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NOVEMBER 2026

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EDITOR’S NOTE Editor Oliver Batt oliver@cimltd.co.uk Publication Manager James Burke jb@mepca.com 01795 509105 Head of Brand Development Jim Bearden jim@mepca.com 01795 509105 Design & Production Grant Waters grant@cimltd.co.uk James Taylor james@cimltd.co.uk Administration Manager Natalie Woollin admin@cimltd.co.uk 01795 509103 Credit Facilities Manager Gwen Lee creditcontrol@cimltd.co.uk 01795 509103 Head of Digital Xhulio Bishtaja digital@cimltd.co.uk Marketing Manager Lucas Payne lucas@cimltd.co.uk Director Tom Woollin tom@cimltd.co.uk Managing Director John Denning © 2026 Cogent Multimedia Limited, 1st Floor, Saphir House, 5 Jubilee Way, Faversham, Kent, ME13 8GD. No part of this magazine may be reproduced or stored in a retrieval system or transmitted in any form – electronic, mechanical or physical – without express prior permission and written consent of the publisher. Contributions are invited and when not accepted will be returned only if accompanied by a fully stamped and addressed envelope. Manuscripts should be typewritten. No responsibility can be taken for drawings, photographs or literary contributions during transmission or in the editor’s hands. In the absence of an agreement the copyright of all contributions, literary, photographic or artistic, belongs to Cogent Multimedia Limited. The publisher accepts no responsibility in respect of advertisements appearing in the magazine and the opinions expressed do not necessarily represent the views of the publisher. The publisher cannot accept liability for any loss arising from the late appearance or nonpublication of any advertisement.

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NOVEMBER 2026

elcome to the November edition of MEPCA magazine. As global energy demand grows exponentially, with it comes one of the defining engineering challenges of our age: meeting global energy demand sustainably. At the heart of this month’s issue is a Sustainability focus, which features a wide range of the latest solutions, case studies and thought leadership concerning the energy crisis, increasing efficiency and reducing waste across industry. Included within this, Titan Enterprises details its practical, engineeringled approach to sustainability; appearing for the first time in these pages, Addcomposites provides a fascinating guide to the use of automated fibre placement for reducing production waste (p.54); and on page 18 MEPCA reports on the Energy Institute’s latest Review of global energy trends, while Atlas Copco shares the latest from the frontline of hydrogen production. On the cover this month is Epicor, whose cover story (p.14) addresses the gap between technological investment and results, and how connectivity and data visibility may hold the answer. Also in this issue, it’s the end of an era as we share Oliver Selby’s last Opinion piece in his tenure as Chair of BARA (p.10) as he hands over the baton, while this month’s Manufacturing Champion has been a vocal advocate for UK manufacturing for decades (p.12) and has “the metal” to call out the UK government’s treatment of SMEs. I hope you enjoy this issue. Oliver Batt, Editor @Mepca-magazine

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

CONTENTS Industry Partners:

FEATURES 8 INDUSTRY NEWS 10 OPINION 12 MANUFACTURING CHAMPION 14-15 COVER STORY 17 SUSTAINABILITY

56 DRIVES, MOTORS & CONTROLS 58 INDUSTRIAL AUCTIONS 60 TEST & MEASUREMENT 68 CONVEYORS 71 EVENTS 78 COMING UP

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INDUSTRY NEWS

LAPP ACHIEVES SALES OF MORE THAN TWO BILLION EUROS FOR THE FIRST TIME

APP Group’s global growth strategy is paying off: In fiscal year 2026 (1 October 2025 – 30 September 2026), the global market leader in integrated solutions for cable and connection technology achieved sales of more than 2.3 billion euros (fiscal year 2025: 1.93 billion euros), according to preliminary figures. These record sales are driven by strong organic growth as well as one-off factors such as copper prices and acquisitions. The Asia-Pacific and Americas regions made a strong contribution to the overall sales growth of the Stuttgartbased connectivity solutions specialist. The EMEA region (Europe, Middle East, Africa) proved resilient despite a persistently challenging market environment and continues to account for the majority of LAPP’s global sales. Matthias Lapp, CEO of the LAPP Group, says: “We are benefiting from our established local presence in the Asian and American growth markets. In Europe, and particularly in Germany, the situation remains challenging. Even though the order intake over recent months has made me more optimistic, it is still far too early for euphoria – particularly because we must always look at Germany in

the context of international competitiveness.” The family-owned company is entering fiscal year 2027 with confidence, but also with the necessary caution due to geopolitical uncertainties. Matthias Lapp: “We have invested heavily in recent years – in production capacity, logistics networks, and digitalisation. The priority now is to utilise these new capacities. We want to grow profitably so that we remain a strong, innovative partner for our customers in the long term.” lapp.com

ABB ROBOTICS INTRODUCES TWO NEW HIGHPERFORMANCE ROBOTS

BB Robotics is expanding its industrial robot portfolio with two new compact, highperformance robots, the IRB 1700 and IRB 1700ID, delivering up to 20 per cent shorter cycle times than comparable robots on the market. “Precision manufacturing across sectors from electronics, automotive, to general industries is facing the pressure to produce more, while maintaining quality and reducing operating costs,” said Craig McDonnell, Managing Director, Business Line Industries, ABB Robotics. “The IRB 1700 family addresses these challenges with a new level of speed, accuracy, reliability and energy efficiency. It gives manufacturers and system integrators a flexible platform for high-performance automation.” Offering payloads from 6 kg to 12 kg across five variants and powered by OmniCoreTM controllers, the new robots help manufacturers increase productivity, with up to 20% shorter cycle times, and improve uptime and reduce operating costs, with up to 15% lower power consumption and service intervals of up to 20,000 hours between oil changes. Precise path repeatability of down to 0.03 mm and joint speeds of up to 700 degrees per second. The new robot offers a footprint 50 per cent smaller than its predecessor, and for even greater packaging efficiency, the IRB 1700ID

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model features ABB Robotics’ Integrated Dressing (ID) design, routing cables and hoses inside the robot arm, simplifying installation across industrial applications. The IRB 1700 family extends ABB Robotics’ comprehensive mechatronics portfolio and ABB Robotics’ development of more autonomous and versatile robotics (AVRTM), with access to an expanding portfolio of programming and AI-powered software, including RobotStudio®, AI Robot Trainer, OmniCore EyeMotion and automatic collision-free path planning. go.abb/robotics

INDUSTRY NEWS

WORLD’S LARGEST HAIRDRYER BUILT The world’s largest hairdryer, which was invented by children and built by South Yorkshire-based Kids Invent Stuff, containing fastenings from precision component distributor Accu, has received a Guinness World Record title.

he fully working hairdryer measures 1.7556 m long and 1.6 m tall, almost seven times the size of a standard household model. It has earned Sheffield inventor Ruth Amos, co-founder of Kids Invent Stuff, another Guinness World Record title and a double-page spread in the newly published Guinness World Records 2027 book. The project began as a competition run by Kids Invent Stuff, the YouTube challenge where young people have the chance to get their invention ideas built by engineers, in association with Huddersfield-based Accu and the Royal Commission for the Exhibition of 1851. Children in the UK and overseas were challenged to invent something worthy of a Guinness World Record title and more than 5,000 ideas came in from inventors aged 4 to 11. The winning concept, a giant hairdryer, came from two young inventors, Kiki and Thea. Ruth and her team of engineers then had to work out how to build it. With no blueprint to follow, the team designed the hairdryer from scratch, scaling up a standard 25 cm dryer by 6.88 times. Inside, a large motor-driven fan pushes air past oven heating elements and through steel ducting. The outer shell is made from expanding foam, filler and fibreglass resin, finished in glossy purple paint. The hairdryer was tested for real in a hair salon on a volunteer and then back at Accu’s warehouse. Accu supplied all the fixings for the build, including stainless steel washers, rivets, self-drilling screws, domed nyloc nuts and socket countersunk screws. These components hold the internal structure, ducting and body together and let the hairdryer run safely at full power. Alastair Morris, Managing Director of Accu, said: “We were really excited to work with Kids Invent Stuff to support a children’s engineering challenge worthy of being a Guinness World Record breaker! Every fastener in the build had an important job to do and it’s brilliant to see our precision components helping to turn these young peoples’ idea into a world record.” Ruth Amos, co-founder of Kids Invent Stuff, said: “There was no rulebook for this one. We had to work everything out from first principles and that’s exactly what engineering is about: imagination, problem-solving and making ideas real. Having Accu’s backing meant we could focus on making it work, knowing the fixings were right.

