MEPCA Magazine May 2025

MAY 2025

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CONTENTS Editor Oliver Batt oliver@cimltd.co.uk Publication Manager James Burke jb@cimltd.co.uk 01795 509105 Account Manager Jim Bearden jim@cimltd.co.uk 01795 509105 Design & Production Grant Waters grant@cimltd.co.uk James Taylor james@cimltd.co.uk Administration Manager Natalie Woollin admin@cimltd.co.uk 01795 509103 Credit Facilities Manager Gwen Lee creditcontrol@cimltd.co.uk 01795 509103 Marketing Manager Lucas Payne lucas@cimltd.co.uk Sales Director Tom Woollin tom@cimltd.co.uk Chief Executive John Denning

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May 2025

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elcome to the May issue of MEPCA magazine.

This bumper issue houses an extensive machine building focus. We begin with a short introduction to the field of machine building, past, present and future, before Festo shares five ways machine builders can improve electric drive systems. Further into this focus, Brainboxes explains the technology behind the latest advances in machine vision, Xometry shares the secrets of agile machine building, REO UK explores how input chokes can mitigate electric interference, and many more articles highlighting emerging technologies and practices in machine building.

Our cover story this month is brought to you by NORD Gear, with a technical article aimed at demystifying the 87Hz characteristic. Often treat as a dark art in motor performance, NORD expertly brings the subject into the light.

As well as our usual sections, including the latest solutions, thought leadership pieces and event previews, our Manufacturing Champion this month deserves a special mention. Andrea Wilson has been campaigning for SME representation for the manufacturing industry for 5 years. Turn to page 10 for the details of how you can help. In addition to signing the petition, follow Andrea’s campaign on LinkedIn, where she is encouraging SMEs to share their own experiences, as she does in this issue. Many companies will have equally frustrating stories to tell, and through these narratives, we can paint a picture of the industry too compelling to ignore.

I hope you enjoy this issue.

Oliver Batt, Editor © 2025 Cogent Multimedia Limited,1st Floor, Saphir House, 5 Jubilee Way, Faversham, Kent, ME13 8GD. No part of this magazine may be reproduced or stored in a retrieval system or transmitted in any form – electronic, mechanical or physical – without express prior permission and written consent of the publisher. Contributions are invited and when not accepted will be returned only if accompanied by a fully stamped and addressed envelope. Manuscripts should be typewritten. No responsibility can be taken for drawings, photographs or literary contributions during transmission or in the editor’s hands. In the absence of an agreement the copyright of all contributions, literary, photographic or artistic, belongs to Cogent Multimedia Limited. The publisher accepts no responsibility in respect of advertisements appearing in the magazine and the opinions expressed do not necessarily represent the views of the publisher. The publisher cannot accept liability for any loss arising from the late appearance or non-publication of any advertisement.

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

CONTENTS Industry Partners:

FEATURES 8 OPINION 10 MANUFACTURING CHAMPION 12 COVER STORY 15 MACHINE BUILDING 48 ROBOTICS

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52 MANUFACTURING SOFTWARE 54 HEALTH & SAFETY 64 FLOW CHEMISTRY 72 EDITOR’S CHOICE 76 EVENT PREVIEW

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INDUSTRY NEWS

LEEA Appointed Liaison for ISO/TC 96 Cranes Technical Committee

T

he Lifting Equipment Engineers Association (LEEA) is thrilled to announce that it has been appointed as a liaison for the ISO/TC 96 Cranes Technical Committee. This is a significant milestone that strengthens LEEA’s ability to represent the interests of its members on a global stage, and to collaborate with key international bodies, such as the European Commission, World Customs Organization, and International Labour Organisation.

The appointment positions LEEA at the forefront of shaping international standards that directly impact the Lifting Industry. The Association will be working closely with experts worldwide to ensure that safety, quality, and best practices are embedded into this international standard.

At the heart of this achievement lies LEEA’s commitment to advocating for its members. This liaison role provides the Association with a powerful platform to ensure members’ concerns and expertise are heard and considered in the

development of crucial international standards. LEEA is dedicated to ensuring these standards reflect the practical realities and challenges faced by its members daily.

Members of LEEA are encouraged to get involved and join its Internal Mirror Committee.

Ross Moloney, CEO of LEEA commented: “We believe that the best standards are developed through collaborative effort.

That’s why we’re inviting our members to join our Internal Mirror Committee. This is your opportunity to influence international standards through directly contributing to the development of ISO standards. Participants will also gain valuable insights helping them to stay ahead of industry trends and regulatory changes. In addition, they can

network and collaborate with experts, fellow professionals and thought leaders. This will strengthen LEEA’s voice and help us to effectively represent your interests on the global stage. Your expertise is invaluable. If you’re passionate about shaping the future of the Lifting Industry, we want to hear from you.”

To register interest in joining LEEA’s Internal Mirror Committee visit the website below. form.jotform.com/LiftingEquipment/ leea-imc-interes

INDUSTRY NEWS

Robotics and Automation 2025 Returns to MTC

T

he highly anticipated Robotics and Automation 2025: Powering Your Future event will return to the Manufacturing Technology Centre (MTC) on June 17-18, 2025. This year’s gathering will include a keynote address from Dr. Bernd Liepert, President of euRobotics AISBL – the European Robotics Association, about the opportunities for UK to forge a bigger robotics market with Europe. The Rt Hon Greg Clark – Chair of the Warwick Manufacturing Group and a member of the Industrial Strategy Advisory Council, which contributes to the development and longterm delivery of HM Government’s industrial strategy, will also be delivering a talk to attendees.

Other highlights include: • Businesses sharing how they successfully navigated their own automation journeys.

• Insights from the West Midlands Robotics Cluster on best practices, innovation opportunities and exciting collaborations around the world.

• Predictions on how the financing landscape is expected to impact technology adoption in the near future with The UK Automation Forum and NatWest.

• Findings from of The Workforce Foresighting Hub’s recent study into the skills required for SMEs to adopt robot automation for metalworking.

• Key findings from the UK Fashion and Textile Association who will be sharing its Advancing Automation and Robotics for Sustainable Manufacturing whitepaper.

MTC’s hosting of Robotics and Automation this year follows recent news that it won the bid to host the European Robotics Forum (ERF) 2027 in Birmingham,

in partnership with University of Birmingham and the Birmingham and West Midlands Convention Bureau.

Mike Wilson, Chief Automation Officer at the MTC, said, “Global instability is driving a growing interest in reshoring manufacturing to increase supply chain resilience. Robotics technology will play a key role in this endeavour. By convening innovators, thought leaders and end users in the field for this year’s event, we’re working to unlock possibilities and encourage greater investment by UK industry in robot automation.” the-mtc.org/robotics-andautomation-2025

OPINION

Playing Catch Up: Automation Investment David Atkinson, UK Head of Manufacturing, SME & Mid-Corporates at Lloyds, considers how greater use of automation can make UK manufacturers more competitive, with insights from Mike Wilson, Chief Automation Officer at the Manufacturing Technology Centre.

T

he robots are coming, but are they coming quickly enough?

According to the latest available data from the International Federation for Robotics, the UK installed 3,830 industrial robots during 2023, which was an all-time high and an increase of 51% on the year before. That is great news, but we still have a long way to go to catch up with our competitors.

The use of robotics and automation by UK manufacturers remains low compared to our competitors; Germany has around nine times as many industrial robots, while France has around double, despite its output being comparable to ours. Although we are the world’s 12th largest manufacturing nation, we’re not even in the top 20 when it comes to robot use.

The UK’s historic aversion to automation is puzzling, especially as it is well understood to be a solution to one of manufacturers’ key challenges: improving productivity.

Productivity and sustainability Robots can transform a business’ operations; enabling the better use of staff, existing machines and space, helping address recruitment challenges, creating more rewarding jobs, boosting yields and streamlining workflows.

Manufacturing often involves repetitive tasks, which colleagues find monotonous and demotivating, leading to quality issues and wastage. Automating time-consuming tasks like these creates consistency, which means less waste and improved efficiency, making manufacturers more sustainable. It also ensures colleagues are better utilised on tasks that add value.

Indeed, Mike Wilson says: “The effectiveness of a machine tool tended by a

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human operator is typically about 60-70%, while a machine tool tended by a robot can be more than 90%.”

And robots are more accessible than they have ever been, even for the smallest manufacturers, with plug and play robots on the market that can be integrated into a production line for a relatively small outlay.

That said, manufacturers considering investing in automation must first do their due diligence; it’s not quite as simple as just buying a robot to replace a human. That starts with strategically identifying those processes where automation can have the biggest impact.

Optimising impact If you aren’t sure where to start, the Manufacturing Technology Centre (MTC)

employs a team of experts who can visit your premises to carry out a free line walk, reviewing how you work and identifying opportunities to automate.

Mike Wilson says: “For firms investing in automation, there is a learning curve that means it is often better to start with a simple application rather than the biggest challenge on the shopfloor.”

Funding is available to support automation investment, including Hire Purchase and leasing products to help spread the cost and bring down barriers to entry. The real cost of automation is the cost of not doing it!

To find out more about the support available from the MTC visit the website below. lloydsbank.com/mtc/support

OPINION

Make Better and Mend As the Association of Electrical and Mechanical Trades (AEMT) celebrates its 80th anniversary, Thomas Marks, the Association’s General Manager and Secretary, outlines why the compromise of repairing electromechanical equipment goes beyond supporting a circular economy.

W

hen you think of repairing something, you may view it as a less positive option than replacing it with like for like.

The age-old phrase ‘make do and mend’ makes it sound like a compromise, like the least favourable option. However, that is often not the case where electromechanical equipment is concerned. Yes, there are energy efficiency gains to be made when replacing old lowvoltage motors with modern alternatives. But, across the spectrum of electromechanical equipment, there are many ways that a skilled repair centre can improve a device as part of the repair process. This might mean improved performance, improved efficiency, or improved reliability.

Take motors as an example. A competent repair shop can do a number of things to improve a motor’s performance. Modern rewinds often use insulation materials with higher thermal ratings than the original, improving motor thermal tolerance and, in turn, the expected lifespan. Tighter winding tolerances can be applied where the repair shop can optimise the winding pattern, reducing losses and improving efficiency beyond the original specs. In some cases, after a rebuild, a motor can be dynamically balanced to tighter tolerances than when it originally left the factory. While bearings can be replaced with higher-quality, low-friction, or insulated bearings to reduce heat and extend Pumps are another area where improvements can be made. During the repair process, impeller and volute geometries can be optimised to improve

efficiency. If appropriate, bronze or cast-iron parts can be replaced with stainless steel, duplex, or hard-coated surfaces to improve corrosion and wear resistance. Modern machining can allow tighter tolerances, reducing internal recirculation and improving pump efficiency. And newer mechanical seals and sleeve designs can be utilised to drastically reduce leakage and maintenance requirements.

There are also ways in which electronic equipment, such as variable speed drives, can be improved. The most common is with component upgrades. Capacitors can be replaced with longer-life, higher temperaturerated versions. Critical resistors or diodes can be replaced with precision, low-drift, or higher-rated variants. While uprated semiconductors can offer faster switching speeds, lower losses, and better thermal performance.

Servo motors can be upgraded with modern digital encoders with higher resolution than older analogue or low-

resolution units. Rewinding can improve electrical symmetry and torque ripple. While higherstrength permanent magnets may be retrofitted for increased torque density.

In addition to these productspecific enhancements, lubrication and cooling systems can be enhanced, surface treatments and coatings can improve anti-corrosion and anti-friction performance, and, of course, condition monitoring sensors can be added to improve ongoing performance and reliability.

Next time you are weighing up whether to repair or replace your electro-mechanical equipment, remember that technology has advanced since many machines were originally built, a third-party repair shop isn’t necessarily limited by mass production cost constraints and repairs can allow optimisation to your specific operational parameters.

And all of this is before we even touch on the environmental benefits. The carbon footprint of a repair is generally much lower than that of a new replacement. Plus, waste materials are minimised, and the demand on natural resources is reduced. This is, of course, the circular economy. While it is right that this phrase has grown in popularity in recent years, the practices have been around for millennia. Indeed, the AEMT has been championing, representing, and supporting the electromechanical sector, and in turn the circular economy, for 80 years this very year.

So maybe we shouldn’t say, ‘make do and mend’ and instead, ‘make better and mend.’ theaemt.com

www.mepca-engineering.com

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MANUFACTURING CHAMPION

Manufacturing Champion of the Month This month we celebrate Andrea Wilson, director of Hone-All Precision Ltd and unrelenting campaigner for an SME manufacturing advocate in parliament. Speaking candidly with our editor, Andrea shares what inspired the campaign and her disappointment at its slow traction.

S

ince Andrea began the campaign for an SME manufacturing advocate 5 years ago, the support has been phenomenal.

However, this support hasn’t translated into action – at the time of the interview, the petition had not yet reached 1,000 signatures. While understandably frustrated, Andrea takes heart from the fact that it has started important conversations among trade associations, membership bodies, and even celebrities.

Speaking with MEPCA’s editor, she explained that it was her experiences as the director of Hone-All Precision that inspired the campaign and shared three specific examples.

Andrea: “One, I’ve been sitting on various skills panels for 27 years now, and we still have a skills shortage. And we’re still having the same conversations that we’ve been having for 27 years.”

The second example came when she applied for a capital equipment grant to fund the purchase of a new machine.

Andrea: “Effectively they told me that, in order to get 20K towards this machine, I had to employ two people. I was buying the machine to avoid exactly that. But the only way I could get it was to add 60k or 80k to my wage bill. Why on earth would you encourage someone to buy capital equipment in order to increase productivity and output, but ask them to increase their headcount, which in turn lowers their productivity levels?”

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The support mechanism was more suited to OEMs, demonstrating the government’s lack of understanding of how SMEs operate.

Andrea: “And thirdly, every time a new MP or Minister for Business comes in – I’ve seen it, I’ve done it and I’ve seen other companies do it, too – we walk around our factories, we sell them on the idea of engineering and manufacturing. We tell them how amazing we are, what we need, etc., and three weeks later, that same MP is in charge of schools or roads. All the work we do to educate them is lost. That’s why we need somebody who has knowledge, who has a passion, who is apolitical, who can stand up to the civil servants and the politicians.”

Oliver: “Without a proper advocate for SME manufacturing and engineering, do you hold out much hope for the industrial strategy in June?”

Andrea: “No, I don’t think it’s going to deliver for SMEs what is needed. It may well give us a roadmap for larger industry, the economy as a whole in terms of industrial planning.

But in terms of engineering and manufacturing, over 90% are SMEs. And I do not believe, based on what I’ve heard and seen so far, that it’s going to address anything of any importance for us in that document.

“So no, I’m not holding out much hope unless they have listened to some of the excellent feedback that’s been given over that consultation period.”

Oliver: “Were you to address our SME readers directly, what would you say to them?”

Andrea: “If you really want change, fight for it. If you really want to see this industry succeed, start telling people how amazing it is … Post images of your lovely, clean, bright factories and dispel the myth of the dark, dirty, demonic factories of old. Because the only way that any of this is going to change is if we all shout together in order to fight it.

So as my posts say: one strong voice, one clear message.”

Get involved with this crucial campaign by taking 5 minutes to sign the petition via the QR code.

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COVER STORY

Demystifying the 87Hz Characteristic The humble three-phase motor and inverter combination is a crucial yet overlooked technology.

Of all the factors that affect the performance of this classic combination, the 87Hz characteristic is one of the most misunderstood. In this illuminating article, NORD Gear offers a clear explanation.

T

he three-phase squirrel-cage induction motor was first developed in the late 1880’s and has since been widely used in industry as the prime mover for most applications, wherever rotary or linear movement is required. As much as 67% of all electricity consumed in industry is used for running these motors, which indicates the scale of their importance.

Originally these motors were connected direct-on-line (DOL) and ran at a fixed speed until the late 1960’s when frequency inverters were developed, giving the ability to vary the speed of an electric motor. At that time, there were issues with reliability due to the motor’s insulation system being insufficient to withstand the higher pulse voltages of frequency inverters, as well as the motor’s misapplication, where the system performance was being compared to other variable speed technology such as DC motors and controllers, which operated under different principles. These issues have long since disappeared, and the three-phase squirrel-cage induction motor and frequency inverter drive system are regarded as highly reliable and flexible with now more than 50% of all motors being driven by frequency inverters.

