, awkward postures, and exposure to vibration and noise. Understanding these realities is pivotal to recognising what your warehouse needs from a forklift. Visibility directly impacts comfort and safety. Some mast designs force operators to crane their necks to see their load and the environment around them, leading to strain and discomfort. Innovations influenced by feedback from operators, particularly those working in tight aisles or high stacking environments, have led to configurations with wider mast windows, nested channels and externally mounted chains and hoses for better forward visibility, as well as narrower overhead guards that allow upwards visibility without compromising protection. Plus, lower cowls and dashboards that provide a better forward view

WAREHOUSE & LOGISTICS

of the fork tips and ground. These improvements help operators avoid awkward head and neck positions and boost confidence and precision. Integrating features like cushioned platforms, adjustable armrests and padding allows operators to shift weight or rest, helping to stave off fatigue over long shifts. For example, operator feedback regarding shock and vibration has led to multiple floor options to improve comfort on stand-up trucks, from factory-integrated cushions to fully suspended floors. Intuitive controls, such as customisable touchscreens that provide performance information, and armrestintegrated, steer-by-wire joystick controls that minimise hand movements help address operator fatigue and improve productivity. Beyond operator ergonomics, operational goals of warehouses have influenced broader forklift technology development, particularly systems that address safety and operator awareness.

OPERATOR ASSIST SOLUTIONS

Operator assist solutions, many of which are now standard from forklift manufacturers, originated from real-world use cases, such as pedestrians walking in front of a lift truck, operators travelling too quickly through crowded areas or around turns, loads sliding off the forks and damaging product, and trucks hitting racking or other equipment. Technologies can help address these challenges. Systems range from simple lights and alarms to advanced stability and object-detection technologies.

TOTAL COST OF OWNERSHIP

Total cost of ownership (TCO) goes beyond the initial financial outlay. When matched optimally with the operation, equipment may offer significant savings over time, helping lower operating costs while boosting uptime. Maintenance and servicing costs, and associated downtime, must be considered, alongside other extra costs. Equipment that is not high quality may be more

likely to require replacement parts or frequent repairs, which can quickly become costly. Reducing that potential service burden and associated downtime can help alleviate costs, so equipment durability and maintenance requirements are essential considerations. Trucks with more durable components, or extended preventive maintenance intervals can require less maintenance overall. Also, some equipment is engineered to make service faster and easier, by prioritising accessibility of serviceable components. The cost and availability of replacement parts is also important. Understanding how well the dealer keeps replacement parts from the original equipment manufacturer (OEM) readily available and reasonably priced.

DATA TO SUPPORT PRODUCTIVITY

Modern forklift telematics gather real-time data like idle time, operator habits, uptime and maintenance indicators, information that was previously difficult to obtain for fleet managers. This helps warehouse managers make informed decisions about training opportunities, equipment utilisation, and safety improvements. In turn, this data also informs engineers on how trucks are used across various working conditions, feeding into future design where real usage patterns shape engineering. By working closely with their equipment manufacturer, and by gathering and integrating real input from forklift operators, dealers, and warehouse professionals, operations can take advantage of lift trucks and technologies that empower them to solve real, everyday warehouse problems. The future of lift truck technology is being shaped by those who use it. A continual dialogue between warehouses and lift truck manufacturers leads to designs and features that aren’t merely engineered in a vacuum, but rather inspired by specific operational challenges. yale.com

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WAREHOUSE & LOGISTICS

TEMP MEASUREMENT IN MODERN WAREHOUSING When people think about warehouse efficiency, they often think about automation, warehouse management systems (WMS) and robotics. While these are all important, one area that can easily be overlooked is temperature measurement. Here, leading temperature sensor manufacturer Labfacility looks at the value of temperature measurement in modern warehousing.

or many businesses, temperature can have a direct impact on product quality, production efficiency and energy use. Whether storing electronic components, chemicals, food products or pharmaceuticals, knowing that temperatures are where they should be gives confidence that products are being handled correctly. As warehouses become more data-driven, businesses are collecting more information than ever before. Alongside inventory levels, order fulfilment and equipment performance, temperature data provides another useful layer of insight. Small changes can often highlight developing issues before they become expensive failures. Another area where temperature measurement can make a difference is energy efficiency. Heating and cooling systems that aren’t operating correctly can increase running costs without anyone realising. Regular temperature checks can help identify these issues early, helping businesses reduce energy consumption while maintaining consistent storage conditions. The type of sensor being used is just as important as the data itself. For applications where temperatures change quickly, fast-response sensors are often the best choice. Fine wire exposed junction thermocouples are widely used because they respond rapidly to temperature changes, making them ideal for testing, validation work and temporary measurements. Their simple design also makes them a cost-effective solution for engineers who need accurate results without complicated installation. As technology continues to develop, warehouses will become even more connected and data led. However, good decisions still depend on good information. Reliable temperature measurement may not be the first thing people think about when improving warehouse performance, but it remains an important part of maintaining quality, reducing waste and improving efficiency. Labfacility is a UK manufacturer of temperature sensors with over 50 years of experience, understanding the vital role accurate temperature measurement plays across industry. Its range of fast-response thermocouples

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includes exposed junction designs helps engineers capture reliable temperature data. Due to its partnerships with Digikey and Farnell, Labfacility’s customers now have multiple convenient ways to access high-quality temperature measurement products. Both Digikey and Farnell stock an extensive selection of Labfacility’s products, including thermocouples, RTDs and Connectors, ensuring engineers can quickly find the specific product needed for an application. With a reliable service and global distribution networks, customers can trust that an order will arrive promptly and with the highest level of care. labfacility.com

WAREHOUSE & LOGISTICS

THE ROLE OF LOADING INFRASTRUCTURE Would warehouse optimisation benefit from re-focusing on the fundamentals? Ian Langan of Thorworld Industries discusses why warehouse performance depends as much on controlling risk as it does on improving speed.

ere’s a controversial opinion: warehouse optimisation has become too focused on automation, systems and data. While these areas are undeniably important, they are increasingly dominating the conversation, often at the expense of the fundamentals. In my experience, this imbalance means inefficiencies and risks continue to persist at one of the most critical points in any operation: the loading bay. This matters because delays at the dock are rarely contained. Around 27 per cent of distribution centres identify the receiving dock as their most congested area1, which shows how often inefficiency originates at the interface between vehicle and building. When that interface slows, the effect is multiplied across every movement, reducing throughput and creating pressure elsewhere in the operation. At the same time, it is one of the most hazardous areas on site. The transport and storage sector continues to report fatal injury rates around 2.5 times higher than the all-industry average2, with a significant proportion of incidents involving moving vehicles. Poor loading conditions do not just affect efficiency, they directly influence safety outcomes. The common factor is variation. Vehicle heights differ, docking positions shift and workload intensity changes throughout the day. Where these variables are not controlled through infrastructure, operators are left to manage them in real time, as they occur. That often leads to repeated adjustments, informal workarounds and an increased likelihood of error. From both a performance and safety perspective, that is where the problem sits. Loading infrastructure is designed to remove that variability. Dock levellers, loading platforms and access systems create a defined transfer point between vehicle and warehouse, reducing reliance on manual correction. When the interface is stable, goods move more predictably and the risk of incidents linked to poor alignment or unstable access is reduced. This becomes more important as warehouse demands increase. A wider mix of vehicle types, higher volumes and tighter turnaround expectations place greater strain on the loading area. Infrastructure that cannot adapt becomes a bottleneck and a safety concern at the same time.