I hope it inspires every child who sees it to think ‘I could build something amazing too.’” The world’s largest hairdryer is the latest collaboration between Accu and Kids Invent Stuff, which have previously worked together on projects including creating combat robots to show young people that engineering is a creative, exciting career path. The Guinness Book of World Records 2027 is out now. The full build story can be seen on the Kids Invent Stuff YouTube channel. accu.co.uk

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OPINION

BUILDING MOMENTUM FOR UK ROBOTICS As Oliver Selby, Key Account Manager, Aerospace and Defence at FANUC UK, comes to the end of his two-year tenure as Chair of the British Automation & Robot Association (BARA), he reflects on the remarkable progress made across our industry and looks ahead to the next chapter under new leadership.

t gives me great pleasure to formally hand over the role of Chair to Rosie Davies of Reeco Automation, who has served as BARA Vice Chair for the past two years. Throughout my tenure, Rosie has been a constant source of support, insight and energy. She has played an active role in helping shape the direction of the association and has been a strong advocate for our members and the wider robotics community. I am delighted to see her step into the Chair position and I have every confidence that BARA will continue to thrive under her leadership. The past two years have been a period of significant change and transformation. One of the most important developments has been the continued evolution of BARA as part of Automate UK. The rebrand and the introduction of new executive leadership have provided fresh momentum and a clear vision for the future. More importantly, these changes have strengthened the organisation and sharpened the focus on delivering meaningful benefits for members. The timing for this renewed focus could not be better. Robotics is no longer confined to traditional manufacturing environments. Today we see innovative robotic technologies transforming healthcare, agriculture, food production, logistics, recycling, infrastructure, public services and many other sectors. As adoption broadens, it becomes increasingly important that industry, government, academia and trade associations work together to provide the support, guidance and confidence organisations need to invest in automation successfully. This is why the recent announcement of the UK’s new Robotics Adoption Hubs is such positive news for our sector. From SHARP, the National Surgical Robotic Adoption Hub, through to HARVEST in Lincoln supporting agri-food innovation, the Yorkshire Robotics Adoption Hub for manufacturing, and specialist programmes focused on waste and recycling, smart cities, Wales and the South West, these initiatives will play an important role in accelerating robotics adoption across a diverse range of industries. The breadth of these hubs reflects the breadth of opportunity. No single organisation can support this journey alone. Success will

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require close cooperation between government agencies, technology providers, end users, research institutions and trade associations. Automate UK and BARA look forward to engaging closely with these new hubs, sharing industry expertise, connecting them with our members and helping ensure that businesses across the UK can access the knowledge and support required to adopt robotics with confidence. While leadership may change, the mission remains the same: to champion robotics and automation, support our members and help unlock greater productivity, competitiveness and innovation across the UK economy. I would like to thank our members, the Automate UK team and my colleagues on the BARA board for their support over the past two years. It has been a privilege to serve as Chair. I look forward to supporting Rosie and watching the association continue to grow and strengthen in the years ahead. automate-uk.com

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18/08/2026 10:30:55

MANUFACTURING CHAMPION

MANUFACTURING CHAMPION OF THE MONTH This month, we celebrate Stephen Morley, President of the Confederation of British Metalforming (CBM) and vocal advocate for UK manufacturing. Speaking with our editor, Stephen discusses the UK’s business environment, critiques the government’s reindustrialisation agenda, and looks to Europe for lessons on appreciating our SMEs.

ike many in the industry, Stephen Morley welcomes in principle the government’s focus on reindustrialisation, but he wants to see these words being backed up with transformative action. This was the crux of his recent critique1 of Prime Minister Andy Burnham’s speech to the Labour Party Conference. The problem, Stephen explained to our editor, is that the cost of doing business in the UK, particularly energy costs and the cost of labour, has created a hostile business environment. Take energy costs, for example; UK businesses pay 50 per cent above the G7 median. This, Stephen insisted, is one of the fundamental things that the government should address before any changes to policy. As well as being President of CBM, Stephen is a serving member of the UK Metals Council and the managing director of SJM Engineering Solutions. Much of his 40 plus year career has been spent working in automative production. The CBM has 200 members, representing 75,000 employees. While they’re not the biggest organisation, he said, they “place above their weight.” This comes down to the organisation’s efforts to be ahead of the curve, which includes lobbying government and creating strong ties to manufacturing organisations globally. Stephen explained that he is in favour of devolution, if it is handled correctly. For that, he recommends looking to Germany’s Mittelstand, a devolution-supported model driven by its SMEs. While Andy Burnham has looked to European manufacturing and the Mittelstand model specifically for his devolution plans, Stephen has long held that one thing would need to change for this to be realised: the UK’s treatment of SMEs, or Small Mistreated Entities, as he has termed them. Despite forming the backbone of industry, SMEs are often overlooked when it comes to policy or grants. Devolution will only work if local states are granted more power to support SMEs. But is the UK manufacturing base too fragmented compared to Germany for the Mittelstand model to work? Stephen insisted not: “I think politics is too fragmented. The bureaucracy is too severe. Given the right leadership in certain areas, we could certainly move things forward.” He went on to provide the West Midlands and other UK

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industrial clusters as examples of how these ideas can succeed here. One frustration that Stephen shares with several of our prior Manufacturing Champions is that, despite manufacturing GDP being “absolutely critical” to the economy, there is a tendency for politicians in the UK to use manufacturing for political point scoring, only to ignore it again once that purpose has been served. As he summarised: “When manufacturing suffers, the country suffers. There’s not enough credence given to manufacturing by politicians. Politicians will pick manufacturing up when it suits them and then just drop it. Manufacturing has got to be one of the cornerstones.” Our readers can expect further insights from Stephen Morley in our Opinion section in the coming months. thecbm.co.uk 1. mepca-engineering.com/cbm-warns-manufacturing-cant-afford-burnham-to-beall-at-sea/

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COVER STORY

TURN MANUFACTURING DATA INTO ACTION A recent report on Smart Manufacturing shows that while businesses are investing in automation, cloud platforms and AI, many executives remain dissatisfied with the results. Here, Mark Feathers, Senior Product Marketing Manager at Epicor, explains how greater connectivity and data-visibility can improve outcomes.

anufacturers continue to be under pressure from every direction: customer expectations are rising, skilled labour is harder to secure, supply chains remain unpredictable and margins are under constant scrutiny. To address this, businesses leaders are investing in automation, connected operations, cloud platforms and artificial intelligence. The challenge is making these technologies work together to improve business measures that matter most. Research in Smart Manufacturing from Lifecycle Insights: “Unlocking Value Through Cloud Data, AI, and Automation”1 highlights a performance and expectation gap that many manufacturers will recognise. The organisations surveyed reported achieving their

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manufacturing targets around 75 per cent of the time, yet only 51 per cent of executives are highly satisfied with those results. Hitting a target most of the time is not the same as having the visibility, agility and control needed to for continuous improvement. The answer is to create a connected operational foundation; one that brings production, inventory, quality, maintenance, finance and customer commitments together. For many manufacturers, cloud ERP provides that foundation.

FROM ISOLATED SYSTEMS TO A CONNECTED VIEW

A modern ERP system can connect the information that

COVER STORY drives daily decisions. When production activity, materials, orders, costs and capacity are visible in one environment, teams can work from a shared version of the truth rather than reconciling spreadsheets and delayed reports. Cloud delivery extends that access across sites, departments and approved remote users, helping people respond to issues while there is still time to act. The research found that 51 per cent of respondents cited collaboration and accessibility among the reasons for moving IT systems to the cloud. Real-time data access followed at 45 per cent, with cost optimisation at 38 per cent. These benefits are closely connected: a cloud ERP platform can give planners, shop-floor leaders, finance teams and executives access to the same current information, without requiring every decision to pass through a specialist or wait for a manual report. This matters when a late supplier delivery threatens a production schedule, when a quality issue requires traceability, or when an important customer asks for an updated commitment. Better data does not remove complexity, but it makes complexity easier to see and manage.

AUTOMATION THAT HELPS PEOPLE DO MORE

Automation is already widespread. Only 6 per cent of surveyed manufacturers report not having automation, while 85 per cent operate with partial automation. Production and data collection are the most common applications, followed by assembly, quality inspection, inventory management and material handling. The next step is to connect that operational automation to ERP processes. Automated data capture can reduce rekeying and improve inventory accuracy. Workflow automation can route approvals, exceptions and tasks to the right person. Planning tools can help teams balance demand, materials and capacity more quickly. The result is not automation for its own sake; it is less time spent on repetitive administration and more time spent on decisions that require experience and judgement.

AI BECOMES PRACTICAL WHEN THE DATA IS READY

AI is most valuable when it is applied to reliable, relevant business and production data. Among manufacturers streaming data to the cloud, 88 per cent have implemented AI or machine learning to analyse production information. Their leading motivations are efficiency and productivity improvement (62 per cent), and better decision-making or process optimisation (47 per cent). These are practical use cases. AI can help identify patterns that indicate an equipment failure, highlight emerging quality problems, recommend process improvements or support more accurate forecasts. AI might identify a pattern suggesting that a machine is likely to fail. Connected to ERP, that insight can trigger a maintenance task, identify affected production orders, check whether alternative capacity is available and show planners which customer commitments could be at risk.

That connection is important because only insights embedded in the flow of work can change an outcome. Cloud ERP can provide the context and workflow needed to turn AI recommendations into controlled, measurable action.