Technology doesn’t stand still; advances in materials, efficiencies, design and knowledge have enabled the humble threephase motor and inverter combination to solve the many challenges thrown at them in the quest for higher torques, wider speed

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ranges, more compact dimensions, to name a few.

As already noted, three-phase squirrelcage induction motors can be connected directly to the line (DOL) supply and operated at a constant voltage and frequency, producing an almost constant, fixed speed drive. When started DOL, the motor has no ramp and accelerates as fast as it can, taking its full starting current every time, which can be as much as 7 x nominal current, it then runs at fixed speed.

When supply is disconnected, the motor coasts to a standstill. Alternatively, they can be connected to a frequency inverter and operated with a variable voltage and variable frequency supply, providing an adjustable ramp up, variable speed capability, and an adjustable ramp down.

Field weakening The operating behaviour of a motor changes

when it is connected to a frequency inverter.

The frequency inverter is connected to the AC supply and produces a variable voltage and variable frequency, supplied to the motor. Discounting any voltage boost, auto boost or sensorless vector adjustments, the output voltage and frequency increase proportionally to what is called “the rated frequency” (i.e., what the motor is expecting), in this case 400V at 50Hz. In simple terms, because the voltage and frequency are proportional the motor operates with a constant flux, this relationship produces a constant torque range from the motor up to 50Hz. When using an inverter, it is possible to drive in excess of 50Hz, however, the voltage remains the same as the supply, therefore above 50Hz the volts/Hz relationship is no

COVER STORY longer the proportional. This is called “field weakening” and it occurs when the power remains constant but the torque drops away. as shown in Fig 1.

When operating the motor in the constant torque range up to 50Hz, it is important to consider that the motor fan is providing less cooling as the motor runs at a slower speed.

An old rule of thumb was that running below 20Hz with constant torque would require forced cooling (assuming 40 deg C ambient). However, with today’s minimum IE3 or higher efficiency motors that run more efficiently and hence cooler, many suppliers claim constant torque down to 10Hz (5:1 speed range) without any additional cooling is possible.

87Hz characteristic It is perfectly acceptable to use the motor in the field weakening area provided the motor develops enough torque for the application.

There is, however, another possibility: the so-called 87 Hz characteristic.

Field weakening of a motor starts if the output voltage of the frequency inverter can no longer be increased – however, its frequency is increased. What is needed should this occur is a wider range where the voltage and frequency can stay in proportion.

To illustrate this, take a motor (generally 4 Pole 1500 r/min) with a 230/400V 50Hz winding, which is standard for motor frame sizes up to and including IEC100 (some motor manufacturers offer this to much larger frame sizes), and connect it in a delta configuration for the 230V winding, then connect this to a 400V inverter but set the rated frequency to 87Hz, the result is a volts/ frequency relationship that is proportional up to 400V 87Hz. However, at 50Hz it reaches 230V and is therefore suitable for a 230V 50Hz motor winding, this can be seen in Fig 2 – the original 230V 50Hz in red and the 400V 87Hz in blue.

As the voltage and frequency are proportional (constant flux), it results in constant torque from zero to the 87Hz or typically 2600 r/min motor speed. The same comments regarding cooling apply, i.e., with the new IE3 motors running down to 10Hz, delivering constant torque without any additional cooling. As a result, the motor can be run from 10Hz to 87Hz constant torque without any additional cooling, a comparison between the 50Hz and 87Hz performance can be seen in Fig 3.

When applying the 87Hz characteristic,

the frequency inverter and motor must be appropriately selected, dimensioned and parameterised.

Considering the motor, given the torque now remains constant until 87Hz the power of any given motor increases by √3. For example, a 1.5kW 4 pole motor becomes a 2.61kW motor as shown in the table (Fig 4); the torque remains constant to 87Hz and then moves into the field weakening area.

The resulting inverter should be a 3 Phase 400V input inverter and selected based on the motor current for the 230V winding – in general it will also match the resulting power @ 87Hz.

Fig 1

Application benefits Depending on the application, there are several benefits from utilising the 87Hz characteristic.

The main benefit being constant Fig 2 torque over a much wider speed range and above the 87Hz it can still be used in the field weakening range.

By running at a higher speed, it is possible to use a higher ratio reduction/gearbox to achieve the desired machine speed. The mechanical advantage of the ratio provides a higher output torque, therefore it may be possible to reduce the original motor size selection. This is particularly Fig 3 interesting where many plants are looking to reduce the number of variants that they have on site.

If the application involves moving a high inertia, the reflected load inertia to the motor shaft is reduced by the ratio squared. Therefore, having a higher gearbox ratio reduces the reflected inertia and results in the system being more dynamic.

Using the 87Hz characteristic is interesting for many reasons Fig 4 and does offer in many cases significant benefits, but there is nothing special in terms of its set-up; it takes a standard three-phase squirrel-cage induction motor and a standard three-phase 400V input frequency inverter. nord.com/en/home-uk.jsp

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Focus On: Machine Building

P18. Festo shares five ways machine builders can improve electric drive systems.

MACHINE BUILDING

Machine Building Past, Present, Future As an introduction to this issue’s extensive machine building focus, MEPCA looks at the story of machine building from its pre-industrial origins to the present day and beyond.

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n the most reductive of terms, a machine is a device comprised of two or more parts, each with a defined function, which together perform a task by changing the direction or magnitude of a force. According to this definition, the earliest type of machine would be the hand axe, or ‘wedge’, which is counted alongside the lever, the wheel and axle, the pulley, the inclined plane, and the screw, as the six examples of ‘simple machines’ according to Renaissance scientists. In this respect, those who created these early tools as their trade would have been the earliest examples of machine builders, but these craftsmen were still quite far removed from machine builders as we understand them today.

What we now understand as machine building has its origins in the Industrial Revolution. However, an important precursor to this, and arguably the first example of real industrialisation, came with the invention of the steam engine by English inventor Thomas Newcomen. Being made of metal and therefore harder to work with than the components of early machines used in textiles, which were predominately made of wood, it required a re-thinking of production processes and, most importantly, precision, standardisation and reproducibility.

In the early 19th century, machine building was pioneered by several key British toolmakers, including Henry Maudslay and Joseph Whitworth. It is here that we see a shift in emphasis from individual specialist toolmakers creating tools in their workshops, to the prevalence of factories, including those specialising in machine building, and the first emergence of it as an independent field. While this evolution started in the United Kingdom, it soon spread to Europe and the USA, where the process of machine building was further perfected by innovative toolmakers and industrialists overseas.

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In the first half of the 19th century, the wooden machinery used in textiles was all but replaced by metal machinery, and this trend spread to the production of many other volume-produced products. The increasing standardisation of machine tools and components, made possible by early machine building, fuelled mass production.

The swift perfection of the production processes further improved on machine building components, which in turn bolstered production capabilities.

In the present day, machine building is a distinct field that broadly encompasses a variety of specialised activities, covering everything needed for the design, component selection, construction, assembly, installation, integration and optimisation of machines, from their simplest to most complex forms.

Where the transition from wooden to metal components, the increasing standardisation, accuracy and reproducibility of machine parts, and dedicated factories birthed the machine building field as we know it, its current evolution is driven by robotics, automation, digitalisation and

artificial intelligence. The Industrial Internet of Things (IIoT) and smart factories are enabling machine builders a new level of performance and predictive maintenance that reduces downtime and allows machine builders a greater level of control and agility.

Advances in additive manufacturing (aka 3D printing) not only allows swift prototyping, but also the creation of ondemand replacements, with some machine building factories even having in-house 3D printing capabilities, able to replace machine components as soon as needed (for more on 3D printing’s impact on procurement, turn to page 32).

The future of machine building will be characterised by increasing automation, with smart factories evermore able to operate and regulate themselves with limited human input, particularly as AI driven systems automate many of the processes, including elements of design, while datadriven insights enable processes to adapt to changing demands in real time. For further emerging technologies in the field, continue reading this machine building focus.

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MACHINE BUILDING

5 Ways to Improve Electric Drive Systems Ben Lloyd, EA Product Manager, Festo, shares five ways machine builders and specifiers can avoid simple errors and optimise the performance of electric automation systems.

E

lectric automation can deliver enhanced efficiency, consistency and precision in many industrial automation applications. However, simple oversights during the design and specification process can cause serious problems, including poor machine performance and premature component failure, and result in higher energy consumption, increased maintenance costs and lower productivity. Here are five ways to avoid these errors and optimise performance:

1. Check which way is up!

Always consider final axis orientation when selecting a drive for a linear axis. This may sound obvious, but it is often overlooked. In our experience, this omission becomes more common as the application becomes more complex. Every axis-motor combination is calculated separately but the orientation direction is frequently forgotten.

Orientation is crucial for optimal performance because a vertical axis requires more torque to lift the load than a horizontal one. Ensure the motor, gearbox, ball screw or toothed belt are not undersized by considering the orientation during the calculation phase.

2. Select the correct gear ratio For the control circuit in a servo system to be stable, the motor’s mass moment of inertia must be proportional to the load.

Otherwise, it may lead to an imbalance. We like to compare it to a light vehicle towing a heavy trailer. The vehicle may have enough power to get the heavy trailer moving, but not enough mass to prevent it from swaying (in crosswinds, for example).

A gearbox is most often used to achieve a good inertia ratio. It reduces the inertia

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Festo’s electronic sizing tool can help specifiers and machine builders to optimise electric drive component selection.

that the load effects on the motor with the gear ratio squared. The right gear ratio will depend on the application.

3. Verify vibration risks Vibration is one of the key environmental conditions that can significantly affect the service life of a linear axis. If not properly addressed, vibrations can cause additional stress and wear on the components, which may not be evident during initial calculations.

Applying a specific factor to the load during calculations will ensure the component achieves its predicted life cycle.

This factor, which accounts for the expected vibration, typically ranges from 1³ to 23. Refer to the component’s manual or datasheet for further guidance.

4. Don’t forget to lubricate Electric automation components are sometimes required to make repeated, very short and precise movements. Concentrated cycles can lead to components’ grease being depleted in this focused area causing sticking or failing due to inadequate lubrication.

An extended stroke, or “lubrication stroke”, should be made periodically to spread the pre-applied grease along the

whole length of the bearing. Ideally, this action would be programmed into the machine software: for instance, at the end of every shift or production series. Lubrication requirements must be considered during the design phase to ensure that all movements are smooth and consistent.

5. Consider cooling cycles Heating and cooling cycles are typically influenced by whether the electric drive must operate continuously or intermittently.

Intermittent operation gives components time to cool down, improving service life and offering the potential to select a less powerful version.

Festo’s Electric Motion Sizing tool helps factor in thermal modelling. Simply enter the dwell times between movements alongside other requirements such as motion, mass and speed. The online tool provides manufacturer-independent suggestions to help find the right combination of servo drive, motor and actuator for the application.

More advice on improving an electronic drive’s performance and life cycle is available in Festo’s eGuide 10 Most Commonly Made Errors With Electric Axes, which is free to download: festo.com/common_errors_electric_axis

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MACHINE BUILDING

mk Strengthens its Conveyor Offering The mk Technology Group have enhanced its market leading conveyor offering with a relaunch of its best-selling GUF-P MINI small belt conveyor and the additional of a new high performance curved belt conveyor.

GUF-P MINI small conveyor mk has given its tried and trusted GUF-P MINI small conveyor an overhaul. The new GUF-P MINI features a whole range of improvements that make it even more versatile and flexible.

This small conveyor series is already renowned for its versatility and flexibility when handling small and light products in systems with limited installation space. The updated version offers even more options for tailored integration into a whole range of different production environments.

The conveyor frame profiles have been further optimised, still standing at a height of just 30 mm but with a range of widths from 50 to 300 mm. That allows for a wider range of configuration options with lengths of up to 3,000 mm, while also facilitating alternative custom requests.

Another new feature is the switch to the standardised 10 mm T-slot in the conveyor frame profile. This feature allows the system to be integrated easily into existing machine frames and enables stands, side rails, initiators and other accessories to be attached on either side.

The choice of drive options and motors has also expanded. Alongside the established asynchronous AC motors, a 24 V DC motor and 48 V stepper motors are also now available, meeting all the requirements of modern applications. The new drive options provide efficient and reliable performance tailored to the specific scenario.

The new 12 mm-diameter knife-edge option ensures that even smaller products can be transferred safely and reliably. All these new features mean the MINI is living up to its name now more than ever.

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New highperformance belt conveyor for conveying goods around corners mk also adds the new KGF-P 2040.02 curved belt conveyor to its curved belt portfolio.

The new KGF-P 2040.02 curved belt conveyor offers a much higher usable width, a greater load capacity and a faster conveying speed in comparison to the previous version, the KGF-P 2040. Its more robust design makes it the ideal solution for Overhauled GUF-P MINI small conveyor demanding applications.

It allows the easy conveyance of piece goods such as cardboard boxes, small load carriers or trays with an overall load of up to 50 kg around 90° curves, while maintaining the alignment of the products. The conveyor has an aluminium profile design and is compatible with all other mk conveyor systems.

Thanks to the latest developments, the conveyor belt is driven by a conical driving roller with a friction-lock connection.

A special guide geometry on the edge continuously guides the belt in stationary ball bearings at the New KGF-P 2040.02 curved belt conveyor outer radius. This allows the belt to run extremely smoothly, even at higher speeds. The drive is mounted on the curve or a right-hand curve. outer edge of the curve, and the three-phase AdaptTech Manufacturing Solutions is the asynchronous motor can be aligned in any only UK and Ireland distributor of the mk way required. conveyors. For more information, please visit The KGF-P 2040.02 is available with an the website below. outer radius of either 1,000 or 1,500 mm, adapt-tech.co.uk both of which have a scale of usable widths.

Each version is available as either a left-hand

EW

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PBC15 Bayonet quick locking Screw clamp connection technology 3 Power + PE + 2 Signal, IP67 Shieldable

www.binder-connector.co.uk

MACHINE BUILDING

AI Vision Systems From rock-paper-scissors to high-performance industrial vision, Brainboxes demonstrates how its Edge processing and PoE gigabit networking is powering the latest machine vision technology.

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I-driven vision systems are transforming industrial automation, delivering speeds and accuracy in manufacturing processes that were unimaginable just five years ago. But to unlock their full potential, these systems need more than just smart algorithms – high-speed, low-latency networking and reliable power delivery are crucial to ensuring seamless performance.

Traditionally, vision systems in manufacturing have been used for basic inspection tasks. Relying on pre-programmed rules and fixed algorithms, they can be highly effective in controlled environments where lighting, materials, and part shapes remain consistent, but are far less suited to complex or changing conditions. AI has transformed vision systems, enabling them to learn from data, adapt to new conditions, and take on increasingly complex manufacturing tasks.

Modern neural networks, powered by open-source frameworks like TensorFlow, don’t depend on predefined rules but instead learn by analysing thousands of images. By training a model to recognise patterns, an AI-driven vision system can classify objects, detect defects and adjust to variations in the production environment, without requiring engineers to program every possible scenario.

To bring these next-generation vision systems to industry, Brainboxes has integrated Power over Ethernet (PoE) gigabit networking, Edge computing, and AI processing, enabling high-performance industrial cameras to connect with real-time machine learning inference. To showcase the technology’s possibilities, Brainboxes has created an interactive demonstration where AI challenges humans to a game of rock-paperscissors. While a fun way to engage with the system, it also demonstrates a powerful shift in industrial automation, where vision systems are moving beyond traditional inspection to enable real-time, intelligent decision-making on production lines and beyond.

Machine learning models can be trained

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on a laptop and deployed on Brainboxes’ BB-400 Industrial Edge Controller to run AI inference at the Edge, enabling real-time decisions without cloud-based processing and reducing both latency and bandwidth demands. With AI providing unprecedented intelligence, PoE gigabit networking delivers the critical infrastructure needed to power and connect these vision systems.

Brainboxes’ SW-595 PoE gigabit and Small Form-Factor Pluggable (SFP) industrial network switch supplies both power and high- speed data over a single Ethernet cable, eliminating the need for separate power sources and allowing cameras to be positioned almost anywhere.

AI vision systems require reliable, high-bandwidth, low-latency connectivity to process images instantly. The gigabit speed of the SW-595 ensures smooth real-time data transmission, while its SFP fibre connectivity supports long-distance deployments, making it ideal for large-scale industrial applications. By combining PoE networking with Edge-based AI processing, Brainboxes enables distributed vision systems to be deployed factory-wide without excessive cabling, power constraints, or network congestion.

The same principles demonstrated in Brainboxes’ AI-powered rock-paper-scissors

game can be applied to solve complex engineering challenges across industry.

