Welcome to the July issue of MEPCA magazine. At the heart of this month’s issue is our Warehouse Automation focus. In today’s warehouses, ever-increasing demand and growing recruitment issues have resulted in a level of pressure comparable to the bottom of the ocean for warehouse operators, as they struggle to meet often-unrealistic fulfilment targets. As any delays in warehouse operations are quickly passed on to the many industries that rely upon them, warehouse automation is becoming ever more crucial. This is demonstrated by the cuttingedge solutions and expertise featured in this issue’s focus.
Included in this month’s focus are insights from Dexory, as the company explains why semiautomated warehouse operations are in danger of being left behind. Delving deeper into the focus, Kärcher UK explores how robotic cleaning systems are revolutionising cleaning outputs, while Pepperl+Fuchs introduces a dash-cam for warehouses, which adds a valuable visual context for tracing faults.
Also within this extensive focus, we take a detailed look at the impact of automation on employee safety, with insights from warehouse safety experts, A-Safe, Troax, and Bureau Veritas.
In our cover story, safety equipment specialist EUCHNER addresses the tendency for companies to neglect safety systems as other operational systems evolve.
Elsewhere in the issue, we have expert opinion pieces from Make UK and AEMT, and we reveal our Manufacturing Champion of the Month. Since beginning this regular feature, an opinion shared by many of our Manufacturing Champions is the important role apprenticeships have in solving the skills shortage, so it is not before time that we celebrate an apprentice.
I hope you enjoy this issue.
@Mepca-magazine
To subscribe to MEPCA visit our website www.mepca-engineering.com or scan the QR code.
Oliver Batt, Editor
ABB Motion Unveils its Motor Strategy
At a recent press event, ABB Motion reinforced the company’s long-term motor efficiency improvement ambitions, and demonstrated why motors, the ‘workhorses’ of industry, are the frontline in decarbonisation and net zero.
Motors are crucial to all industries and used everywhere from robotics to wastewater management; if it has latitudinal or longitudinal motion, spins, or flows, a motor is likely responsible.
Presenting the briefing hosted by Cadence Innovation Marketing in May, representatives of ABB Motion shared the company’s ambitious plans for the future of the motor industry.
Division President of IEC Low Voltage Motors Stefan Floeck’s opening commentary highlighted the importance of addressing motor efficiency: “45% of the world’s electricity powers motors. By 2040, the number of motors will double.”
To reach net zero ambitions, energy efficiency is crucial. With motors accounting for one third of all industrial facilities’ energy consumption, net zero and the decarbonisation of industry will only be possible by making motors greener. Doing so has the potential to reduce global electricity consumption by up to 10%.
ABB’s motors are 98% recyclable, highly repairable, and have industry-leading life spans. They have also developed recycling or ‘take-back’ programmes to enable the easier recycling of motors and the use of recycled components to reduce waste going to landfill in China and India. Since 2011, they have pioneered synchronous reluctance motors (SynRMs), which are not only highly efficient and cost-effective but more sustainable due to not requiring rare-earth magnets.
With ABB’s motor efficiency ambitions and achievements outlined, Ivor Vidjen, Global Head of Strategy & Business Development for IEC LV Motors, further brought the company’s decarbonisation strategy to life, showing the overarching economic benefit
and business case behind it. He explained that energy intensity, the measure of how much energy is used in order to produce one US dollar of GDP, has stalled at 2% per year.
If it remains at this level, it jeopardises industry decarbonisation, and it ultimately needs to increase to 4%, something that ABB believes is achievable. However, as Ivor explained, it is all well and good having an internal strategy, but it has been important that they stress test this hypothesis against the industry.
To do so, they undertook a detailed survey of circa 3,000 customers and partners, questioning them on energy efficiency, adaptation and investments. Their findings were encouraging. For example, 94% of those surveyed plan on making energy saving investments. Ivor explained that part of ABB’s job is to make a business case for those that are still on the fence.
Alongside commercial factors, the survey found that the motivation of those surveyed was also driven external factors, such as energy efficiency standards and regulatory bodies, which employ “subsidies” or
“punitive measures” to encourage efficiency. Accreditation is also an important factor. He revealed that ABB are the first motor company to gain EPD (Environmental Product Declaration) accreditation, a feat that was highly admin-intensive.
Daniel Eberli, Head of Product Management, explained that pushing the boundaries of technology and helping their customers and partners find solutions has always been part of ABB’s DNA. This is perfectly illustrated by ABB’s IE6 classed motors.
The current highest codified efficiency class of motors is IE5, defined as “UltraPremium Efficiency” by the International Electrotechnical Commission (IEC), but ABB’s magnet-free SynRM motors are classed as IE6. By applying the same logic of efficiency improvement that separated IE4 from IE5, ABB were able to logically determine the benchmarks needed for the next motor efficiency class – it was no surprise to hear that they are already working towards IE7.
new.abb.com/service/motion
Pumps and Seals for Reducing Repair Costs
In tough applications, robust pumps are essential, but as Börger UK explains here, if maintenance and repair costs have escalated to the point of ridiculousness, it is time to consider alternatives.
Pumping Titanium Dioxide isn’t the easiest. Used primarily for consumer electrical goods with its brilliant white colour, this slurry solution of titanium dioxide powder and base/carrier fluid is extremely abrasive. Certainly not for any old pump, but when the cost of a brand-new replacement is cheaper than a repair, then it’s a true no brainer not to improve the economics of the process.
Such a scenario presented itself recently to a rotary lobe pump manufacturer, who has already created a very successful track record at plants in the same areas of industrial Humberside and North Lincolnshire. As a low-friction, almost pulsation-free pump, it would meet the requirement for Titanium Dioxide to be gentle on the important pigments, but what about the pressures and the seals?
“We knew that with our ONIXline pumps, we could handle demanding high pressures up to 16 bar”, said David Brown, Managing Director of Börger UK. “And with no wearing parts, plus Maintenance-In-Place, we were very confident that servicing and repair costs would be significantly lower; almost a drop in the ocean to what they were before, especially when one accounts for all the manhours.”
Brown pointed to a previous Börger installation for National Grid, where previously, the existing units had to be winched out, with the additional cost of also having to bring in two fitters; plus jacking up the screw pump in order to cut the main rotor in half.
He added: “A breakdown or even a standard maintenance overhaul at this underground National Grid location had become an extremely time-consuming health and safety event lasting up to two
and half days, with huge costs attached to it. And this was before any new parts were required, which would invariably add to the downtime and escalating costs. Thankfully, pump technology and innovation continues to accelerate so that there are far more economic options available, which are just as effective and reliable for even the toughest of processes.”
The price of pump seals is also an increasingly important factor in purchasing decisions, with many end users having a preferred manufacturer.
Vacuum and pressure at the same time
Brown continued: “We’ve also worked very hard on all the variables that a seal has to cope with, so now we have vacuum and pressure at the same time, on the same seal, dynamically from one side of the pump to the other, which is quite rare. Most pumps have either got a vacuum or a pressure at the seal face, but we’ve got both. This is very innovative, so no surprise it is in demand.”
Close to the Titanium Oxide plant, Börger has also supplied numerous pumps to a large water company effluent plant, and to a refinery, where the challenge was to provide a pump for a high viscosity (50% solid content) application requiring 14.5 bar and a temperature of 70°C. Achieving the right balance between high internal fluid temperatures and ATEX surface temperature limits on the outside was also a stern test.
Only basic tools required
“For maintenance at the processing plant for the Titanium Dioxide,” said Börger’s David Brown, “all that’s required now is to lift out and work on the pump head, with only basic tools required.
“Everything is far more compact and a much smaller footprint than what was there before. It proves that that you don’t have to pay through the nose for new pumps and seals, even when the application is a particularly demanding one.”
boerger.com
The Trade Union Resurgence
As membership of trade unions rises, Verity Davidge, Policy Director at Make UK, examines the reasons behind this increase and offers advice to businesses preparing for the associated changes in employment law.
The UK is in the middle of a trade union resurgence. The Employment Rights Bill looks likely to repeal much of the Trade Union Act 2016 this year, changing the trade union landscape. Membership of trade unions is on the rise once again. Although numbers are below historic highs, this time retail and specialist professions in the private sector are driving the increase.
The changing world of work is one factor influencing this growth in trade union membership, with the shift towards remote and hybrid working, the expansion of automation and the explosion of the gig economy all heightening employees’ need for collective representation.
The government’s upcoming legal changes to strengthen workers’ rights, along with the successful negotiations on public sector pay rises, are also making union membership look a lot more appealing. So how can businesses prepare for these changes?
Understanding the current laws around union recognition and collective bargaining is key, with the Government introducing significant amendments to trade union legislation through the Employment Rights Bill, which is currently going through the commons.
Proposed changes include day-one rights against unfair dismissal (previously requiring two years’ employment), new contracts for zero-hours workers, and paternity leave. Furthermore, there is a simplified union recognition process to reduce membership thresholds and get rid of some procedures, with calls for an ‘opt in’ to trade unions to be automatic.
In the context of these changes taking place, how can companies work successfully with trade unions?
As with any relationship, mutual trust and communication are key, with a respect for different viewpoints and a willingness to have regular and constructive meetings essential for nipping issues in the bud. In addition, companies should ensure managers are fully trained and supported to navigate difficult conversations handle negotiations to avoid industrial action. Open communication with all staff is vital, regardless of whether they’re a union member or not.
Trade unions are redefining their priorities – and businesses need to adapt to these changing expectations. However, with a positive approach, employee relations can also be kept positive, together with a mix of preventative measures alongside effective negotiation and dispute resolution. It is also crucial to be proactive about engaging with unions, which can prevent issues or disputes from escalating.
In the event that negotiations are needed, a collaborative approach works best, with a willingness to listen, compromise and be respectful – supported by the use of datadriven insights – recommended for fairer outcomes. However, if there are disputes, a structured resolution process like mediation can help find solutions that work for both sides.
With a stronger trade union landscape on the horizon as employment laws continue to evolve, employers need to stay one-step ahead. Balancing the needs of business with trade union demands and employee rights will require a strategic approach, fostering open dialogue and making sure of compliance with new regulations.
By preparing for change in this fastmoving landscape, companies will be in the best position to work with the trade unions and approach the future with a motivated workforce. makeuk.org
It’s Time to Embrace Repairability
In a world grappling with climate imperatives, rising costs, and resource scarcity, the message from consumers is clear: they want the right to repair. Thomas Marks, AEMT’s General Manager and Secretary, explains the importance of repairability.
Across the consumer market, we are seeing major brands wake up to a shift in public sentiment. People want products that last longer, and when they do break, they want to be able to fix them.
One of the most compelling examples comes from Philips, which recently launched its “Fixables” programme. This initiative allows customers to download 3D-printable files for select parts of their products, such as a comb attachment for the OneBlade trimmer. Instead of waiting weeks for a minor replacement or discarding a stillfunctional product, users can print a new part themselves. It’s a simple concept with profound implications: empower the consumer, reduce waste, and prolong product life.
Other manufacturers are following suit. Logitech has partnered with the repairchampioning website iFixit to provide spare parts and detailed repair guides, making it easier for consumers to fix their devices rather than replace them. Framework, the modular laptop company, has built its entire business model around repairability, offering laptops with easily swappable components. And Fairphone has long been a pioneer in this space, designing smartphones that allow users to replace batteries, screens, and cameras with basic tools.
What unites these companies is a recognition of the growing consumer demand for sustainable, repairable products. They see the value in aligning with a circular economy — one that keeps products and materials in use for as long as possible, reducing waste and saving resources.
Yet, when we turn our attention to the world of industrial equipment, this mindset is still relatively rare. There are manufacturers
of industrial equipment who embrace repairability; those designing products with ease of repair as a consideration and improving aftersales support with documentation and spares availability. But the scale of adoption feels, to me, to be behind the consumer space.