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There is also an operational resilience aspect. Over two million working days are lost each year in transport and storage3 due to work related injury and ill health, demonstrating how closely safety and productivity are linked. Reducing friction at the loading point supports both. When we develop loading solutions with customers, this is the balance we’re striving for, because warehouse optimisation is not purely about moving faster, but about maintaining control under pressure. Where loading infrastructure is correctly specified and maintained, businesses are better able to manage risk, sustain throughput and avoid the repeated inefficiencies that limit performance on a daily basis, while most importantly keeping employees as safe as possible. thorworld.co.uk mmh.com/article/warehouse_dc_operations_survey_2022_recalibrating_

operations_and_spend 2

manualhandlingtraining.org.uk/blog/warehouse-accidents-statistics-uk

hse.gov.uk/statistics/assets/docs/transportation.pdf

WAREHOUSE & LOGISTICS

EFFICIENT SOLUTIONS FOR WAREHOUSING Warehouses and distribution hubs are essential for the storage and transportation of raw materials and finished goods, making uninterrupted – often 24/7 – operation critical. As drive technology can account for up to 70 per cent of operating costs, energy efficiency is a key consideration for drive systems, making them a source of efficiency and cost-saving in warehouse and distribution.

mproving efficiency not only helps reduce energy expenditure, but also supports sustainability goals by lowering a company’s CO₂ footprint. Advanced drive solutions for warehouses and distribution centres help reduce both operating costs and CO₂ emissions. NORD DRIVESYSTEMS’ drive solutions are highly reliable, energy-efficient and controlled by intelligent drive electronics. By combining motors, gear units, and drive electronics from its modular product range, NORD can deliver customised solutions tailored to specific customer requirements and warehouse applications. Typical applications include horizontal and vertical conveyor systems, roller conveyors, chain conveyors, turntables, sorting systems, palletisers and packaging lines.

DECENTRALISED SOLUTION

NORD has developed the decentralised LogiDrive solution specifically for warehouses and distribution centres. This efficient combination of energy-saving geared motors and intelligent drive electronics is available in two versions: LogiDrive Advanced and LogiDrive Basic. LogiDrive Advanced combines an IE5+ synchronous motor with a NORDAC FLEX inverter, focusing on maximum energy efficiency, reduced system variants, and a lower Total Cost of Ownership. LogiDrive Basic features an IE3 motor paired with a NORDAC ON frequency inverter, offering a cost-effective solution designed to reduce operating expenses.

KEY ADVANTAGES

LogiDrive is compact, lightweight and suitable for universal installation. It offers integrated brake control, high overload capacity, and straightforward installation. Thanks to its plug-and-play functionality and convenient plug connections, the system is highly service-friendly. Its decentralised design significantly reduces the complexity and cost of cabling. In the event of maintenance or a malfunction, only the affected drive unit needs to be replaced, minimising downtime and simplifying servicing. Available for power ratings from 0.12 kW, LogiDrive helps reduce energy consumption and CO₂ emissions,

particularly when combined with highly efficient IE5+ motors. The system provides smooth starting and stopping characteristics and supports decentralised frequency converters, including ASi, bus and Ethernet communication, as well as PROFIsafe and FSoE safety functions. A further advantage of the LogiDrive concept is its broad power and torque range, which allows a significant reduction in the number of drive variants required. The system maintains excellent performance even at low speeds and under partial load conditions. Fewer drive variants mean lower inventory requirements, simplified spare parts management and reduced administrative costs, which further contributes to a lower Total Cost of Ownership.

GLOBAL CERTIFICATION AND SUPPORT

NORD’s drive technology meets international standards and certification requirements, and the company is supported by a worldwide network of subsidiaries and sales partners. nord.com

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WAREHOUSE & LOGISTICS

MOVING BEYOND THE BOTTLENECK Due to mounting service pressures, warehouses, distribution hubs and logistics firms are especially vulnerable to operational bottlenecks. Here, Paul Eyre, Global Director, Machine Vision, Zebra Technologies, explains how actionable AI is solving the “Blockage Response” in logistics.

Paul Eyre, Global Director, Machine Vision, Zebra Technologies

cross Europe, reports from the largest delivery organisations tell us that parcel volumes keep going up, with spikes during the Christmas shopping period, largely driven by domestic and international e-commerce and consumer preference for home and locker delivery. Logistics firms also face growing competition from new entrants, the need to scale to be profitable, and cost pressures. Warehouses and distribution hubs are also facing pressure from tighter service-level agreements built on continually rising consumer expectations. • Yet on average, 35 per cent of regular online shoppers in the EU encountered an issue last year. • The most common problem was slower delivery1 than expected, reported by one in five consumers (20 per cent), along with wrong or damaged goods (11 per cent). • Similar experiences are seen in the UK, with 28 per cent of consumers saying2 their parcel was delayed. Negative customer experience can result in requests for refunds and compensation, additional costs with return logistics, and weakened trust and loyalty.

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It means physical infrastructure and workforce efficiency are paramount. A lot of focus is given to more speed through automation, with faster conveyors and faster sortation being an obvious lever, but what about maintaining that speed?

CAN’T STOP MOVING

In high-volume fulfilment centres, conveyor networks and automated sorters have one job: never stop running. It’s a system made up of various decision points, with continuous motion essential to the flow of receiving, sorting, picking, packing, and shipping. Delays are measured in seconds because every second has consequences that can stack up quickly: recirculating packages, reduced throughput, delayed shipments, missed deadlines and unmet business objectives. And with 48 per cent of logistics leaders saying3 operational efficiency improvements are a top priority over the next three years, this ripple effect creates operational pressure to treat every potential slowdown as critical. Conveyor line blockages trigger responses needing

WAREHOUSE & LOGISTICS

investigation as quickly as possible to keep the system operational. The issue is the blockage and the uncertainty around it.

THE “BLOCKAGE RESPONSE”

True and false blockage alerts can trigger the same blockage response. When a temporary slowdown is mistaken for a real blockage, outbound lanes can be unnecessarily shut down, forcing packages to recirculate back through the system. Teams are pulled into investigations, conveyors can get halted unnecessarily, packages recirculate and productivity takes a hit. False blockages create almost as much slowdown as real ones, cause repeated interruptions, lead to eventual “alert fatigue” and build a costly pattern of inefficient labour use and less predictable throughput. Industry leaders are now looking to more efficient machine vision-enabled technology to enhance and protect continuous operations.

FROM TRADITIONAL SENSORS TO PRACTICAL AI

Traditional blockage detection relies on photoelectric sensors which often have a limited view: blocked or not blocked. Conveyor lines are faster, package flows denser, and parcels vary widely in shape, weight, and material. For these sensors, a temporary slowdown can often look like a real blockage, and the only thing that’s certain is the continued accumulation of false blockage alerts triggering responses that lead to actual slowdowns and costly package recirculation. The context behind every potential blockage has never been more critical. The latest approach to blockage detection utilises machine vision, powered by practical AI to continuously inspect a live video feed or rapid series of images. By analysing this visual data, the AI can form a highly accurate, objective opinion on the actual status of the packages and their flow, providing that context in a way

that’s precise, predictable and automated. Smart cameras mounted above the conveyor monitor package flow in real time, while software analyses factors such as velocity, congestion, and flow patterns using edge computing, meaning the processing happens instantly, right at the point of activity. When the system identifies a true blockage, operators can receive timely alerts with visual evidence so they know where to respond and what to expect. When the system recognises a false blockage, packages can continue moving and personnel can stay focused on more important work. Thanks to recent advancements in both AI software and edge-processing hardware, organisations can finally solve these long-standing fulfilment problems. AI-powered blockage detection is designed to do exactly that.