AI-driven vision systems are already helping engineers instantly identify faults and improve quality control, reducing waste and inefficiencies. The technology also enables highly detailed inspections, detecting subtle defects like hairline cracks in metal components, flaws that would typically go unnoticed by traditional inspection methods.

Rather than relying on physical, locallyattached sensors, PoE-powered cameras capture real-time video, which is processed at the Edge by AI to count and classify widgets, ensuring optimal production flow. At the same time, remote condition monitoring is easier than ever, with AI-driven vision systems tracking equipment wear, detecting anomalies, and instantly alerting engineers to maintenance needs, helping to prevent costly unplanned downtime.

Brainboxes’ interactive rock-paperscissors demo provides a firsthand look at real-time AI inference, ultra-low latency video streaming and PoE gigabit networking, giving engineers a chance to see cuttingedge AI vision technology in action.

Brainboxes will be showcasing the demo at global events throughout 2025. brainboxes.com/events/2025-showschedule

MACHINE BUILDING

Agile Machine Building The adoption of digital technologies and new, more efficient production methods is revolutionising machine building. Learn how on-demand manufacturing offers advantages to machine builders by streamlining engineering workflows, courtesy of Xometry, a leading on-demand manufacturer.

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he traditional machine building process, often characterised by lengthy lead times and rigid production schedules is transforming.

On-demand manufacturing, leveraging digital technologies and flexible production methods, is emerging as a powerful digital approach to streamlining development, reducing costs and accelerating innovation within the industry At its core, on-demand manufacturing allows for the production of parts and components only when needed. This approach contrasts sharply with traditional methods that necessitate large-batch production and extensive inventory management. For machine builders, this translates to a radical shift in how they approach prototyping, production, and even maintenance.

One of the most significant advantages lies in the accelerated prototyping phase.

Traditional machine building often involves costly and time-consuming tooling and setup for each iteration. On-demand services, particularly those utilising additive manufacturing (3D printing) and CNC machining, enable rapid prototyping.

Engineers can quickly design, test and refine components, significantly shortening the development cycle and allowing for faster market entry. This iterative design process, facilitated by on-demand production, fosters innovation and enables the creation of more optimised and efficient machines.

Furthermore, on-demand manufacturing eliminates the need for large upfront investments in tooling and inventory. This is particularly beneficial for small and medium-sized enterprises (SMEs) that may lack the financial resources for extensive tooling and storage. By producing parts only when required, companies can reduce capital expenditure and minimise the risk of obsolescence. This flexibility also allows for agile responses to changing market

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Engineer using on-demand manufacturing platform Xometry.

demands and customer specifications.

The impact extends beyond prototyping and production. On-demand manufacturing is revolutionising maintenance and spare parts management. Machine downtime can be costly, and the availability of replacement parts is crucial for minimising disruptions.

Traditionally, machine builders have had to maintain extensive inventories of spare parts, often incurring significant storage costs. On-demand manufacturing allows for the rapid fabrication of replacement parts as needed, reducing inventory and minimising downtime. This capability is particularly valuable for older machines or those requiring specialised components.

The adoption of on-demand manufacturing is also driving the digitisation of the machine building industry. Digital design tools, AI-driven manufacturing platforms, and automated production processes are becoming increasingly

integrated, creating a more interconnected and efficient ecosystem. This digital thread enables seamless communication between designers, manufacturers and end-users, facilitating collaboration and optimising the entire machine lifecycle.

On-demand manufacturing offers significant advantages for machine builders, enabling them to streamline their operations, reduce costs, and accelerate innovation.

As digital technologies continue to advance and on-demand manufacturing services become more accessible, the machine building industry will likely witness a further shift towards more agile and responsive production models. This transformation will ultimately lead to the development of more efficient, customised, and sustainable machines, benefiting both manufacturers and end-users alike. xometry.uk

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MACHINE BUILDING

Input Chokes with Variable Speed Drives Variable Frequency Drives (VFDS) are crucial for regulating electric motor speeds, but they generate electrical disturbances that must be mitigated. In this article, electronics manufacturer REO UK explores the function, benefits and design considerations of input chokes in VFD applications.

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FDs have become indispensable in modern industrial applications, providing precise control over motor speed and torque while improving efficiency and energy savings.

However, VFDs introduce certain electrical disturbances, including high-frequency radio frequency interference (RFI) and harmonic distortion. These disturbances must be effectively managed to comply with regulatory standards and maintain system performance. One of the most effective solutions for mitigating power quality issues associated with VFDs is using mains chokes, also known as line chokes or line reactors.

These passive components are usually manufactured from copper and electrical grade steel and are connected in series with the mains supply. They reduce harmonic distortion, limit inrush currents, and protect electrical equipment from transients.

Understanding variable frequency drives VFDs regulate electric motors’ speed by varying the supplied power’s frequency and voltage. They typically consist of three primary sections: 1. Rectifier stage: converts incoming AC power to DC. 2. DC bus: filters and stores DC energy.

3. Inverter stage: converts DC power back into AC with a variable frequency and voltage, which controls the motor speed.

While VFDs improve motor control and efficiency, the conversion process generates significant electrical noise and harmonic distortion. These harmonics can lead to excessive heating in electrical components, increased losses, and disturbances in

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nearby equipment, making power quality management a critical consideration.

The role of input chokes Input chokes are passive inductive components installed in series between the power supply and the VFD, usually constructed from copper windings and a laminated iron core. Once installed, they require no maintenance and will tend to last as long as the installation is required to operate. Their primary function is to introduce impedance into the electrical system, which helps control the flow of

harmonic currents and protect sensitive components. The key benefits of input chokes include: 1. Harmonic mitigation VFDs, being non-linear loads, generate harmonic currents that distort the power supply waveform. These harmonics can cause overheating in transformers, cables, and other electrical equipment, leading to system inefficiencies and failures. By increasing line impedance, input chokes reduce the magnitude of harmonic currents and improve overall power quality.

2. Inrush current reduction:

MACHINE BUILDING VFDs can draw large inrush currents upon startup, causing sudden voltage dips and stressing electrical components. Input chokes limit the rate of change of current (di/dt), thereby controlling inrush currents and preventing damage to the VFD and associated equipment.

3. Transient protection: Voltage spikes and transients, which can occur due to switching events or external disturbances, pose a risk to VFDs and connected motors. Input chokes act as buffers, absorbing and dampening these transients to enhance system reliability.

Benefits of using input chokes Incorporating input chokes into VFD systems provides several advantages: 1. Improved power quality: by filtering harmonics and transients, input chokes ensure a cleaner power supply, reducing interference and improving system stability.

2. Extended equipment life: reducing electrical and thermal stress on VFDs, motors, and other components prolongs their operational lifespan, reducing maintenance and replacement costs.

3. Enhanced motor performance: a smoother current and voltage profile leads to more stable motor operation with less noise and vibration, improving efficiency and longevity.

4. Regulatory compliance: many industrial standards, such as IEEE 519, limit harmonic distortion levels. Input chokes help meet these requirements, avoiding penalties and operational disruptions.

5. Reduced RMS current and energy consumption: input chokes contribute to reducing root mean square (RMS) current, which translates into lower energy consumption and cost savings.

Design considerations for input chokes Selecting and implementing input chokes requires careful consideration of several factors: Inductance value: • Input chokes are typically rated to cause a voltage drop between 2% and 4% on the line voltage. This rating significantly impacts harmonic reduction and RMS current levels.

• As illustrated in Figure 1, a 22 kW VSD without a choke exhibits high harmonic distortion, while using 2% and 4% chokes reduces Total Harmonic Current Distortion (THDi) by approximately 19% and 36%,

respectively.

Voltage and current ratings: • The choke must be rated to handle the maximum expected voltage and current without excessive heating or voltage drop.

• Undersized chokes can overheat and fail, while oversized chokes may be unnecessarily expensive.

Thermal management: • Proper ventilation or cooling must be ensured to prevent overheating.

Water-cooled chokes can be viable in environments with space constraints or controlled ambient temperatures.

Installation location: • Chokes should be placed close to the VFD to minimise impedance mismatches and ensure optimal performance.

• High ingress protection (IP54 or greater) units allow standalone drives to be mounted in control rooms without additional enclosures.

Energy consumption and cost savings Input chokes improve energy efficiency in VFD applications by reducing harmonic and overall RMS currents. Lower RMS current results in: • Reduced heat generation in electrical components.

• Lower energy losses, contributing to longterm operational cost savings.

• Improved system reliability and performance.

As shown in Figure 2. a 2% input choke can lower RMS current by 8.7%, while a 4% choke achieves a reduction of 17.2%, This significant decrease translates into lower power consumption and improved efficiency across the electrical network.

To quantify the financial benefits, consider

the following examples based on standard drive sizes: • 11 kW Drive: Annual savings of £574.2 (2% choke) and £1135.2 (4% choke).

• 50 kW Drive: Annual savings of £2610.0 (2% choke) and £5160.0 (4% choke).

• 160 kW Drive: Annual savings of £8352.0 (2% choke) and £16512.0 (4% choke).

These savings are based on an assumption of 4,000 operating hours per year and an electricity cost of £0.15 per kWh, demonstrating the significant economic advantages of implementing input chokes in VFD applications.

Conclusion Input chokes are essential in VFD applications, addressing key challenges such as harmonic distortion, inrush current and transient voltage spikes. By improving power quality, extending equipment life and enhancing motor performance, input chokes contribute to the efficiency and reliability of industrial electrical systems. Proper selection and implementation are crucial for maximising these benefits and ensuring compliance with industry standards. Under optimal conditions, input chokes can achieve a 17% reduction in input current, leading to substantial energy and cost savings over time. reo.co.uk

www.mepca-engineering.com

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MACHINE BUILDING

The Critical Role of Competency In machinery design and industrial automation, competency is the foundation of safety. It’s not optional; it’s essential. From engineers and machine builders to end-users, having the right knowledge and skills directly affects not just safety, but also efficiency, compliance and operational resilience.

Why competency matters When competency is lacking during design or integration, machines can reach the end-user with unsafe designs or missing documentation. This leads to poor installation, dangerous operation, and inadequate maintenance – increasing the risk of serious incidents.

Non-compliance at the design stage often results in costly retrofits, downtime and regulatory headaches. But the stakes go beyond financial. Unsafe machinery can cause injuries, damage, legal penalties and brand damage. In the worst cases, the HSE can issue fines, stop work, or pursue criminal charges.

For anyone involved in a machine’s lifecycle, design, build, or operation – competency must be a strategic priority.

Competency prevents hazards before they happen Many workplace incidents are linked to human error, often due to insufficient training, poor risk awareness, or unfamiliarity with automation systems.

A common gap is hazard identification.

Without solid understanding of risk assessment, key dangers are missed, leading to avoidable incidents. Misuse of safety features is another issue.

Advanced safety systems are only effective when understood and correctly applied. If misunderstood or deliberately bypassed, they become useless.

Poor competency also undermines maintenance practices. Inadequate lockout/ tagout knowledge, outdated systems unsuited to modern automation, makeshift repairs, and overlooked faults all pose serious risks.

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Navigating the regulatory landscape Understanding the regulatory environment is central to machinery safety. Regulations like PUWER and the Supply of Machinery (Safety) Regulations set out the requirements for the safe use and supply of machinery, whilst standards such as ISO 13849 and IEC 60204 define clear expectations.

Significantly, the new EU Machinery Regulation (EU) 2023/1230 replaces the older Machinery Directive, introducing updates that affect design, documentation, and digital compliance. Staying current is critical, and that’s where competency bridges the gap between theory and safe, compliant practice.

Despite clear frameworks, noncompliance is widespread. Often it stems from unclear responsibilities, misinterpretation of standards, or simple lack of awareness.

Skilled professionals close these gaps and ensure safety is built-in, not bolted on.

Building and sustaining competency Competency isn’t achieved through a single training session – it’s built over time through formal training, practical experience, and mentorship.

Structured programmes offer a solid base. CPD-accredited courses focused on real-world topics like risk assessment and ISO 13849 give learners not just knowledge, but practical tools. EUCHNER UK provides such training, helping machine builders and users alike tackle safety challenges with confidence.

However, training alone isn’t enough.

Hands-on experience, when paired with good instruction, helps workers apply best

practices without developing risky habits.

Add mentorship, and this is a powerful tool for accelerating learning and embedding a safety-first culture. Senior engineers play a crucial role in transferring knowledge and guiding smart decisions.

Staying up to date is also vital. Evolving standards like ISO 13849 and ISO 14119 can reshape how machinery is designed and operated. Ongoing learning ensures companies stay compliant and ready for what’s next.

Final thought Competency in machinery safety isn’t a tickbox, it’s a competitive advantage. A trained, safety- aware team minimises risk, avoids downtime and delivers compliance with confidence.

EUCHNER UK invests in building lasting competency. The company’s CPD accredited courses cover essential safety topics, and its consultancy services help apply these principles in real-world settings.

From design reviews to compliance planning, EUCHNER UK supports informed, effective decisions at every stage. Investing in competency is investing in the future.

To explore how EUCHNER UK supports training and safety goals, visit the company’s website.

EUCHNER.co.uk/safety-services/ training

MACHNINE BUILDING

Big Cobots & HeightAdjustable Bases It would be easy to assume that the increased size of collaborative robots (cobots) would make height-adjustable bases obsolete. However, as LINAK, developer of electric linear actuators, demonstrates, the two can in fact serve as complementary solutions for efficient palletising.

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s the trend of cobot palletising continues to rise since 2020, the automation of palletising tasks has expanded significantly.

Among the latest advancements are big cobots, which offer impressive versatility with a reach of up to 1.8 meters and payload capacities of 25 kg or more, making them a game-changer in material handling.

Traditionally, compact cobots, with a reach of approximately 1.3 meters, required height-adjustable bases to access the upper levels of pallets. The introduction of big cobots raises the question: are heightadjustable bases still necessary? While big cobots simplify palletiser design and can handle heavier products, certain situations still call for height-adjustable pedestals. The increased forces generated by big cobots necessitate a more stable base, leading to an update of LINAK’s ELEVATE™ lifting column for cobot palletisers, now featuring stroke lengths of up to 1100 mm.

In this release, LINAK explores various configurations for stacking at different heights and palletising heavy goods, before then clarifying the appropriate cobot sizes and the scenarios in which a heightadjustable base, such as the ELEVATE lifting column, is beneficial.

The palletising market offers a diverse range of setup options. To assist in determining the suitability of the ELEVATE column for specific applications, LINAK have compiled B10 data to align the column’s estimated lifetime with palletiser requirements. Duty cycle data is also available to evaluate whether a palletiser equipped with an ELEVATE lifting column can meet production line cycle times.

Optimal setup options for palletising solutions The height at which goods can be palletised largely depends on the size of the cobot and its base. However, applications often require more than just reach; factors such as cobot path planning and pallet size also play crucial roles. Adding a lifting column can simplify programming and reduce collision risks by allowing the cobot to operate at safer positions.

For palletising goods up to 2 meters, businesses can opt for a big cobot with a reach of approximately 1.8 meters, eliminating the need for a height-adjustable base. However, if space constraints or brand preferences make a big cobot impractical, pairing a compact 1.3-meter cobot with an ELEVATE lifting column can be a viable solution. For broader pallets or low-height boxes, an ELEVATE with a 700 mm stroke may be more suitable.

Maximising stacking heights For operations requiring stacking heights of up to 2.4 meters, particularly for shipping containers and trucks, big cobots alone may

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not suffice. In such cases, an ELEVATE with an 1100 mm stroke can facilitate stacking on common pallet sizes. This configuration ensures stability during operation, accommodating both big and compact cobots.

When considering additional stacking heights for compatibility with Automated Mobile Robots (AMRs) or Automated Guided Vehicles (AGVs), it is essential to factor in extra height. To achieve a palletising height of 2.8 meters, integrating an ELEVATE lifting column with a big cobot is necessary.

Palletising heavy goods Big cobots can generally handle payloads of up to 20 kg with long reach or heavier items up to 30 kg with limited reach. For palletising goods over 25 kg at heights above 2 meters, options are limited. Combining a heavy payload cobot with an ELEVATE lifting column allows for stacking heights up to 2.3 meters, ensuring stability even under higher forces.

For further information about the ELEVATE lifting column for cobot palletisers, please visit the website below. linak.co.uk

ELEVATE™ your cobot palletiser to the next level The ELEVATE™ lifting column extends the range of your cobot palletiser, taking performance to new heights.