BUILD CONFIDENCE WITH SECURITY AND A CLEAR ROADMAP

Manufacturers are right to take security seriously. The report found that 86 per cent have connected operational technology networks to the internet, but approaches vary. Among organisations that do not send industrial control data to the cloud, 49 per cent cited cybersecurity as the primary barrier. Legacy integration, data quality, skills and system reliability also need careful attention. A successful transformation therefore needs more than a technology purchase. It needs a practical roadmap, strong governance and a partner that understands both manufacturing operations and business outcomes. Cybersecurity should be designed into the architecture, while data quality, user adoption and measurable value should be managed from the beginning. Manufacturers are already investing in automation, cloud and AI. The next step is to connect those investments, so that information generated on the shop floor can influence planning, maintenance, inventory, quality and customer decisions as events unfold. The goal is a manufacturing operation that can see what is happening, understand what it means and act sooner. If disconnected systems are making that difficult, Epicor’s manufacturing specialists can show manufacturers how a connected cloud ERP approach can help turn production data into practical action. To read the report, visit Epicor’s website. epicor.com epicor.com/en-gb/resources/library/manufacturing/ebook-how-to-unlock-value-

through-cloud-data/

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FOCUS ON: SUSTAINABILITY

SUSTAINABILITY

ENERGY MATTERS: DIVERSIFYING SUPPLY An insatiable growth in energy demand coupled with short-term thinking has contributed to a global energy crisis. The UK’s industrial future – and the future of our planet – relies on us solving it sustainably. MEPCA reports on a recent energy-focused press briefing, featuring speakers from the Energy Institute and Atlas Copco.

iscussions around sustainability in manufacturing tend to lead back to one thing: energy. Where it comes from. Who supplied it. How it’s generated. And, of course, the market rate. These are important questions for businesses trying to survive under the pressure of unprecedented energy costs, but equally, these questions are also at the forefront of Net-Zero and decarbonisation ambitions. The Statistical Review of World Energy has long proven to be an invaluable resource for charting global energy trends, shaping economic and political priorities. Now in its 75th edition, the latest Review offers an extensive analysis of changes in the global energy system in 2025, at a global,

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regional and country level, and charts how it responded to geopolitical, economic and environmental challenges.

RECORD LEVELS OF RENEWABLES BUT EMISSIONS RISE

Delivering the keynote at an-energy focused press briefing, Selene Law, head of the Statistical Review of World Energy1 at the Energy Institute began with the key findings, the most encouraging of which being that renewables (that is, solar, wind and green hydrogen generated energy) were the fastest growing energy source for the second year in a row, with solar making up the lion’s share of this growth (71 per cent). This, Law said, was driven by the increasing

SUSTAINABILITY

We believe that the global electricity system has reached a tipping point, and from here on fossil fuels will be declining in the power sector. Selene Law, head of the Statistical Review of World Energy at the Energy Institute. affordability of solar panels. In other good news, 2025 was the first full year when the UK didn’t burn any coal in its energy system. Fossil fuel demand has remained fairly static. Overall, however, global CO2 emissions, which include both energy-related and process emissions have risen by 1.1 per cent. A major contributing factor to this has been the rise in global coal consumption by 0.7 per cent, which has largely been driven by the US. Law commented: “Growth in US coal consumption is the main reason why we have seen global CO2 emissions rise this year. In fact, the US is by far the biggest contributor to this.” China, in comparison to the US and globally, has excelled in renewables and electrification, with its own coal consumption remaining flat in 2025. “But, make no mistake,” Law said; “China is still by far the biggest CO2 emitter in the world.” As the Review is a meticulously collated retrospective account of the prior year’s global energy trends, Law was reluctant to make predictions but did, however, comment: “We believe that the global electricity system has reached a tipping point, and from here on fossil fuels will be declining in the power sector,” and she went on to offer the lower cost and speed of delivery of both panel and battery technology for solar energy as logical drivers. Electrification, renewables and other alternative energy sources have caused the demand for batteries, particularly lithium batteries, to rocket: in just 10 years demand for

lithium has grown from virtually nothing to 292 kilotons. Given this jump in demand, the environmental damage of lithium extraction should be noted. Traditional lithium extraction consumes large amounts of land and water and has a significant carbon impact, and that is without considering the challenges around the disposal and recycling of lithium-ion batteries. Newer extraction methods, such DLE (direct lithium extraction), which uses lithium-rich wastewater from the oil industry, reduce water usage and greenhouse gas emissions2. As the review highlighted, the global energy picture is highly complex. While there is a strong trend of global energy sources diversifying away from fossil fuel use, with America doubling down on coal and oil, and with China’s commendable renewables and electrification progress being only part of its wider emissions picture, there is still a way to go. However, the energy sector, and particularly the technology underpinning alternative sources of energy, continues to mature. One such area is in hydrogen.

THE HYDROGEN BOTTLENECK HAS SHIFTED

While hydrogen wasn’t specifically highlighted during the Energy Institute presentation, low-emission hydrogen has grown 20 per cent in 2025, but it makes less than 1 per cent of global hydrogen output. Hydrogen energy, particularly green or low-emission hydrogen energy, has maintained a buzz around it

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SUSTAINABILITY

for years and remains central to the UK’s industrial decarbonisation plans. Despite support from policy and considerable investment from government, until now many hydrogen projects have been stuck in the pilot phase. But according to Chris Hyde, Business Line Manager, Air & Gas Applications at Atlas Copco, that bottleneck is now shifting. Hyde referenced the Gartner Hype Cycle, which charts the development of innovative technologies from the initial technology trigger or “hype” to reality and actual deployment, to explain that hydrogen’s progress through the cycle has now seen Atlas Copco getting “real, actionable solutions” from the market (reaching the reality stage), but challenges remain before these projects can move from inertia to deployment. “The challenge now is less about demonstrating that hydrogen can work and more about creating the conditions in which projects can operate reliably and commercially at scale.” Hyde summarised.

THE CHALLENGES FACING HYDROGEN ROLLOUT

Policy and technology have created a better environment for hydrogen. The biggest challenges to the UK’s hydrogen are now commercial and infrastructure-related. Of the challenges impacting project delivery, the first and most critical is confirming demand, i.e., who will buy it, at what volumes and in what form, and where it is wanted. These factors are critical for determining the application and therefore plant design. Another key challenge is the

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cost comparison of hydrogen per kilo compared to existing energy on the market, with green hydrogen proving the costliest. There are also specific technical challenges related to green hydrogen, which we will address later. While green hydrogen – hydrogen produced using renewable electricity for electrolysis – has been the most hyped, Hyde believes that efforts to make hydrogen more competitive, whatever the colour3, will help drive green and low-carbon hydrogen. “Producers need confidence that there will be long-term demand for the hydrogen they generate, while potential off-takers need greater certainty around price, availability and supply before they commit to changing processes or equipment,” he explained. Further challenges noted included project delivery cycles, and infrastructure, which Hyde described as huge challenge for hydrogen, and one that is certainly holding back the UK market. For manufacturers, these challenges often boil down to infrastructure issues: production, storage, transport and use. As Hyde commented: “From our point of view, that energy discussion really needs to turn into plant design and then deployment. And that’s going to need to be to really push this forward.” One element of that infrastructure that Atlas Copco was here to focus on today was compression. While Hyde explained that compression was just a “small piece of a puzzle in delivering electricity or energy to the enduser,” for many applications it is vital due to continued infrastructure challenges holding back the UK hydrogen

SUSTAINABILITY rollout: “We have to look at compression, and designing those systems for use in operating locations and factories without that infrastructure.” Atlas Copco’s latest product for supporting the UK hydrogen market is a robust compressor system designed for these challenges.

H2Y HYDRAULIC BOOSTER

The H2Y is a high-pressure, hydraulic booster for hydrogen, with a 100 per cent oil-free compression system. Depending on the application, the H2Y can be configured for discharge pressures of up to 1,000 bar(g). While not every application will require compression, for those that do, the H2Y has been designed for “plugand-play” enabling it to be added to any customer system as part of their process. Of course, ensuring operation reliability in hydrogen is by no means that simple. Getting into the more technical side of the product’s use, Hyde explained that hydrogen supply conditions change from customer to customer, meaning that the H2Y has to handle changes in pressure, temperature and location. While it’s built for this purpose – for example, the variable inlet pressure enables it to respond to changes in upstream pressure – to ensure operational reliability in each application, Atlas Copco insists on being part of the project. “This is not just a standard solution that we look at and quote and pass to customers as part of their projects,” Hyde clarified, “We want to be involved in the application of the project to ensure the correct machine is selected, the correct size, and that we provide the electrolyser or crackers, and the correct pressure for their end users.”

The challenge now is less about demonstrating that hydrogen can work and more about creating the conditions in which projects can operate reliably and commercially at scale.

GREEN HYDROGEN

As mentioned above, green hydrogen projects have specific technical challenges over other colours. Here, Hyde explains what these challenges are and how they impact practical delivery and therefore determine the specification of the compression technology. “Green hydrogen presents a particular engineering challenge because production is closely linked to renewable electricity and electrolysis,” Hyde explained. “Unlike a process built around a relatively stable feed, hydrogen output can change as renewable power availability and electrolyser operation vary, creating fluctuations in flow and inlet pressure.” “The compression system therefore needs to be specified around the real operating profile rather than a single design point. Variable inlet pressure capability, appropriate turndown and control, and the ability to respond efficiently as production changes are particularly important. “Reliability is also critical because compression sits between hydrogen production and its storage, transport or use. Depending on the project, modular or containerised systems can simplify integration, while predictive maintenance and minimising hydrogen losses during start and stop cycles can help improve availability and operating efficiency as projects move from pilot scale into continuous operation,” he concluded.

Chris Hyde, Business Line Manager, Air & Gas Applications at Atlas Copco.