CONCLUSION

Actionable AI on the frontline is solving a modern-day fulfilment problem by minimising the manual intervention and labour impact associated with clearing false alerts. It provides teams with a scalable step they can take toward modernisation with immediate ROI. It also offers maintenance teams more reliability and predictability in their operation. And it gives associates a tool that supports and improves their productivity without the need for any additional training. Automating fulfilment is a modern-day necessity. But in an environment where customer satisfaction is the be-all, end-all, how you empower your existing automation can matter even more than how much you automate. Read more about practical AI for conveyor operations here: bit.ly/4w3nZB9 1, ecommercenews.eu/35-of-eu-online-shoppers-report-problems/ 2, commonslibrary.parliament.uk/research-briefings/cbp-10614/ 3. bit.ly/4wKCrOr

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WAREHOUSE & LOGISTICS

ZERO TRAINING, ZERO DOWNTIME Modern distribution environments are often unpredictable, yet automated palletisers are often built around predictability. To build truly resilient operations, logistics leaders must look past rigid automation scripts and instead examine why conventional systems fail in real-world scenarios and how next-generation spatial AI is rewriting the rules of material handling.

he modern supply chain is increasingly volatile, forcing warehouse, distribution, and fulfilment centres to grapple with acute labour shortages, surging throughput demands and an unpredictable mix of inventory. While automation is frequently championed as the ultimate remedy to these operational strains, traditional approaches to automated palletising often introduce a hidden bottleneck that slows down the entire facility.

WHY LEGACY SYSTEMS STRUGGLE

Most automated palletising systems excel under one condition: absolute uniformity. They are built to process predictable, repetitive runs of the exact same SKU. However, modern distribution environments are rarely uniform. When forced to handle high-variability workflows,

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traditional automation architectures reveal three critical flaws. Firstly, they are vulnerable to an SKU ingestion & training bottleneck. Legacy robotic systems require extensive, predetermined sequencing and exhaustive data ingestion. If a package layout changes, a new box size is introduced, or a vendor updates their printed packaging, the system typically produces a fault. Overcoming this requires manual retraining and system reprogramming, grinding throughput to a halt. Secondly, many mixed-case automation platforms rely heavily on advanced planning manifests, assuming perfect data accuracy and flawless upstream sequencing. Because these rigid AI models cannot easily adapt when mistakes occur, errors can cascade, making it difficult for operators to locate and rectify the root cause.

WAREHOUSE & LOGISTICS Lastly, traditional vision systems are notoriously sensitive to shifting factory conditions. Variations in ambient lighting, reflective packing tape, or the presence of unexpected slip sheets frequently disrupt object recognition, resulting in failed picks and increased manual intervention.

OVERCOMING CHAOS WITH REAL-TIME SPATIAL AI

As explored by Marianne Santoro in her article, Beyond AI: Zen and the Art of Box Packing1, the core problem with traditional logistics platforms is their reliance on predictability in an inherently unpredictable environment. True technological resilience requires a shift away from rigid pre-planning, and instead mirror human adaptability. By translating this philosophy into a practical engineering solution, Liberty Robotics developed a system tailored precisely for the chaos of modern logistics, using 3D volumetric sensors originally developed and perfected for manufacturing operations over the past 10 years. Liberty Robotics’ solutions blend algorithmic logic with on-the-fly flexibility needed to navigate unique situations and spontaneous variables encountered in the field.

WHY VPACK™ SOLVES THE PALLETISING PUZZLE BETTER

The Random Case Palletiser systematically neutralises the friction points of legacy systems by replacing preprogrammed patterns with real-time spatial intelligence: • Eliminating the training deficit via “pick on first sight”. While some vision systems require downtime to learn new box parameters, the VPack™ algorithm measures box dimensions in milliseconds and calculates ideal placement almost instantly. The system remains entirely indifferent to the type of printing on the boxes, changing case sizes, or changes in End-of-Arm Tooling (EoAT). It also handles boxes of any dimension, colour, or print pattern automatically. • Streamlined real-time stacking algorithms. To solve the complex challenge of stacking mixed-case pallets more effectively than traditional models, the system dynamically processes spatial data with advanced GPU acceleration. It pairs this with two core innovations: firstly, it merges appearance and depth data via a proprietary 3D vision system to maximise data quality directly at the pick point; secondly, by utilising predictive algorithms and weights derived from running extensive offline simulations per situation to ensure the robot prioritises maximum load stability and tight volumetric density. • Recovery mode for continuous operation. In a real warehouse, extra boxes are added unexpectedly, and stacks shift. Legacy systems are blind to these changes, which risks detrimental pallet collisions and collapses. The VPack™ system features a recovery mode, making it simple to capture another image of the pallet if a box was added or another manual change was made.

HIGH-VOLUME PERFORMANCE BUILT FOR EXISTING LAYOUTS The operational metrics achieved by the VPack™ system

demonstrate that flexibility does not require a compromise on speed: • Throughput Rates: depending on the application, the system achieves 300 picks per hour and up to 700 picks per hour with a dual robot gantry setup, ensuring that 3D vision processing operates significantly faster than physical robotic gripping and unloading tasks. • Volumetric Density: reaches a 70 per cent to 80 per cent packing fill efficiency, maximising trailer and container utilisation. • Environmental Resilience: the 3D vision technology is entirely immune to ambient factory lighting conditions, ignoring the glare from reflective tape or flickering lights.

SYSTEM INTEGRATION FLEXIBILITY

• Compact Footprint: fits easily into tight layouts, starting at 300 square feet within the fence and expanding up to 600 square feet with an optional infeed conveyor. • AMR Interface Conveyors: seamlessly transfers completed, mixed-case pallets to Autonomous Mobile Robots without manual intervention. • Robots on Rails: offers an optional Robotic Transfer Unit to increase pick and build locations, allowing the system to assemble up to 10 pallets simultaneously. This highly-adaptable hardware footprint allows facilities to drop the system directly into existing conveyor and material handling lines without undergoing expensive, topto-bottom warehouse redesigns.

FUTURE-PROOFING THE FLOOR

Conquering modern warehouse shortages requires moving away from rigid automation frameworks that break under variance. By deploying Liberty Robotics’ VPack™ zerotraining vision AI, logistics facilities gain a system that thrives on randomness. It provides a reliable pathway to continuous, high-efficiency operations, solving the mixedcase puzzle one unexpected box at a time. For more information on VPack™, visit: liberty-robotics.com 1. liberty-robotics.com/beyond-ai-zen-and-the-art-of-box-packing/

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WAREHOUSE & LOGISTICS

MAKING MATERIAL HANDLING EFFORTLESS From AVGs and AMRs to conveyors and palletisers, high-performance drive technologies are the secret to effortless material handling, explains Nigel Evans, Marcomms Manager, Sumitomo Drive Technologies.

oving materials from A to B with minimal disruption is business critical in a wide range of industries. From distribution and logistics, to packaging, production lines and warehousing, organisations of all sizes rely on efficient automated product delivery day in, day out. Equipment ranging from AGVs and AMRs to conveyors and palletisers rely on precise, reliable drive technologies to deliver the unwavering service demanded by businesses worldwide. “In today’s fast-moving material handling environments, precise control of movement and product delivery can be the difference between a seamless operation and costly downtime,” comments Marcomms Manager Nigel Evans. “Whether it’s an AGV navigating a warehouse floor, a conveyor running 24/7/365, or a palletiser handling rapid start/stop cycles, the requirement for robust, precise,

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and reliable drive technologies has never been greater. “Our broad portfolio of gears, motors, drives, and fully integrated drive solutions includes products specifically designed to meet the unique challenges of material handling applications,

WAREHOUSE & LOGISTICS delivering the shock-load resistance, energy efficiency, and compact engineering the industry demands.”