Cynics might point out that EU Right to Repair legislation, introduced as part of the European Green Deal and reinforced by the EcoDesign Directive, currently applies to a specific set of household and electronic appliances, suggesting this is driving the change we are seeing. However, while the EU’s Right to Repair legislation has primarily targeted household appliances and consumer electronics, there is a clear trajectory toward including industrial equipment such as electric motors and pumps.
away from closed systems toward open, collaborative ecosystems.
At the Association of Electrical and Mechanical Trades (AEMT), we work with a wide range of repair specialists who see first-hand how much valuable equipment is discarded simply because it wasn’t designed to be repaired. This is not only wasteful but also expensive. Repairing industrial machinery can be more cost-effective than replacing it, particularly when considering downtime, installation, and integration costs.
Designing for repairability in industrial equipment isn’t just about making spare parts available. It’s about embracing modular design principles, improving documentation, supporting third-party repairers, and moving
Philips’ Fixables programme is just one example of what could be a broader transformation in product design and customer support. If individuals can 3D print a replacement part for a personal trimmer, why shouldn’t a maintenance engineer be able to access similar files or guides for a faulty motor coupling or panel component?
We must take inspiration from these developments. Industrial equipment manufacturers have an opportunity — and, I would argue, an obligation — to respond. By prioritising repairability, they not only reduce costs for their customers and help the environment but also future-proof their own businesses in an increasingly sustainabilitydriven world.
The right to repair isn’t just a consumer trend. It’s a cultural shift. It’s time our sector caught up.
theaemt.com
Manufacturing Champion of the Month
This month, MEPCA has taken the opportunity to celebrate a rising star of engineering. Introducing Lewis Morley, Engineering Apprentice at Festo. Lewis shares his views on apprenticeships, why he chose a career in engineering, and how it felt to have his dedication recognised at PPMA 2024.
The opinion that apprenticeships are crucial for combating the industry’s growing recruitment problem has been common among our Manufacturing Champions. Our July Champion demonstrates why.
Since beginning his apprenticeship at Festo in September 2022, Lewis Morley has been an exemplary apprentice, highly commended by Festo, the BFPA, and awarded Automate UK’s Rising Star of the Year 2024. Here, he provides his insights.
What makes an apprenticeship such an effective route into engineering?
An apprenticeship offers young people a direct route into industry, offering something different compared to the traditional route of university. From the start at Festo, I have been able to work with innovative automation technology, helping implement these new technologies into real industry. Alongside this, I have been studying for 3 years towards a bachelor’s in electrical engineering. I enjoy the balance between my days at college and my time at work; it’s really rewarding to take the theory I’m learning in the classroom and apply it to real products and applications at Festo. This hands-on experience consolidates my understanding, and makes the learning feel more meaningful. You’re not just studying concepts — you’re seeing how they work in practice.
At what point did you realise you wanted to pursue a career in engineering?
When I was younger, I was always curious
about how things worked—constantly taking things apart and figuring out how to put them back together (much to my parents’ dismay!). But it was really at the end of secondary school, while weighing up options for sixth form or college, when I decided to specialise. I chose to attend a dedicated engineering college, where enthusiastic and supportive teachers introduced me to the various fields of engineering. From that point on, I knew I wanted to go straight into a job through an apprenticeship—but I also wanted to push myself further and continue progressing towards higher qualifications to build a long-term career in the industry. This is why I chose the degree apprenticeship route.
What did winning the Automate UK Rising Star of the Year award at PPMA last year mean to you?
I was shocked when my name was announced – I really couldn’t quite believe it. It felt special to be recognised on a national stage like that, especially so early in my career. For me, it really confirmed that I was doing the right things in my apprenticeship, and it has really given me a boost of confidence and determination to finish my apprenticeship and immerse myself into a full-time role in the industry, which has already given me so much opportunity. It’s something I can look back on with pride going forward.
What advice do you have for STEM students considering a career in industry?
Apply yourself and don’t be put off. Speaking from experience, I used to think
industry was a daunting and difficult path to break into—but the reality is quite different. A lot of manufacturers and engineering firms are actively looking for apprentices and young engineers to help close a growing skills gap, and the opportunities out there are only increasing. My advice is to take every opportunity that comes your way, even if it feels outside your comfort zone. And, ultimately, if you don’t ask, you don’t get. Sometimes just showing interest can open the first door – if you’re enthusiastic about engineering then employers will recognise that and will see your potential.
festo.com/gb/en
Unlocking the Power of Machinery Safety
It is commonplace for safety systems to be operated independently from other systems. As facilities grow smarter and more automated, safety systems are at risk of being left behind.
Safety equipment specialist EUCHNER explains why it is so crucial that safety systems evolve.
As manufacturing, fulfilment, and logistics facilities become smarter and more autonomous, safety systems must evolve too. Increasingly, that means moving beyond hardwired, standalone devices to intelligent, networked systems that integrate directly into automation architectures.
At the centre of this evolution are guard locking devices like EUCHNER’s MGB2 Modular, which now offer direct communication with Safety PLCs over industrial Ethernet. Combined with access control systems like the CKS2 RFID key system, these devices enable flexible, scalable safety solutions that meet the demands of modern production environments.
From isolation to integration
Traditionally, safety functions like guard locking, interlocks, emergency stops and access control operated independently from the main control system, hardwired to central safety relays. While reliable, this model can be limiting in dynamic facilities where production lines change frequently and uptime is critical.
Hardwired safety adds wiring complexity, increases panel space and limits diagnostics, often turning safety into something that must be worked around rather than built in.
That’s changing. Ethernet-based safety networks such as PROFIsafe over PROFINET, CIP Safety over EtherNet/IP, and FSoE over EtherCAT allow guard locking devices to communicate with the control system over the same network. This delivers a fully integrated, safety-certified communication channel with advanced functionality, real-time diagnostics, and scalability.
Devices like the MGB2 Modular benefit
from simplified installation, reduced panel space and software-based commissioning. Real-time diagnostics mean faults can be located quickly, without time-consuming manual checks. These protocols support decentralised architectures, enabling devices to be repositioned or reconfigured without major rewiring. Moreover, they meet rigorous
safety standards BS EN ISO 13849-1, and BS EN IEC 62061to achieve the highest performance levels in machinery safety of Ple and SIL3.
MGB2: built for the networked era
The MGB2 Modular is a perfect example
of connected safety in action. Designed for demanding applications in manufacturing and logistics, it combines guard locking, control functions and diagnostics in a single device.
Its standout feature is native support for Ethernet-based safety, enabling direct integration with all major safety networks and seamless communication with Safety PLCs. There’s no need to route individual safety contacts to a central cabinet. All status, diagnostics, and access requests are transmitted via the network, often viewable on existing HMI or SCADA systems.
This integration simplifies engineering and enhances visibility. Expansion modules
allow additional components like emergency stops, selector switches, or signal lights to be connected and addressed over the network, reducing the need for separate control components and making operator interfaces more intuitive.
Smarter access with the CKS2
Access control isn’t just about compliance, it’s about enabling safe, efficient interventions. In facilities where temporary access is often needed (e.g., to clear a jam or make quick adjustments), traditional mechanical key systems can be restrictive.
The CKS2 RFID key system provides a modern alternative. It replaces mechanical keys with coded RFID ones connected directly to the safety network, streamlining access control without compromising safety.
A typical workflow involves removing a key from an MGB2 or control station to gain access to a safeguarded area. In some cases, the key is inserted into a second reader inside the zone to enable safe functions like jog mode or diagnostics. Only when all keys are returned can the system restart.
This electronic approach removes the physical limitations of mechanical systems while maintaining strict control. Integrated
with the safety PLC, access can be logged, restricted, or granted dynamically, improving safety, reducing downtime, and cutting administrative burden.
Designed for evolving environments
Facilities are constantly evolving new lines, reconfigured layouts, and increasing automation. In such environments, adaptability is essential.
With devices like the MGB2 and CKS2 connected to the network, changes become easier to implement. New modules can be added with minimal reconfiguration, diagnostics can be performed remotely, and safety functions are monitored in sync with the rest of the automation system.
This also opens the door to predictive maintenance. With data flowing from each safety device, wear, misalignment, or unusual usage patterns can be detected early, avoiding unplanned shutdowns and improving reliability.
One device, global flexibility
For global operations, standardising on a single platform is a strategic win. The MGB2 Modular supports all major safety protocols, allowing the same hardware to be deployed across facilities regardless of the PLC vendor.
This simplifies sourcing, reduces engineering effort, and future-proofs safety investments. As operations expand, the same safety devices can move with them, supporting scalable, consistent safety across regions.
Connected safety is better safety
Automation is about more than speed and efficiency, it’s also about safety. That safety must be just as smart and connected as the systems it protects.
By choosing Ethernet-connected devices like the MGB2 Modular and CKS2, manufacturers gain not just compliance, but control, transparency and agility.
Whether in a smart warehouse, an automotive line, or high-speed packaging plant, connected safety is becoming the new standard, enabling a safer, smarter and more resilient future.
For further information, visit EUCHNER’s website.
euchner.co.uk
Focus On: Warehouse Automation
Sponsored by
P16-17. Learn why successful warehouse operations start with automation.
Investing in Resilience
Warehouses that rely on manual or semi-automated processes risk being left behind. Discover here why future-ready warehouses start with automation and how Dexory’s warehouse intelligence platform, DexoryView, can deliver 219% ROI in less than 6 months.
Warehouses are under immense pressure to perform. The days of manual inventory checks and siloed data are gone, or should be. Forward-thinking businesses are recognising that automation isn’t a “nice to have”; it’s a necessity for efficiency, accuracy, and long-term competitiveness. But where should that investment go, and how quickly can it pay off?
According to a Forrester Total Economic Impact™ (TEI) study commissioned by Dexory in December 2024, companies deploying DexoryView—a warehouse intelligence platform powered by autonomous robotics and real-time analytics—achieved an impressive 219% return on investment (ROI) over three years, with a payback period of under 6 months.
So, why are businesses betting big on warehouse automation? And how can they be sure that the return is real?
The case for automation: more than a cost-cutting tool
When businesses consider automated inventory management, two key benefits usually come to mind first: improved stock accuracy and reducing labour costs, and for good reason. Knowing exactly what’s in a warehouse, at any time, is the foundation of efficient operations, and if a business can save money at the same time, even better. However, the truth is that inventory automation is about much more than just accuracy and streamlining labour-intensive tasks. The right system doesn’t just track stock, it transforms a warehouses operations, frees up team members, and drives serious cost savings. And as warehouses get larger, stock keeping units (SKU) multiply, and supply chains become more complex, manual inventory tracking simply can’t keep up. The true value lies in
visibility, adaptability, and speed.
Today’s warehouses are dynamic engines at the heart of the supply chain. Yet many still rely on outdated, manual processes that limit insight, increase risk, and constrain performance.
According to Forrester’s interviews with leading logistics and warehouse operations teams, businesses were previously relying on staff using forklifts and spreadsheets to perform time-consuming inventory counts. This resulted in:
• Poor inventory accuracy
• Excessive stockholding
• Lost pallets and time-consuming investigations
• Operational downtime during audits
• Suboptimal use of warehouse space
• Declining customer satisfaction due to delayed or incomplete orders
These inefficiencies are expensive, and they scale with every warehouse added.
DexoryView: automation with intelligence
DexoryView is more than an automation tool. It’s a full-stack solution combining autonomous robots that scan warehouses from floor to ceiling with an AI-powered platform that turns real-time data into actionable insights.
The robots autonomously collect data at speed (up to 10,000 locations per hour), removing the need for forklifts and manual checks. DexoryView then maps this data into a live digital twin of the facility, surfacing discrepancies, tracking inventory movement, and uncovering optimisation opportunities across operations.
To evaluate the business impact of DexoryView, Forrester Consulting built a composite organisation representing a global 3PL with $2 billion in annual revenue and 300 warehouses worldwide. This hypothetical company implemented
Dexory autonomous robot scanning warehouse aisles with DexoryView platform displaying real-time inventory data and digital twin visualisation
DexoryView across three warehouses over three years. The results were significant. What stands out is how fast those benefits begin to accumulate. With a payback period of less than 6 months, DexoryView pays off long before many capital investments reach break-even.