LOOKING AHEAD

It is hoped that, come the 2026 Review, the renewables trend will continue upwards, with solar and wind and lowemission hydrogen contributing to larger portion of global demand. While the 2025 Review has painted a fragmented view of global energy, one thing that is clear, as demonstrated by Atlas Copco, is that the technology that underpins the growth of renewables and electrification will mature more rapidly, increasing applicability to a point that renewables become the most logical as well as environmentally conscious choice for most applications. At this point, however, changing the global energy infrastructure to support wider renewables rollout remains one of he most pressing engineering challenges of our time. energyinst.org atlascopco.com/en-uk/compressors www.energyinst.org/statistical-review

knowledge.energyinst.org/new-energy-world/article?id=140107

nationalgrid.com/stories/energy-explained/hydrogen-colour-spectrum

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SUSTAINABILITY

5 WAYS TO IMPROVE PLASTICS PROCESSING From reducing waste and lowering energy demand, to gaining better control of production, Summit Systems offers five practical ways to improve sustainability in plastics processing.

or plastics processors, sustainability is not just about switching materials or setting long-term carbon targets. Often, some of the biggest improvements come from making the production process itself more efficient. At Summit Systems, sustainability is seen as an operational outcome: use less energy, waste less material, improve visibility and keep valuable resources in the process for longer. Here are five practical areas where plastics manufacturers can make a measurable difference.

1. REDUCE ENERGY USED IN MATERIAL DRYING

Drying can be one of the most energy-intensive parts of plastics processing, but the technology selected makes a significant difference. Vacuum drying uses heat and vacuum rather than continually regenerating desiccant, helping reduce drying energy and shorten the time material spends at temperature. The key is choosing the right drying technology for the material, throughput and production pattern, rather than simply replacing like-forlike.

2. GAIN TIGHTER CONTROL OF MATERIAL USE

Small dosing inaccuracies can quickly become significant material costs across thousands or millions of parts. Accurate gravimetric blending can help reduce unnecessary use of masterbatch, additives and virgin material, while supporting greater use of regrind and PCR. Combining this with material tracking gives processors greater visibility of actual consumption and recycled content.

3. MAKE PROCESS COOLING WORK HARDER

Cooling is another major opportunity for reducing energy demand. Precise temperature and flow control can improve cycle stability, reduce rejects and shorten cycle times, lowering the energy consumed per good part. Free cooling can further reduce demand by using lower ambient temperatures to reduce the load placed on mechanical chillers.

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4. KEEP PRODUCTION SCRAP IN THE LOOP

Clean production waste, such as sprues, runners and trim, still has value. By granulating suitable scrap and returning it directly to production, processors can create a much shorter material loop, reducing disposal, transport and the requirement for additional virgin material.

5. LOOK AT THE WHOLE PROCESS

The biggest gains rarely come from one machine in isolation. Material handling, drying, blending, cooling, recycling and process data all influence each other. A joined-up approach makes it easier to identify where energy, material and time are being lost and where improvements will have the greatest impact. For Summit Systems, the starting point is simple: identify the inefficiency, quantify the opportunity and engineer the improvement. By taking a more connected approach to plastics processing, manufacturers can reduce waste, lower energy demand and gain better control of production. The result is not only improved environmental performance, but a more efficient, resilient and commercially competitive operation. summitsystems.co.uk

Smarter Processing. Lower Impact. From material handling and drying through to blending, dosing, cooling, recycling and traceability, Summit Systems delivers solutions for more sustainable plastics processing. Use Less Energy

Waste Less Material

Improve Process Visibility

Reduce Logistics Demand

Talk to Summit Systems about improving the sustainability of your plastics processes

www.summitsystems.co.uk | hello@summitsystems.co.uk

SUSTAINABILITY

ENDOLINE RANDOM CASE SEALER RE-ENGINEERED Endoline Automation has completed a major redesign of its established 7048 Fully Automatic Random Case Sealer, enhancing energy efficiency, reducing its footprint and simplifying operation and maintenance for increasingly automated production environments.

volving from Endoline’s established 704 random case sealer, the 7048 builds on decades of proven reliability and longevity. Its redesign brings that established platform in line with the demands of today’s increasingly automated production environments. The latest generation has now been comprehensively re-engineered to reflect the requirements of increasingly automated manufacturing facilities, while retaining the flexibility and performance that have underpinned the system’s adoption. A central focus of the redesign has been simplifying the machine. Cable requirements within the 7048 have been significantly reduced, helping to improve reliability, simplify maintenance and reduce build time. New sliding access doors have also enabled Endoline to reduce the machine’s overall footprint to less than one metre wide, helping manufacturers accommodate greater levels of automation where factory floor space is at a premium. Machine access has been improved further as part of the redesign, alongside an intuitive HMI interface developed to make the system easier to operate and service, supporting faster intervention and minimising unnecessary downtime. Designed for production environments requiring flexibility across multiple case formats, the 7048 automatically seals cases arriving in random sequence without the need for manual adjustment. The system detects the height and width of each incoming case and adjusts automatically to accommodate different sizes, removing the need to pre-sort cases before sealing. Its four-column construction provides stability during rapid height adjustments and enables the machine to consistently seal cases at speeds of up to 14 cases per minute, while the chassis is engineered for continuous production environments. Andrew Yates, Managing Director of Endoline Automation, commented: “The 7048 has been part of our portfolio for many years, but manufacturing environments have changed considerably during that time. Automation

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Endoline Automation’s newly redesigned 7048 Fully Automatic Random Case Sealer

has increased, factory space is under greater pressure and manufacturers quite rightly expect equipment to be easier to operate, maintain and integrate. “Rather than changing the fundamental principles of a system that has proved itself over many years, we have looked closely at how we could evolve the design around those changing requirements. Reducing the footprint, simplifying the machine and improving access all contribute to making the latest 7048 better suited to the production environments our customers are operating today.” The redesign forms part of Endoline’s wider focus on continually evolving its established automation portfolio in response to changing manufacturing requirements. By combining proven machine principles with updated engineering and controls, the company aims to help manufacturers increase automation without unnecessarily adding complexity to their production lines. endoline-automation.com

SUSTAINABILITY

HOW TO CUT WASTE AND SAVE RESOURCES Southgate Global is helping customers cut waste and save resources in the warehouse this peak season with five simple steps to operate more sustainably.

he leading specialist in packing equipment, consumables, servicing and solutions for logistics and fulfilment operations, is supporting its customers through its Eco Product Framework, a simple checklist to evaluate its product range. The aim being to ensure that every offering to its customers is considered through a sustainability lens, and items that already deliver on that promise are highlighted. This framework, the 5Rs, helps Southgate and its customers to take achievable and immediate steps towards a reduced environmental impact; all without compromising on product quality and operational performance. The five segments, consisting of: Reduce, Reuse, Recycle, Replace and Repair, provide a structure to review Southgate’s product range, with each existing and new product reviewed against these criteria. • Reduce: focuses on products that decrease the production of waste or help to save raw materials or energy through smarter material choice or automated systems, such as Southgate’s strapping and wrapping machines. • Reuse: spotlights products that help customers cut down on consumables and extend asset life in fast-paced logistics environments, such as Southgate’s shredders, which repurpose cardboard into void fill. • Recycle: highlights products made from recycled content or are recyclable after use, including Southgate’s Edge Boards.

• Replace: looks at items which can be upgraded to more eco-friendly and efficient options for customers, such as switching from virgin plastic air pillows to 30 per cent fully certified recycled-content ones. • Repair: focuses on extending the life of material handling equipment and packing machinery, from carts and trolleys through to strapping machines, reducing downtime, consumption and raw material usage. Gavin Gill, Head of Compliance at Southgate Global, said: “Sustainability is a core operational priority for organisations. It is no longer viewed as just a compliance issue or tick box exercise, but a factor that is influencing every aspect of operations. For us, sustainability means designing, sourcing and delivering packing and fulfilment solutions that meet today’s operational needs while measurably reducing the environmental and social burden on tomorrow’s world. By reviewing our current inventory and practices with our Eco Product Framework, we can continue to make rapid steps towards helping ourselves and our customers reduce their carbon footprint.” The framework is just part of Southgate’s wider commitment to sustainable operations. In 2023, with the help of One Carbon World, it achieved carbon neutrality for Scopes 1 and 2. It has also achieved a Silver EcoVadis rating, showcasing its focus on driving sustainability both within its operation and the wider industry. southgateglobal.com

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SUSTAINABILITY

ASSESS DRIVE-SYSTEM ENERGY USE Energy usage in industrial plant changes throughout the day, so when over 67 per cent of all electricity used in industry is used to drive electric motors, it makes sense to start there to reduce energy cost.

onveyors start and stop, product loads vary, and equipment may operate for long periods at partial capacity. A motor or gear unit originally selected only from its rated power may therefore not reflect what the application requires. Measuring the operating pattern can reveal mismatches that are difficult to identify from specifications alone; it can also uncover hidden energy waste and flag oversized or inefficient drives. By installing a measurement unit, called the ECO BOX, between the drive and its power supply, the energy consumption of a selected drive application under normal operating conditions can be examined. Electrical data such as current and voltage is then recorded in real time. Monitoring typically depends on the application but can be from a few hours or can continue for about two months, capturing sustained loads, peaks and irregular operating conditions across production cycles. The duration helps build a load profile that reflects variation over time rather than a single momentary reading. Our engineers use the recorded data to assess the drive’s actual demands and compare the existing configuration with alternative drive-system options. The analysis can help identify equipment that is oversized, inefficient under its typical load, or otherwise poorly matched to the application. The assessment can include systems with components from different manufacturers, so it can be applied to existing installations as well as to equipment supplied by one provider. Possible changes may include selecting a more appropriately rated motor, gear unit or inverter, or choosing equipment that performs more efficiently across the required speed range. In installations with many drives, the analysis may also identify opportunities to reduce the number of different drive variants. Standardisation can affect spare-parts holdings, purchasing, maintenance and logistics as well as the drives themselves. After a change is implemented, a second measurement can be used to check the system’s performance and compare it with the earlier baseline. This helps establish whether the expected improvement occurred under operating conditions. Actual results depend on the application, operating schedule, equipment and modifications made.