PRECISION NAVIGATION

AGVs and AMRs rely on precise and accurate navigation to stay on track. Smartris, a packaged drive solution designed specifically for AGVs and AMRs, combines a cycloidal gearbox, servo motor, and drive controller in a single compact, plug-and-play package, delivering consistently smooth operation that ensures loads reach their destinations on time, every time. Conveyors, sorting systems and palletisers require smooth, consistent and reliable control of movement to deliver a huge variety of materials from A to B. Sumitomo Drive Technologies’ patented CYCLO gearmotors use a unique ‘gearless’ cycloidal design, resulting in minimal vibration, up to 500 per cent momentary shock-load capacity, and low backlash, making them ideal for the start/stop demands of conveyors, sorting systems and palletisers. Standard drives and custom engineered drive solutions are widely used in a variety of airport logistics applications, including complex airport baggage handling systems. As a long-standing industry leader in providing gear drives which are highly efficient and extremely quiet, Sumitomo Drive Technologies’ gears are ideal for the air transport industry which demands the highest levels of customer service. “Unrivalled shock load resistance is one of the biggest advantages our customers see,” continues Nigel. “In material handling environments where conveyors can start, stop, and jam unexpectedly, this means fewer breakdowns, less damage, and longer service life. “CYCLO gears also have fewer moving parts than traditional gear systems. In ‘around the clock’ material handling operations where downtime can be expensive, this translates directly into higher productivity and lower total cost of ownership. And because our gearmotors deliver significant power output in small packages, they’re ideal for environments where space is at a premium - for example, warehouses, distribution centres, ports and quarries, making installation easier and system design more flexible.”

EFFICIENCY AND PERFORMANCE Motorised equipment used in material handling applications must be capable of moving different weights, shapes and sizes, smoothly and efficiently across a diverse range of industrial settings – from automated warehouses to industrial assembly lines, mining plants and ports. Lafert’s HP dynamic motors provide high performance control, acceleration, braking and peak torque, while IE5 efficiency and synchronisation

capability allow for maximum speed management in a compact and robust package. “Energy efficiency is a growing priority across the material handling sector,” explains Nigel. “Our HP range achieves Ultra-Premium IE5 efficiency by combining the electrical design of brushless servo motors with the mechanical design of AC induction motors. In environments that are ‘always on’, this delivers significant energy savings that contribute directly to a customer’s ESG goals. Our HP Combi, which pairs an IE5 motor with an integrated VFD, can reduce energy costs by up to 50 per cent.” Variable frequency drives (VFDs) enhance the performance and energy efficiency of material handling systems by providing precise motor speed control, reducing wear and tear, improving safety, and enabling optimal utilisation of power. They play a vital role in achieving smooth and efficient material flow across a wide variety of industrial settings; from automated storage and retrieval systems (ASRS) and conveyors, to palletisers and depalletisers. Invertek Drives offers a wide range of high-performance VFDs used in material handling applications around the world. Visit the company’s website to find out more. “Moving goods such as powders, ingredients, aggregates, products, baggage, packages and much more all have slightly different requirements; our team’s technical expertise coupled with our extensive product range, ensures the best solution for each specific material handling application. This is why we are trusted by material handling OEMs and end-users in a hugely diverse range of applications and environments all over the world,” concludes Nigel. emeia.sumitomodrive.com/en-gb

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DRIVES, MOTORS & CONTROLS

POWER FOR PRECISE LINEAR ACTUATORS Drive specialist STOBER has significantly improved the performance of its rack and pinion gearboxes using new calculation methods and optimisation techniques. Here, Martin Preece, Head of UK Subsidiary for STOBER discusses what this means for users.

STOBER offers an innovative system concept for rack and pinion gearboxes. The applications include automation & robotics.

ith its rack and pinion gearboxes, STOBER offers compact, dynamic solutions for linear motions. Now, thanks to new FEM calculation methods and optimised microgeometries, the drive specialist is significantly increasing their performance. The results have been validated in extensive test series. Users benefit from higher feed forces with the same compact design. This opens up more options for space-saving machine concepts, especially for large machine tools. Martin Preece, Head of UK Subsidiary for STOBER explains: “We have further increased the performance of our rack and pinion gearboxes; a combination of the proven PH planetary gearboxes and ZTR and ZTRS pinions for sophisticated drive concepts or use in feed axes. “Depending on the size, the maximum feed forces can now be up to 20 percent higher than before. This further strengthens our ability to compete on the market.” The higher values are based on new FEM calculation methods that examined the loads from the interaction of the torque and pinion forces in more detail. STOBER also improved the microgeometry of the toothing and validated the results in extensive test series. The optimisations are part of the continuous further development of the mechanical drive components in

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terms of power density, dynamics and process reliability. “Our rack and pinion gearboxes are capable of delivering feed forces up to 124 kN,” continues Martin, “making them particularly suitable for large machine tools and machining centres. This enables us to respond optimally to the growing demand for these powerful and compact solutions in international markets without having to pass cost increases on to our customers.” For mechanical engineers, the higher performance yields concrete advantages. In many applications, smaller sizes can be used, which reduces installation space, weight and costs. At the same time, the axis systems become more dynamic. This enables more compact and economical machine concepts, especially for large portal machines with several synchronised drives. The higher performance values have already been incorporated into STOBER’s catalogues, design tools and online configurator. Martin concludes: “With our extensive product portfolio, STOBER offers maximum flexibility for implementing linear motion with high precision. The motor, gearbox, pinion and gear rack allow custom combinations.” For more information, please visit the company’s website. stober.co.uk

Accessible, Accurate and Affordable Noise Monitoring Improve workplace safety with a personal noise dosimeter that anyone can use.

The TSI OmniWear Noise™ Personal Dosimeter

is designed to bring professional-grade noise monitoring to a wider range of industries and users. ▪ Lightweight, rugged design ▪ Intuitive mobile app ▪ Multi-device monitoring ▪ Seamless data reporting For more information on the TSI OmniWear Noise™ Dosimeter please visit:

tsi.com/omniwear

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PROCESS CONTROL

PRECISION GAS SENSING

In demanding process environments, precision gas monitoring is vital for process control and product quality. This article by Hamamatsu examines the significant advancements brought by Quantum Cascade Lasers (QCLs) in enhancing gas analysis techniques.

rocess control is essential in highly regulated industries such as pharmaceuticals and chemicals, where product quality must be maintained throughout manufacturing. Process Analytical Technologies (PAT) support this by enabling real-time monitoring of critical process parameters, often through continuous analysis of gas-phase reactants and by-products. This approach provides direct insight into reaction progress and stability, enabling faster intervention and improved regulatory assurance. Gas monitoring in these environments includes volatile and semi-volatile organic compounds, residual solvents, and common process gases such as CO₂, CO, and NH₃. In catalytic and hydrogenation systems, analysis of off-gas composition provides continuous feedback on reaction conditions within the PAT framework. Optical gas sensing is essential to these applications as they measure molecular absorption at characteristic wavelengths, allowing concentration to be determined according to the Beer–Lambert law. Mid-infrared (MIR) sensing (3–11 µm) is particularly effective because many industrially relevant gases exhibit strong, distinct absorption features in this region, enabling reliable identification even within complex mixtures. Quantum cascade lasers (QCLs) are especially suited to MIR sensing due to their tuneable, spectrally precise emission. They offer extremely narrow linewidths, typically below 1 MHz, which is critical for resolving overlapping absorption features. Their high brightness and beam quality support long optical path lengths in multi-pass gas cells, enhancing sensitivity to ppb levels. In addition, QCLs enable rapid modulation and wavelength tuning, allowing fast measurement cycles and high-speed analysis under varying flow conditions. This capability supports tighter real-time process control and frequent monitoring of key parameters. Despite these advantages, several challenges affect wider adoption. Limited wall-plug efficiency leads to significant heat generation, requiring thermoelectric cooling and stable drive electronics. These factors increase system size, power requirements and integration complexity. Hamamatsu can support users with in-house expertise to overcome these challenges.