Beyond the numbers: operational and strategic wins
While the financial results speak volumes, the operational improvements enabled by DexoryView are equally compelling.
1. Inventory accuracy
With daily scans, organisations reported inventory accuracy reaching 99.9%, a massive leap from the industry norm. This not only improves planning and reduces write-offs, but also builds trust with customers.
2. Staff productivity and retention
By automating cycle counting, businesses reallocated staff to higher-value tasks instead of eliminating roles, boosting morale, efficiency and retention. In one case, four cycle counters and a researcher were redeployed to revenue-generating departments.
3. Space optimisation
Real-time visibility into empty slots and overstocked areas meant smarter use of every square metre. The platform’s insights allowed one company to reduce stockholding time by 30%, increasing pallet churn and revenue per square metre.
4. Faster, cleaner audits
With automated daily reports, audit preparation no longer requires halting operations. One company reduced its audit prep time from five days to zero.
5. Health, safety, and cleanliness
The presence of Dexory robots led to improved warehouse conditions, from fewer forklifts on the floor to cleaner aisles and more legible barcodes. This translated into improved safety and even a 99.4% employee retention rate.
The real cost of waiting
Forrester’s study also highlights the risk of inaction. Businesses that delay automation
face mounting costs, operational rigidity and customer dissatisfaction. In a sector where real-time responsiveness is the new competitive edge, visibility gaps can cost millions.
Here’s what businesses stand to lose by sticking with manual or semi-automated processes:
• Labour-intensive operations are prone to error
• Overstocking and space inefficiencies
• Fines from missed SLAs
• Lost customer trust due to fulfilment errors
• Slow adaptation to market fluctuations
A scalable model for growth
Crucially, DexoryView’s benefits are scalable. The composite company only implemented the platform in three warehouses, yet unlocked nearly $3 million in net value. As companies expand usage across sites, standardised processes and centralised insights help scale performance consistently. With no upfront hardware purchase –Dexory retains ownership of the robot and provides full support through a subscription model – scaling is both fast and costeffective.
Automation with ROI that’s real and fast
In an environment where every decision must be justified by measurable outcomes,
DexoryView proves that warehouse automation can go beyond promise and deliver tangible impact.
With autonomous robots, AI-driven analytics, and real-time visibility, DexoryView enables not just automation, but transformation, turning warehouses into adaptive, data-powered assets.
As Forrester’s TEI study shows, DexoryView can deliver 219% ROI and a payback in under 6 months. That’s not just a good investment – it is a strategic imperative.
• $867K from automated cycle counting efficiencies
• $693K from reduced fines due to better fulfilment
• $264K in reduced racking damage
• $216K saved on empty location checks
• $254K in reduced audit fees
Total quantified benefits: $4.3 million
Total risk-adjusted costs: $1.35 million
Net present value (NPV): $2.96 million
Dexory robot performing high-rack inventory scan while DexoryView highlights empty locations, stock discrepancies, and optimisation insights
5 Strategies for Inventory Accuracy
Keeping inventory accurate in a warehouse can feel like a never-ending challenge, especially when operations scale up and order volumes increase. Here, Dexory shares five key strategies that help warehouses maintain 99.9% inventory accuracy, minimise human error and make stock tracking seamless.
1. Implement real-time inventory tracking
Let’s start with the most powerful change a warehouse can make: real-time inventory tracking. How to achieve this:
Automated stock-scanning robots: improve confidence in inventory data by having a robot scan shelves daily.
Barcode tracking: barcode scanners improve visibility, making stock movement easier to track. They also reduce picking errors and speed up order fulfilment.
Cloud-based inventory management: using a system that updates in real-time means that every department—warehouse, logistics, sales—sees the same up-to-date stock levels, preventing miscommunications.
2. Conduct regular and automated cycle counts
Relying on a once-a-year full inventory audit is risky. By the time errors are found, they’ve likely caused weeks or months of operational issues. Best practices for cycle counting:
ABC analysis: not all stock is equal; prioritise high-value and fast-moving items (Category A) for frequent cycle counts, while lower-priority stock (Categories B & C) can be counted less often.
Automated cycle counting: manually counting stock is time-consuming and prone to mistakes. Using robots or AIdriven inventory checks ensures accurate, unbiased results without human error.
Random spot checks: high-risk stock locations, such as return areas or frequently accessed shelves, should be checked more often to prevent accumulating errors.
3. Improve warehouse organisation and layout
Even with the best tracking systems, a disorganised warehouse makes mistakes
more likely. How to improve organisation:
Slotting strategy: place frequently picked items in easy-to-reach locations, while low-turnover items can be stored in less accessible areas.
Clear signage and labelling: every aisle, bin, and shelf should be clearly labelled. Misplaced stock is often the result of unclear location markers.
Fixed vs. dynamic storage: some warehouses benefit from fixed storage locations, where each SKU has a designated place. Others use AI-driven dynamic storage, where stock is placed based on movement patterns.
4. Minimise inventory handling errors with standardised processes
Even with advanced systems in place, human errors in stock handling remain one of the biggest causes of inventory discrepancies. How to reduce handling mistakes:
Enforce a ‘Scan Everything’ policy: every stock movement (inbound, outbound, and internal transfers) should be scanned and recorded in real-time.
Introduce error-proofing (Poka-Yoke) techniques: mistake-proofing methods like barcode scanning validation, pick-to-light systems, and automated alerts.
Use visual cues for stock accuracy: colour-coded shelf labels, digital displays, and AI-powered vision systems can make it easier to identify stock location errors at a glance.
5. Reduce human errors with robotics and automation
Even the best employees make mistakes, especially when pressure is high and
order volumes surge. Key technologies to consider:
Autonomous Mobile Robots (AMRs): robots can autonomously scan and validate stock, ensuring discrepancies are caught before they impact order fulfilment.
AI-powered vision systems with robots: AI-based cameras detect misplaced stock and flag errors instantly.
Automated order picking: pick-and-place robotic systems reduce mispicks, increasing accuracy and fulfilment speed.
Final thoughts: accuracy = profitability
Keeping warehouse inventory accurate is all about building a more efficient, profitable operation. By implementing automation, companies can eliminate stock discrepancies, cut costs and improve fulfilment speeds. Dexory’s AI-powered warehouse intelligence platform helps warehouses achieve unmatched accuracy and efficiency with real-time data insights. dexory.com
The Total Economic Impact™ of Dexory DexoryView
A Forrester Total Economic Impact™ study commissioned by Dexory, December 2024
According to a Forrester Total Economic Impact™ study commissioned by Dexory in December 2024, the key benefits and results that customers can achieve by utilizing DexoryView include:
Safely Navigating the Augmented Warehouse
In under a decade, warehouse operations have gone through a drastic transformation through automation, with many manual processes becoming outdated. While this has arguably resulted in an improvement in safety for warehouse operatives overall, it has also introduced novel hazards. In this feature, MEPCA examines the impact of automation on warehouse safety.
AAccording to research by Forbes1, Warehouse Worker is the third most dangerous profession in the UK, with a danger rating of 25, one point less than Police Officer (26), while Firefighter understandably tops the chart with a rating of 66.
What makes warehouses such dangerous working environments? As employees navigate the stacks and aisles at speed, they are at risk of slips and trips, and boxes falling on them from height. Then there are manual handling and ergonomic strains and
injuries, as well as the risk of collisions with forklifts, and chemical hazards from cleaning products and certain stock items. The ever-increasing pressure of order fulfilment speeds exacerbates all of these dangers.
Automation can help reduce injuries and risks to Warehouse Workers by eliminating repetitive manual tasks, or reducing the requirement for them to work in riskassociated areas of a warehouse, such as loading docks, mezzanines, or areas with high concentrations of vehicle traffic.
A-SAFE provides workplace safety solutions globally, including to warehouses,
where the practical impact of automation has been plain to see. We spoke to A-SAFE CEO James Smith, who explained:
“Automation means fewer people, less risk. When implemented safely, automation can reduce the number of risky manual tasks employees face. Take heavy lifting or repetitive movement; those jobs tend to cause strain injuries over time. If a cobot takes that on, the strain disappears. AMRs can also reduce foot traffic by handling transport runs, which reduces the chances of pedestrian-vehicle interaction.”
However, the ability of automation to
improve safety is only part of the story. As warehouses introduce new technologies, such as collaborative robots (cobots), AMRs (Autonomous Mobile Robots), conveyor systems and AI tools, etc., they unavoidably introduce new hazards into the warehouse environment, including heavy, fast moving machinery and high voltage power sources.
Amazon, which operates at the pinnacle of automated warehouse operations, has been criticised for the injury rates at its Californian facilities2. The Strategic Organizing Center (SOC) report found that Amazon warehouse employees suffered injuries at twice the rate of other warehouse staff. More alarming still, the report found that, in 2021, the injury rate of Amazon warehouses with robotic-sorting was 28% higher than facilities without.
That is not to say, necessarily, that the automation systems are at fault, or indeed that automation makes a warehouse less safe, as there are many factors involved, but it does raise some concerns.
How can warehouses ensure that they integrate automation effectively and safely into their businesses, mitigating any risk to employees by design? To address this, we must first look at some of the common hazards associated with automation.
The hazards of automation
Troax designs and implements warehouse partitioning, with automated warehouse accounting for a growing segment of the company’s market. As such, they commonly design and deliver partitioning to protect employees from automated systems (and automations from misuse by employees).
Speaking to MEPCA, Will Sabin, Sales Office Manager, who oversees both technical sales office sites in the UK (Kingswinford & Swindon offices), broke down what he saw as the main hazards introduced into warehouses by automation.
First among them are the mechanical hazards of automated systems, i.e., the moving parts and machinery, as he explained: “Automated robots, conveyor systems and automated vehicles can all cause risk of collision or entrapment when integrated into a manual warehouse environment”. This risk is compounded by the introduction of new processes into a warehouse, as “fast moving equipment coupled with a loud working environment may reduce an employee’s awareness of their surroundings”, leading to a risk of accident.
Another factor is the unplanned start-
“Risk depends on layout, behaviour and flow, not just whether a robot or person is doing the task.
Automation doesn’t simplify risk. It shifts where it sits.”
James Smith, COE, A-SAFE.
up of machinery. Will explained that machines, including cobots, could power on automatically if not properly guarded.
Lastly, he pointed out a hazard common to any warehouse regardless of the level of automation: operator error. “Without the correct training, workers may unknowingly misuse equipment or enter restricted zones”.
A-SAFE’s James Smith agreed that operators entering restricted areas are a major hazard associated with automation in warehouses:
“Unauthorised entry into automation zones is the main hazard. Automation typically operates in defined areas, but the surrounding space remains active with people and vehicles. This creates a high risk of accidental contact, especially near goods movement routes.”
James also addressed a common misconception around warehouse automation: that it removes people entirely. “In reality, most systems operate in specific zones while surrounding areas remain active with manual work. That’s where risk builds—
at the edges, where people or vehicles cross into automated zones without control measures.
“Automation performs best with standardised loads, but logistics often involves mixed shapes and sizes. That forces systems to slow down or adapt, which introduces unpredictable movement. Manual labour remains essential in fast-paced areas, where segregation from vehicles is still needed. A fixed safety setup rarely covers this mix. Risk depends on layout, behaviour and flow, not just whether a robot or person is doing the task. Automation doesn’t simplify risk. It shifts where it sits.”
Safely integrating automation
Equipped with a better understanding of how automation changes the risks to warehouse operatives, we now turn to what steps companies can take to uphold the safety of their employees when implementing warehouse automation systems.
Will Sabin recommends firstly
James Smith, CEO, A-SAFE
understanding where the hazards are and work from there: “Start with a full risk assessment to identify the hazards and then plan how to control them.