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8/17/23 8:03 AM

MACHINE BUILDING

Rethinking Procurement in Machine Building Midlands 3D, one of the largest 3D print manufacturers in the UK, shares 5 principles to unlock the benefits of the strategic use of 3D Printing.

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nformation about adopting 3D Printing is often centred on the technology and its applications.

As manufacturers move greater volumes of parts over to 3D Printing, it becomes more important to build an appropriate procurement strategy – one that unlocks the true value of adopting the process.

Principle 1: the economics of 3D print production are different In most manufacturing processes, producing more of a single part in one run is key to getting a lower cost per part, and therefore a lower price. For procurement, the trade-off becomes price per part versus the cost of stockpiling what might be many months of actual requirement. To get a true part cost, the money tied up in excess stock must be considered. With 3D print manufacturing, and especially with technologies like HP MJF printing, that is not the case.

Due to 3D Printing’s minimal start-up costs and zero machine downtime, the cost to the manufacturer of making the last part is practically the same as the price of the first, mitigating the need to tie up money in excess parts. Therefore, the “per part” cost of a 3D printed part is a much truer reflection of the actual cost to the business.

Principle 2: better pricing comes from better machine utilisation The real variable cost in technologies such as MJF printing comes from running the machines themselves. In every production run, there is a volume of print space to fill.

The more efficiently the 3D printer fills that cube with parts, the lower the overall cost of the production run, and the more attractive the pricing they are able to offer.

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Principle 3: variance rather than volume becomes your friend In each order, it actually makes more sense to order a variety of different parts at the same time, rather than trying to maximise the volume of a single part and storing the excess. This enables the print provider to maximise machine utilisation.

Principle 4: consolidate the 4 P’s: Prototype, Part, Product & Process As soon as a customer lets go of the notion of ordering large volumes of a single variant as the key to getting the best price, then consolidating what might have been separate orders with differing suppliers all into a single manufacturing agreement, and even a single order within that agreement, makes most sense.

• Prototypes can be made cost effectively, right alongside anything else the business needs using the same process as the final product.

• Parts for a wide variety of products, or indeed sets of parts for individual products, can all be made simultaneously.

• Products can be manufactured alongside everything else, and the more printed parts, the better the pricing becomes.

• Process: additional applications for 3D Printing present themselves as customers review their assembly line and related business processes.

Principle 5: a 3D Printing procurement strategy can be a win-win These principles provide a more competitive edge as adoption of the technology grows.

By consolidating the 4 P’s into a strategic agreement with a single manufacturer, the greater this competitive advantage becomes. And it’s a win for the manufacturer too; the more “printed part” variance in each order, the greater their production efficiency.

Summary Procurement strategy for 3D Printing must evolve from “one off” prototyping and low-variance volume production. Building a higher value and more strategic relationship between manufacturer and customer can unlock a wealth of opportunities.

It’s all part of the maturation of an industry, still only a decade or two in the making, and that Midlands 3D is willing to provide guidance to make happen. midlands3d.com

MACHINE BUILDING

DC/DC Converters in Automation & Control DC/DC converters play a critical role in a variety of industries such as industrial automation, robotics, motor control, and power management systems. Here, Ideal Power, provider of specialist power solutions, clarifies how DC/DC converters work and why they are so crucial.

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C/DC converters play a critical role in a variety of industries such as industrial automation, robotics, motor control, and power management systems. They ensure stable voltage regulation, improving the efficiency and reliability of controllers, motors, sensors and communication networks. In modern industrial environments, where precision and uptime are essential, these converters help maintain consistent power delivery.

What is a DC/DC converter, and why is it important?

A DC/DC converter adjusts DC voltage levels to ensure electrical systems receive stable and precise power. Many applications rely on accurate voltage regulation to protect sensitive components and maintain reliable operation. Without proper conversion, power fluctuations can cause inefficiencies, malfunctions or system failures.

DC/DC converters are essential across industries, optimising power distribution, enhancing energy efficiency, and reducing heat generation, which improves system reliability and longevity, even in demanding environments.

What are the main types of DC/DC converters?

Isolated DC/DC Converters provide galvanic isolation, reducing electrical noise and enhancing safety in robotics, industrial sensors, and control networks.

In contrast, non-Isolated DC/DC Converters are compact and efficient, making them ideal for motor drives, embedded systems, and factory automation where isolation is not required.

Buck and Boost regulators also play an important role in voltage regulation, in

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both Step-Up and Step-Down variations.

Step-Down reduce voltage for low-power applications like sensors and control circuits, while Step-Up increase voltage for highpower applications, including motor drives and industrial power supplies.

What are the key features of DC/DC converters?

DC/DC converters are designed to provide efficient, stable and reliable power conversion across various applications. Their voltage regulation and stability are critical for ensuring consistent power delivery, which prevents fluctuations that can disrupt system performance.

High energy efficiency is also a key feature, as it minimises power loss, thereby improving system efficiency and reducing heat generation. Additionally, isolated models offer galvanic separation that helps reduce electrical interference and enhances safety.

Their compact and versatile design also enables integration into space-constrained environments.

As DC/DC converters are built to be durable in harsh conditions they are capable of withstanding high temperatures, vibrations and unstable power sources, which is essential for demanding applications. Many

models also incorporate advanced thermal management solutions, such as heat sinks or active cooling systems, to prevent overheating and extend their operational life.

What are the most common uses for DC/DC converters?

• PLCs, HMIs, and Controllers • Motor Drives & Motion Control • Robotics & CNC Machinery • Industrial Sensors & IoT Devices • Power Redundancy & Backup • Communication & Networking • Safety & Emergency Systems • Railway & Transportation • Medical Equipment • Renewable Energy

How Ideal Power can help Ideal Power specialises in DC/DC power solutions designed to meet the needs of diverse industries. Its extensive product range is built to deliver precise and efficient voltage regulation, ensuring optimal performance, energy efficiency, and compliance with industry standards such as UKCA, CE, RoHS, and REACH. Idealpower.co.uk

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Find out more at www.idealpower.co.uk or call us on 01733 309865

MACHINE BUILDING

Custom-made Connectors and Cabling As customers demand more intelligent and adaptable machinery, machine builders are increasingly seeking solutions that allow them to embrace flexible production. In answer, HARTING UK, manufacturer of industrial connection technology, introduces a versatile range of cabling and connector solutions.

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he Han-Modular® series from HARTING allows machine builders to create a flexible and versatile solution by combining individual inserts for different transmission media into standard-sized industrial connector housings, enabling a wide range of customisable combination options.

With the new Han-Modular® Domino range, machine builders have even more options, thanks to space savings of up to 50%. In addition, by dividing the mating face in two, even larger contacts can be accommodated, allowing power, signal, data or compressed air to be combined in one module, reducing the total number of interfaces required.

As a result, difficult to reach assembly areas can be equipped more efficiently or opened up for assembly. With the addition of the new Domino range, there are now over 250 modules to choose from and many thousands of potential combinations available, increasing design flexibility.

They are also compatible with standard components of the Han-Modular® series so they can be easily integrated into existing systems and machinery.

In addition, the Han-Eco® range allows machine builders to pre-assemble and mount inserts into housings from the rear, rather than the traditional method of installing cables through the bulkhead before assembling the contact inserts. This method gives users the flexibility to pre-assemble the switch cabinet units and cable harnesses separately.

Han-Eco® is manufactured from highperformance polyamide plastic, which complies with standards IEC 61948 and EN 45545-2. The range offers IP65 protection

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and substantial weight savings compared to traditional metal housings. In addition, the hoods and housings are suitable for both indoor and outdoor applications and are entirely compatible with standard metal Han® housings, meaning both variants can be integrated into existing production equipment.

HARTING solutions are characterised by an efficient plug & play system, which eliminates errors by ensuring plug-in security with the help of coding.

They offer the largest variety of termination technologies on the market and have now expanded this portfolio with the new Han® Push-In range.

The connection technology behind the Han® Push-In represents a refinement of the cage connection method, which is particularly well suited to field termination thanks to its speed and ease of use. It allows fast and uncomplicated assembly of connectors whilst ensuring consistent quality and robustness. As a result, assembly times in the field are reduced by up to 30%.

Han® Push-In allows machine builders to assemble several conductor variations, ranging from stranded conductors to conductors with ferrules (insulated and uninsulated) and solid conductors.

Combined with a wide selection of inserts from the Han® portfolio, customers now enjoy a wide range of connectivity solutions.

Alongside standard connectors, HARTING

also design and build custom cable assemblies, with custom cable lengths and a range of plastic or metal housings. All customised products are built at HARTING’s manufacturing facility in Northampton and are based on market-leading connectors from the extensive HARTING range.

Services include installing components, efficiently routing cable harnesses and fabrication. To assist machine builders further, HARTING’s in-house design team can create a 3D CAD visualisation of the build beforehand to ensure absolute accuracy before manufacturing begins.

The HARTING manufacturing facility holds ISO 9001 certification for Quality Management, the ISO 14001 Environmental Standard and UL certification for Wiring Harnesses ZPFW2 / ZPFW8.

To learn more about HARTING UK’s manufacturing capabilities and customised solutions, please visit the company’s website. harting.com/en-GB/harting-customisedsolutions

The next level of modular industrial connectors.

Han-Modular® Domino Modules Robust technology for industrial transformation.

The first modular connector with a hybrid module configuration ■ Smaller and lighter connectors allow space savings of up to 50% ■ Compatible with components of the Han-Modular® series, the market standard for modular industrial connectors ■ Flexible and scalable to the respective need ■ Sustainability through consistent modularisation ■ Reduction of installation times by combining several individual connections

One Range. No Limits: www.HARTING.com/domino

MACHINE BUILDING

How to Choose the Right Industrial PC Industrial PCs are crucial component of countless industrial operations. However, selecting the correct PC for a specific application can be daunting. Fortunately, Relec Electronics is on hand to provide advice.

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hen it comes to selecting the perfect industrial PC, the choices can feel as complex as the applications they support. Whether the requirement is for automating a production line, running data acquisition software, or managing industrial IoT systems, the industrial PC chosen needs to align with the specific requirements. But with so many options available — from compact embedded systems to rugged, highperformance machines — how do buyers decide?

What is an Industrial PC? An industrial PC is a computer specifically designed for harsh environments, built to withstand extreme temperatures, vibration, shock, dust, and sometimes even water or chemicals. Unlike consumer PCs, industrial PCs prioritise reliability and long-term operation, often running 24/7 in demanding conditions.

Industrial PCs can come in a variety of form factors, from fanless compact designs to larger, fully rugged enclosures. The industrial PC market has grown rapidly, with leading manufacturers like DFI producing systems that meet the needs of smart manufacturing, automation, transportation, and energy industries.

Key factors to consider when choosing an Industrial PC:

1. Performance requirements (CPU & memory) Your choice should start with understanding your processing needs. Machine vision applications need significant GPU power, while basic data logging requires low processing overhead.

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• For heavy processing: consider the VC500-CMS-MXM, which supports Intel® Xeon processors and up to 64GB memory.

• For lighter applications: the EC700-ADN offers efficient Intel® Atom® performance with a compact footprint.

2. Environmental conditions Will the system operate on a clean production floor, or will it be exposed to outdoor conditions, dust, vibration, or moisture?

• For rugged environments: the ECX700ADP with IP67/IP69K certification offers superior protection against water and dust.

• For controlled environments: the EC543ADS balances performance with cost for standard industrial setups.

3. Form factor and mounting options Space constraints are common in industrial settings, so understanding the size and mounting flexibility matters.

• For ultra-compact installations: the EC70AADP (181.6 x 57 x 118.4mm) fits where space is extremely limited.

• For expandable systems: the VC500-CMS offers flexibility without compromising on processing power.

4. Connectivity, expansion, and OS compatibility What peripherals and devices will the system need to interface with? Check for necessary ports — DisplayPort, HDMI, USB, VGA — and expansion slots for future upgrades.

Another critical factor is the operating system (OS). Relec’s partners can pre-load or offer Windows 10, Windows 11, and for select models, Linux — giving the flexibility to choose the platform that best supports the industrial application.

5. Operating temperature range From freezing cold outdoor sites to scorching hot factory floors, an industrial PC needs to endure it all.

• Extreme temperature tolerance: both the VC500-CMS and ECX700-ADP handle temperatures as low as -20°C and up to 70°C. • Moderate climates: systems like the EC543-ADS work well in standard industrial temperatures up to 60°C.

Why choosing the right industrial PC matters Selecting the wrong system can lead to unexpected system failures and costly downtime, compatibility headaches with sensors, cameras, or machinery, and leads to performance bottlenecks that slow down operations. On the flip side, investing in a tailored industrial PC ensures long-term reliability in harsh environments, seamless integration with existing infrastructure, and scalable performance. Choosing the right industrial PC isn’t just about specs — it’s about ensuring seamless operation, long-term reliability, and adaptability to future demands. By carefully assessing the environment, processing needs, and connectivity requirements, it is possible to select the perfect system. relec.co.uk

BUILT For the extremes

trusted everywhere

INDUSTRIAL COMPUTING

MACHINE BUILDING

Programmable Linear Measurement Encoders Process automation, machine building and increasing the efficiency of systems require highly precise equipment – encoders are such equipment. Designed for field programmable linear measurement, the latest encoders are easy-to-install, high-res solutions.

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he encoder is part of the automation system, thanks to which it is possible to determine the efficiency of various types of machines.

With proper knowledge of encoder functionality and the ability to use them, it is possible to increase the company’s productivity – in other words, encoders save time and money and improve results. The encoder allows control of the movement, drive and operation of individual machine components, and then – most importantly from a business perspective – to optimise operations.

Model TR1 Tru-Trac® The Model TR1 Tru-Trac® established itself as a versatile solution for tracking velocity, position, and distance across diverse surfaces. This compact unit ingeniously combines three critical components: an encoder, measuring wheel, and springloaded torsion arm.

What makes the TR1 stand out is its adaptability. With a design allowing installation in various orientations, adjustable torsion load, and a field-reversible threaded shaft for mounting from either side, it delivers flexibility where it matters most. The TR1 performs reliably at speeds reaching 3000 feet per minute and offers multiple wheel material options to suit specific application requirements.

Durability is another hallmark of the TR1 encoder, featuring a conductive composite housing that minimises static build-up while ensuring longevity in demanding environments.

TRP Tru-TracPro Building on this solid foundation, Encoder Products group developed the TRP TruTracPro™ - an advanced measuring wheel

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system that offers improved performance and additional features compared to previous encoder model.

The TRP maintains all the mechanical advantages of its predecessor while introducing transformative programmable capabilities. This ready-to-integrate package comes equipped with field programmability, allowing for resolution adjustments anywhere from 1 to an impressive 100,000 CPR (counts per revolution).

System integrators particularly appreciate the TRP’s flexibility. With 40 unique waveforms available, the encoder can be fine-tuned in-situ without hardware modifications. The innovative “Teach Index” feature enables precise location setting, while field calibration capabilities enhance overall accuracy.

Perhaps most valuable is the TRP’s ability to adapt through software rather than hardware changes. The encoder stores user settings alongside factory defaults in internal memory, and the free, downloadable programmer software ensures fast implementation. This softwarebased approach eliminates the common requirement to change wheel sizes for different applications, potentially reducing inventory costs while simplifying system design.

Applications across industries Both encoders have found applications across numerous sectors including: machine building and robotics, automation and sorting systems, aerospace applications, food and beverage production printing operations, material handling, and mobile equipment.

These versatile tools excel in specialised applications like cut-to-length operations, spooling, length measurement and print

registration—anywhere precise linear measurement is crucial.

The value proposition The evolution from TR1 to TRP represents how thoughtful engineering can enhance already reliable technology. While the TR1 continues to serve as an excellent generalpurpose solution, the TRP offers advanced capabilities for applications requiring higher precision and programmability.

Together, these encoders exemplify how motion feedback technology continues to advance, enabling manufacturers to achieve greater efficiency, reduce costs and improve production results—proving that sometimes, the smallest components make the biggest difference in industrial performance.

See the TR1 and TRP at the show!

Encoder Products will be exhibiting at the Smart Manufacturing Week, happening 4-5 June, at NEC Birmingham. Smart Manufacturing Week will host live demonstrations of the latest technologies transforming the industry. Visit them at Stand 5/H80. encoder.co.uk

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The one-year IOA Diploma in Acoustics and Noise Control includes the General Principles of Acoustics, Laboratory and Experimental Methods, a project and two specialist modules chosen from:

Established for more than 50 years, the Institute provides graduates and those with a proven interest in acoustics the chance to become a recognised member of a vibrant and active global network with regular UK meetings and CPD.