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The central purpose of the assessment is to replace assumptions about drive use with operating data. All too often equipment is being replaced blind, with motors, gearboxes and drive-systems being swapped out like-forlike, year-on-year, without any checks on where the energy is being used. The potential outcomes of the monitoring and changes include lower electricity consumption and associated carbon emissions, as well as reduced costs related to maintenance, wear or administration. These effects should be evaluated for each installation using its measured load profile and the costs of any proposed changes, then the evidence used to determine whether an efficiency upgrade or system simplification is technically and economically justified. NORD ECO Service – WINNER of the MHEA Sustainability Award 2025 nord.com

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SUSTAINABILITY

BEYOND EFFICIENCY: LEAN MANUFACTURING For manufacturers trying to prioritise improvement projects, it can often mean focusing on sustainability or operational performance, yet the two needn’t be in competition. Here, automation specialist Bosch Rexroth looks at how lean manufacturing can support more sustainable production.

ustainability is increasingly important for manufacturers, but identifying practical improvements can be difficult. Rather than treating it as a separate objective, businesses should consider how improved production processes can support operational performance and more responsible use of materials, equipment and energy. Lean manufacturing provides a useful starting point. It focuses on identifying and reducing activities that do not add value. Unnecessary movement, overproduction, excess inventory, waiting time and avoidable defects all create waste. Addressing these inefficiencies helps manufacturers use existing resources more effectively while improving consistency and productivity. For Bosch Rexroth, improvement begins with understanding the complete production process. Combining automation expertise with connected technologies gives manufacturers greater visibility of system performance, helping teams identify bottlenecks, inefficient steps and opportunities for continuous improvement. This broader view is essential because changes in one area can affect quality, output and resource use elsewhere. Digitalisation can strengthen this approach. Bosch Rexroth’s ctrlX AUTOMATION is an open, modular platform connecting machine control, IT and IoT. It allows automation solutions to be tailored to specific requirements, while the Linux-based ctrlX OS connects components and supports data-driven production environments. Apps such as Node-RED and Universal Machine Connector can collect the data required for simulation applications and AI-integrated solutions. This can simplify data collection and processing, whether activity takes place at the edge or in the cloud. Connected information and greater visibility of equipment condition can then support better decisions about machine utilisation, production performance, and identify potential issues earlier for a more targeted approach to maintenance. However, technology alone is not the answer. The greatest opportunity often comes from combining digital tools with lean thinking and a clear understanding of where value is created across the entire production process. This is where Bosch Rexroth’s engineering expertise can

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add value. From automation and control technologies to software and connected solutions, Bosch Rexroth works with manufacturers and machine builders to develop production systems that are flexible, transparent and capable of continuous improvement. Its automation portfolio can span individual components through to complete systems, allowing solutions to be tailored to the application. The objective is to understand the processes: where time, materials and resources are being used, where waste occurs and where improvements can be made. As manufacturers look to improve productivity alongside their environmental performance, these priorities do not necessarily have to compete. By combining lean principles, engineering expertise and connected technologies, manufacturers can take a practical approach to reducing avoidable waste while continuously improving production. Ultimately, more responsible manufacturing starts with better understanding. boschrexroth.co.uk

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SUSTAINABILITY

ENGINEERING-LED SUSTAINABILITY Titan Enterprises is taking a practical, engineering-led approach to sustainability, integrating environmental considerations into product development, manufacturing, sourcing and customer applications.

or Titan Enterprises, sustainability sits firmly within the focus of reducing the environmental impact of its own operations, while also considering the wider lifecycle and industrial use of its products. As a specialist manufacturer of liquid flow measurement equipment, Titan prioritises how its technology, materials, manufacturing processes and engineering expertise can contribute to more sustainable outcomes throughout the lifecycle of its products and the applications in which they are used. This approach is reflected in Titan’s Environmental Policy, which identifies reducing waste, energy consumption and transportation, reviewing product design and investigating alternative materials as key areas for continuous improvement. “Environmental responsibility has to be approached as a long-term engineering challenge,” says Neil Hannay, Senior R&D Engineer at Titan Enterprises. “It is about the decisions we make from the raw materials and how we manufacture, to the energy we consume and how our products enable customers to adopt new technologies and processes.”

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REDUCING ENVIRONMENTAL IMPACT AT SOURCE

Energy consumption has been a key area of focus for Titan, a milestone being the installation of two solar panel arrays at its UK manufacturing facility in 2024, helping to generate renewable electricity and offset approximately six tonnes of CO₂ annually. Alongside renewable energy generation, Titan is improving energy efficiency within its facility, from upgrading lighting and reviewing manufacturing processes to identifying opportunities to reduce consumption. Waste reduction is another area where practical changes can deliver tangible benefits. Moving from printed technical documentation to QR-code-based digital information, as well as replacing traditional packaging materials with recyclable cardboard and biodegradable fillers, has reduced paper use and improved access to technical data. Titan is also investigating opportunities to recycle old or rejected electronic PCBs generated through R&D and production, extending the focus on resource efficiency beyond the manufacturing process itself.

SUSTAINABILITY ENGINEERING FOR A CHANGING MATERIALS LANDSCAPE

Product development is another important component of Titan’s sustainability strategy. The company is actively investigating alternative materials to reduce reliance on substances of increasing environmental concern, while still meeting the demanding performance, regulatory and durability requirements of flow measurement applications. This includes ongoing evaluation of PFAS-free materials for its turbine flowmeter range as regulatory scrutiny of fluorinated substances increases. Titan is currently testing alternative materials to assess their chemical resistance, dimensional stability, longevity and flow performance within the complete flowmeter design.

SUPPORTING CUSTOMERS IN THE TRANSITION

Titan’s sustainability approach also extends to the applications where its flowmeters operate. A case in point is the company’s work with Grinsty Rail, whose vehicle-mounted de-icing systems moved towards a more environmentally friendly, biodegradable de-icing fluid. The change in fluid formulation created an engineering challenge. The alternative fluid had different physical characteristics, including higher viscosity and a colour that affected the operation of the existing optical flow sensors used in the system. Titan worked with Grinsty Rail to identify a suitable alternative, with their OG2 oval gear flowmeter selected to provide reliable measurement of the new fluid. The case demonstrates how adopting a more environmentally responsible fluid can create secondary technical challenges – and how flow measurement technology can play an enabling role in the transition to more sustainable products and processes.

SUSTAINABILITY THROUGH PRECISION

The ability to accurately control and measure liquid volumes is itself an important part of resource efficiency. Whether dosing chemicals, lubricants, cleaning agents or other process fluids, precise flow measurement can help minimise over-dosing, reduce waste and ensure that processes operate consistently. Titan’s development of increasingly capable low-flow technologies, including ultrasonic measurement below 2 ml/min, is opening opportunities where precise control of small liquid volumes is critical.

ENGINEER SUSTAINABLE SUPPLY CHAINS Alongside product innovation, Titan is strengthening

Environmental responsibility has to be approached as a longterm engineering challenge. Neil Hannay, Senior R&D Engineer at Titan Enterprises.

relationships with UK-based suppliers, while diversifying its supply chain and exploring alternative materials to enhance resilience and reduce environmental impact. “Working closely with our suppliers gives us much greater visibility of what is possible,” says Jeremy Thorne, Operations Manager at Titan Enterprises. “It enables us to investigate different materials and manufacturing approaches while maintaining the quality and reliability our customers expect.”