“Use of a strong physical safety guard such as mesh panels and interlocked gates is important to segregate people from dangerous areas – but make sure that all equipment meets current UK safety standards.”
He added, “It’s also important to clearly mark zones where people and machines operate; using signs to guide safe movement and train staff so they know how to work safely around any new technology.”
Expanding on this crucial separation, James: “To achieve this, you can’t rely on old layouts or generic barrier systems. You’ve got to look at the real risks on your site, i.e., vehicle and people route mapping, and pay strict attention to any reported near misses.
“Before anything else, walk the floor and understand the workflow – what’s automated and what isn’t. Don’t just rely on CAD drawings or layout plans. Watch how forklifts, AMRs and people move during peak and off-peak hours. Do they share tight corners? Are there blind spots at intersections? Are speed limits realistic based on the activity in each zone? Go beyond visual inspections and get real data on where risks are forming and reduce the risk accordingly with the right solutions.”
This level of scrutiny needs to be applied to the suppliers of any element of the automation system. Will advised that warehouses should always “work with suppliers who take safety seriously and offer ongoing support. A well-planned, safetyfocused setup not only meets regulations; it also keeps your people, property and processes safe.”
Related to this, both our commentators highlighted the importance of adhering to safety standards when implementing automation systems, including Performance Level (PL), which, Will explained, is determined by the seriousness of risk and frequency a worker is exposed to it.
James insisted that the only way to not know if an element of the automation system is fit for purpose is if its performance is tested and verified by an independent body: “Independent testing by bodies like TÜV Nord and certification under PAS 13 confirm that the specification reflects real-world capability.”
He concluded, “When protection has been tested against the risk it’s meant to
“A well-planned, safety-focused setup not only meets regulations, it also keeps your people, property and processes safe.”
Will Sabin, Sales Office Manager, Troax.
withstand, you know it belongs in your facility.”
Compliance with Bureau Veritas
To explore warehouse automation safety further, through the lens of compliance, we turned to the experienced team at Bureau Veritas. As globally established machine safety specialists, Bureau Veritas offers independent and impartial consultancy or verification services to companies implementing warehouse automation systems.
Its team helps with compliance at every
step of the process, from the initial design stages, where they help build a clear specification that will meet compliance, through to implementation with design reviews, hazard assessments and documentation reviews. Post-installation, they conduct a full inspection and testing to ensure the system meets the compliance specifications.
As they regularly act as final verification services after the fact, they are well aware of the most commonly made mistakes:
“Many automation projects consist of multiple pieces of equipment being combined to perform as one system. One
Will Sabin, Sales Office Manager, Troax
key area commonly overlooked is failing to identify who is responsible for the safety and compliance of the overall system integration, usually accompanied by a mistaken belief that purchasing individually compliant pieces of equipment automatically results in a compliant system once integrated.”
However, it is not always enough to employ a third-party integrator. To illustrate this, they recalled an instance involving a new production line that included several robots; unaware of all safety related integration requirements, the integrator had unknowingly provided a non-conforming system. For this reason, they recommend confirming the proposed safety and compliance responsibilities with a third-party integrator upfront.
Should the warehouse operation have doubts about the compliance of any aspect of its installation, Bureau Veritas recommends getting an urgent review by a verified and experienced body to identify areas of non-conformity and put in place a plan of corrective action. Meanwhile, the business should swiftly implement appropriate short-term safety containment methods until the issues can be permanently resolved.
When it comes to human-robot collaboration, which is often a focal point when people consider warehouse automation, Bureau Veritas’ specialists start with a fundamental question:
“Does it really need to be collaborative?”
As humans and robots interacting in a shared space bring increasing risk, it is important to question whether it is justified.
“The company needs to fully understand the potential complexities of designing, implementing and maintaining a collaborative system, and not be drawn in with thinking because they buy an ‘off the shelf
collaborative robot’ it is inherently safe for their application, when in reality they are merely ‘collaborative capable’, which still requires the necessary steps to be taken to establish a safe and compliant solution.”
Bureau Veritas instead recommends defining whether a collaborative system, with its potential complexity and cost, is the optimal choice, or if a non-collaborative solution would be equally as effective.
In their final remarks, the Bureau Veritas team offered advice to companies considering warehouse automation:
“Companies should always bear in mind that compliance with the CE/UKCA legislative frameworks is mandatory and should not be left as an afterthought. Early engagement with specialists in the discipline is vital to achieving a right first-time solution, helping avoid costly and disruptive rework, and preventing personnel exposure to potentially hazardous situations.”
To conclude
Warehouse automation is an inevitable progression for the industry, and it can
certainly improve safety for employees. However, as discussed above, this comes with several caveats. Businesses should always do a full risk analysis, and scope any system of automation around an accurate and data-led understanding of the site’s processes, workflows and safety risks.
If considering a system of human-robot collaboration, a business should consider whether the risk is justified.
By taking a pragmatic approach to safety and compliance when implementing automations system, businesses can enhance warehouse operation efficiency and protect their employees, helping to move the industry towards a point where the time since last accident is measured in years rather than days.
Discover how investing in an automated sorting solution enabled Irish postal service An Post to deliver a record-breaking Christmas with BS Handling Systems’ partner, EAE Solutions.
As parcel volumes in Ireland continue to grow, An Post has responded with a major investment in automation at its Portlaoise Mail Centre. The project – delivered by BS Handling Systems’ partner, EAE Solutions – has significantly increased both processing efficiency and capacity, enabling An Post to handle its highest-ever volume of Christmas parcels in 2024.
Eoin Sweeney, Engineering Project Manager at An Post, led the automation project. “In 2024, EAE Solutions won a competitive tender process we had for the automation of parcels,” says Eoin. “Since then, we’ve found them to be a very innovative company with in-depth technical knowledge and experience.”
An end-to-end automation solution
Working closely with EAE Solutions, An Post installed a slimline sorter system designed to handle a wide variety of parcel types, from standard e-commerce boxes to smaller and more difficult items.
“We sort our larger items, smaller items, and difficult items in our parcel stream,” explains Eoin. “We found the slimline sorter
to be perfectly suitable for this. We’ve increased our capacity and efficiency across these parcel streams and have also significantly increased our e-commerce parcel stream in Portlaoise as a result.”
The solution provided by EAE Solutions ticked every box, and then some. “What we got in this project was not just a machine, but a fully fledged system and solution to the issues we had to deal with here,” says Eoin. “They really moved quickly with us and showed a good degree of flexibility and speed to get the machine up and running as quickly as they have.”
Fast implementation, immediate impact
With the sorting solution operational in time for peak season, the benefits were clear almost immediately.
“With this project, we’ve been able to drastically increase both the efficiency and capacity of the parcels process in Portlaoise,” says Eoin. “And with that, we’ve been able to deliver the highest volume of parcels this Christmas from An Post than we ever had.”
According to Eoin, speed and responsiveness were key to the project’s success: “EAE Solutions were able to quickly take onboard our specific needs
for this project. Rather than just meeting the minimum requirements of the tender, they looked at our full end-to-end process and delivered a solution that truly met our operational goals.”
A professional, forwardthinking partner
For An Post, the project was not only a successful investment in automation, but also the beginning of a valuable partnership.
“EAE has proven itself to be both a professional and innovative company to work with,” says Eoin. “We both learned a lot in this project – both An Post and EAE Solutions – about what it takes to deliver a quick and efficient solution to an acute problem.”
With additional automation opportunities on the horizon, Eoin sees this as just the beginning: “I look forward to working with EAE Solutions on future projects we have upcoming.”
EAE Solutions recently formed an exclusive UK partnership with BS Handling Systems. Under this agreement, BS Handlings are now the turnkey integrator for EAE Solutions in the UK. For more information on EAE’s sortation solutions, visit the website below. bshandlingsystems.com
.... to a fresh and innovative approach to turnkey solutions
E-CROSS SORTER
CONVEYORS
Supercharge Your Warehouse Cleaning
Garreth Anderson, Technical Sales Manager for Robotics & Digital at Kärcher UK, explores how welcoming robotic cleaning services can revolutionise cleaning outputs in the warehouse sector.
In a sector where time, money and efficiency are paramount, automating routine tasks like cleaning can offer significant advantages for those in the warehouse and logistics sector.
Manual floor cleaning in large logistics centres or manufacturing warehouses is not only labour-intensive but also timeconsuming. By introducing automation through advanced technology, businesses can redeploy valuable staff to focus on skilled, high-priority tasks. This not only improves productivity but also addresses growing workforce challenges in the sector.
Alongside efficiency, consistency is another major benefit of robotic cleaning. Unlike manual cleaning, which can vary depending on the individual, automated products accommodate pre-set cleaning parameters such as water usage, detergent levels and cleaning speed, ensuring that cleaning is optimised for both quality and resource efficiency. In high-traffic areas where hygiene is critical, such consistency helps maintain safe, clean environments without constant supervision – ultimately reducing costs and improving operational efficiency.
Safety, of course, is a vital consideration in warehouses and is something that automated cleaning products can massively help with. For example, Kärcher’s KIRA B 50 boasts integrated laser scanners, 3D cameras and a powerful on-board computer, making it capable of 360 detection of its surrounding areas with quick reactions and reliable navigation to ensure safety. It detects changes in its surroundings and initiates evasive manoeuvres, while integrated light modules notify people nearby of the robot’s behaviour, such as turning or charging. KIRA B 50 is safety certified for use in public areas according to the new industry standard.
What’s more, to maximise KIRA B 50’s autonomy, the optional docking station
allows the unit to re-fill its water tank, drain wastewater, rinse the tank and recharge its battery with no intervention. All functions on the robot are easy to operate via the large touch display featuring an intuitive menu and user guidance, allowing for multiple user profiles and even different language options. Ease of use is a key advantage to introducing automation into a warehouse’s cleaning operations – making for a streamlined and effective process from start to finish.
In addition to performance and safety, automated cleaning also supports sustainability goals – a growing priority for many in the sector. The KIRA B 50 allows precise control over water and detergent usage, helping reduce unnecessary waste and environmental impact. Its lithium-ion battery ensures energy-efficient operation,
while autonomous scheduling minimises idle time and maximises operational uptime. By using only the resources needed for each job, warehouses can lower their carbon footprint without compromising on cleanliness. This not only supports corporate sustainability targets but also reflects a forward-thinking approach to facilities management in an increasingly ecoconscious industry.
Ultimately, through welcoming automation into a warehouse’s cleaning operations, businesses can expect consistently outstanding results, even on textured or uneven floors, in turn, freeing up cleaners to manage more complex cleaning tasks.
For more information, please visit Kärcher’s website.
kaercher.com/uk/
Making Automation More Accessible
Automated trailer loading systems (ATLS) are often considered the domain of large-scale manufacturing facilities and distribution centres. However, as Tomi Korhonen, Managing Director, Actiw Oy, part of the Joloda Hydraroll Group, explains, new solutions are suited to a wider range of businesses, including Direct-to-Consumer (D2C) applications.
Areport by STIQ recently confirmed a rule of thumb that automation needs to deliver return on investment (ROI) in three years or less for a business case to compete with manual flows. In the world of logistics, this is not unique to automated trailer loading systems (ATLS). However, ATLS are proving a good example of how accessibility to automation is changing. A greater variety of solutions with different price points and capabilities is helping open up the benefits of automated pallet handling to a far wider range of companies – but they may not be aware.
Expanding the definition of ROI
The benefits of an automated trailer loading system are vast: reduced loading times lead to higher throughput and operational cost savings, in addition to improved safety, accuracy and consistency. However, many logistics operators are still early on in their automation journey. Labour shortages, safety concerns, and rising operational costs may be accelerating interest in automated solutions, but hesitancy remains due to cost, space constraints, and operational rigidity –all of which influence their viability for certain use cases.