• Building Acoustics • Regulation and Assessment of Noise • Environmental Noise: Measurement, Prediction and Control • Noise and Vibration Control Engineering

The Diploma is taught to candidates in centres across the UK and via distance learning tutorials, also facilitating candidates abroad. Find out more at: www.ioa.org.uk/education-training

FOR MORE INFORMATION: www.ioa.org.uk E: education@ioa.org.uk T: +44 (0)300 999 9675 Institute of Acoustics, Silbury Court, 406 Silbury Boulevard, Milton Keynes MK9 2AF

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03/04/2025 15:44

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MACHINE BUILDING

Level Up Your Safety STOBER has developed the SX6 safety module specifically for use with its SC6 and SI6 drive controllers, adding numerous safety features to the range of functions of the two 6th generation devices. Martin Preece, Head of STOBER’s UK Subsidiary, details the benefits.

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he 6th generation range offers powerful drive controllers for high-efficiency, multi-axis applications. It includes the compact SC6 stand-alone device as well as the SI6, which eliminates the need for redundant power supply units thanks to a central supply module and was designed for controller-based applications in multi-axis drive systems.

The SX6 safety module represents a brand-new addition to the range and can be equipped as an option for both series. It is suitable for safety-related applications up to SIL 3, PL e (category 4) in accordance with DIN 61800-5-2 or DIN EN ISO 13849-1. The SX6 enables the conventional Safe Torque Off (STO), Safe Stop 1 (SS1) and Safe Stop 2 (SS2) stop functions.

A specific highlight is that the STO safety function can also be activated individually for each axis on multi-axis controllers. The SX6 also features Safely-Limited Speed (SLS) and Safe Speed Range (SSR), Safe Direction (SDI), Safely-Limited Increment (SLI) and Safe Operating Stop (SOS).

As Martin Preece explains: “We have developed the SX6 safety module in

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close collaboration with safe automation technology specialists Pilz GmbH & Co. “To enhance the productivity and availability of the machine, we have broadened the monitoring systems for safety functions beyond the fundamental standardised requirements.”

Martin continues: “Through positionbased limit value monitoring and the proactive suppression of interference signals, we can achieve the desired limit values with minimal disruption.

“Featuring a consistent two-channel structure, the SX6 tests the integrated components upon every device start-up, after every STO and during operation. This eliminates cyclical function tests of safety functions that are subject to documentation at the end-customer‘s location.”

STOBER has also revised the switchoff channels of the STO and SS1 stop functions. At five and six milliseconds, respectively, they have become significantly faster. These short-worst- case response times, minimised safety distances and, above all, fast restoration of availability significantly reduce downtimes for customers and thus increase system availability.

SX6 is controlled via EtherCAT. This is based on the secure Safety-over-EtherCAT protocol (Fail Safe over EtherCAT, FSoE).

The benefits at a glance • FsoE Certified Product • Extended safety functions up to SIL 3, PLe, category 4 • Compatible with SC6 and SI6 drive controllers • No safety encoder necessary • Free selection of motors and cables • Elimination of standstill or speed monitors • Straightforward project configuration and commissioning • Simple, quick service concept Martin concludes: “What’s more, no special motors, encoders, cables or standstill or speed monitors are required to operate the SX6. When servicing is required, companies can use an SD card as a data storage device to transfer an existing safety configuration to other controllers quickly and easily. It represents a new level of safety for a wide variety of industries and applications.” stober.co.uk

www.mepca-engineering.com

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MACHINE BUILDING

Your Partner in Machine Vision Lighting Introducing TPL Vision, manufacturer of high-performance LED lighting for machine vision systems in industrial settings. With a track record of innovation and award-winning solutions, the company has established itself as a global expert in machine vision illumination.

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PL Visions product’s support applications like sorting, pickand-place, quality control, code reading, and presence/ absence detection. In addition to their exceptional quality, its modular lighting designs simplify product selection, enabling users to fine-tune their illumination output for optimal results.

The company operates from two strategic location: a Supply Chain and Manufacturing Centre in La Chevrolière, France, and a Sales and Design Office in Perth, UK. This allows it to combine European manufacturing excellence with close customer support and product innovation.

Lighting is crucial in machine vision systems for industrial automation, directly impacting the accuracy of inspections, measurements and quality control.

Proper lighting ensures consistent, highquality images and minimises reflections or shadows, with options like diffuse, directional, or collimated lighting to suit different applications.

TPL Vision’s diverse range of LED lighting solutions are tailored to real-world machine vision tasks. Its products, including polarised, modular, and high-output models, enhance image quality and support industries like automotive, robotics, food packaging, and pharmaceuticals. With precise control over light intensity, angle, and wavelength, these systems ensure accurate, repeatable results for tasks like defect detection and object recognition.

The company offer both standard lighting products and fully customised OEM solutions. Whether customers are looking for off-the-shelf solutions or co-developed, application-specific designs, TPL Vision has the flexibility and expertise to deliver. Its OEM collaborations often include tailored optics, mechanical designs, and communication

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interfaces to integrate perfectly into a customer’s system architecture.

TPL Vision’s lighting solutions are used in a variety of industries—from automotive assembly lines to sterile pharmaceutical production. Each sector presents its own unique challenges: automotive manufacturing demands micron-level precision, while food packaging requires strict hygiene and inspection under variable surfaces and materials. TPL Vision delivers targeted, high-efficiency illumination for improving visual clarity, enhancing system reliability, and ultimately helping businesses reduce errors and ensure consistent product quality.

At the heart of TPL Vision is a commitment to expert technical support. The company’s experienced team works closely with customers to identify and recommend the ideal lighting solution for every project; from initial concept to final implementation, their customised guidance, feasibility analysis, and hands-on consultation maximises the performance of machine vision systems.

To match the lighting solution perfectly to the application, TPL Vision offers free material loans and in-house feasibility testing.

Since many vision systems can only be optimised under real-world conditions, this allows customers to test equipment in their environment before making a final decision.

TPL Vision also offer a free loan service for standard products, allowing customers to evaluate the ideal lighting solution for their application without upfront investment. This trial-based approach ensures performance, compatibility and application fit before purchase.

Using TPL Visions dedicated feasibility lab, customers can send samples for its skilled application engineers to assess. The results are documented with high-resolution sample images and detailed technical recommendations. If the suggested solution meets the application’s goals, customers can then request a loan unit to validate performance on-site before making a purchase.

In conclusion, lighting is not just a supporting element in machine vision—it is a key enabler of accurate, consistent and reliable system performance. TPL Vision is dedicated to delivering high-quality, flexible and future-ready LED lighting solutions that boost productivity and precision across all sectors. With locations in France and the UK, TPL Vision utilises its blend of standard products and bespoke OEM offerings, and its technical expertise, to help customers unlock the full potential of their machine vision systems. tpl-vision.com

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MACHINE BUILDING

Compactness is Key for System Integrators Precision measurement and control instruments are crucial for optimising and maintaining machinery. Bronkhorst High-Tech, the low-flow specialist, provides insights on the many applications of flow meters and controllers.

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riginal Equipment Manufacturers (OEMs) and machine builders rely on high-quality components to ensure their equipment performs optimally. One such critical component is the flow meter and controller, which plays a vital role in various applications. Bronkhorst High-Tech, a leading supplier of low-flow measurement and control solutions, has been providing these essential components for over 40 years. Here, it shares some of the use cases of this versatile technology.

In the analytical market, flow meters and controllers are used in gas chromatography (GC), high-performance liquid chromatography (HPLC), and mass spectrometry (MS) systems. These instruments ensure accurate and fast response flow measurements, which are crucial for the precise analysis of samples.

For instance, in GC systems, mass flow controllers help create stable gas mixtures for calibrating chromatographs. Similarly, in HPLC and MS applications, flow controllers provide reliable and reproducible flow control, enhancing the performance of these analytical instruments.

In the bioprocessing and bioreactor market, these instruments are used to control the flow of gases and liquids in bioreactors. Accurate flow control is essential for maintaining optimal conditions for cell growth and product formation. Mass flow controllers ensure precise dosing of gases like oxygen and carbon dioxide, which are critical for the bioprocessing environment.

This application highlights the importance of reliable flow control in achieving consistent and high-quality bioprocessing outcomes.

In the semiconductor fabrication industry, flow meters and controllers are often integrated into load ports and used for the

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Series of flow controllers inside a gas cabinet

replacement of bubbler systems. These instruments provide stable and accurate flow control of gases like nitrogen, which is essential for maintaining the purity and quality of semiconductor wafers. Compact and cost-effective solutions are highly valued in this industry, where precision and reliability are paramount.

In the food and beverage industry, flow controllers are used for the precise dosage of liquid additives. For example, in the production of beverages, ice cream and chocolate, accurate dosing of flavourings and preservatives is crucial for ensuring consistent product quality. Mass flow controllers provide the necessary precision and reliability for these applications, making them a trusted partner for OEMs in the food and beverage sector.

As demonstrated above, flow meters and

controllers are indispensable components in the machine building industry. By integrating flow measurement and control devices, machine builders can enhance the precision, reliability, and efficiency of their equipment, ultimately contributing to the success of their operations.

Bronkhorst’s reputation for reliable products, compact design, and cocreation approach sets them apart in the OEM market. In addition to their standard instruments, Bronkhorst offers tailor-made ‘specials’ for system integration applications.

This flexibility allows OEMs to achieve compactness and cost reduction, which are key factors in their business. Bronkhorst’s expertise and innovative solutions have made them a trusted supplier for OEMs and machine builders worldwide. bronkhorst.com

ROBOTICS

KUKA to Showcase Cutting-edge Robotics KUKA Robotics, a global leader in intelligent industrial automation, is set to make a major impact at Automation UK 2025 (Coventry Building Society Arena on 7-8 May 2025), one of the UK’s premier events for the manufacturing industry, with its cutting-edge robotics and automation solutions.

K

UKA is inviting industry professionals to experience the very best in robotic automation, software innovation and customer service by visiting stands A80 and E90 at this year’s Automation UK event.

With over 125 years of engineering experience and expertise, KUKA continues to redefine industrial automation, offering manufacturers a wide range of cost-effective solutions. Visitors to the Automation UK show will have the opportunity to explore the company’s full portfolio of high-performance industrial robots, and an extensive suite of software and digital tools that support seamless automation integration.

KUKA’s presence at Automation UK 2025 will focus on how its advanced technologies help manufacturers across all sectors to boost efficiency, enhance product quality, reduce operational costs, and ultimately increase profitability – making automation accessible, scalable and future-proof.

A complete automation ecosystem At the heart of KUKA’s stand (A80) will be a display of its portfolio of latest-generation industrial robots, showcasing the precision, speed and adaptability that modern production lines demand. From compact six-axis models ideal for intricate assembly tasks, to heavy-duty robots capable of handling large payloads, KUKA’s hardware reflects the company’s commitment to quality and versatility.

Complementing its impressive robot hardware, KUKA will also showcase its my.KUKA online customer portal, and demonstrate the iiQoT remote condition monitoring and KUKA.Sim simulation

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software platforms, among others. Available via the KUKA digital sphere, these software tools allow for intuitive programming, simulation, and integration, reducing commissioning time and providing real-time performance insights that drive smarter decision-making on the factory floor.

Visitors can also see a live demonstration and explore KUKA’s autonomous mobile robotics (AMR) solutions on Stand E90.

Learn how these advanced AMRs and supporting software are transforming intralogistics by enabling flexible, intelligent material transport within complex production environments.

Expert industry insights In addition to the live exhibits, KUKA will also contribute to the show’s educational programme with two seminar sessions led

by Kevin Kolkea, one of the company’s leading robotics experts.

On day one, Kolkea will explore how robotic systems are revolutionising joining applications such as welding, gluing and riveting. Attendees will gain insight into how advanced robotics can improve consistency, quality and throughput in joining processes, while reducing waste and manual labour challenges.

In his session on day two, Kolkea will provide a deep dive into the latest developments in robotic arc welding. From sensor-guided automation to AI-driven optimisation, he will outline key innovations that are shaping the future of welding in high-precision manufacturing environments.

Both sessions are ideal for engineers, production managers, and decision-makers looking to stay ahead of the curve in their automation strategies, whether experienced or new to robotics.

Enjoy KUKA hospitality on stand A80 KUKA Robotics is proud to be part of Automation UK 2025 and looks forward to connecting with industry professionals from across the UK and beyond. Whether you’re at the beginning of your automation journey or looking to take your operations to the next level, KUKA’s team will be on hand to discuss your unique challenges and demonstrate tailored solutions that deliver real-world results.

Don’t miss the chance to explore KUKA’s state-of-the-art robotic technology, engage with industry experts, and be inspired by the future of automation. Register now for Automation UK 2025 and ensure you visit KUKA on stands A80 and E90.

For more information and to register for the exhibition, visit the event’s website; to make an appointment with a KUKA automation specialist, go to the company’s website. automation-uk.co.uk kuka.com/en-gb/company/kukalocations

Keeping your production flowing

Visit us on Stands A80 &E90

www.kuka.com/products/amr-autonomous-mobile-robotics

See the full range of KUKA industrial robots, Autonomous Mobile Robots (AMRs), software & digital tools demos, and meet our expert team at Automation UK on Stands A80 & E90 KUKA AMR ad - Apr25_AUK.indd 1

KUKA Robotics UK Ltd T: +44(0)121 505 9970 E: info-uk@kuka.com www.kuka.com

09/04/2025 19:22:28

ROBOTICS

Game-changing Cheese Facility Automation Endoline Robotics has transformed operations at a major UK cheese processing plant with the installation of a £1.27 million fully automated case packing and palletising line—delivering a robust solution to ongoing staffing shortages, extreme working conditions, and rising production demands.

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aced with the challenge of maintaining high output in a cold, labour-intensive environment, the cheese processor partnered with Endoline to overhaul its end-of-line operation. Within the site’s existing 21 m x 11.5 m footprint, Endoline designed and installed a compact, high-performance system that modernised processes without the need for expansion. Crucially, the installation was two-phased, allowing uninterrupted production.

The impact has been significant – replacing the repetitive manual tasks previously carried out by over nine operators while delivering a sharp increase in performance and productivity. Workforce safety and morale improved dramatically, and the system also introduced a new level of precision and consistency to every packed case of cheese.

Supplying over 100,000 tonnes of grated cheese annually to wholesalers, food service operators, and pizza chains, the company had long faced challenges in retaining staff due to the physical demands of the job and the plant’s constant 5°C environment.

Precision engineering in a compact space Previously reliant on a manual Lazy Susanstyle packing station, the site was hindered by slow throughput and frequent product damage. Manual handling of gas-flushed pillow packs often led to nitrogen leaks, inconsistent stacking, and high return rates.

Endoline Robotics delivered a fully integrated, high-speed automated line within the tight constraints of the existing layout.

Every centimetre of space was maximised to accommodate a sophisticated setup

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that includes three Endoline fully automatic case erectors, three FANUC Delta robots with rotating PIAB vacuum grippers, three Endoline case sealers, three labelling stations, three checkweighers, and an integrated stretch wrapper and pallet labeller.

A central multi-tasking FANUC M-410-iC robot manages palletising across all three lines.

Using barcode scanners and rising pallet stacks to determine position, the robot efficiently services three pallet stations. This smart motion planning has saved valuable space and equipment costs while cutting 5–6 seconds off every pallet changeover cycle, boosting efficiency.

Delicate handling, highspeed throughput Cheese pillow packs, ranging from 1kg to 6kg, are conveyed via multi-level systems from production to the loading cell. At the infeed, Endoline’s automatic case erectors prepare each case before the Delta robots take over.

Designed for chilled environments, the robots’ rotating suction-cup end effectors delicately rotate each pack 90° and place them into consistent formations. This smooth, controlled motion has eliminated pack ruptures, significantly reducing waste.

Filled cases are sealed and labelled using a GSI1-compliant Markem-Imaje print-andapply system, checkweighed, and passed to the palletising zone via a central trunk conveyor.

Operating six days a week, 24 hours a day, the system processes up to eight cases

per minute per line—delivering a high-speed, hands-free end-of-line solution.

Built for the future With capacity to process and palletise up to 28,800 product cases every 24 hours—more than double the previous manual output— the facility has become a benchmark for cold-environment automation. Each case is handled with repeatable precision, while overall throughput and quality assurance have reached new heights.