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Ongoing developments are helping to address these limitations. Improvements in photonic integration, fibre coupling, and dual-comb QCL systems are enabling more compact and robust designs. At the system level, hybrid architectures combining distributed low-cost sensors with high-precision QCL nodes are supporting broader industrial deployment. Precise gas monitoring remains critical for maintaining control in demanding process environments. MIR optical sensing, particularly using QCLs, enables selective and sensitive detection of key gases in complex mixtures. While cost and integration challenges remain, increasing regulatory requirements and tighter process specifications are strengthening the case for QCL-based solutions in continuous industrial monitoring. Learn more about Hamamatsu Photonics optical gas sensing solutions at: hamamatsu.com

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BUSINESS OPERATIONS

THE RISKS SHAPING MANUFACTURING Drawing on findings from Gallagher’s latest Business Risk Index – based on insights from 1,000 UK business leaders – Neil Hodgson, Managing Director of Risk Management Solutions & Business Assist at Gallagher, explores the challenges currently facing manufacturers and what organisations can do to strengthen resilience in an increasingly uncertain environment.

he research highlights the unique pressures reshaping today’s commercial landscape and for manufacturers the high cost of materials is the standout concern, cited by 88 per cent of respondents. From raw materials and stock to essential components, rising costs are placing immense strain on profitability. For manufacturers operating on tight margins, these increases are particularly difficult to absorb, often forcing tough decisions around pricing, production and investment. Closely following this is the high cost of operations, highlighted by 77 per cent of respondents. Energy, rent, logistics and other overheads are creating sustained financial pressures. For many manufacturers, these operational challenges are not just short-term hurdles but ongoing issues that require careful management to maintain competitiveness. Adding to these pressures is the growing intensity of competition within the sector, with 66 per cent of manufacturers identifying it as a key concern. Whether driven by new entrants, shifting demand, or decreased need for certain products, competitive pressures are prompting organisations to reassess their positioning and value propositions. Overlaying these challenges is the burden of imposed costs, such as National Insurance increases, which 64 per cent of respondents flagged as a significant issue. These additional financial commitments, often outside of a business’s control, can influence hiring decisions, investment plans and overall growth ambitions. Beyond these immediate cost and competitive pressures, manufacturers are also navigating broader risks such as regulatory changes, supply chain disruptions and the challenge of adopting new technologies like AI. These factors not only impact day-to-day operations but also influence long-term strategic decisions, from hiring and training to innovation investment. Taken together, these findings paint a picture of a sector balancing immediate financial pressures with longerterm strategic imperatives. For many manufacturers, the challenge lies not just in identifying these risks, but in understanding how they interact and what steps can be

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taken to manage them effectively. “Taking a structured approach to risk is becoming increasingly important. It’s not just about protecting against what might go wrong, it’s about giving manufacturers the confidence to move forward, even in uncertain conditions.” Neil Hodgson, Managing Director, Risk Management Solutions & Business Assist, Gallagher. This is where working with an experienced insurance broker can make a tangible difference. By helping manufacturers assess their risk landscape holistically—from operational exposures and supply chain vulnerabilities to emerging risks—brokers can support more informed decision-making. With pressures coming from all directions, having a broader perspective can help manufacturers not only respond to today’s challenges but prepare more confidently for the future.

Download Gallagher’s full 2026 Business Risk Index report here

TEST & MEASUREMENT

WHY ENGINEERS CHOOSE THE HP1000 High-pressure applications demand pressure transmitters that deliver exceptional accuracy, reliability and durability. Whether monitoring hydraulic systems, test equipment or energy infrastructure, engineers need confidence that their pressure measurement solution will perform under extreme conditions.

he HP1000 Series from ESI Technology is designed specifically for pressures up to 5,000 bar (72,500 psi). Combining a robust one-piece titanium sensing assembly with proven Silicon-on-Sapphire (SOS) sensor technology, the HP1000 delivers dependable performance in some of the world’s most demanding industrial environments.

BUILT FOR EXTREME CONDITIONS

Unlike conventional pressure transmitters, the HP1000 features a one-piece titanium sensing assembly, where the diaphragm and pressure housing are machined from a single piece of titanium alloy. Eliminating welded joints from the pressure boundary improves strength, enhances long-term reliability and enables the transmitter to withstand high-pressure spikes and transients. Titanium also provides excellent corrosion resistance, making the HP1000 well suited to harsh industrial environments.

THE ADVANTAGES OF SILICON-ONSAPPHIRE TECHNOLOGY

At the heart of the HP1000 is ESI’s advanced Silicon-onSapphire (SOS) sensor technology. SOS sensors provide excellent long-term stability, outstanding accuracy and reliable performance across a wide temperature range. The sapphire substrate offers exceptional electrical insulation, helping maintain consistent measurements even in challenging operating conditions. These benefits allow engineers to achieve precise, repeatable pressure measurements throughout the product’s service life.

DESIGNED FOR HYDROGEN APPLICATIONS

To support the growing hydrogen sector, ESI also offers the HP1000H, a hydrogen-compatible version of the transmitter. Featuring hydrogen-compatible titanium wetted parts and tested in accordance with ISO 11114 standards, each approved unit is supplied with certification confirming its suitability for hydrogen service. This makes the HP1000H an ideal solution for hydrogen storage, refuelling stations, distribution infrastructure and test facilities.

CERTIFIED FOR DEMANDING INDUSTRIES The HP1000 Series is available with ATEX and IECEx

Intrinsically Safe certification on 4 to 20 mA models, enabling safe installation in hazardous gas, dust and mining environments. For marine and offshore applications, DNV approval is also available, providing confidence that the transmitter meets recognised maritime standards.

A TRUSTED HIGH-PRESSURE MEASUREMENT SOLUTION

Combining high-pressure capability, robust titanium construction, advanced SOS sensor technology and a range of certification options, the HP1000 Series offers a dependable solution for critical pressure measurement applications. Whether used in industrial testing, energy systems, marine installations or emerging hydrogen infrastructure, the HP1000 delivers the accuracy, durability and reliability engineers depend on when measuring extreme pressures. esi-tec.com

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PUMPS & PUMPING SYSTEMS

THE PERFECT PUMP FOR THE APPLICATION In any industrial sector, pumps play a critical role in the safe, efficient and precise transfer of liquids throughout various stages of production. From raw material handling to formulation, blending, filtration, and final product transfer, the integrity of a production processes depends heavily on the performance and suitability of the pumps employed.

hile choosing the right pumps is crucial for operational efficiency, it also directly impacts product quality, safety, regulatory compliance and overall process reliability. VERDER understands this. Its pumps can manage a diverse range of fluids, that may vary widely in viscosity, chemical composition, and sensitivity to contamination; therefore, pumps must be constructed from materials that are compatible with the specific fluid being transferred to maintain product purity and ensure that there is no risk of corrosion, leaching, or unwanted chemical reactions. Precision is another critical operational factor for companies to ensure accurate dosing and metering of liquids, sometimes in small volumes. To ensure reliability and consistency, peristaltic pumps, diaphragm pump and other positive displacement pump types are preferred for their ability to deliver consistent flow rates and minimise shear, which is especially important when handling sensitive biological materials.

PROCESS RELIABILITY AND MONITORING CAPABILITIES

Process reliability and uptime are vital across all industries, where production interruptions can lead to significant financial losses and supply chain disruptions. Modern pumps often incorporate automation and monitoring capabilities, enabling real-time performance tracking and proactive maintenance to reduce the risk of pump failure and unscheduled downtime. In summary, the selection of pumps for a production process is a critical decision with far-reaching implications. The right pump ensures fluid compatibility, product purity, process accuracy and regulatory compliance, while also supporting operational efficiency and sustainability. Investing in high-quality, application-specific pumps is essential for manufacturers seeking to uphold the highest standards of product safety and quality in highly regulated and competitive industries.