While the throughput of pallets is high, constrained warehouse footprints, semiautomated or manual upstream operations (such as delivering directly to a customer that uses a forklift truck to unload pallets), or a large distance between two facilities, can make full-scale automation – and the required modifications to existing infrastructure and trailer fleets – more difficult to justify.
there are many other value drivers that need to be considered – particularly in specialised environments.
What’s needed is a middle ground: solutions that offer a range of costs and capabilities for more businesses to introduce automation into their pallet loading and unloading processes and receive a fast return on their investment.
Filling the market gap
There’s a clear gap in the market for compact, low-commitment automated trailer loading systems that can enable businesses to increase their daily loading capacity without requiring extensive modifications to existing site and fleet infrastructure. New developments are beginning to fill that gap. Modular, bolt-on systems now exist that allow for a wide range of pallet types and complex load patterns (manual or automated), and integrate with all standard docks. These approaches reduce upfront cost while still improving efficiency, productivity, and safety. The new LoadMatic Lite from Actiw, a subsidiary of the Joloda Hydraroll Group, is capable of loading full,
standard, non-modified trucks and trailers in just six minutes. Pallets are staged at the rear or side of the dock using forklifts, electric pallet stackers, or AGVs, queued, and then loaded in one shot with precision.
Conclusion
For many companies, trailer loading has remained unchanged for decades. However, faced with workforce challenges, rising demand, and a general requirement to achieve more with less, automation is necessary for all businesses to help improve reliability, safety and resilience. But, of course, only if it is financially viable. For most companies, this means an ROI in less than three years.
A broader range of solutions and price points are now available so that growing businesses don’t need to dive straight into fully automated systems but can begin to reap the benefits and evolve their operations over time. In doing so, they build a more sustainable foundation for future automation and competitive advantage. joloda.com/about-us/actiw/
automated loading for any truck or trailer within 6 minutes
Improved Safety Reduced Loading Time Reduced Product Damage De-manned Operations
LoadMatic Lite is a versatile, entry-level Automated Truck Loading System, ideal for manufacturers and distribution centres looking to increase their daily load volume beyond what’s achievable with manual forklift operations - all without major site changes or fleet modifications.
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CMMS Integration for Smarter Warehousing
Specialist software provider PEMAC details how integrating a CMMS (Computerised Maintenance Management System) improved efficiency and safety across a life sciences manufacturer’s operations – most notably in stock management and traceability.
Today’s warehouses play a critical role beyond mere storage; they act as essential hubs for production. In life sciences particularly, manufacturing, efficiency and safety are critical; not just for operational success, but for regulatory compliance and product quality. One global manufacturer has transformed its maintenance operations by integrating its PEMAC Assets CMMS with warehouse and storage systems. The result: faster maintenance, reduced downtime, and better traceability, all powered by automation.
The hidden cost of manual maintenance
Before implementing its new system, the facility’s technicians were regularly delayed by inefficient spare parts retrieval. They often spent significant time manually locating stock, cross-checking inventory records, or waiting for unavailable items. Errors such as selecting the wrong part were common and costly.
These manual processes didn’t just slow things down, they directly impacted maintenance schedules, increased the risk of stockouts, and added pressure to already time-sensitive repair work.
Seamless integration in action
To eliminate these inefficiencies, the company integrated three key technologies:
• PEMAC ASSETS CMMS to manage work orders, inventory, and asset data
• mpx/WMS for real-time warehouse management
• Kardex and HÄNEL vertical carousel systems for automated, goods-to-person storage and retrieval.
Now, when a technician logs a work order
in PEMAC ASSETS, any assigned spare parts are automatically requested from the warehouse via the mpx/WMS system.
The integrated carousel units retrieve the correct parts and deliver them straight to the technician, without a single manual step.
Efficiency that speaks for itself
The results were immediate and measurable. The company reported a significant reduction in time spent on parts retrieval, helping technicians focus more on actual maintenance tasks. This automation also improved Overall Equipment Effectiveness (OEE) by reducing downtime and keeping planned maintenance on track.
The facility also saw cost savings from reduced errors, better inventory control, and less excess stock. Automating the retrieval process meant fewer incorrect picks, which previously led to delays and, in some cases, unnecessary equipment damage or rework.
Safer, more compliant operations
In highly regulated environments, traceability and compliance are as important as speed. With the new system, the facility gained full traceability of every part used, linking it to specific work orders and assets. This data is now captured and updated in real-time, reducing the risk of using outdated or incompatible components.
The integration also supports regulatory compliance with standards tied to quality
management systems (QMS), by ensuring consistent documentation, up-to-date maintenance records, and easier audit preparation.
Inventory intelligence
With live data shared between the CMMS and WMS, the business now enjoys much greater visibility over parts usage and stock levels. This has enabled better forecasting, fewer emergency orders, and a leaner, more cost-effective inventory model.
Future-ready maintenance
By integrating PEMAC ASSETS with mpx/WMS and automated storage, this life sciences manufacturer has created a smarter, faster and safer maintenance operation, one that’s fully aligned with the demands of Industry 4.0.
Want to improve efficiency, cut downtime, and stay compliant? Get in touch with the PEMAC team to find out how a connected CMMS and warehouse system can transform a business’ operations. pemac.com
MRP System Replaces 70’s Inventory Software
Food packaging specialist Hovat drastically transformed its production and stock control by swapping Vietnam War-era inventory software for a cloud-based MRP system. Read on for Hovat’s journey.
Hovat is a Kent-based printed packaging and labeling manufacturer providing solutions mainly for the food industry. Celebrating over 50 years in business, the company has built a reputation for innovation, adopting diverse techniques in the sectors it serves over the decades.
Owned by packaging conglomerate Grafham Holdings, Hovat is a sizable operation with 75 full-time employees and an annual revenue exceeding £11 million. With two manufacturing locations, an in-house design department, and a large warehouse, managing the company’s inventory and production activities requires high levels of control—control that only a short while ago was lacking—the company’s inventory software was almost as old as the company itself.
Ancient stock management system was hindering efficiency
When Hovat’s Head of Finance, Colin Britton, came aboard in 2023, one of his first tasks was to oversee the company’s transition to a new operations management software solution.
“When I joined, they used software developed in the 70s. It was originally used to record stock for the Vietnam War! The software was running on ancient 8-bit computers, and since the system’s parent company had lost most of its clientele over the years, the maintenance cost was pushed onto the few remaining clients. So, we were paying around £2,500 a month for the package,” he says, “It was a no-brainer that we needed to move to something more modern.”
Colin then came across MRPeasy during a web search. This fully cloud-based
package promised a combination of cost efficiency, ease of use, and rugged functionalities, including comprehensive traceability.
Guided onboarding delivered quick results
The process of acquiring new software began in September 2023. Having a production setup of considerable size and complexity, Hovat’s management decided to opt for an assisted implementation early on.
Colin picked one of MRPeasy’s longstanding UK partners, Smart Manufacture, to aid with setting up and transitioning to the new system. This greatly eased the transition to the new system, completed in May 2024. “Our employees have taken to using MRPeasy very well,” Colin says.
Full traceability with no paper trail
When asked about the core benefits
MRPeasy has brought to the manufacturer, Colin first brings out MRPeasy’s ability to streamline communication between departments, contractors, and suppliers:
“Previously, everything was done by printing hard copies. The printers would start printing at six every morning to get a pile of printouts for the day. Now we can email suppliers purchase orders or copies of drawings straight within the system. We’ve saved thousands of pounds on postage alone in less than a year since moving to MRPeasy.
“It’s a lot easier to trace anything now – just a simple report, accessible straight
within the app. We’re saving hours and hours compared to the old way of tracing any item.”
Accurate costing and realtime access to financial information
MRPeasy has also greatly simplified Colin’s work as Financial Director. For one, the ability to log on and manage the finances of Hovat’s two facilities from anywhere has been instrumental. “I took my computer to Australia on a business trip, and I could work from halfway around the globe,” he muses.
Unit pricing and cost accuracy have seen large improvements as well. In the old software, all invoicing was done on a monthly basis, so Colin had no idea of the true margins per product.
Thanks to MRPeasy’s exporting tools, accounting and financial auditing have also become greatly simplified. Colin notes: “Because we couldn’t export anything to Excel before, analysing things was difficult for the auditors. Now, they can get any report on the screen and pop it out as a CSV if needed.”
mrpeasy.com
A Dash Cam for High-Bay Operations
Even in highly automated warehouses, one thing is often missing: visual context. Without it, tracing faults is slow, incomplete, or simply impossible. Pepperl+Fuchs, sensing technology manufacturer, introduces a ‘dash cam’ for industry, able to record relevant situations for analysis and optimisation.
Automated high-bay warehouses with stacker cranes are a cornerstone of modern intralogistics. They enable rapid storage and retrieval while making optimal use of available space. In deep-freeze environments, their components must withstand extreme conditions down to –30°C. The cold chain must remain uninterrupted throughout every stage of goods handling. Even a few minutes of downtime in cold storage can lead to lost throughput and rising operational costs. When this happens, there’s often no apparent trace of what went wrong or why. What if you could replay exactly what happened, with no guesswork and no delay?
The Solution
Mount an industrial event camera directly onto the stacker crane to monitor storage and retrieval operations. It continuously records the last 60 seconds of live video into an integrated circular buffer. When a fault or predefined event occurs, the camera automatically transfers this buffered footage, and 60 seconds after the trigger, it is stored permanently on an SD card.
The camera only records relevant scenarios, helping maintenance teams quickly identify root causes and understand subsequent system behaviour. These targeted image sequences are invaluable for immediate fault analysis and long-term process optimisation.
The Benefits
Event-based storage offers a more innovative alternative to continuous video recording, reducing data overhead while providing instant access to critical footage. Each video includes a text overlay showing the date, time, and relevant error messages. Trigger signals can be captured directly from the control system via a digital input.
The password-protected user interface is accessible via any web browser and allows live HD monitoring and straightforward configuration. No additional PC hardware is required for integration or storage. The REST API also enables the development of custom user interfaces and full integration into existing IT infrastructure.
An optional integrated heating system
supports reliable operation in deep-freeze and outdoor environments, maintaining full functionality from -30 °C to +50°C. The event camera’s IP65 protection rating ensures durability in harsh industrial conditions.
Event Camera at a glance
A rugged industrial camera that stores video sequences of relevant events, recording targeted footage for efficient fault analysis and process optimisation. The camera can be easily integrated into existing systems without need of additional PC hardware. What’s more, it can be accessed via a web browser or custom-programmed interface. Unlike standard video systems, the VOC records only what matters — before and after an event — and thrives in the harshest environments. Paired with the R2000 for precise collision avoidance, it creates a resilient, fully integrated automation solution.
Advanced LiDAR technology
The R2000 LiDAR sensor for obstacle detection provides unmatched precision with 360° performance.
A stable scanning axis and an angular resolution of up to 0.071 degrees enable the R2000 to detect objects as small as 1 mm. The resulting monitoring field begins right below the pallet base, allowing it to reliably detect even the smallest objects. The setup is simple; with user-friendly PACTware software, the four user-configurable detection fields can be set in just a few minutes.
R2000 at a glance
Offering the highest angular resolution of any digital I/O scanner on the market—0.071°— the R2000 enables detection of extremely small objects, while providing great all-round visibility due to its 360° measurement capabilities. In addition, the R2000’s stable scanning axis ensures precise monitoring of the scan surface, while its four userconfigurable detection fields can be linked to the outputs in a few steps, making it incredibly easy to configure. Also available, is an infrared laser version, which offers a range of up to 30 m.
Visit the company’s website to discover the Powerful 2-D Laser Scanner (2-D LiDAR Sensor) of the R2000 Series and more warehouse solutions. pepperl-fuchs.com
Technical Features
• HD livestream via Real-Time Streaming Protocol (RTSP)
• Digital hardware input for a trigger sensor or signal
• Internal circular buffer for 60 seconds before and after each event
• SD card capacity for up to 10,000 video sequences
• Quick, intuitive classification of relevant recordings
• REST API for seamless integration into IT systems
• Operating temperature: –30°C to +50°C
• IP65-rated enclosure for protection against dust and water jets
Bespoke Automated Fulfilment Solution
Here, Reeco, an internationally recognised integrator of localised automation solutions, demonstrates how a bespoke automation solution involving depalletisers and AMRs optimised a fresh dog food company’s fulfilment practices.