Beyond speed and efficiency, automation has delivered lasting operational resilience.

Packing bottlenecks have been eliminated, and former manual staff have been reallocated to higher-value roles, reducing cold exposure and improving morale.

Andrew Yates, Managing Director of Endoline Automation, commented: “This installation is a true reflection of Endoline’s engineering expertise—designing a highly efficient, fully automated solution that not only meets the challenges of operating in cold environments but also maximises every inch of available space. It’s a smart, innovative setup that’s enabling our customer to work more productively than ever within a compact footprint.” endoline-robotics.com

Complete end-of-line automation solution provider.

Endoline specialise in the design, manufacture and installation of high quality end-of-line packaging machinery.

• Case Erecting • Case Packing • Case Sealing • Palletising

www.endoline-robotics.com +44 (0)1767 316422 sales@endoline-robtics.com

MANUFACTURING SOFTWARE

Smarter Purchasing and Inventory Tracking In the following case study, an industrial cleaning equipment manufacturer demonstrates how implementing the right Enterprise Resource Planning (ERP) software resulted in significant operational improvements.

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fter a disastrous experience with their first software, Arcus Cleaning Systems found the perfect solution for managing their operations. “MRPeasy has been brilliant for us,” says Ryan Brogan, Director.

The tipping point came when a stock system update wiped out months of data, leaving the team frustrated and without recourse.

“We spent weeks trying to recover the information,” Ryan says. “It was a costly and stressful experience.”

Industrial cleaning solutions for niche markets

Finding the right solution

Arcus Cleaning Systems is a manufacturer and supplier of industrial cleaning equipment, based in Lisburn, Northern Ireland. Established in 2019 by brothers Ryan and Conor Brogan, the company focuses on creating tailored solutions for industries with specific cleaning needs.

Their portfolio includes tank and container cleaning systems designed to handle anything from 25-litre drums to 1,000-litre intermediate bulk containers (IBCs).

In the early years, the brothers relied on manual systems to manage the operation.

Excel spreadsheets were used to track BOMs (Bill of Materials) and inventory levels while flagged emails served as a makeshift procurement system. However, as the company expanded, these manual processes became cumbersome and prone to errors.

“We knew from the start that we wanted an MRP system,” Ryan shares. “But finding one that suited our company size and budget was a challenge.”

Disastrous experience with the wrong system Arcus first implemented a system renowned for its simplicity and affordability, but it fell short in key areas. “Its functionality was too rigid,” Ryan recalls. “We assumed it would adapt to our operations, but it was quite the opposite.”

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After the debacle, Ryan and his team found an alternative: MRPeasy. The software’s positive reviews and modular design convinced them to try it.

“MRPeasy stood out because it was scalable and straightforward,” Ryan notes.

“It had all the core functionalities we needed without the unnecessary complexity of larger systems.

The implementation process, which included data migration, SOP development, and staff training, took five to six months.

Despite balancing the setup with day-to-day operations, the team found the process straightforward.

“Compared to our previous experience, MRPeasy was night and day,” Ryan remarks. “The support team was responsive and genuinely helpful. Every issue we raised was resolved quickly and accurately.”

Huge improvements in purchasing and inventory tracking Since adopting MRPeasy, the company has seen dramatic improvements across multiple areas of their business.

“Our purchasing is completely transformed,” Ryan explains. “We no longer rely on flagged emails or manual updates.

Requirements come up at the right time based on supplier lead times, and we can create purchase orders directly from those requirements. We review pending POs each

week, check if deliveries have arrived on time, and follow up with suppliers if needed.

It’s a huge improvement.”

MRPeasy has also eliminated the reliance on spreadsheets for inventory tracking. The system’s real-time updates ensure that stock levels are always accurate and aging stock is identified and prioritised for sales.

“It’s easy to manage FIFO stock rotation now, ensuring we use the oldest inventory first,” Ryan says.

Software has given the company confidence From a wider perspective, the system provides Arcus with comprehensive insights into their operations, from project profitability to lead time accuracy.

“We can track every project stage, see our profit per project, identify delays, and adjust processes as needed. The ability to track profitability has been especially important, allowing us to make incremental improvements and increase margins,” Ryan explains.

According to Ryan, MRPeasy has given their team confidence in their processes: “It’s streamlined everything from purchasing to production, allowing us to focus on innovation and customer satisfaction.” mrpeasy.com

HEALTH & SAFETY

Renewables-powered Safety Manufacturers In the following Q&A, Sarah Mlundira – Global Head of Technical Department at Castell Safety International, part of the Sentric Safety Group – addresses safety in the OEM market, explains Castell’s sustainability ambitions, and highlights opportunities for improving safety within the industry.

In the rapidly growing OEM market, safety is a high priority. What advice does Castell, and the Sentric Safety Group, have for OEMs that are reviewing their current safety protocols?

For OEMs, embedding safety into product design from the outset is crucial. Our key advice is to adopt a proactive rather than reactive approach. This means integrating certified, future-proof safety solutions that not only comply with current regulations but also anticipate evolving industry standards.

Collaborating with experienced safety partners like us ensures that safety systems are not just an add-on but a fundamental part of the machinery’s functionality.

Additionally, embracing modular and scalable safety solutions will help OEMs maintain flexibility as automation and regulatory landscapes evolve. A comprehensive risk assessment and regular safety audits should also be a core part of their ongoing safety strategy.

We also encourage OEMs to implement a trapped key interlocking system, as it can offer a significant advantage by demonstrating to end-customers that safety is a top priority. This added layer of protection helps reduce the risk of human error.

In 2023, Castell and the Sentric Safety Group joined WindEurope, further demonstrating its commitment to sustainability. What are the Sentric Safety Group’s sustainability ambitions for 2025 and beyond?

Our commitment to sustainability is

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deeply embedded in our mission to create safer workplaces while minimising environmental impact. We are continuously working to enhance the sustainability of our manufacturing processes, reduce our carbon footprint, and increase the use of recyclable and sustainable materials in our safety solutions. Currently, our operations at Castell are powered by 100% renewable electricity, with 44% selfgenerated by 322 solar panels installed on site. We have achieved 99% LED lighting coverage across our facilities, significantly improving energy efficiency. Recent upgrades to our boilers, air conditioning, and heating systems have led to a 35% reduction in on-site energy consumption.

We also ensure that our general waste is diverted from landfill through incineration, which is converted into renewable electricity, and we work with certified commercial waste collectors to recycle paper, cardboard, wood, and metal. To further our environmental goals, we are installing EV chargers across our car parks and are committed to transitioning our entire fleet to electric or hybrid vehicles.

As part of our forward-looking vision, we are investing in the development of energyefficient safety systems that align with the renewable energy sector’s objectives. Our involvement with WindEurope underscores this commitment, supporting the safe and sustainable operation of wind farms and other renewable energy facilities, and helping to ensure a safer, greener future for all.

Of all the industries that Castell and the Sentric Safety Group regularly provide safety solutions to, which industry shows the greatest opportunity for improvement, and what are the challenges?

While all industries benefit from continuous safety enhancements, the recycling and waste management sector presents unique challenges and opportunities. With the rise of automation, increased material volumes, and evolving environmental regulations, it’s more important than ever to prioritise effective safety measures. By adopting interlocking systems and conducting thorough risk assessments, facilities can strengthen their safety culture, reduce the likelihood of incidents, and support more efficient, reliable operations across the sector. sentricsafetygroup.com

NO COMPROMISE ON SAFETY The Sentric Safety Group unites the world’s leading safety brands to create the long-term protection of people, productivity, and business reputation

Learn about our safety solutions in the energy and industry sectors on our website

www.sentricsafetygroup.com

HEALTH & SAFETY

Dedicated to Industrial Safety Despite evolving standards of safety, industrial sites remain among the most hazardous work environments. Fortunately, there are those committed to site safety. Here, MEPCA speaks to James Ward, Project Engineer at Frontline Safety, on the benefits of fixed detection systems and more.

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ames has worked in industrial safety for 20 years and has gained extensive experience in delivering gas and fire safety solutions worldwide, in often challenging environments. In many ways, he exemplifies Frontline Safety’s approach – bringing expert experience to bear on any given safety application.

What are the key advantages of fixed gas detection systems compared to portable detectors?

I would say you use those two elements in conjunction with one another, and you look for the benefits of both, as opposed to saying that one is definitely advantageous over the other.

However, with a fixed system, once it’s up and running, it is running 24-7. It doesn’t need any manual input. You don’t need to change a battery or recharge a unit. A fixed system is constantly keeping that plant and those people safe. And if it’s a plant-wide system, an alarm can be enunciated through the entire plant to other control systems that increase the fan speed or shutdown particular equipment. It is not as easy to do that with portable equipment.

A fixed system also enables a series of engineering controls to be put in place before you send anybody into hazardous situation, or if somebody were to bypass the confined space entry rules, they might find themselves in a situation where they’re entering a space that has a potentially harmful mix of gases in it. If you have the opportunity to fit a fixed system within that space, you avoid a situation where somebody would be entering an

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environment without prior knowledge the hazards.

How does Frontline Safety help manufacturers enhance their gas safety strategies across automated and industrial environments?

When Frontline Safety work with a manufacturer within their environment, it comes down to the wealth of experience we have to draw on. I am just one of a number of engineers who have similar levels of experience across slightly different industries.

It’s the knowledge needed to move forward through a project, at whatever stage of the project we become involved; whether it’s the initial kind of site survey or audits of old systems, whether it’s looking at designing new systems or upgrades, or testing systems, or commissioning new systems. We’ve got engineers who’ve been in the industry long enough to have seen those problems, and who understand the benefits of the products on the market and how they would suit that specific application.

We’re here as engineers, to solve the problem however it needs to be solved.

Why should manufacturers trust Frontline Safety as their fixed gas detection partner?

Frontline Safety is not tied to one specific manufacturer. We’re here to deliver a

solution, as engineers, to the problem irrespective of whether gas detection technology is from manufacturer A or manufacturer B. We provide solutions that combine the technologies that are available with depth and breadth of our experience.

We did some work a few years ago to identify the core values of Frontline Safety.

We use the word EPIC to summarise our core values. It stands for empowerment, pursuit of excellence, integrity and commitment. It really encompasses what we’re trying to do as a company. It’s easy to be swayed by corporate slogans, but there is a lot of integrity and honesty in it.

Any tradesperson has pride in their work, but if you’re in the safety industry, you’ll have a pride in keeping people safe and that expectation and your own personal goals and targets to do that are forthright in what you do all the time. frontline-safety.co.uk

MATERIALS HANDLING

The Fastest Way to Workflow Efficiency In manufacturing, every second counts – and downtime counts ten times as much. DMNWESTINGHOUSE, a supplier of rotary valves and diverter valves, explains how emerging technology is making speed the new standard in servicing.

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MN-WESTINGHOUSE has been a trusted supplier of rotary valves and diverter valves for a large range of dry bulk solids processing industries for decades. True to the company’s promise to provide future-proof value, its experts continue monitoring the performance of its products in practice, including in the context of customer feedback and emerging new technologies and practices.

Such new technologies offer new possibilities – and it is this potential to update and improve that eventually culminated in the launch of the PTD plug diverter valve in the first quarter of 2025.

The PTD does away with hours and hours of service time – and that translates to more uptime and reduced expenses. With the PTD plug diverter valve, servicing is quick and effective, resulting in a seamless, glue-free experience that makes workflow faster than ever.

Meet the PTD plug diverter valve The PTD plug diverter valve is especially designed to route powders and pellets in pneumatic conveying systems with minimum degradation. Precision machining, proper sealing and an obstruction-free internal geometry guarantee a smooth passage of product.

The user-friendly, foolproof design enables quick on-site internal examination, servicing, and – when necessary – replacement of seals. The PTD design features no moving parts on the outside and complies with all current guidelines regarding safety in the workplace.

The PTD plug diverter valve at a glance • Aluminium housing and end covers,

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installed with a dual-pipe plug (two-channel design) • All product contact surfaces are stainless steel AISI 316/DIN 1.4404 • No moving parts on the outside • Three FDA and EC 1935/2004-compliant silicone belly seals guarantee the sealing between housing and plug • Pressure-tight body, ensuring no atmospheric leakage • Fitted with static belly seals, the standard PTD is suitable for systems with positive pressures up to 3 barg • Fitted with inflatable belly seals, the PTD is suitable for systems with positive pressures up to 6 barg • Pressure shock resistant up to 10 barg1 • The PTD with static belly seals is standard supplied with solenoid valve and inductive position sensors. As an option, a terminal box, can be selected • The PTD with inflatable belly seals is supplied with a complete electro-pneumatic control system, including solenoids, terminal box and inductive position sensors • The standard diverter is suitable for product temperatures ranging from -25 to 80°C at ambient temperatures of -10 to 40°C. Versions suitable for higher temperatures are available on request • Versions with electrical drive and/or wearresistant pipes available • EC 1935/2004 compliant • ATEX 2014/34/EU certification available The PTD plug diverter valve is suitable for a range of dry bulk solids processing industries: Aquaculture, Animal feed, (EV)

Batteries, Biomass, (Petro) Chemicals, Cosmetics, Dairy, Food, Infant formula, Minerals, Paint, Pet food, Pharmaceuticals, Plastics, Recycling, and Rubber.

Benefits of the PTD plug diverter valve A selection of the improved, value adding properties of the PTD: • Easy, two-sided access – service the diverter from the most convenient side • Glue-free belly seals • Quick-connection position sensors • Easy-release actuator linkage • Reinforced jacking points • Minimal service required

Conclusion The PTD plug diverter valve exemplifies DMN-WESTINGHOUSE’s commitment to providing the world of dry bulk solids handling with future-proof value. Applicable for a range of industries, the PTD slashes servicing time significantly, while offering unparalleled ease of use. The PTD plug diverter valve offers the fastest way to efficiency. dmnwestinghouse.com Size 200 excluded

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MATERIALS HANDLING

Shaping the Future of Bulk Processing In today’s fast-evolving industrial landscape, the demand for smarter, safer and more adaptable material handling systems is at an all-time high. Read on to discover how turnkey material handling systems are revolutionising bulk processing in manufacturing.

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rom pharmaceuticals to food production, manufacturers face constant pressure to improve efficiency, meet stringent regulatory standards, and reduce manual intervention—all while maintaining operational flexibility.

One solution gaining traction is the adoption of turnkey material handling systems: fully integrated, custom-engineered solutions designed to meet the precise needs of each production environment.

These systems go beyond equipment supply—they encompass design, installation, support, and optimisation from concept to completion.

Traditional, one-size-fits-all machinery often struggles in environments where space, product integrity, and hygiene are critical. Customised turnkey systems address these challenges by aligning seamlessly with a facility’s layout, compliance requirements, and throughput goals.

Key benefits include: • Tailored design to operational flow, product type and space constraints • Compliance with sector-specific standards • Reduced downtime through smoother integration and long-term support • Improved safety and ergonomics, minimising manual handling and exposure risks As the industry pivots toward more automated and accountable processes, the choice of partner becomes just as critical as the systems themselves. Many manufacturers are turning to companies such as Summit Dynamic Solutions – known for delivering highly engineered material handling systems that align with the realities of modern production.

Dynamic Solutions, based in Tamworth, UK and supported by engineers across the UK and Ireland, has established itself as a go-to partner for organisations seeking precisionbuilt, turnkey handling systems. It serves a wide range of industries—including food, pharma, plastics, rubber, chemicals, and automotive.

The company’s methodology reflects a consultative, problem-solving mind-set. As part of this, Summit provide in-depth site assessments and material flow analysis and bespoke system design for compliance, safety and throughput. What’s more, Summit’s local installation teams deliver minimal disruption and seamless integration.

The company’s portfolio includes ergonomic “rip & tip” stations for safe and efficient manual unloading; mechanical and pneumatic conveyors, tailored to specific material properties and hygiene levels; engineered storage solutions such as hoppers, silos, and day bins with features like level alarms and gravity-fed discharge.

A partner-led approach

One of the most overlooked aspects of turnkey system design is what happens

With over 35 years of experience, Summit

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Essential for quality and compliance Beyond transportation, maintaining material quality through effective storage and separation is critical. Summit addresses this with: sieving and dedusting systems that preserve product purity; dust control and containment features for cleaner, safer environments; and designs that support traceability and reduce product loss.

These systems are engineered with a deep understanding of operational risks and built to meet or exceed global regulatory standards.