LONG-TERM SUSTAINABLE GROWTH

Titan recognises that there is no single change that will make manufacturing sustainable. Instead, the company is taking a cumulative approach, combining renewable energy, waste reduction, responsible material selection, supply chain development, product longevity and engineering innovation. This also reflects the company’s wider commitment to continuous environmental improvement under its Environmental Policy. As Titan looks towards the future, sustainability will remain closely linked to its investment in R&D and its relationships with OEMs and end users. From helping customers measure alternative, environmentally responsible fluids to developing flowmeters using new materials and technologies, the company sees precision flow measurement as an important part of the wider engineering response to environmental challenges. “Our objective is not to treat sustainability as a separate initiative,” concludes Neil Hannay. “We want it to become part of how we think about design engineering, manufacturing and supporting our customers. By making considered improvements across the business, we can reduce our own environmental impact while helping customers develop more efficient and sustainable systems.” For more information, visit Titan Enterprises’ website. flowmeters.co.uk

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SUSTAINABILITY

INDUSTRIAL ETHERNET IN ENERGY EFFICIENCY As the industry moves towards renewable energies and energy generation becomes more decentralised, Industrial Ethernet and SPE networks are playing a significant role in integrating energy sources and consumers to the energy grid.

ingle Pair Ethernet (SPE) as a transmission protocol is already widely standardised today. It ensures the cost-effective use of Ethernet in every aspect of industrial automation by using one pair of wires to transmit data at speeds up to 1GBit/s. This makes SPE ideal for industrial applications in the age of Industry 4.0 and IIoT. SPE, delivered via HARTING’s T1 Industrial connector, allows equipment to connect via end-to-end IP-based communications right up to the field level. The T1 Industrial supplies both data and power via Power over Data Line (PoDL) across a single pair of wires in an IEC 63171-6 industrial interface, bringing Ethernet from the cloud to every sensor and enabling Industry 4.0. Industrial Ethernet and SPE networks are also of crucial significance in the transition to renewable energy. Only by expanding data networks to every energy consumer will efficient and intelligent energy infrastructures be enabled. Ethernet, as a reliable and widely used technology for data transmission, plays a key role in integrating energy sources and consumers into the power grid. The move away from fossil fuels towards renewable energies will lead to a change in energy sources and an increasing decentralisation of energy generation. Wind farms, solar power plants and other renewable sources are being built where they are most efficient, as is the production of alternative energy sources such as hydrogen. This is where networking enters the picture. Ethernet enables efficient communication and control between decentralised energy systems and the power grid. Networking allows renewable energy sources to be interconnected so they can share surplus energy and compensate for high levels of demand. This significantly improves the overall efficiency and reliability of the electricity grid. In addition, communication via Ethernet enables real-time monitoring and control of energy generation, allowing for adaptation to current demand. Ethernet also promotes the development of smart grids. By implementing intelligent technologies and communication systems, consumers will be able to manage their energy consumption more efficiently. This allows for improved integration of electric vehicles, home storage systems and other energy-efficient technologies. Networking is also crucial for the success of energy

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management systems within industry. Ethernet-based solutions enable the comprehensive monitoring and analysis of energy consumption in real time, which in turn leads to better energy efficiency and lower costs. By intelligently analysing data over longer periods of time, algorithms can predict demand within a certain framework. Implementing intelligent technologies and smart grids will create sustainable and efficient energy infrastructures that are essential for a successful energy transition. To learn more about Single Pair Ethernet, please visit HARTING’s website. harting.com/en-GB/single-pair-ethernet

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SUSTAINABILITY

DECARBONISING THE LOADING BAY While electrifying equipment is helping manufacturers to decarbonise their manufacturing operations, there are often more fundamental operational inefficiencies to resolve first. Here, Wouter Satijn, Chief Revenue Officer, Joloda Hydraroll, explains why electrification isn’t enough.

anufacturers are investing heavily in decarbonisation: electrifying equipment, improving building efficiency and generating renewable energy on site. Yet one part of the operation is frequently overlooked: the loading bay. A business can electrify its forklift fleet and still retain an inefficient loading process. If every pallet must still be driven individually into a trailer, the energy source may have changed, but the repeated movements, vehicle dwell time and bottlenecks remain. Electrification is not the same as elimination. The sustainability question is not only “what powers the forklift?” but “does that forklift journey need to happen at all?” For high-volume, repeatable operations, automated trailer loading can transfer complete loads between the dock and trailer in minutes rather than moving pallets one at a time. This reduces repetitive forklift miles and can shorten vehicle turnaround times. In a closed-loop shuttle operation, such as moving finished goods from a factory to a warehouse and returning for the next load, faster loading and unloading can reduce the number of forklifts, trailers and tractor units needed to move the same volume of goods. Fewer movements can also reduce congestion around the loading bay. But the opportunity does not stop at the factory-towarehouse shuttle. Automated loading can also support the next stage of the journey, moving finished products from a manufacturer’s warehouse to a customer or retailer distribution centre. Rather than loading the outbound trailer pallet by pallet with a forklift, the manufacturer can automate the process, whether the trailer is its own, operated by a 3PL, or provided by the customer. This means fewer forklift movements and faster turnaround at the loading bay. Decarbonisation is not only about consuming less energy; it is also about needing fewer assets to do the same job. Where the same throughput can be achieved with fewer forklift miles, fewer forklifts and, in some operations, fewer trailers and tractor units, both efficiency and environmental performance can improve. Reduced

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truck dwell time also keeps vehicles moving and improves asset utilisation, rather than leaving them waiting at the dock. Faster, more predictable loading can also reduce the space required for staging goods, forklift parking and charging, and waiting trailers. Better visibility of loading times and asset utilisation can highlight further opportunities to reduce waiting time, energy use and waste. Automation should not be treated as inherently sustainable. The real question is: where can automation remove unnecessary movement, assets, energy use and delay? For manufacturers serious about decarbonisation, netzero thinking cannot stop at the production line. The loading bay and onward journey need to be part of the strategy too. Before investing in another electric forklift, it may be worth asking a more fundamental question: do we need that forklift movement at all? joloda.com

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SUSTAINABILITY

PIPE TEMPERATURE AND ENERGY EFFICIENCY Temperature sensors reveal issues with heating and cooling systems before they impact industrial processes. But by making inefficiencies visible, they can also support sustainability efforts. Here, UK temperature sensor manufacturer Labfacility looks at how pipe temperature monitoring supports energy efficiency.

or manufacturers looking to reduce energy consumption, a useful starting point is understanding where heat is going. Heating and cooling are essential to many industrial processes, but an incorrect setting, unexpected heat loss or equipment running longer than necessary can add to operating costs. Temperature measurement gives engineers the information needed to investigate these issues. By monitoring key points in a process, engineers can compare actual conditions with the intended operating range, identify changes over time and check the effect of any adjustments made. Consistent readings can also provide a baseline against which future improvements are assessed. Pipework is one place to start. Surface temperature readings can help indicate how a heating or cooling system is behaving. For example, a change in readings at a consistent measurement point may prompt an engineer to check the process, insulation or control settings. The reading alone will not identify the cause, but it can show where further investigation is needed. UK temperature sensor manufacturer Labfacility offers a pipe surface jubilee clip style thermocouple for measuring temperature on suitable pipework. Its stainless steel clamp has an adjustable diameter, helping position the sensor against the pipe surface. The grounded tip is designed for fast response, allowing changes in surface temperature to be detected promptly. Type K and Type J versions are available, with fittings for pipe diameters of 13–20 mm, 22– 30 mm, 30–45 mm and 40–55 mm. The sensor is supplied with glass fibre insulation and stainless steel overbraid. As with any surface measurement, installation and interpretation matter. The sensor needs good contact with the pipe. It measures the outside surface temperature, which may differ from the temperature of the fluid inside. Engineers should consider insulation, ambient conditions and the purpose of the measurement when assessing the results. The greatest value comes from using temperature data to guide action. If readings show an unexpected trend, a team can inspect the equipment, make a change and measure again. Recording results alongside operating conditions helps distinguish a persistent problem from

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a normal change in production demand. Comparing readings taken under similar conditions makes changes easier to evaluate. This approach can support wider sustainability work by helping manufacturers identify opportunities to improve energy efficiency and check whether changes have delivered the intended result. It also provides useful evidence for maintenance and process reviews. A temperature sensor cannot deliver an energy saving on its own. It makes conditions visible, giving engineers a stronger basis for decisions that can improve efficiency while maintaining process performance. labfacility.com

SUSTAINABILITY

PRESSURE MEASUREMENT MATTERS FOR HYDROGEN

Hydrogen is attracting increasing attention as part of the transition towards lower-carbon energy. From green hydrogen production and storage to transport and industrial applications, the technology is developing rapidly. But behind every hydrogen system is a less glamorous, yet essential, requirement: accurate pressure measurement.

ressure plays a role throughout the hydrogen value chain. Electrolysers produce hydrogen under pressure, while compression systems increase pressure for storage and transport. Hydrogen can also be stored in high-pressure vessels before being delivered to where it is needed. This creates some interesting challenges for pressure measurement. Hydrogen is a very small molecule, which means it can behave differently from many conventional gases. Pressure sensors and transmitters must therefore be carefully designed and selected to ensure reliable performance when exposed to hydrogen over long periods.

MATERIALS MATTER

The materials used in a pressure transmitter can make a significant difference when measuring hydrogen. Components need to be compatible with the medium, while the sensing technology must provide stable and repeatable measurements. This is particularly important in high-pressure applications. Hydrogen systems can operate at pressures of hundreds of bars, so pressure measurement equipment needs to cope with both the pressure itself and the characteristics of the gas. At ESI Technology, hydrogen compatibility is considered during the design and development of specialist pressure measurement solutions. ESI’s silicon-on-sapphire (SOS) technology provides a robust sensing platform, while its hydrogen-compatible products have been developed for applications where material compatibility and long-term stability are important.