Reeco has recently successfully delivered a fully customised depalletising and product transfer solution to meet fulfilment needs at fresh dog food company Butternut Box. The implementation of an automated product handling system has helped the growing brand to upscale its capabilities and improve efficiency at its new fulfilment facility. The new solution has also significantly reduced the need for manual handling and enabled the redeployment of staff members onto higher-skilled processes along the fulfilment line.
End-of-line efficiencies to support growth
Butternut Box is the go-to subscription service for high-quality fresh food for dogs. They wanted to increase throughput and optimise end-of-line efficiencies both to meet increasing demand and to plan for future growth in a scalable, modular way. The Reeco design team rose to the challenge, designing a bespoke system
that could handle goods movements taking place partially inside a freezer, as well as transfer products from conveyors at different heights. Critically, of course, the full system also needed to work safely and efficiently alongside fulfilment staff.
“Reeco has been a brilliant partner, working closely with us through the entire process right from design, through to installation and maintenance. They’ve delivered an excellent localised automation solution, which puts us in an excellent position for future growth in a modular fashion.” Marc Crossfield, Head of Engineering & Capital Projects, Butternut Box.
A truly bespoke solution
At the start of the production line, six Reeco RB2000 depalletisers unload crates of fresh dog food, which are then transported via a fleet of 18 OMRON AMRs to fulfilment stations, where operators pack unique customer orders.
The AMRs feature custom top modules from one of Reeco’s integration partners, Dimalog, which allow product collection and delivery between different line heights. The
fleet is managed via a single interface and is integrated with an on-site ERP system to manage product demand and delivery. For orders heading to mainland Europe, a Reeco RB2000 palletiser with EasyStack software is used to transfer goods onto Euro pallets ready for shipping.
The design team at Reeco worked in close conjunction with Butternut Box to create an optimised layout and system design across critical stages in the fulfilment line. They used detailed CAD drawings to map out the AMR area, including calculating distances and heights in order to simulate and verify the desired movement of goods. This was followed by physical testing using the initial simulation overlaid on the physical layout of the production environment to create an optimal plan for reliable AMR traffic movement.
The localised automation supplier of choice
The project is a perfect example of how the successful deployment of cutting-edge AMR technology can make a very real difference to operational excellence.
reeco.co.uk
end-of-line efficiency with accessible automation.
From production line to dispatch, automating stages of your product transfer is easier than you think.
Pioneers in the adoption and implementation of cobot technology, Reeco makes end-of-line automation achievable to production lines of all sizes.
From case forming, packing, and sealing, right through to conveying, palletising, pallet movements, and remote monitoring, our automation solutions are trusted by leading brands around the world.
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Cobot palletising
Autonomous transport (AMR)
Case forming
Case packing
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Chat to a member of our team for a no-obligation discussion about integrating automation at your facility:
Case forming
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Palletising
Pallet movement
A Single Digital Thread for Logistics
Bringing together information technology (IT) and operational technology (OT) across many and varied systems in logistics requires a new approach to automation, one that will build the digital foundation for the entire sector. Dave Sutton, Product Marketing Manager for Industrial Automation at Schneider Electric, explains the benefits of a single digital thread for logistic operations.
Logistics is the backbone of many industries, and historically has been an early adopter of advanced technologies to improve efficiency. Despite this readiness to advance, logistics is facing pressure to handle higher demand with less staff in almost all applications. This is driven largely by ongoing skills shortages, rapid expansion of e-commerce, and increasing complex supply chains, as shown in a 2023 Capital Recruitment Group report1. Each of these challenges shows a need for a new approach to create a single digital thread running throughout IT and OT systems that will deliver value for end users, system integrators, and OEMs serving the vital sector.
Universal automation
With logistics being an early adopter of technology, especially robotics, the sector is seeing challenges when integrating existing systems. Often these are based on proprietary technology that was developed by individual suppliers and was not designed to plug seamlessly into systems from other vendors. This restricts innovation and limit a business’ agility.
Universal automation has now been introduced to overcome this. It is a technology-enabler based on the IEC 61499 standard, representing a community of automation users, technology vendors and academics, and organised by an independent non-profit association. In practice, universal automation creates a
shared automation layer that will oversee multiple proprietary systems.
That means IT and OT systems will work together seamlessly and that best-in-class hardware and software can be deployed to meet changing needs regardless of what is already installed. It also unlocks nextgeneration capabilities that play a role in efficiency and sustainability.
Single digital thread
Open automation enables a continuous flow of data and communication across all assets in a system, even legacy assets without digital capabilities can have sensors added to feed real-time analysis. This creates a digital thread linking disparate systems, enabling logistics operators to monitor,
control, and optimise operations across a single facility, large enterprise, or even an entire supply chain.
Using open and vendor-agnostic systems reduces the need to upskill workers to have deep expertise across a wide range of proprietary technologies, ensuring their vital job knowledge can be applied anywhere in the sector. Focusing on a single universal platform that controls multiple technologies simplifies the learning curve for new team members while enabling existing staff to extend their skills further. A recent report2 from Capital Recruitment Group highlights a demand for staff with knowledge of automation, AI and data analytics, who can reduce cost and improve efficiency.
By adopting open automation, system integrators, OEMs and end users can create a foundation for logistics professionals to develop the skills they need to get the most of every system while lowering the bar to new entrants and attracting new talent to workforce. The key is that new and existing employees can make decisions based on data.
Logistics operations must constantly contend with fluctuating demand and seasonal changes, requiring a level of agility to repurpose legacy assets, scale up or down and seamlessly integrate new technology to respond quickly to market
shifts. Universal automation supports this, enabling anyone in the logistics sector including OEMs and SIs to maintain agility and grow their business through added value. Operators will have the information they need to adapt to new products without extensive hardware changes. Meanwhile, OEMs can support their customers with new machines safe in the knowledge they can integrate with current facilities, and SIs can scale up to support more customers on a digital transformation journey.
The digital thread running throughout logistics operations with universal automation can also be applied to the increasingly complex, and sometimes global, supply chain. For example, communication and realtime data visibility of warehouse management systems, manufacturing operations, and distribution means issues across the supply chain can be anticipated. Logistics professionals can make informed decisions and track performance metrics with a complete overview. As mentioned, logistics is the backbone of many industries so any improvements and optimisation within a facility will have a wide impact. With universal automation in place, improvements can be applied across a very diverse supply chain with each business collaborating to ultimately deliver a better service for the consumer.
The benefits of a single digital thread
reach far beyond just the manufacturing example. For parcel and post operations, consumers expect faster delivery, which places immense pressure on the workforce. AI-driven sorting technologies and analytics are a potential solution to enhance accuracy but enabling it requires all components across IT and OT to communicate. In baggage handling, particularly in airports, new technology that streamlines check-in or security is consistently being added. Again, with a digital foundation any number of new technologies can be added without integration challenges, ensuring airports can improve customer satisfaction.
The ability to connect systems and build a digital foundation will play an important role in the future of logistics. By putting a shared automation layer in place, the broad and varied industry will have the tools to improve efficiency, business resiliency, and sustainability while navigating the challenges of the sector. End users, system integrators, and OEMs can remain at the forefront of technology, collaborating across the supply chain and building the logistics ecosystem of the future.
se.com
1. https://bit.ly/3ZtDq7y
2. https://bit.ly/3Zxvxy2
Enabling Intelligent Robotics Collaboration
Warehouses are increasingly turning to robotic solutions to meet consumer demand, but deploying these solutions is technically challenging. Here, leading communication device developers Brainboxes explains how intelligent underlying systems are the key to redefining warehouse robotics.
As consumer expectations for rapid delivery continue to rise, warehouses are under increased pressure to move goods not only faster, but also with greater accuracy and efficiency. To meet these demands, many facilities are turning to logistics robots capable of autonomously navigating aisles, retrieving items, and transporting stock throughout the warehouse.
At the core of these robots exists a complex system of sensors, controls, and real-time data processing that enables them to operate effectively in dynamic industrial environments. Various sensors such as LIDAR, encoders, cameras, and bump sensors provide the data needed for autonomous navigation and item handling.
However, the successful deployment of these robots presents significant technical challenges. This includes the need for precisely controlled actuators and motors to ensure accurate handling of goods, while maintaining consistent real-time responsiveness. Additionally, the robots must operate reliably under harsh conditions, while offering support for remote diagnostics with a modular, scalable system design. Minimal wiring is also critical to simplify installation and reduce potential failure points.
The Brainboxes BB-400 Edge Controller offers a reliable and flexible solution to these challenges. Designed for industrial use, the BB-400 features a rugged design and wide operating temperature range, making it ideal for continuous 24/7 operation in logistics environments. By processing sensor data locally and enabling fast decisionmaking, the BB-400 minimises downtime, speeds up response times, and ultimately maximises operational efficiency and profits.
These rapid response times are crucial for successfully enabling real-time navigation and task execution.
Integrated with Node-RED for logic and flow control, the BB-400 enables the robot to use accurate data to navigate and make quick decisions. Additionally, the Edge Controller facilitates communication with warehouse management systems, whether hosted locally or in the cloud.
To extend system capabilities, engineers can incorporate Brainboxes Remote IO modules. Their flexible mounting options, DIN-rail or board-mounted, allow the devices to be easily installed within robot enclosures, enabling seamless integration of additional safety circuits and control mechanisms.
The Remote IO devices provide a streamlined method for interfacing with external systems such as lifts, safety gates, and door sensors. By handling digital and analog inputs and outputs, these compact modules extend the robot’s sensory systems beyond its physical bounds, Brainboxes Remote IO provides full remote visibility and control of inputs and output, an essential capability in expansive warehouse
environments where robots work across wide areas and downtime must be kept to a minimum.
Integrating the BB-400 and Remote IO devices into the same environment as logistics robots turns a basic automated setup into a truly intelligent system. Instead of just following pre-programmed routes, the robots gain awareness of their surroundings through real- time data, such as sensor inputs, machine status, and control signals. This means they can respond to what’s happening around them, work in sync with other equipment, and connect directly to warehouse management systems, resulting in a smarter, more responsive logistics workflow that reduces downtime, improves coordination, and makes automation easier to scale.
Brainboxes devices simplify maintenance, accelerate deployment, and enable scalable connectivity that evolves with operational needs. With flexible communication protocols and intuitive web-based configuration, integration into existing infrastructure is straightforward and efficient. brainboxes.com
mk Conveyor URCap
Real-Time Location Systems.
The next step in warehouse efficiency.
• Track the position of forklift trucks and other transport vehicles.
• RFID tags on individual products or pallets.
• Forklift reads all the tags on a pallet.
• Combine height data from forks with location data and RFID data.
• Software automatically tracks every movement of products.
Fast and easy communication between the mk belt conveyor and UR cobot
mk URCap offers an intuitive interface for controlling up to 2 belt conveyors
No programming knowledge required
Drive Solutions for Parcel Warehouses
Drive technology is a crucial component of a warehouse’s conveyor belt system. In the following case study, leading logistics company DHL demonstrates how employing the latest drive technology can improve efficiency and enhance sustainability.
DHL is an internationally operating transport services provider and one of the world’s leading logistics companies. By 2050, DHL wants to reduce its logistics-related emissions to zero. The topic of energy efficiency is therefore of highest priority. For the construction of the new air freight hub at the Cologne Bonn Airport, the focus has also been on latest technology and sustainable solutions.