EXPERTISE IN PUMP SOLUTIONS

With its well-known brands Packo, Verderflex and Verderair, VERDER has a wide range of pumping solutions to provide

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the most effective pump for customers’ requirements. Whether it is about pumps, advice, service, maintenance, or spare parts, VERDER has various solutions for a company’s process line, and it is able to create a long lasting, cost effective, energy efficient and sustainable system that supports adherence to regulatory standards set by agencies, such as the FDA and EMA, and contributes to both environmental and economic goals.

VERDER: ENABLING PROGRESS

The Verder Group is a family-owned business established over 65 years ago in the Netherlands; the group consists of a worldwide network of production and distribution companies involved in the development and distribution of industrial and hygienic pumps, pumping systems, high-tech equipment for quality control, research and development into solid material (solids sample preparation and analytical technologies). verder.com

✓ Peristaltic Pumps – Ideal for abrasive, corrosive and shear-sensitive media. ✓ Diaphragm Pumps – Handles aggressive, viscous and solids-laden fluids with safe dry-run capability. ✓ Lobe Pumps – Hygienic, low-shear pumping with smooth, pulsation-free flow for sensitive and high-viscosity applications. ✓ Dosing Pumps – Accurate, repeatable chemical dosing delivering precise flow control and reduced chemical consumption.

DIGITALISATION

INVENTORY SOFTWARE VS. ERP Many growing manufacturers turn to inventory management software to cure their stock-related ailments, but simple inventory software might not be enough if it lacks manufacturing-centric features. Given that inventory cannot be separated from production, a manufacturing ERP can often be the better choice.

he biggest reason manufacturers outgrow inventory software is simple: inventory decisions depend on production decisions. In a manufacturing business, stock levels do not tell the whole story. A component may be physically in the warehouse but already allocated to another job. A finished product may be in stock but reserved for a customer. A raw material may look available in the system, but it may have already been used in production on the shop floor. A purchase order may be open, but the supplier may not deliver in time for the planned production date. This means that inventory tracking alone is not enough; manufacturers need to understand availability in context. That context comes from BOMs, sales orders, material planning, procurement and production schedules. A bill of materials defines which materials and components are required to make a product. Material planning uses BOMs, demand, lead times, current stock levels and open orders to calculate what needs to be purchased or produced. Production planning determines when materials are needed. Procurement ensures they arrive on time. Costing shows how material, labour, overhead and landed costs affect profitability. If these functions are disconnected from inventory management, the company may have stock data but still lack operational control. This is where standalone inventory software can become frustrating. It may give warehouse staff better visibility, but production planners still have to work outside the system. Buyers still have to manually check requirements. Sales teams still need to ask someone whether an order can be delivered. Managers still do not have a reliable view of production readiness, cost, or capacity. In other words, the inventory system becomes another silo.

WHY MANUFACTURING ERP IS USUALLY THE BETTER CHOICE

For manufacturers, a manufacturing ERP solution such as MRPeasy is usually the better choice because inventory is inseparable from the rest of the operation. Standalone inventory software can help companies improve stock tracking, warehouse management, barcode scanning, reorder points, and inventory control. But

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manufacturing inventory is shaped by sales, quoting, BOMs, procurement, MRP, production planning, costing, warehousing, and order fulfilment. If those processes are disconnected, inventory software eventually becomes another tool that teams have to work around. It may show stock levels, but it cannot provide the full context needed to make reliable manufacturing decisions. A manufacturing ERP solves this by connecting inventory with the processes that create, move, consume, purchase, cost and sell stock. It gives manufacturers one system for managing materials, production, purchasing, sales orders, warehouse operations and financial visibility.

INVENTORY SOFTWARE VS. ERP: WHICH IS BETTER?

For basic stock tracking, inventory software can be enough for a while. But for manufacturers that want better planning, automation, operational efficiency, cost control and real-time data across the business, a manufacturing ERP is the stronger long-term solution. mrpeasy.com

EVENTS

MEPCA AT SMART MANUFACTURING WEEK 3-4 June, MEPCA joined 13,500 professionals across the manufacturing and engineering sectors at NEC, Birmingham for Smart Manufacturing Week 2026, a show that celebrates the industry’s present while paving the way for its future.

his year’s Smart Manufacturing Week built on the success of previous years, with a more varied conference programme, a breathtaking array of exhibitors and technological demonstrations, and even more opportunities to network. On top of this, the roving mariachi band, all-day DJ, mirror-clad performers and a variety of food vans gave the show a festival vibe. The spectacle of Accu Fight Fest proved popular amongst attendees (MEPCA included) and it appeared to draw large crowds both days. It was possibly one of the most dramatic exhibitions ever attempted at a trade show. For all its novelty, there was more to Accu Fight Fest than simple fun – or nostalgia for long running British television series, Robot Wars – as it demonstrated real-world engineering capabilities. We watched from the safety of Xometry’s stand as Torx, its sponsored robot, rendered its opponent immobile in the ring. Based on that demonstration, it was no surprise to later learn that Torx went on to win Fight Fest, notching up an impressive eight wins.

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Xometry did more than simply sponsor the robot; they armed it with a CNC-machined beater bar, produced using Xometry’s on-demand manufacturing network. The bar, which was machined to production-grade standards, was constructed from high-strength, chromium-molybdenum alloy and hardened to 40–45 HRC. The result was a robotstopper that gave Torx the edge. At Online Cleaning Technologies’ stand, we experienced the latest drone technology for industrial cleaning. Alex M., Drone Services Engineer, showed us the Elios 3 drone, which is designed to access dangerous or hard-to-reach places for cleaning and maintenance in the Power & Energy sector. Using LIDAR, Elios 3 can build precise 3D models to help maintenance teams identify defects. Video footage showed the drone navigating a seemingly unending and claustrophobic chimney stack. The impact of the technology hits home when you consider the alternative: sending a human maintenance operative. Chris Lloyd, Chief Solutions & Technology Officer, Syspro

EVENTS

The Elios 3

AN INTELLIGENT SYSTEM OF OUTCOME

Our editor had the privilege of speaking with Chris Lloyd, Chief Solutions & Technology Officer at Syspro, shortly before he was due to speak on The AI and Industrial Data Theatre Stage, to discuss Manufacturing’s Intelligent Era. “Manufacturing has been a tough battleground for intelligence to break into because it is such a connected ecosystem of multiple variables,” Chris said, before explaining that without operational context, AI can only provide insights or point solutions, but it isn’t able to provide decisions or meaningful outcomes. To get industrial AI working in a way that will deliver this intelligence, Chris insisted that there are three things have to be true at the same time. Firstly, a system with a “full operational understanding” of the business, from lot traceability and inventory all the way through to the nuances of business terminology. Secondly, an enterprise grade system for real-time decision making, “a system of action,” rather than that of retrospect. “And the last component is layering on intelligence across a domain,” he continued, “which means that you’ve got the system that supports it, you’ve got the enterprise operational intelligence, and you can connect to all the OT systems where the shop floor actually runs. That gives you enterprise or industrial AI.” Another issue Chris commonly sees is adoption being driven by the intention to employ an AI solution for its own sake rather than focusing on an outcome. This has to be flipped on its head to get the most out of enterprise AI. “It means that the company shifts from looking for features and functionality to driving specific outcomes,” he summarised. In Chris’ experience of the UK manufacturing sector, it is in a fairly strong position to benefit from manufacturing intelligence, however, it faces specific challenges. One key factor is the “tribal knowledge” locked away in UK

operations, which will first need to be extracted and processed in natural language before it can be used for enterprise intelligence. Fortunately, with current advances in AI this is highly achievable: “AI can run multiple deterministic models, compare them, and then draw a probabilistic model on top of it. That is what humans did historically that you couldn’t unlock, which now AI brings to the table, which removes the tribal knowledge. “So, the way that the UK manufacturers need to start tackling this is making sure they’ve got A), a system that understands their organisational context, B), have the systems that can react in real time, and then C), start layering AI on top of it,” Chris advised. Having addressed some of the current challenges of manufacturing intelligence, the discussion concluded with a look at what hurdles it may face in the near future. Chris fears that we’re going to see software providers building “moats” around their solutions in “a restrictive, defensive model,” locking down their logic and sources code, etc. Whereas progress will be driven by the opposite approach. He predicts that the software providers that will “win the next wave” will be those on the offensive; those “using AI to drive outcomes in the new modern world, connecting into more systems, providing trust, providing orchestration.” “The next decade is going to belong to the providers of an intelligent system of outcome,” he concludes. MEPCA would like to thank Chris Lloyd for speaking with our editor, and everyone else who welcomed the team to their stands, along with organisers, Nineteen Group, who once again delivered an event that went above and beyond. smartmanufacturingweek.com