FROM PRODUCTION TO STORAGE

Pressure measurement requirements can vary considerably depending on where the transmitter is used. In hydrogen production, pressure measurement can help monitor processes within an electrolyser system. During compression and storage, transmitters may need to withstand much higher pressures. Equipment used in these applications must also be suitable for the

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surrounding environment and meet the relevant industry requirements. For ESI, this means looking beyond simply measuring pressure; the pressure range, materials, sensing technology, temperature, connection and environmental conditions all need to be considered together. As the hydrogen economy develops, pressure measurement will continue to be one of the small but important pieces of the wider system. Reliable measurements help engineers understand what is happening inside the process and support safe, efficient operation. Hydrogen may be one of the smallest molecules on the planet, but measuring it reliably is no small challenge. For more information about ESI’s hydrogen-compatible pressure measurement solutions, visit the company’s website. esi-tec.com

SUSTAINABILITY

LASER CLEANING BOOSTS SUSTAINABILITY A state-of-the-art laser cleaning machine has significantly reduced Wolverhampton Electro Plating’s (WEP) carbon usage, and the business believes greater sustainability benefits are still possible.

EP, part of the Anochrome Group, is the only metal finisher in the world to invest in groundbreaking new laser technology for cleaning and pre-treatment of parts. The SLCR Lasertechnik LAMA™ machine challenges the traditional pre-treat processes for zinc flake application by dip spin by effectively cleaning nuts, bolts and parts in bulk without the need for water, chemicals or shotblasting. Laser cleaning reduces WEP’s carbon footprint by more than 35 per cent in comparison with traditional techniques and saves tens of thousands of cubic litres of water over a year. While results from the first six months of operation have been impressive, leaders at WEP believe there is still more to come. Denis Rainbird, General Manager at WEP, said: “Before protective coatings are applied, parts need to be thoroughly cleaned. In the past this has been achieved in bulk processing with a series of chemical baths and rinses, often followed by shotblasting. “This uses substantial amounts of water, chemicals, electricity and gas, which is harmful to the environment. “The SLCR Lasertechnik LAMA™ machine is changing how we operate. We took delivery of the equipment in March after three years of regular dialogue, testing and meetings, and the results have been excellent. “We are ramping up capacity and discussions have already been held over whether we roll out more laser cleaning machines across the Group to further reduce our carbon footprint.” SLCR designed the technology in partnership with DÖRKEN. The machine is currently working at between 400kg and 500kg per hour, and it is hoped capacity could increase to 600 kg in the near future. It is unlikely that traditional, chemical-based pre-treat cleaning will ever be eliminated entirely since some parts are too large or awkwardly shaped to be put into baskets, but the Anochrome Group believes it is possible to get to the point where 80 per cent of parts are cleaned with laser technology within three years. In addition to the environmental benefits, the introduction of laser technology has the potential to extend the period between cleaning and coating

Denis Rainbird, General Manager at WEPbox application. Initial observations have been positive, although this benefit has not yet been formally proven. Denis added: “During the testing period, SLCR were cleaning samples by laser and shipping them back to Anochrome for further coating, but the parts were held up by customs for around six weeks. “We eventually received the parts and assumed they would be ruined. We were surprised to discover they were in almost perfect condition.” The purchase of the LAMA machine follows other recent investments at WEP, including the introduction of a fourth dip-spin line last year. WEP specialises in bulk-processing capabilities via dip spin lines, barrel zinc and zinc nickel electroplating lines, together with mechanical barrel plating of zinc, tin zinc and Almac. anochrome.com

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SUSTAINABILITY

RECYCLING WASTE FUEL OIL FOR HEAT Rather than being discarded, waste oils and fuels can be repurposed as fuel for industrial heat generation, recovering useful energy from materials that would otherwise go to waste. North Ridge Pumps shares how a manufacturer of outflow heaters benefited in practice.

ontaminated waste oils and fuels arise from a variety of sources, ranging from misfuelling incidents, used cooking oils and accumulated sludge from drained fuel tanks. Despite their waste classification, these materials can offer valuable opportunities for energy recovery. A manufacturer of outflow heaters was looking for 8 transfer pumps to handle D recycled fuel oil at around 10 cP viscosity. Due to the fuel’s high sulphur content, previous contamination and quality, its only viable use was for process heating of fluids in a variety of projects for Bitumen/Asphalt plant, which would otherwise use virgin fossil fuel for heating. Investing in the right pumping and heating solution can deliver significant savings throughout the life of a system. By using recovered fuel oil on site, businesses can reduce heating costs, avoid waste oil disposal expenses and improve the overall return on their investment.

NORTH RIDGE PUMP’S SOLUTION

The manufacturer’s heaters had a feed requirement of 50 L/min (3,000 L/h), and the pumps needed to handle the fuel at temperatures between 80°C and 100°C and produce pressures of up to 4 bar for optimal burning. As an independent pump manufacturer, North Ridge Pumps is not restricted to a single pumping technology, allowing it to select the most suitable solution for each application. Considering the varying viscosity of the fuel oil, the potential presence of solid particles and the need to maintain consistent pressure to the burners despite fluctuating flow requirements, North Ridge specified its DN range of progressing cavity pumps. Progressing cavity pumps are usually chosen for transferring waste oils and oil-water emulsions, as their low-shear pumping action minimises disruption to suspended oil droplets. Indeed, progressing cavity pumps were rated by the Society of Petroleum Engineers (SPE) in their research Paper SPE182041 as the preferred pump for transferring oil droplets. This was because the droplets were disturbed the least during handling when compared with pumps using lobe, vane and screw technologies. The DN range was chosen for this application as it

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incorporates a space saving compact design where the motor is directly coupled to the drive, an induction hardened rotor that resists pitting and wear, ensuring longevity and a patented pin joint, which enables the pump to freely rotate in either direction. In addition, they will handle the oil droplets gently, produce a constant volume of flow at varying pressures, are affected very little by changes in viscosity and handle solids without issue. These factors all help preserve the emulsion characteristics where required and improve the efficiency of downstream separation and filtration processes. northridgepumps.com 1. onepetro.org/SPE

Expert solutions for the metering, mixing and dispensing of all types of adhesives, resins and sealants as well as many other fluids and pastes.

Rockingham Systems are proud to announce the release of two new dispensing systems UDispense 1 and UDipsense 2, designed and controlled on a UR Robot, formally approved for use by Universal Robotic themselves. With native control on the robots, you can set recipes, control and oversee your dispensing setup, from the robot teach pendant itself, a fully integrated robotic dispensing solution. UDIspense 1 is for use in dispensing packaged materials such as syringes, cartridges and dual cartridges, whereas UDispense 2 is designed for use with bulk materials, this could be using a pressure tank or feed pump for low to medium viscosity materials or using a high-pressure ram pump for high viscosity paste like materials. Rockingham Systems can supply the full turn-key solution from tank to tip, or the system can be purchased as controller only and used with other dispensing hardware to ensure simple integration and setup for your Universal Robots dispensing application with all the controls you would expect from a precision dispense setup.

Adhesive Metering & Dispensing Systems

Sandwich Panel Systems

Turn-Key Automation

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6-axis Collaborative Robot Systems Cartesian Gantry Systems. 6-Axis Industrial Robot Systems. Fully Custom Automated Production Lines

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SUSTAINABILITY

DRIVING EFFICIENCY WITH DRIVE DESIGN Sustainability is influencing the way engineers design, manufacture and operate machinery. The focus is often on renewable energy, materials and manufacturing processes, but how energy efficient machines are when operating is also key. Central to a machine’s efficiency is the design of its drive system.

more energy efficient drive system can be the result of small adjustments that have a colossal impact over time. This is particularly the case for systems that run continuously or for many hours a day, which, over a machine’s life cycle, amounts to thousands of operational hours.

MAKING EVERY WATT COUNT

An energy efficient drive system relies on matching the motor, gearbox and drive system to the specific demands of the application. This can help avoid unnecessary energy consumption whilst still delivering the performance required. This is one of the driving principles behind compact, application-focused solutions such as Parvalux’s Compact Drive. Beyond making the drive smaller, the sustainability benefit comes from embedding efficiency into the overall engineering design.

COMPACT ISN’T JUST ABOUT SIZE

Space is an important consideration in machine design, and engineers are increasingly asked to fit more functionality into smaller footprints. The Compact Drive addresses this challenge by integrating motor and gearbox technology into a more streamlined package. Wider benefits of the Compact Drive system include fewer or smaller components, resulting in a more efficient use of materials and manufacturing resources.

BENEFITS OF LIFE CYCLE EFFICIENCY

Whilst there is little doubt that building a more energy efficient compact drive system has many benefits, measuring this efficiency over the whole life cycle can have wide-reaching implications. A drive that operates efficiently, reliably and for a long service life reduces the need for replacement, helping equipment operators manage energy consumption over a longer period. This is why factors such as efficiency, durability, maintainability and application suitability all have an important role to play in sustainable engineering. Sustainability, therefore, doesn’t mean investing in new technology; instead, it can be achieved by improving

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established technologies, and finding innovative ways of applying them.