Project requirements
Since 1 August 2019, the newest air freight hub at the Cologne Bonn Airport has been part of the DHL network. The logistics centre provides a warehouse space of 12,000 m2 and a sorting capacity of 10,000 parcels per hour. A 400-metre main sorter and a 200-metre flyer sorter sort the different parcel sizes – 24 hours a day, six days a week. Added to this are conveyors with a total length of 2.5 km, which are operated by NORD Drivesystems and feature a belt speed of up to 2 m/s and an acceleration of up to 5 m/s2.
Climate-friendly logistics
As the world’s leading logistics company, DHL assumes the responsibility to set a good example in terms of sustainability, and it is investing heavily in environmentally friendly logistics solutions. For the conveyor belt motors, energy efficiency as well as short maintenance intervals have also been the main requirement. 800 highly efficient, variant-reduced LogiDrive drive systems from NORD Drivesystems guarantee energy-saving, reliable and lowmaintenance operation. The drive solutions were individually tailored to DHL’s customer requirements and enable an exceptional energy balance with optimum cost efficiency.
Reduced energy consumption and fast ROI
The operation of parcel distribution centres is energy-intensive. Highly efficient drive systems such as the NORD LogiDrive significantly reduce energy consumption and therefore CO2 emissions. In this way, they decisively contribute to more sustainability and climate protection in logistics. Furthermore, a fast Return on Investment (ROI) is achieved due to their high efficiency.
Application solution
The LogiDrive drive units from NORD are characterised by high efficiency, fast ramp times (up to 5 m/s2), compact design, minimum maintenance requirements and a long service life. They ensure energy-saving, safe and smooth operation at DHL.
Highly efficient, variantreduced LogiDrive drive systems
The system uses a combination of an IE4 permanent magnet synchronous motor (rated powers from 1.1 up to 5.5 kW), a two-stage bevel gear unit or a helical gear unit and a NORDAC LINK frequency inverter, which is installed close to the motor. A
variant with a helical gear unit is used for merge applications, which require particularly high dynamics and speeds. By using IE4 synchronous motors, the LogiDrive drive systems reveal their maximum savings potential in partial load and partial speed ranges. This makes them suitable for reducing the number of variants and allows a significant reduction of costs throughout the product service life, leading to improved Total Cost of Ownership (TCO).
Service-friendly plug-andplay technology
All NORDAC LINK frequency inverter connections are made via simple plug connectors and have been individually configured for DHL. A total of 12 plugs are available for encoder feedback, safe stop and others. In addition, the frequency inverters are equipped with a maintenance switch and a key switch for setup operation. An integrated Ethernet based bus system was also implemented. To complete the drive solution, NORD also supplied all relevant the cables. Potential sources of error were thus eliminated, facilitating fast and easy commissioning. nord.com/en/home-uk.jsp
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Drive Systems
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Gearbox Motor Inverter
From Collaboration to Dispense Innovation
In this enlightening case study, Titan Enterprises details how it collaborated with partner RWC to overcome design complexities and deliver a breakthrough beer dispensing solution.
Since designing their first beverage flowmeter in the early 1990s, Titan Enterprises, a leading UK manufacturer of liquid flow measurement solutions, has had a long-standing supplier relationship with John Guest, part of the RWC’s family of brands.
Starting out in 1949 as Reliance Manufacturing Company Pty Ltd (RMC) with a drive to transform industry, RWC was later born from the desire to challenge convention. A major landmark for the company came in 2018 with the acquisition of John Guest and its globally renowned push-fit brands.
Titan’s NSF-Approved beverage meter, 800-series turbine flowmeters, and the Atrato® ultrasonic flowmeter range, all incorporate John Guest connectors, which are extensively used in the food and beverage industry for their specialised ‘pushto-connect’ solutions.
A partnership built on trusted technology and precision engineering
In 2023, following years of evolving innovation since the launch of JG PolarClean by John Guest in 2010, RWC teamed up with Titan Enterprises to deliver an exciting solution for the beverage industry. A mutual customer discussion sparked the R&D collaboration, as users were already pairing RWC’s PolarClean push-fit connectors alongside Titan’s Beverage meters in beer dispensing systems. However, integrating the two products required additional modifications – introducing cost and complexity to a customer’s installation. Together, RWC and Titan set out to change that.
To simplify installation and enhance efficiency, RWC and Titan began a
partnership that led Titan to leverage its expertise in turbine technology and design, while RWC contributed its innovative tooling capabilities. The aim of the collaborative project was to provide a streamlined, stateof-the-art single unit for beer dispensing systems by fully integrating Titan’s turbine flow technology within RWC’s pioneering PolarClean connector.
Phil Lacey, RWC’s Global Fluid Tech Business Development Director, stated: “When we knew we needed a flowmeter for our PolarClean system, Titan made absolute sense as they are the market leader in the space. They have been an absolute pleasure to develop this product with and we look forward to seeing how the wider market receives this new innovation.”
Overcoming challenges through collaboration
The primary challenge was fitting the turbine into the PolarClean tube/connector without compromising either system. Through workshops, prototyping and design, the teams developed a modified version of RWC’s straight PolarClean union. SLA (stereolithography apparatus) 3D-printed models were used to create prototypes, which were then tested and calibrated by Titan before customer trials.
Neil Hannay, Senior R&D Engineer at Titan Enterprises, reflected: “Working with RWC was refreshing. Their expertise in toolmaking made the development and prototyping process a smooth journey. Open, frank and realistic discussions, along with regular meetings, kept the project on track.”
Josh Smith, Project Manager at RWC, explained: “By combining Titan’s expertise in flowmeters and our own expertise in push-fit technology, this new product has represented a shared commitment to quality, innovation and delivering value to our customers.”
Delivering a differentiated solution to customers
Once the final design was validated, RWC developed the injection moulding tool for the PolarClean body, while Titan managed the sensor and turbine technology. After minor modifications, the first units were shipped to customers for final performance validation.
The partnership resulted in a fully integrated innovative solution for the beverage industry: the JG PolarClean system uses ‘tube-in-tube’ technology to ensure beer is kept extra cold and
conditioned from the keg to the beer font, even without the need for a cellar. Featuring a standard 3-wire connector, this state-ofthe-art product simplifies beer dispense system installations. The JG PolarClean Coaxial Flow Meter accurately measures liquid flow enabling system users to monitor demand or supply usage in coaxial cooling systems.
A true collaborative product
This successful partnership continues into product commercialisation, where RWC manages key aspects of the base PolarClean product, packaging, and labelling, while Titan oversees critical flow measurement components, assembly and testing. RWC assembles the connector, and Titan completes the build and testing before shipping the finished flowmeter unit to the
end-user customer under the JG PolarClean banner.
As a truly combined product, the technical data and installation instructions are cobranded, bringing together the technology and expertise of two highly respected international brands. This successful partnership demonstrates how collaboration can drive innovation, streamline installation, and enhance product reliability in the beverage industry.
Browse Titan Enterprises’ website for optimised flow measurement devices for OEM applications, visit Titan Enterprises website; for information about RWC’s JG PolarClean Coaxial Flow Meter and their intelligent push-fit technologies, visit John Guest’s website. flowmeters.co.uk johnguest.com/gb/en
UR Cobot-Controllable mk Belt Conveyors
AdaptTech, the sole UK & Ireland distributor for mk Technology Group’s conveyors, explains how the versatile GUF-P 2000 belt conveyor can readily integrate with cobot applications.
mk’s GUF-P 2000 series of belt conveyors are true all-rounders, with a large selection of drives, tails, stands and belt types for outstanding variability. They are based on the mk 2000 aluminium profile range, which provides high load-bearing capacity and a torsion-resistant structure.
In addition to its low height of 50 mm and a compact ø 53 mm driving roll – which can be coated with rubber according to the application – the conveyor also offers a wide range of different belt types. As with all mk belt conveyor systems, the crowned design of the driving and idler rollers ensures significantly easier belt adjustment. The system is available with an optional stationary or rolling knife edge.
System slots running along both sides (10 mm slot width in accordance with mk’s profile technology) allow installers to easily integrate the conveyors into existing machine frames, or to attach stands, side rails, sensors and other accessories. In addition to AdaptTech’s wide selection of side rails and stands, it also offers a standard range of end stops and electrical accessories. A further quality feature of this conveyor system is the stainless steel sheet, installed below where the belt runs, which ensures long-term wear resistance of the belt.
The mk Technology Group is now also part of the Universal Robots partner network and provides GUF-P 2000 belt conveyor technology, which can be integrated quickly and simply into a cobot application through the URCap plug-in to control operation mode and speed of the conveyor.
mk provides all users of Universal Robots with individual GUF-P 2000 belt conveyors for simple integration in their cobot application. The convenient URCap plug-in simplifies the set-up and programming of the conveyor.
The UR+-approved belt conveyor GUF-P 2000 has a suitable version for every application. Conveyors are available in widths from 50 to 800 mm and lengths up to 10,000 mm. In addition, maximum total loads of 75 kg and speeds of up to 80 m/ min are possible. As belt conveyors generally transport the goods without any special requirements in terms of their position or support geometry, they are particularly suitable for vision-supported processes. Since the belt conveyor is constructed in a modular aluminium profile construction, it has T-slots in the conveyor frame on both sides. These facilitate integration into the system, as well as enabling side rails, sensors and other accessories to be attached.
The mk-Conveyors-URCap plug-andplay solution ensures fast and problem free communication between the conveyors and the cobots. It is compatible with all UR models in the e-series. Installation is simple and the intuitive user interface allows control of up to 2 belt conveyors. The conveyor
receives the commands for start/stop, direction and speed via the plug-in, but can also convey goods up to a sensor signal or for a certain period of time. The process layout remains customisable, even without programming knowledge.
As the sole UK & Ireland distributor for mk conveyors, AdaptTech can help businesses optimise their UR cobot processes and use mk belt conveyors together with the free URCap plug-in. Contact AdaptTech to find out more.
adapt-tech.co.uk
It is an opportunity to network to learn from each other. It is an opportunity to think of something or see something you never thought would happen. It is the sense of community and collaboration that is very important for our industry.
Stephen Phipson CBE, CEO
Make
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engineering
Invertek Drives Wins Award for Enterprise
Invertek Drives Ltd, a global leader in variable frequency drive (VFD) technology, has been awarded with The King’s Award for Enterprise - International Trade 2025, recognising continuous growth in overseas sales.
The UK-based designer and manufacturer, part of Sumitomo Heavy Industries Ltd, has demonstrated remarkable international growth. Exports now represent 95 per cent of total sales, reinforcing its position as a leading innovator in energy efficient motor control solutions. The company has doubled in size to 420 employees since 2018 at its headquarters in Welshpool, Powys.
The award acknowledges Invertek’s impressive 149% growth over a six year period – achieved despite global challenges including the COVID-19 pandemic, Brexit, and electronics supply chain disruptions.
Shaun Dean, Chairman of Invertek Drives, Executive Vice President of Sumitomo Heavy Industries, and Managing Director of SHI (Europe), added: “This King’s Award demonstrates how Invertek has successfully expanded its global footprint while maintaining the technical excellence and innovation that have always been its hallmarks.
“The impressive international growth is a testament to the strategic alignment between Invertek’s capabilities and the increasing global demand for energy efficient solutions. As part of the Sumitomo Heavy Industries group, Invertek continues to strengthen our collective position in key markets worldwide, since its acquisition in 2019. The ability to utilise UK based talent on a global platform is a key driver of our success.”
Adrian Ellam, CEO of Invertek Drives, headquartered at Welshpool, Powys, said: “This prestigious recognition validates our international business strategy and commitment to creating innovative, energy efficient solutions for global markets. Our VFDs play a crucial role in helping industries worldwide reduce energy consumption,
optimise processes, and minimise environmental impact – all increasingly important as businesses focus on sustainability and operational efficiency.”
Invertek has developed a multifaceted international trade strategy combining a global network of sales partners with strategic wholly-owned subsidiaries in key markets including the USA, Spain, Germany, and Poland. This approach has enabled the company to effectively penetrate diverse markets and establish strong footholds in various regions.