Support, sustainability and long-term value

after installation. Summit sets itself apart with robust after-sales support, offering on-site training and maintenance, system refurbishments and upgrades, and responsive technical support packages.

This long-term partnership model not only reduces total cost of ownership but also supports sustainability goals through better system longevity and reduced waste.

As the global manufacturing sector continues to pursue cleaner, leaner, and more agile operations, companies increasingly need partners who bring not just machinery—but expertise, collaboration, and a shared commitment to operational excellence.

Whether scaling production, modernising legacy equipment, or building a facility from the ground up, the shift toward customised, integrated material handling systems represents a broader evolution in industrial operations—one that prioritises flexibility, compliance and long-term performance.

In that landscape, Summit Dynamic Solutions has earned its place as a partner of choice—combining engineering expertise with hands-on experience to help manufacturers meet today’s demands and tomorrow’s ambitions. summitdynamicsolutions.co.uk

ENCLOSURES

Innovations in Enclosure Cooling Systems Introducing STEGO’s Filter Fan Plus series. By rethinking traditional fan systems, STEGO engineers have introduced tangible benefits that enhance efficiency, safety and user experience.

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nnovation often starts with refining what already works. This philosophy guided the development of the STEGO Filter Fan Plus series—an advanced cooling solution designed to optimise air performance in control cabinets.

Three key advantages of the Filter Fan Plus Series: • Air-Flap Technology – maximizes air capacity while ensuring superior protection.

• Twist-Lock System – enables quick, toolfree installation.

• Flexible Airflow Direction – direction of airflow can be IN or OUT

Revolutionising airflow with flap technology Traditional filter fans rely on filter mats to prevent dust intrusion, but these mats also restrict airflow. STEGO’s innovative approach removes the need for filter mats in air-expelling components, significantly increasing air exchange efficiency. The introduction of flap technology ensures unobstructed airflow while protecting the enclosure from dust and debris. When the fan is inactive, the flaps close automatically, safeguarding the interior.

This improvement enhances cooling performance without modifying existing mounting cut-outs or increasing fan capacity.

The result? Smarter, more efficient air circulation.

Seamless Installation with the Twist-Lock System User experience was a priority in the Filter Fan Plus series. With a six-level twist-lock mechanism, the fan secures into a recess from the outside, no tools required. This intuitive design allows technicians to achieve a stable installation with a simple twist and click. The system is compatible with wall

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thicknesses from 1 to 4 mm, making it a versatile solution for various cabinet designs.

Customisable airflow: IN or OUT? Enclosure cooling follows two principles: drawing cool air in (IN) or expelling warm air out (OUT). STEGO provides both configurations:

Airflow direction IN Opting for a classic design brings us to the FPI system of STEGO filter fans. This is the most recognised method: the filter fan with a filter mat is placed at the bottom and draws outside air into the enclosure. The air rises, cools the inside of the enclosure and forces the warm inside air out of the air outlet. The flap technology allows the warm air to be expelled outwards unimpeded (Fig 1).

Fig 1

Airflow direction OUT For applications that require trapped heat released from a panel or enclosure faster, STEGO recommends actively expelling the heat using the FPO system. To achieve this, the fan is placed towards the top of the control cabinet and combined with effective flap technology. This way, the heat dissipates faster from this critical area. At the bottom of the control cabinet, an entry filter with a filter mat is required to bring in cool air from outside (Fig 2).

Filter fans remain one of the most effective methods for cooling control enclosure, and the Filter Fan Plus series takes this concept to the next level. With increased airflow, enhanced safety features, and reduced maintenance costs, this system delivers performance and reliability. Independent certifications from VDE and UL attest to its compliance with rigorous safety standards.

When paired with a hose-proof hood accessory, the Filter Fan Plus series achieves an IP56 protection rating, reinforcing its

Fig 2

resilience against dust and moisture. By minimizing filter replacements, this solution improves efficiency and reduces operational costs.

With its blend of innovation, performance and practicality, the Filter Fan Plus series sets a new benchmark for enclosure cooling, ensuring optimal conditions with minimal effort. stego-group.com

MADE TO MEASURE Smart Current Sensor ESS 076 Measuring electricity digitally and in real time.

ESS 076 sensors help to increase the energy efficiency of industrial systems.

www.stego-group.com

FLOW CHEMISTRY

The Secret to Green Chemistry Mechanochemistry is an important emerging methodology in industrial chemistry, providing both productivity and environmental benefits. WAB-Group, the Flow Chemistry specialist, demystifies mechanochemistry and introduces a range of products that use it to great effect.

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he Beckmann Rearrangement (BKR method) is a wellestablished and effective process in organic chemistry.

BKR is the acid-induced rearrangement of oximes to produce amides, utilised for incorporating nitrogen atoms into a wide range of chemical structures, including for the synthesis of Acetaminophen, better known under the brand name Paracetamol, among many other common pharmaceuticals.

However, the traditional BKR method’s reliance on toxic solvents, inefficient energy consumption, excessive waste, in the form of ammonium sulphate, and sub-optimal yields.

Introducing mechanochemistry. By no means a new concept, with documentation of its use dating back to 314 B.C.1, mechanochemical reactions are understood to be “chemical transformations initiated or sustained by mechanical force”2.

Mechanochemistry is considered to be a major factor in the chemical industry’s contribution to the United Nations Goals for Sustainable Development (Agenda 2030)3, as it complies with several Green Chemistry principles.

The main advantages of mechanochemistry: • Possibility of solvent-free reactions • Better mixing of primary materials • Excellent surface renewal of the reactants • Higher productivity • Energy savings • Cost savings • Reactions can take place at lower temperatures In the case of Paracetamol production, BKR is augmented with bead mill technology, which operates on the principles of impact and attrition to break particles into smaller sizes. This reduces

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the requirement for the solvents traditionally used for this purpose, while also increasing overall efficiency and improving yield.

In Flow Chemistry, chemical processes take place in a continuously flowing stream contrary to batch production. This offers several compelling advantages that can be highly beneficial in various industries.

WAB’s product range utilise the latest in mechanochemical technology to enhance the inherent efficiencies of Flow Chemistry, enabling manufacturers to operate both production and research and development practices in a greener, more sustainable way.

WAB mechanchemical reactors WAB’s mechanchemical reactors utilise bead mill technology to optimise chemical reactions. WAB mechanochemical reactors have proven their positive impact to reduce solvents, energy consumption and toxic waste. Powered by novel, patented technology (DYNO®-ACCELERATOR), the reactor improves the conversion, yield and selectivity of the chemical reactions and optimise reaction costs in various application fields, including pharmaceuticals, food & beverage, cosmetics, electro technology, pyrotechnics, and many more.

How it works A mechanochemical reactor with 0.5 litre reaction volume filled with 0.8 mm diameter beads contains more than 800,000 beads.

The high rotational speed of the accelerators

speed-up the beads and create billions of impacts where shock, pressure, shear, friction, impact and torsion apply. These impacts enhance the chemical reaction and create a constant renewal of the surface of the reactants. The high turbulences lead to an excellent mixing, exceptional homogeneity and therefore fast conversion, outstanding yield and selectivity. The residence time is settable and independent from the energy input. This allows the process to be conducted at the optimum operating point.

Crucially, WAB’s solutions scale up from milligrams to tons, providing mechanochemical reactors that are suitable for research and development laboratories, all the way up to production-level. The full range of WAB’s mechanochemical products can be found on its website. wab-group.com/en/ friedheim.co.uk Romain Geib, Evelina Colacino and Ludovic Gremaud: Sustainable Beckmann Rearrangement using Bead-Milling Technology: The Route to Paracetamol. doi.org/10.1002/ cssc.202301921 2 Do, Jean-Louis & Frišcic, Tomislav. Mechanochemistry: A Force of Synthesis. ACS Central Science 2017, 3, 1, 13–19.

3 https://sdgs.un.org/2030agenda 1

SUSTAINABILITY

The Role of Metal Recycling Metal is at the heart of UK manufacturing, forming the backbone of industries from automotive and aerospace to construction and consumer goods. The good news for businesses is that virtually all metals can be recycled into high-quality new materials, as sustainable waste management expert Waste Mission explains.

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ith the UK recycling around 10 million tonnes of metal annually, metal recovery plays a crucial role in driving a circular economy and reducing industrial waste.

With the landfill tax increasing in April 2025, the financial case for recycling is stronger than ever. Metal recycling not only diverts valuable resources from landfill but also aligns with the circular economy principles that are becoming increasingly important in regulatory and consumer landscapes.

Why metal recycling matters Recycling metals offers multiple benefits, from cost savings to reduced environmental impact. According to EU figures, using recycled steel instead of virgin material cuts air pollution by 86%, water use by 40%, and water pollution by 76%. For manufacturers, this means lower raw material costs, reduced carbon footprints, and enhanced sustainability credentials.

Environmental impact Scrap metal recycling is a powerful asset for environmental conservation. It saves energy, minimises the use of natural resources, and reduces CO2 emissions. For instance, recycling copper saves significant energy, requiring just a tenth of the energy needed to extract the source material. Similarly, recycling aluminium can save up to 80% of the energy used to produce it initially.

Economic advantages You can make money from scrap metal by transforming it into valuable resources,

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enabling businesses to generate revenue from materials that might otherwise be discarded. Utilising recycled metals also reduces production costs, helping businesses to stay competitive.

Common metals’ recycling potential Aluminium is one of the most recycled metals globally. Recycled aluminium retains its properties indefinitely and requires just 5% of the energy used in primary production.

Steel is the most widely used metal in the world, with over 3,500 grades available.

Steel is also one of the most recycled materials, with a 98% recovery rate.

Copper is a vital component in electrical wiring, plumbing, and industrial machinery. It is 100% recyclable; 60% of all copper ever mined is still used today.

Brass & Bronze. Used in bearings, gears, and decorative fixtures, these alloys retain their durability and corrosion resistance even after multiple recycling cycles.

Lead is a heavy metal commonly found in batteries, roofing, and radiation shielding.

Due to its toxicity, lead disposal in landfills is illegal, but it remains one of the most efficiently recycled metals.

Partnering with Waste Mission Waste Mission houses many specialist recycling divisions. Its carbide division focuses on recycling carbide by breaking it down into a powder, which can then be used to make new carbide products.

Its WEEE division safely disposes of and recycles unwanted electronics.

Disposing of these items incorrectly can lead to hazardous substances leaking out or potentially releasing toxic substances such

as mercury and cadmium, which can be problematic for human health.

Waste Mission also has a cable recycling division that strips the cables to remove valuable metals, mostly aluminium and copper. These metals are melted down and repurposed into new products.

Why recycle metal?

Deloitte’s ‘2023 Sustainable Consumer’ survey1 revealed that 30% of consumers had stopped buying products due to ethical or sustainability-related concerns. Additionally, almost 63% see circularity as an important buying factor according to Reso Insights.

With the rising demand for eco-friendly products, businesses must answer the dual call of conscience and commerce. By prioritising metal recycling, UK manufacturers play a crucial role in reducing industrial waste, conserving natural resources, and building a future that’s a few shades greener.

Speak to Waste Mission today to book a waste review. wastemission.com deloitte.com/uk/en/Industries/consumer/perspectives/the-

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sustainable-consumer.html

MANUFACTURER OF HIGH QUALITY ANTI VIBRATION PRODUCTS, MOUNTS & BUSHES FOR OVER 70 YEARS

RUBBER ENGINE MOUNTS • PEDESTAL MOUNTS • CAB / CONE MOUNTS • RUBBER BOBBIN MOUNTS RUBBER BUFFERS / RUBBER STOPS • RUBBER BUSHES / SUSPENSION BUSHES • UNIVERSAL MOUNTS • LEVELLING FEET

01282 878200 SALES@FIBET.CO.UK WWW.FIBET.CO.UK

www.mepca-engineering.com

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HVAC

Revolting Against Industry Norms Andrew Jones, the Technical Director at Axair Fans, talks about how Axair have dug deep and put the work in behind the scenes to challenge the status quo of the antiquated fan industry to better serve their customer base.

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’ll be frank, our team have worked their backsides off to ensure we had the tangible evidence to back up what we’ve been saying for months and months. I’ll reiterate quickly for anyone who may have missed previous pieces I’ve shared here. Niche markets dominated by tradition and transactional relationships ruled by industry giants urgently needed for change. So, a year ago, Axair Fans launched our bold and disruptive “We’re Revolting” campaign, not just to capture attention but to champion a fundamental shift in the way industrial fan suppliers engage with their customers, or the other way around. This wasn’t a gimmick or a fleeting marketing stunt; it was, and remains, a declaration of our commitment to redefining what value should look like in this industry.

The Why: breaking the mould of an antiquated fan industry The industrial fan sector has long been rooted in practices that prioritise products over people. At Axair, we’ve always placed an emphasis on people being our greatest assets, but we’ve encountered frustrations from customers who’ve had to navigate complicated processes, insufficient technical support, and a lack of meaningful customer service from other suppliers. The often chose the big industry giants as they feared smaller companies believing they’re not as good, because let’s be honest no one ever got fired for hiring IBM as the saying goes. Yet evidence shows that for decades, the status quo has been characterised by minimal pre-sales engagement with companies, showing a limited understanding of customer specific needs during the buying process, while post-sales is let down by inadequate troubleshooting and follow up support, and a focus on the transaction rather than

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long term partnerships built on trust and customer centric solutions.

We launched “We’re Revolting” to make a clear statement: we’re rejecting this outdated model. More than that, we’re proving that industrial fan supply can, and should, offer more.

The What: a customercentric revolution At the heart of Axair’s core values lies a series of actions that elevate customer experience and redefine supplier accountability. Here’s what we’re revolting against, and what we’re doing instead, from sales-first to solutions-first, from delays to immediate action, from silence to continuous support, from cold interactions to meaningful relationships all neatly packaged in a striking visual with the balls to back it up. Ultimately, it boils down to what we do best; we engineer trust.

The How: transparency and accountability Launching a campaign as audacious as “We’re Revolting” required more than words; it demanded actionable proof that challenging the status quo came with positive benefits for the customer.

Transparency has been one our guiding values for years but recently we’ve made it clear to customers what they can expect from us around enhanced technical expertise, customer centric internal culture, and measurable

outcomes that demonstrate the tangible impact of our approach to you the customer.

Basically, we show our customers that they’re partnering with a team that cares about their success.

While “We’re Revolting” is a bold statement about our mission, it’s also a call to action for the industry as a whole.

Customers deserve more than products; they deserve a partner who understands their challenges and invests in their longterm success. This revolution is a leading movement that will live beyond you all seeing the visuals, it isn’t just about redefining who we are, it’s about reimagining the standards of the entire industrial fan industry. Because when customers trust their suppliers, innovation thrives, efficiency improves, and everyone wins. axair-fans.co.uk

Michael Hambleton (Hambo) National Business Development Manager

You think their pre-sales expertise is bad.

Ours is revolting.

Yes! We got your attention, and you heard us correctly. We’re revolting - changing the rules of the industrial fan game, breaking the mould. Response times that take some companies days, only take us minutes. Pre-sales and after-sales support is based around your needs not theirs. Our job is to empower you to make better fan buying decisions.

So as they say in Stoke, viva la revolution!

Axair. Revolutionary Fan Expertise.

www.axair-fans.co.uk

INDUSTRIAL AUCTIONS

The Evolution of Industrial Auctions Just as the industries it serves evolve, so too must the industrial auction market. Industrial Auctions, an international operating online auctioneer, explains the benefits of embracing this digital revolution in the buying and selling of industrial equipment.

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he industrial auction market has undergone a huge transformation over the years.

Whereas companies used to rely on physical auctions, the rise of online platforms has made trading machinery and equipment more accessible, efficient and transparent worldwide.

From physical auctions to digital trading Traditional (industrial) auctions took place at fixed locations, where buyers and sellers met to trade machinery and equipment. This was a time-consuming process, with high organisational costs and limited access for international buyers. With the introduction of the internet and e-commerce in the 1990s, there was a shift to online auctions, which allowed companies to buy and sell equipment faster and more efficiently.

Industrial Auctions has embraced this digital revolution, offering a sophisticated auction platform where companies worldwide can access a wide range of used machinery. This has not only increased the speed of transactions, but also improved the transparency and reliability of the process.

Advantages of online industrial auctions Moving to online auctions offers numerous advantages for both buyers and sellers.