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EVENTS

UK METALS EXPO 2026 TO BE UNMISSABLE This 4-5 November 2026, NEC Birmingham, UK Metal Expo returns, co-located with Advanced Engineering and Lab Innovations. Learn why it’s the one event operations teams working in the metal industry cannot afford to miss.

et’s be honest, the average manufacturing professional does not need another event on the calendar. What they need is the right one. UK Metals Expo – taking place on 4-5 November 2026 at the NEC Birmingham– has spent several years earning that title for the UK metals supply chain, and in 2026 it takes a significant step further. Free registration is now open, and if you work in operations, production, procurement or engineering where metals are central to what you do, here’s why it belongs in your diary. The event is built around a simple but genuinely useful premise: walk one circuit of the hall and you move through the entire metals supply chain. Primary producers, stockholders and service centres sit alongside processors, fabricators, surface finishers, recyclers and technology suppliers. For a production manager benchmarking new suppliers, or a procurement engineer trying to understand what alternatives exist beyond their current panel, that compression of time and effort is hard to replicate any other way. Two days in Birmingham replacing weeks of calls, site visits and separate supplier meetings.

WHAT’S DIFFERENT IN 2026?

This year, UK Metals Expo is co-located with Advanced Engineering and Lab Innovations for the first time, creating one of the largest manufacturing event clusters in the UK. Over 15,000 attendees are expected across the three events, with 750+ exhibitors bringing together materials,

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machinery, technology and testing solutions under one roof. For engineers who need to see both their metals supply chain and wider manufacturing innovation in the same trip, this is a more efficient use of two days than the event has ever been before. The free conference programme, running across four theatres, has also been sharpened for 2026 with a particular focus on the challenges that are actually keeping production and procurement teams busy right now; CBAM and trade policy, supply chain resilience, decarbonisation in practice, automation, and skills. These aren’t panel discussions designed to fill a slot. They are sessions built for people who will act on what they hear. Attendees can register now for free on the website below.

INTERESTED IN EXHIBITING?

If your business supplies materials, processing services, machinery, technology or solutions into the metals and manufacturing sector, UK Metals Expo gives you direct access to a concentrated audience of buyers, specifiers, engineers and operations managers who are looking for what you offer. With co-location bringing even more attendees this November, there has never been a stronger case for exhibiting. Enquire about exhibiting via the QR code. ukmetalsexpo.co.uk

Co-Located with:

4 & 5 November 2026, NEC Birmingham

Home of the UK metals supply chain Where the full metals industry connects, collaborates and does business

300+ exhibitors

15,000+ 100+

attendees across 2 co-located shows

speakers

30+

seminars across 4 Theatres

Supported by key industry bodies:

LEARN MORE ABOUT THE EVENT Visit ukmetalsexpo.com UKMET_26_Advert_Exhibiting in 2026_A4-V3.indd A4-V3.indd 1 2026_

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EVENTS

HANNOVER MESSE: A COMPETITIVE FUTURE HANNOVER MESSE 2026 showed that industry is responding to today’s economic challenges with practical, future-focused solutions. Artificial intelligence, automation, robotics and digitalisation emerged as the key technologies driving greater efficiency, resilience and competitiveness across the manufacturing sector.

he event attracted around 110,000 visitors from across the globe. Although attendance was slightly lower than in 2025 due to airline and public transport strikes, the exhibition maintained a strong international profile, with around 40% of visitors travelling from overseas. China, Brazil, the United States, Japan and South Korea were among the largest international delegations. Jochen Köckler, CEO of Deutsche Messe AG, described this year’s event as both a technology showcase and a source of inspiration, emphasising that Europe already has the tools needed to remain competitive. The focus now, he said, must be on implementing these innovations more rapidly. Across the exhibition halls, companies demonstrated AI-powered production systems capable of automating processes, predicting maintenance needs and improving operational efficiency. Humanoid robots, advanced automation technologies and new energy infrastructure solutions also highlighted the industry’s progress towards more sustainable and intelligent manufacturing. The exhibition attracted significant political and business attention, with German Chancellor Friedrich Merz, Brazilian President Luiz Inácio Lula da Silva, senior European officials and leading executives from Siemens and SAP among those attending. Their presence reinforced HANNOVER MESSE’s role as a key platform for industrial dialogue and international cooperation. Despite showcasing technological innovation, industry leaders also highlighted the challenges facing European manufacturers, including rising costs, regulatory complexity and geopolitical uncertainty. Representatives from ZVEI and VDMA called for faster deregulation and policy reforms to enable companies to compete more effectively in areas such as industrial AI and advanced manufacturing. While acknowledging these obstacles, exhibitors reported productive discussions, strong international interest and promising business opportunities throughout the event. Partner Country Brazil made a significant contribution, presenting its strengths in industrial technology, energy and digital transformation. The partnership also reflected growing cooperation between Europe and Latin America, supported by the anticipated implementation of the

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Mercosur agreement. The exhibition introduced several successful new features, including an improved hall layout, practical Masterclasses and the Centre Stage programme, which attracted around 30,000 visitors with presentations, discussions and expert insights. Looking ahead, HANNOVER MESSE will continue evolving in 2027 with the launch of Europe Energy Week alongside the exhibition and a revised four-day format designed to maximise visitor engagement. AI applications and their integration into real industrial processes will remain central themes as the event continues to support the future development of global manufacturing. hannovermesse.de/en/

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EVENTS

MED-TECH EXPO 2026 REVIEW 3–4 June, NEC Birmingham, Med-Tech Expo 2026 reaffirmed its position as the UK’s leading event for medical device manufacturing, bringing together the technologies, expertise and industry leaders shaping the future of healthcare innovation.

ver two busy days at the NEC Birmingham, Med-Tech Expo 2026 valuable insights, practical solutions and meaningful networking opportunities for professionals across the medical technology supply chain.

A COMPREHENSIVE MEDICAL MANUFACTURING SHOWCASE

One of Med-Tech Expo’s greatest strengths is its ability to unite every stage of the medical device manufacturing process under one roof. The exhibition featured a diverse range of suppliers and solution providers, including component manufacturers, materials specialists, cleanroom experts, automation providers, contract manufacturers, testing laboratories and regulatory consultants. Paul Marshall, CEO, Rapid Fluidics, commented: “This is actually our sixth time exhibiting at the Med-Tech Expo. There’s been a handful of really interesting new leads and that’s the great thing about doing a show like this, you find people come out of the woodwork and they have the most amazing application.” A highlight of the event was the Start-Up Zone, bringing visitors face-to-face with a range of new start-up companies from across the med-tech sector who wouldn’t normally exhibit. Jacqui O’Connor, Founder of MedScan3D – one of the companies exhibiting on the Start-Up Zone – said: “We’ve already booked for next year! It’s been a great event.”