Demonstrating operational resilience, Invertek strategically stocked critical components before Brexit and the pandemic, enabling uninterrupted manufacturing capabilities when competitors faced production challenges due to supplier issues. This foresight allowed the company to fulfil record global orders and strengthen its international market presence even during industry-wide delays.
The company has reinforced its
commitment to long-term growth with a major expansion of its UK production, warehouse, and distribution facility, completed in 2024. This investment has increased capacity to meet growing international demand for its Optidrive range of VFDs, which are renowned for their versatility across manufacturing, HVAC, water treatment and renewable energy applications.
“Our success in international markets stems from our customer-centric, partnership driven approach,” added Adrian. “By prioritising adaptability, innovation, sustainability, and digital engagement, we’ve been able to navigate the complexities of the global marketplace while delivering exceptional value to customers worldwide.”
The King’s Awards for Enterprise are the most prestigious business awards in the UK, with winning businesses able to use the esteemed King’s Awards Emblem for the next five years.
invertekdrives.com
Adrian Ellam, CEO of Invertek Drives at its global HQ in the UK
Axair Cuts Energy Use at Grade I-Listed Hall
In the following case study, leading independent UK industrial fan supplier Axair Fans provides a candid account of how its fan array solution cut energy usage at prestigious Grade I-listed building while upgrading the ventilation.
When our client reached out about their plans to upgrade the ventilation at the grade building, we were all ears, even with it being a few days until the Christmas break. No one was on the slow mince pie lull here for sure. The client had just completed a whole-building energy assessment and were looking for smart ways to cut carbon emissions. With funding from Salix, a scheme that helps the public sector reduce emissions in line with the UK’s net-zero targets, they were ready to make some serious changes.
The building itself? A stunner. Built in the 1440s, Grade I listed, and steeped in history, with a Grade II listed wing thrown in for good measure. You’d expect a heritage site like this to come with restrictions galore, but in this case? Not really. Access was straightforward, ceiling heights were generous, and removing the old gear wasn’t going to be a headache. That meant we could focus on doing what we do best: upgrading their tired, old, belt-driven fans with something modern, efficient, and energy-saving.
The client’s main goal was a solid return on investment. They weren’t overly concerned with things like stock availability or cost as long as the outcome was right. That said, we still had to think smart, after all, this is a space that banquets and other highprofile events, so noisy fans were a no-go.
They’d already spoken to a bunch of ventilation companies, but most didn’t engage seriously, especially with limited info and it being right before Christmas. But we don’t do the whole “Let’s talk in January.” Even that close to Christmas. We treat every project with the same energy, whether it’s a last-minute job or a large-scale long-term plan. So, we rolled up our sleeves, took
a proper consultative approach, and dug into the details to find the right solution that would hit their CO2 emission and energy reduction targets.
Here’s what we did: we removed 28 fan sets and replaced them with 14 new supply units and 14 exhaust units. These covered the entire building, all based on detailed specs provided by the M&E consultant, including airflow duties and absorbed power figures.
The setup included a mix of 1x1, 2x1, and a hefty 4x2 fan array that formed a plenum chamber in the basement plant room that covered efficient air distribution to all the other air handing units. That chamber helped smooth out the airflow, making the whole system more efficient and quieter.
Now, we won’t lie, this one took time. We went through 24 spec revisions with the M&E team to get everything spot on. But both sides stayed motivated, and the result
was worth it.
Like any complex install, we hit a few bumps, particularly with ModBus connectivity. Normally, controls sit with the BMS team, but this time, we got hands-on. Our tech team collaborated directly with them and the component manufacturers to sort out register issues and ensure everything was commissioned without a hitch.
Final readings showed a clear reduction in energy use (although we didn’t get official numbers from the client but they old us, so that counts). But the real win? We’ve continued to work with both the contractor and the consultant on more projects off the back of this one.
Thinking of a retrofit? Contact Axair for a no obligation chat and see how quickly you can cut energy costs and CO2.
axair-fans.co.uk
Revolt. Reshape. Revolutionise.
take
We challenged an industry by revolting, and you listened. But that message, bold as it was, only scratched the surface. It’s easy to say you’re different. It’s harder to be different, every day, with every quote, call, and customer. That’s what our team does. So now, we’re passing the spotlight to them, the doers, the thinkers, the rebels, because they’re the reason this revolution is real. From first quote to final fan delivery, these are the faces turning revolt into results. Get in touch, and join the fan revolution. Axair. Revolutionary Fan Expertise.
Fabien Carbonell
UK Metals Expo 2025: Seizing the Moment
Faced with increasing tariffs and deepening trade barriers, the UK metals industry shifts to reinvention, and this bold change in mood will be in ample evidence at the UK Metals Expo 2025.
Asecond Trump presidency could harden US tariffs and deepen trade barriers, threatening UK metals supply chains. Instead of folding, Whitehall has fought back with a bold strategy: £500 million to convert Port Talbot to electric arc, a £2.5 billion National Wealth Fund for green steel and scrap reuse, and targeted support for Scunthorpe. Suddenly, the sector has real backing to cut carbon, secure domestic supply, and compete globally.
The challenge is urgent, with CBAM, Chinese oversupply, volatile energy prices, and a persistent skills gap, but the mood has shifted from survival to reinvention.
The UK Metals Expo 2025, on 10–11 September at NEC Birmingham, is where that transformation comes into focus.
What to expect at UK Metals Expo 2025
In 2025, over 8,000 senior professionals from 51 countries, representing sectors such as aerospace, automotive, defence, energy, construction, advanced manufacturing, and precision engineering, are expected to attend, ready to explore innovations and strategies shaping the next decade.
With over 400 exhibitors, more than 30 hours of free seminars, and deep engagement across the supply chain, the Expo drives business, investment, partnerships, and transformation.
On the show floor
Confirmed exhibitors include Tata Steel, Hydro Aluminium, Swiss Steel, Epicor, Cortizo, Righton Blackburns, and Van Leeuwen, along with global leaders such as Outokumpu, ArcelorMittal, Ametek GB, Atlas Copco, Behringer, Bikar
Aerospace, Bridgnorth Aluminium, Bright Steels, British Stainless Steel Association, Cast Metals Federation, Confederation of British Metalforming (CBM), Inductotherm, Innoval, Langley Alloys, Maher, MEPS, Masteel, National Tube Stockholders, NeoNickel, Servosteel, Stainless Steel Services, Strugal, TW Metals, and Wieland Nemco.
Expect:
• 400+ exhibitors showcasing raw materials, automation, digitalisation, forming and joining tech.
• Live demos with working systems proving capabilities in forming, joining, finishing, inspection, and digital control.
• The chance to connect with solution providers and decision-makers under one roof.
“We met key players from across the industry – an unmissable opportunity,” said Tata Steel UK CEO.
Conference highlights: big topics, real solutions.
UK Metals Expo 2025 tackles the industry’s most urgent challenges and biggest opportunities, with insights from top leaders:
• New supply chain opportunities in automotive, defence, and energy.
• Trade and tariff insights with projections through 2026.
• CBAM, decarbonisation, and ESG front and centre as regulations and investor pressure intensify.
• Tackling scrap leakage and building capacity for green steel as the shift to electric arc furnace production accelerates
• Innovation in alloys and advanced materials, enabling higher performance, improved efficiency, and sustainability.
• Dedicated theatres on Steel, Aluminium, Innovation, and Technology, sponsored by
Tata Steel, Hydro Aluminium, and Epicor.
• Mentoring and Careers Day on 11 September – a brand-new initiative uniting universities, veteran reskilling programmes, and institutions like IET and IOM3 to tackle the sector’s critical skills gap and support the next generation of talent.
• 30+ hours of free seminars, delivering practical insight and strategic vision.
Lord Rupert Redesdale, Chair of UK Metals Expo, sums it up:
“The UK Government has placed metals at the heart of its Industrial Strategy this year, and UK Metals Expo is its driving force. The leading trade show for the entire metals supply chain is back, bigger and more essential than ever.”
UK Metals Expo is a working marketplace, where engineers, buyers, suppliers, and policymakers meet face to face to close the gap between boardroom strategy and shop floor delivery. It’s where attendees can see solutions in action, assess real options, and rip off competitive advantage by connecting people, processes and technology.
Stand shoulder to shoulder with a passionate community, gain insights, contacts, and solutions to stay competitive, and make smarter business decisions.
ukmetalsexpo.com
3D Print Manufacturing
Midlands 3D Printing
T: 01785 594389
E: sales@midlands3d.com
W: www.midlands3d.com
Anti Vibration Products, Mounts & Bushes
Fibet Rubber Bonding (UK) Ltd
T: 01282 878200
E: sales@fibet.co.uk
W: www.fibet.co.uk
Connectors & Cabling Solutions
CEMBRE Ltd
T: 01675 470 440
E: sales@cembre.co.uk
W: www.cembre.com/en
Design-In Power Supply Solutions
Ideal Power
T: 01733 309865
E: salessupport@idealpower.co.uk
W: www.idealpower.co.uk
Drives, Motors & Gears
Flow Meters
Nord
T: 01235 534404
E: GB-sales@nord.com
W: www.nord.com
Industrial Fans
Axair Fans UK Limited
T: 01782 349 430
E: sales@axair-fans.co.uk
W: www.axair-fans.co.uk
Machine Safety
Schmersal UK Ltd
T: 01684 571980
E: uksupport@schmersal.com
W: www.schmersal.co.uk
Marking Solutions
T-Mark
T: 0330 153 8320
E: sales@t-mark.co.uk
W: www.t-mark.co.uk
Pressure Measurement Specialists
ESI Technology Ltd
T: +44 (0)1978262255
E: sales@esi-tec.com
W: www.esi-tec.com
Robotics & Automation
KUKA Robotics UK Ltd
T: 0121 505 9970
E: sales.uk@kuka.com
W: www.kuka.com
Sensors
Titan Enterprises Ltd
T: +44 (0)1935 812790
E: sales@flowmeters.co.uk
W: www.flowmeters.co.uk
High Shear Mixing Equipment
Silverson Machines Ltd
T: +44 (0)1494 786331
E: sales@silverson.co.uk
W: www.silverson.co.uk
Industrial Communications
Brainboxes
T: + 44 (0) 151 220 2500
E: sales@brainboxes.com
W: www.brainboxes.com
Intoware
T: 0115 977 8969
E: hello@intoware.com
W: www.intoware.com
IFM Electronic
T: 020 8213-0000
E: enquiry.gb@ifm.com
W: www.ifm.com
PLUS Automation Ltd
T: 0121 58 222 58
E: Sales@PLUSAutomation.co.uk
W: www.PLUSAutomation.co.uk
Storage Solutions
BITO Storage Systems Ltd.
T: 02476 388 852
E: Info.uk@bito.com
W: www.bito.com
Test & Inspection
AMETEK Land (Land Instruments International)
T: +44 1246 417691
E: land.enquiry@ametek.com
W: www.ametek-land.com
THE WORLD’S SMALLEST ELECTRONIC SOLENOID INTERLOCK
With dimensions of just 119.5 x 40 x 20 mm, the AZM40 is the smallest electronic solenoid interlock in the world. This makes it especially suitable for small safety doors and flaps. Despite its compact size it has an amazing 2000 newton interlocking force and 25 Newton latching force.
Thanks to the 180° angle flexibility of the actuator, it can approach the AZM40 on a stepless basis, making the interlock also suitable for flaps which do not close at 90° or those that open upwards to a 45° angle. This means the angle flexibility helps the interlock easily fit into compact spaces and difficult to access areas.
In the event of a power cut, the AZM40 retains the current position. This ensures safe operation, whatever the status of the machine. Even if there are hazardous run-on movements, the safety door remains locked in the event of a power failure. Another advantage of the bistable principle is the consistently low energy consumption, as the interlock only requires power when the door is to be locked or unlocked.
SCHMERSAL | Enigma Business Park Malvern, Worcestershire, WR14 1GL