Among those benefits is accessibility, as companies can participate in auctions worldwide without having to be physically present. This method also enhances efficiency – with today’s advanced communication methods, participants can be quickly informed of new auctions and offers, significantly shortening the lead time and enabling machines to change ownership more rapidly.

Online auctions also enhance

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transparency, as lots come with detailed descriptions, photos and videos, allowing buyers to make informed decisions. Finally, this digital approach can lead to cost savings, as buyers can bid from their own locations without needing to travel to the auction, which can lead to more rational decision-making.

How Industrial Auctions is responding to this evolution Industrial Auctions is an international operating online auctioneer, specialised in the food and beverage industry, and is committed to transparency, reliability and service-oriented. For example, it provides: • Viewing days & detailed machine information – buyers can view detailed photos, videos and descriptions in advance.

Additional information can be requested if required.

• Easy online bidding – through its platform,

companies worldwide can bid on industrial machines without physical limitations.

• Safe & fair bidding process – its auction model offers real-time bidding, clear terms and no hidden costs.

• Full service: from auction to transport – if desired, Industrial Auctions can arrange dismantling, transport and leave (former) production locations broom-clean.

The future of the industrial auction market Industrial Auctions continues to look for improvements so that buyers and sellers can always rely on a user-friendly, reliable and future-proof platform.

For companies that are looking for used machines from the food and beverage industry or seeking to sell their surplus equipment easily and transparently – discover the auctions on Industrial Auctions.

Industrial-auctions.com

EDITOR’S CHOICE

ABB Robotics UK Open Day ABB Robotics to hold Open Day at its Customer Experience Centre in Milton Keynes on May 15, highlighting latest developments in robotic and machine automation, featuring live demonstrations and insights on the latest advances in robotic and machine automation technologies

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BB Robotics will be holding an Open Day at its Milton Keynes Customer Experience Centre on Thursday, 15th May, highlighting the benefits offered by the latest robotic and machine automation technologies. Featuring live demonstrations, interactive sessions and expert insights, the event will show how automation is opening possibilities for transformation and growth across industries in the UK and Ireland.

“With over four million robots currently in use, the world is seeing an acceleration in the adoption of robotic and machine automation technologies as businesses looks for ways to improve efficiency, flexibility, productivity, and sustainability.” said Alan Conn, Managing Director of ABB Robotics UK & Ireland. “Our Open Day will highlight how UK and Irish businesses can use ABB’s technologies to enhance their competitiveness. With a full range of products and software on show, including examples of our AI-enabled robots, the event will underline how our robots and machine automation solutions can boost productivity and open new pathways to becoming more sustainable.”

The event will feature four dedicated zones. In the Digital Zone, visitors will experience demonstrations of RobotStudio® virtual robot programming tool, AR and VR viewers for factory floor visualization, and the OptiFact factory management tool for optimizing production operations.

The Cobot Zone will highlight the versatility and safety of ABB’s cobots, including a live demonstration of a cobot-based pharmaceuticals cell. The zone will also feature ABB’s GoFa™ cobots for industrial applications, plus an insight into ABB’s

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Ecosystem Program, which provides easy access to approved third-party equipment and software.

The Industry Zone will present a range of robotic applications for various industries, with demonstrations of arc welding, machine tending, high-speed picking and packing, autonomous mobile robots (AMRs) and automated logistics handling. It will also cover the potential for improved productivity, efficiency, and sustainability in other sectors such as food and beverage, healthcare, and retail.

Finally, the Customer Service Zone will focus on how ABB supports customers

through services including training courses, technical help and assistance and robot refurbishment services.

The event will also give attendees the opportunity to interact with ABB’s robotics and machine automation experts and learn how the technologies are addressing key trends such as smart factories that are shaping the future of manufacturing and industry.

For a chance to see the future of automation in action, visit the Open Day landing page below. bit.ly/ABBRoboticsUKOpenDay

Inspiring the future of engineering and manufacturing

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 UK

2 days

400+

6 free

8,800+

suppliers

of networking

to attend forums

1000s

engineering professionals

of innovative solutions

Association partners

Scan here for exhibiting enquiries Enquire to exhibit today aeuk@easyfairs.com | +44 (0)20 3196 4300 advancedengineeringuk.com

Co-located with

EDITOR’S CHOICE

Leuze Introduces New LiDAR Laser Scanners Leuze is expanding its product portfolio with LiDAR technology: New ROD 300 series of laser scanners for accurate contour measurement and ROD 500 for precise AGV navigation.

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he new laser scanners in the ROD 300 series for contour measurement and the ROD 500 series as a high- resolution variant for navigation tasks are characterized by high scanning rates with simultaneously high angular resolution.

Whether on a conveyor or on an automated guided vehicle system: When sensors are used to detect contours, precision and attention to detail are what count. Leuze is launching two new laser scanner series that are perfectly suited for this. The devices of the ROD 300 series reliably detect contours even during fast production and logistics processes. Thanks to their high scanning rates and angular resolution, the laser scanners of the ROD 500 series are optimally suited for navigation tasks. Another advantage is the sensors’ integrated window monitoring, which detects if the optics window becomes dirty.

This enables predictive maintenance and contributes to high system availability.

Perfection in precision The devices of the ROD 300/500 series scan at a frequency of up to 80 Hz. This means that moving objects are reliably detected and the data quality remains optimal even at high speeds. With their high angular resolution of 0.025° at 10 Hz , the laser scanners of the ROD 500 series determine the contour of the parts even with high-gloss or matt surfaces. The new laser scanners can be integrated into almost all production processes. Their rugged design also contributes to this: protection class IP 67, high-quality aluminum base and the builtin laser diode make the ROD 300/500 laser scanners resistant to external influences.

The sensors also work in temperature ranges from -30 °C to +60 °C. This makes them suitable for applications in both the deep-freeze sector and for high-temperature requirements, such as in battery production.

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The new laser scanners in the ROD 300 series for contour measurement and the ROD 500 series as a high-resolution variant for navigation tasks.

With their high resolution of 0.025°, the laser scanners of the ROD 500 series can precisely determine the contour of parts, even with different surfaces (high-gloss or matt).

With curiosity and determination, the Sensor People from Leuze have been creating innovations and technological milestones in industrial automation for 60 years. They are driven by the success of their customers. Yesterday. Today. Tomorrow. The technology leader’s high-tech product range

includes a number of different sensors for the field of automation technology. Among these are switching and measuring sensors, identification systems, and data transmission and image processing solutions. leuze.com

21st & 22nd May 2025 The NEC, Birmingham, UK

Running as part of the CHEMUK 2025 Group of Events

FREE ENTRY

WHEN ERED PRE-REGIST

2 Packed Days Hundreds of Exhibitors Panel Sessions Plant & Process Intensification Control & Instrumentation CHEMICAL 4.0 Automation / Digitisation Plant Management Flow & Thermal Solutions Thousands of Specialist Products... plus more!

Supporting Media Partner

PRE-REGISTER FOR FREE ENTRY! Supporting Partners include:

21st & 22nd May 2025 REGISTER FREE AT WWW.CHEMICALUKEXPO.COM MEPCA A4 0724 ENG.indd 1

03/03/2025 16:13

EVENT PREVIEW

The Manufacturing Solutions of Tomorrow The NEC Birmingham will once again play host to Smart Manufacturing Week, the UK’s largest manufacturing and engineering exhibition on 4–5 June 2025. Read on for what to expect from this year’s unmissable show.

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mart Manufacturing Week brings together a powerful lineup including Smart Factory Expo, Drives & Controls, Maintec, Design + Engineering Expo, and the Air-Tech, Fluid Power and Systems zones.

The show’s educational programme comprises seven Solutions Theatres covering Digital Transformation, Industrial Data & AI, IIoT & Connectivity, Design & Innovation, Automation & Robotics, Leadership & Strategy and Maintenance.

Each of these theatres will deliver practical, actionable insights that manufacturers can apply directly to improve their operations.

A session visitors should be sure not to miss will be delivered by the ‘Godfather of Industry 4.0’, Professor Henrik von Scheel.

His talk, The Future of Manufacturing: Megatrends that Shape the Next Decade, will examine the forces that will dominate the manufacturing landscape in the years ahead, including smart automation, AI integration and the evolving dynamics of the workforce.

It’s an essential part of a visit for those looking to stay ahead in the fast-evolving manufacturing landscape.

In addition, the event will continue its commitment to inspiring the next generation through its STEM Programme – Manufacturers & Engineers of the Future, sponsored by FANUC. Now extended to include school year students, as well as those in further education, hundreds of students and apprentices will have the chance to interact directly with industry experts, offering a hands-on introduction to the exciting world of advanced manufacturing and engineering. As part of the programme, visitors can also witness the FANUC WorldSkills UK Industrial Robotics Competition qualifier.

Emphasising the ‘industry under one

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roof’ nature of the event is the presence of prominent exhibitors including Schneider Electric, FANUC UK, 3M, Epicor, Binder UK, Cembre, Charter Controls, Ericsson, Hoffmann Group, and ifm Electronic.

Alongside other big names, the exhibition floor will showcase the most influential players in industry.

Amongst these giant players are the startups and innovative small businesses set to revolutionise the sector. Part of Smart Factory Expo, ‘Innovation Alley’ will feature emerging manufacturing technologies from early-stage businesses, providing an opportunity to source the transformative technologies that promise to shape manufacturing over the next decade. New for 2025 is ‘Smart Tank,’ where these entrepreneurs will pitch their products and services to a panel of experts.

For some fun, the popular Guitar Legends competition returns, with a 3D-printed guitar for the winner, plus the house band The Shadow Monkeys will pop up all around the event and return with their signature high energy and crowd-pleasing hits to close out the first evening’s visitor party. Meanwhile, the Best of British Showcase celebrates

the finest in UK manufacturing, spotlighting groundbreaking designs, pioneering methods, and export successes.

With so much to explore, Visitor Trails are the perfect way to navigate Smart Manufacturing Week with ease. These curated pathways help attendees make the most of their time, guiding them to the most relevant exhibitors, must-see presentations, and technologies based on their interests.

Whether seeking the latest innovation and smart technology advancements or looking for groundbreaking sustainability and circular economy solutions, or products and services designed specifically for SMEs, these tailored routes ensure nothing is missed out.

Smart Manufacturing Week takes place at the NEC Birmingham on the 4th-5th of June 2025. Other exhibitions taking place at the NEC at the same time include Automechanika run by Messe Frankfurt; Med-Tech Innovation Expo and TCT 3Sixty from Rapid News Group; and Subcon from the Mark Allen Group. One visitor badge provides access to all events. For more information and to register for free visit the website below. bit.ly/mepca

4-5 JUNE 2025 | NEC, Birmingham

The Festival of Advanced Manufacturing & Engineering Featuring over 450 exhibitors and welcoming 13,000 visitors, it’s your one-stop destination for cutting-edge solutions in smart factories, automation, AI, maintenance, design engineering, and more.

Also gain access to events including

Organised by

smartmanufacturingweek.com

EVENT PREVIEW

Further Expert Speakers Announced Automate UK has announced further expert speakers to lead the seminar session at its upcoming exhibition for automation, robotics and machine vision: Automation UK 2025.

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urther to the announcement that Jake Hall, the “Manufacturing Millennial” would be making his first UK appearance at the show as a Keynote Speaker, a number of additional high-profile guest speakers for the event, which returns to the Coventry Building Society Arena on 7-8 May 2025 have now been unveiled.

Organised by Automate UK, the event provides exhibitors and visitors throughout the industry a prime opportunity to network with their peers, showcase state-of-the-art technology solutions and benefit from the insight and knowledge shared by a host of expert guest speakers.

Special guests leading seminars focused on the latest trends and developments within the field include Mike Loughran of Rockwell, Daniel Smalley of Siemens, and Kevin Kolkea of KUKA. Scott McKenna, Chief Operating Officer at Automate UK, said: “With five theatres at our disposal we have an expert and a topic to suit everyone attending this year’s show and we are proud of the diverse itinerary of insight and knowledge we have to share with visitors.

“Our seminars will cover a wealth of information from how to attract and retain emerging talent in manufacturing in light of the skills shortage currently impacting the sector, to updates in safety standards and how collaborative robot applications are being adjusted to facilitate it.

“To give visitors the opportunity to get the most from the event, we’ve begun a series of pre-show webinars, which will set the stage for what’s to come at Automation UK 2025 and ensure that attendees have access to the best possible tools when it comes to expanding their knowledge, exploring new technologies, or gaining strategic insights,” said Scott.

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The dates and topics of the webinars can be found on the link below.

Among the leading manufacturers and suppliers of automation, robotics and vision technology exhibiting at Automation UK 2025 are ABB, FANUC, KUKA, Rockwell, Siemens, Schneider, SICK, and Schubert UK.

Registering for the show could not be easier, simply visit the website, where a complete list of exhibitors can be found, along with further information about the event. automation-uk.co.uk/pre-eventwebinars automation-uk.co.uk

Your portal to a whole world of automation Automation UK 2025 7-8 May CBS Arena Coventry

Transform your business at Automation UK 2025. See the latest innovations in automation, robotics and vision technology, gain expert insights from keynote speakers and watch exciting live demonstrations. With our new Mobile Robots Demo Zone and exclusive networking

Register for your free pass

opportunities, you too can unleash the power of automation.

#AUK2025

For more information visit automation-uk.co.uk

AutomationUK_Show_Press_A4_MEPCA.indd 1

03/03/2025 17:45

EVENT PREVIEW

What to expect at TCT 3Sixty The UK’s definitive industrial 3D printing and additive manufacturing event is set to return to the NEC Birmingham on 4-5 June 2025. This must-attend event is essential for engineering, manufacturing and design professionals eager to discover the latest tech advancements and network with industry leaders.

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CT 3Sixty will tackle the evolving challenges and opportunities in additive manufacturing, offering insights into industrial applications, prototyping innovations and strategies for incorporating 3D printing into mainstream production. Over two days, attendees will explore the future of product design and manufacturing with guidance from leading expert experts.

This year will see over 150 exhibitors including Boston Micro Fabrication, Spee3D, Formlabs, Additec, Additive-X, 3T Additive Manufacturing, Scott Bader, Laser Lines, EOS and Carbon present cuttingedge technologies intended to improve manufacturing and design processes.

This year’s conference introduces two exciting new stages: the TCT Additive Insights Stage and the TCT Innovation Stage. The TCT Additive Insights Stage will feature thought leadership from global industry leaders, covering the most pressing topics in the sector.

Meanwhile, the TCT Innovation Stage will be focused on the latest product releases and groundbreaking research from the UK’s top R&D sectors.

Speakers include Alex Champion from UK Strategic Command (MOD); Anthony Foy, Technical Director at Breakthrough Sports; Matthew Bailey, Lead Technologist at ATI and Sylvia Heisel, CEO of Heisel who will share their insights and visions for the industry’s trends and breakthroughs.

Beyond the main event, exciting activities include the annual TCT Awards, celebrating excellence in additive manufacturing; the third TCT UK User Group meeting, a platform for professional idea exchange; and the MOD’s Project Tampa second meeting,

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enabling Project TAMPA contributors to look firsthand at the UK AM sector.

Duncan Wood, CEO of The TCT Group, remarked, “TCT 3Sixty is crucial for those involved or interested in 3D printing and additive manufacturing. We’re thrilled to welcome back our community, offering an unparalleled experience of learning, innovation and networking.”

All registered visitors will get access to co-located events at the NEC Birmingham

including Med-Tech Innovation Expo, Automechanika Birmingham, Design & Engineering Expo, Smart Factory Expo, Drives and Controls, Maintec and Subcon. Together, these events offer a comprehensive platform that spans multiple vertical sectors, delivering unparalleled value to attendees and exhibitors alike.

For more information and registration, visit the website below. tct3sixty.com

SCAN ME

The must-attend event for buyers, designers, and engineers looking to evaluate, adopt or optimise 3D printing and additive manufacturing within their business.

Register Now! www.tct3sixty.com

AWARDS

3D Print Manufacturing

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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

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

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

Sensors

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

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

Industrial Communications Brainboxes T: + 44 (0) 151 220 2500 E: sales@brainboxes.com W: www.brainboxes.com Intoware T: 0115 977 8969 E: hello@intoware.com W: www.intoware.com

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

Ideal Power T: 01733 309865 E: salessupport@idealpower.co.uk W: www.idealpower.co.uk

Drives, Motors & Gears

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Machine Safety

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

Design-In Power Supply Solutions

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

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

Connectors & Cabling Solutions

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Industrial Fans

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

Anti Vibration Products, Mounts & Bushes

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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