CONFERENCE PROGRAMME DELIVERED VALUABLE INDUSTRY INSIGHT

The free-to-attend conference programme complemented the exhibition with a strong focus on the issues currently shaping the medical technology sector. Key themes included digital transformation, regulatory compliance, innovation in product development, and the future of healthcare manufacturing. A highlight of the insights Stage was the panel session “Beyond Price: How Value Based Procurement is Reshaping NHS MedTech”, which brought together key policy architects and industry leaders to discuss the practical application of modern NHS framework agreements. The panel was chaired by Chris Whitehouse,

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with panellists David Lawson from DHSC and Ismail Hanif from Essity. Discussion centred on the structural shift in tender evaluation rules, with particular debate around the implementation of the mandatory 40/60 scoring split directive.

NETWORKING AND INDUSTRY COLLABORATION

Beyond the technologies and conference sessions, MedTech Expo once again demonstrated its value as a key meeting place for the medical technology community. Engineers, product developers, manufacturing specialists, quality professionals, regulatory experts and business leaders gathered to exchange ideas, build partnerships and discuss shared challenges. The event’s focused audience created an environment conducive to meaningful conversations and productive networking. For many attendees, the opportunity to engage directly with suppliers, customer, and industry peers was just as valuable as the technologies on display. This collaborative atmosphere reinforced the event’s role in supporting innovation and growth across the UK’s medical device sector. The next Med-Tech Expo event will take place 15-16 September 2027 at the NEC Birmingham is expected to continue building on this momentum, further strengthening its position as the UK’s essential gathering for medical technology professionals. med-techexpo.com

EVENTS

SMART MANUFACTURING WEEK 2026 TRIUMPHS Smart Manufacturing Week 2026 has officially concluded, marking the most successful edition in the event’s history. Reflecting the accelerating pace of industrial digitalisation and automation, this year’s show welcomed 13,405 visitors, reinforcing its position as the UK’s leading event for advanced manufacturing and engineering.

he quality of attendance continued to rise, with purchasing power increasing from 78 per cent to 81 per cent of visitors. Engagement levels also reached new heights, with a record 871 meetings booked through the event app, creating valuable opportunities for collaboration and business growth. Across two days, attendees explored the latest innovations from 437 exhibitors showcasing technologies spanning robotics, artificial intelligence, digital transformation and sustainable manufacturing. A major feature of this year’s event was the partnership with Alibaba.com as Official Agentic Business Partner. The company showcased Accio Work, its agentic AI platform, alongside a bespoke Event Edition Agent developed exclusively for Smart Manufacturing Week. “Addressing the real challenges facing industry is at the core of what we do at The Manufacturer and Smart Manufacturing Week,” said Grace Gilling, Managing Director of Hennik Research, part of Nineteen Group. “This year’s event was a powerful reflection of that purpose in action, with a vibrant show floor full of meaningful conversations, new connections and fresh ideas.” Beyond the technology on display, Smart Manufacturing Week delivered a festival-style atmosphere unlike any other industrial event. Visitors were greeted by mariachi musicians, mirror-suited performers and an all-day DJ, while the hugely popular Accu Fight Fest robot battles drew crowds throughout the show. The event’s extensive conference programme also attracted packed audiences. One standout session featured a panel chaired by Chris Dungey, the governmentappointed National AI Champion for Advanced Manufacturing, exploring how manufacturers can move from AI ambition to implementation. Elsewhere, speakers shared practical insights on innovation, automation and data-driven manufacturing. Gareth Knopp of Bucher Municipal highlighted how simulation and AI are transforming product development, while Fine Lady Bakeries’ Kayode Adisa explored the importance of effective data flow and automation strategies. Supporting the next generation of talent remained a key priority. The STEM Showcase featured apprentices

from Rolls-Royce, Festo and Balmoral Tanks sharing their experiences, while organisations including Stemettes, The Smallpeice Trust, The Engineering Trust and STEM on Track engaged directly with students considering careers in engineering and manufacturing. Networking and collaboration remained central to the event. Initiatives such as the SMMT Meet the Buyer Programme strengthened supply chain connections, while the Manufacturing Digitalisation Summit attracted 232 senior industry leaders to discuss the practical implementation of digital technologies. “We keep coming back to this show because we see it getting bigger and bigger. And we see the buzz around UK manufacturing.” Phil Lewis, Senior Vice President, Infor. Smart Manufacturing Week returns to the NEC Birmingham on 9–10 June 2027, where visitors can look forward to an expanded Factory of the Future immersive demonstrator developed in partnership with AMIC. If 2026 proved anything, it is that the future of manufacturing is already taking shape. smartmanufacturingweek.com

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EVENTS

1ST KEYNOTE SPEAKER FOR PPMA SHOW® 2026 Organisers of the PPMA Show®, which returns to the NEC, Birmingham in September, have announced the first keynote speaker for the event: Dr Kevin Fong, a doctor and broadcaster who has held prestigious positions with NASA and NHS England.

isitors to the UK’s biggest processing and packaging machinery, robotics and industrial vision event, which takes place from 2224 September, will have the opportunity to hear from Kevin, who will share insight of his first-hand experience in high-risk situations in his keynote speech, Leading Through Uncertainty, on the first day of the show. Organised by Automate UK, the PPMA Show®, offers valuable insight into innovative technologies, live equipment demonstrations, and networking opportunities to industry professionals from across the entire manufacturing spectrum. Scott McKenna, Chief Operating Officer for Automate UK, said: “Every year we promise visitors to the PPMA Show® access to unique expert-led seminars, and we are thrilled that Kevin has agreed to share his extensive knowledge and experience in our first keynote address at the event. “Kevin is best known for his work with NASA’s Human Adaptation and Countermeasures Office in Houston, Texas, further to which he developed an interest in high risk, high reliability teams and the science behind their success or failure. He was subsequently appointed as a National Clinical Adviser to NHS England during the Covid-19 pandemic, and flies as an air ambulance emergency doctor. “In addition to these inspirational roles, Kevin is a

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multi-award-winning author and broadcaster, currently presenting his BBC Radio 4 series Artificial Human following the success of his BBC World Service podcast 13 Minutes to the Moon, which focused on NASA’s first landing on the Moon and the rescue of Apollo 13. “Needless to say, his keynote speech is going to be exceptional. Kevin will share his unique insight into how teams cope with risk, uncertainty and making decisions under pressure in some of the most intense scenarios imaginable, making his address a must-attend seminar at the event,” he said. Now in its 39th year, the PPMA Show® 2026 will give more than 350 exhibitors and 1,500 brands the opportunity to cast a spotlight on their products and expertise, showcasing cutting-edge technology and solutions to optimise performance, reduce costs, and future-proof their businesses. Once again, the event will include a live demo theatre where selected exhibitors will launch technology directly to attendees and participate in daily innovation tours to expand upon it and show them how to harness it within their own businesses. Attendance for The PPMA Show® 2026 is free. To register, visit: ppmashow.co.uk

22 - 24 September 2026 l NEC, Birmingham

See automation take centre stage at the Greatest Processing & Packaging Show - the PPMA Show® 2026, held at the NEC, Birmingham from 22 to 24 September. Meet over 350 exhibitors, discover the latest technologies, experience live demonstrations and network with new contacts. Scan the QR code to reserve your free pass today.

e ppmashow@automate-uk.com w ppmashow.co.uk

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COMING UP IN THE SEPTEMBER ISSUE FOOD PROCESSING Also featured in the September issue: TEST & MEASUREMENT MANUFACTURING SOFTWARE MATERIAL HANDLING MANUFACTURING CHAMPION INDUSTRY NEWS EXPERT OPINIONS Events covered in the September issue:

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