PARVALUX YOUR EFFICIENT PARTNER

The transition towards more a sustainable industry requires contributions at every stage of the machine development. Drive systems are only one component, but by focusing on efficient motors and gearboxes, appropriate sizing and compact system design, engineers can ensure that energy use is optimised. Solutions such as the Parvalux Compact Drive demonstrate how modern drive technology supports this approach. It combines performance, integration and efficiency in a package designed around the needs of contemporary machinery and specific application requirements. For more information about the Compact Drive visit Parvalux’s website. parvalux.com

when space is limited Compact Drive 280mm x 104mm x 90mm

PMDC Equivalent 390mm x 178mm x 90mm

Equipped with integrated electronics and providing up to 60 Nm of nominal torque, the Compact Drive from Parvalux offers an average size reduction of 50% when compared to equivalent PMDC geared motor solutions. Contact your local sales engineer, found at parvalux.com/local-contact, to find out more

SUSTAINABILITY

UNDERSTANDING BATTERIES Complementary X-ray imaging and thermal measurements help engineers investigate battery structure and behaviour, while X-ray absorption spectroscopy adds insight into electrode chemistry. Quantum Design UK and Ireland details how understanding batteries is invaluable in electrification and renewables storage.

atteries underpin the electrification of transport and industrial equipment, while helping renewable energy systems match generation with demand. Their sustainability, however, depends on more than the energy they store. Manufacturing quality, operating efficiency and useful life all influence how effectively materials and resources are used. For engineers, this creates a practical challenge: understanding why a cell performs well, why another deteriorates, and which changes will improve reliability. Electrical measurements establish capacity, resistance and cycling performance, but they cannot always explain the underlying cause of a problem. Combining structural imaging, thermal measurements and chemical analysis provides a broader basis for investigation.

LOOKING INSIDE THE CELL

A battery is a complex assembly of electrodes, separators, current collectors and connections. Internal geometry matters because variations in assembly or damage can affect performance. Inspecting a cell without dismantling it helps preserve evidence that might otherwise be disturbed during preparation. ADVACAM WidePIX detectors provide photon-counting X-ray imaging for integration into radiography and computed tomography systems. Radiography produces projection images; CT combines multiple projections to reconstruct internal structure in three dimensions. In a suitably configured battery investigation, these methods can help assess electrode alignment, deformation, voids and other structural irregularities. WidePIX uses tiled detector technology to extend the imaging area. Spectral configurations, including WidePIX CHROMATIC, discriminate photons using energy thresholds, providing additional contrast based on differences in X-ray attenuation. This can help distinguish materials that are difficult to separate using a conventional greyscale image alone. The important consideration is the complete imaging arrangement. Detectability depends on the X-ray source, cell construction, scan geometry and reconstruction, as well as the detector. Pixel pitch alone does not establish

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Car battery the smallest defect a system can resolve. Selecting an appropriate configuration therefore starts with the feature the engineer needs to investigate.

FOLLOWING THE HEAT

Structural information becomes more useful when related to operating behaviour. Infrared thermography measures temperature distributions across visible surfaces, allowing engineers to follow how a cell, connection or module heats and cools during a test. InfraTec’s ImageIR camera series uses cooled infrared detectors and offers configurations suited to demanding research and measurement tasks. Depending on the model and optics, high spatial resolution, thermal sensitivity and acquisition speed support the study of local temperature differences and transient events. Trigger interfaces allow thermal acquisition to be synchronised with other test equipment. For battery development, this can support comparisons

SUSTAINABILITY

Lithium-Ion batteries

of charging strategies, cooling arrangements and connection designs. A repeatable hot spot may prompt investigation of a resistive joint, uneven loading or inadequate heat removal. In manufacturing, appropriately designed thermographic inspections can also support the assessment of coatings, separators and joining processes. Interpretation requires care. Thermography measures surface behaviour, so an internal heat source may appear later or spread across the casing. Emissivity, reflections, viewing angle and environmental conditions influence the measurement. Controlled procedures are essential when comparing samples or assessing a design change.

CONNECTING STRUCTURE AND BEHAVIOUR Consider an illustrative investigation in which one cell develops a warmer region than comparable cells during an identical load cycle. Thermal imaging identifies where and when the difference appears. X-ray imaging can then examine the corresponding internal region for a structural explanation. Electrical data helps determine whether the observation accompanies a change in resistance or capacity. These measurements provide complementary evidence rather than an automatic diagnosis. A visible irregularity and a thermal anomaly may be related, but that relationship needs testing. Repeated measurements under controlled conditions, supported where necessary by further analysis, help engineers distinguish a manufacturing issue from ageing or a test artefact. Recording state of charge, current, ambient temperature and sample history alongside each measurement makes comparisons more meaningful. A consistent sample identifier also helps teams follow the same cell through imaging, cycling and subsequent laboratory analysis. For electrification, the resulting evidence can guide cell selection, connection design and thermal management under demanding loads. For renewable energy storage, investigations can focus on repeated cycling, temperature

Sigray Li-Ion Battery Cathode on Sigray TriLambda

uniformity and degradation over extended service. In both settings, the aim is to translate observations into practical improvements.

ADDING ELECTRODE CHEMISTRY

Some questions require chemical information. Sigray’s QuantumLeap-H2000 brings X-ray absorption spectroscopy, or XAS, into the laboratory, with both transmission and fluorescence measurement modes. XAS probes selected elements to investigate their chemical state and local atomic environment. The near-edge region, known as XANES, provides information relevant to oxidation state, while extended fine structure, or EXAFS, supports analysis of neighbouring atoms and bond distances. For battery electrodes, these measurements can help researchers examine how transition-metal chemistry changes between charge states or after cycling. Fluorescence mode offers an option for samples that are challenging in transmission, subject to suitable preparation and measurement conditions.

BETTER EVIDENCE, BETTER USE OF RESOURCES

The sustainability value of battery investigation lies in the decisions it supports: identifying defects earlier, reducing avoidable rework, improving thermal design and understanding the mechanisms that limit service life. ADVACAM WidePIX and InfraTec ImageIR address complementary structural and thermal questions, with QuantumLeap-H2000 adding chemical insight where needed. For manufacturers and researchers, a well-designed measurement programme connects these observations with electrical performance. That understanding helps turn battery development into more reliable electrification and more effective renewable energy storage. qd-uki.co.uk

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SUSTAINABILITY

ROBOT ACCURACY AND THE CIRCULAR ECONOMY

Sustainability in manufacturing is often framed as a materials question: recycled content, renewable energy, lower-carbon logistics. Robot accuracy rarely makes that list, yet it should be a prominent consideration. INSPHERE, provider of intelligent automation solutions, makes a case for why robot accuracy belongs in the circular economy.

very robot cell drifts over time. Thermal variation, mechanical wear, payload changes and tooling movement gradually build up, causing deviations from the programmed path. Left unmeasured, this creates scrap, rework and unplanned downtime; each one a hidden material and energy cost, long before it reaches a sustainability report. For manufacturers under pressure to cut waste and support circular material flows, the impact is clear. A part machined, drilled or welded outside tolerance either becomes scrap, or consumes further energy and labour to correct.

WASTED RESOURCES

In aerospace and automotive cells, scrap linked to positional accuracy has been shown to run into hundreds of thousands of pounds a year, per cell. That is also hundreds of thousands of pounds of raw material, energy and process time that never reaches a usable product. There is an energy dimension too, one that sits alongside the robotics story this issue also covers. Every recalibration, program touch-up or reworked part consumes energy a right-first-time process would not. As robot cells run faster and closer to tolerance limits, that energy penalty scales with them, quietly working against the same efficiency gains automation is meant to deliver.

RELIABILITY AND CONSISTENCY ARE KEY

Circular strategies depend on consistency. Output that stays within specification is far easier to reuse, remanufacture or recycle at value; output that drifts out of tolerance typically is not. This is where INSPHERE’s IONA and ORA platforms contribute directly. IONA continuously measures what a robot is actually doing in production, rather than assuming it matches the original program. ORA compares that measured activity in a live digital twin and corrects it in-process, before drift becomes scrap.

LIVING UP TO OUR PROMISES

The same capability supports a second group of manufacturers: those building the equipment the

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sustainability sector itself depends on — wind turbine components, battery and EV assemblies, hydrogen and recycling infrastructure — where tolerances are unforgiving and the cost of failure is high. For these businesses, robot accuracy isn’t a productivity nice-to-have, it’s part of delivering on the sustainability promise their own product makes. Robot drift is inevitable. Treating it as a controlled variable turns automation into a genuine contributor to sustainability, not purely a commercial measure. If robot drift is costing material, energy and time, INSPHERE can help. IONA and ORA measure robot accuracy continuously and correct it in-process, keeping production within tolerance. Visit INSPHERE’s website for more information. insphereltd.com

The circular economy needs more accurate robots That’s where INSPHERE come in. Precise positional data from IONA.

A live digital twin and in-process control from ORA. Sensor data and robot control software work together turning robot drift into a controlled variable — cutting scrap, energy waste and rework across advanced manufacturing. Discover how improved precision can support your sustainability goals. Contact us today at insphereltd.com

Intelligent automation solutions

PUMPS & PUMPING SYSTEMS

ROSEMAUND FARM DISTILLERY At Rosemaund Farm Distillery near Hereford, where a new premium single malt English whisky is being produced, a Landia pump is playing a crucial role in the handling of the production site’s wastewater.

ocated where the highly successful Chase vodka and gin brand was produced until purchased by Diageo and moved to Scotland, the Landia pump (in a low-lying reception tank), transfers wastewater and run-off liquid from site up to two above-ground storage tanks. The Landia unit (a DG-I 50 4.0kW 3000rpm high-pressure chopper pump) has replaced an old positive displacement pump that was struggling with solid particles that were restricting flow, whereas the Landia Chopper Pump, with its external knife system continuously reduces particle sizes. “The old pump was adapted from a previous use,” said Distillery Manager Will Skinner, “and wasn’t really designed for an application where solids need to be dealt with efficiently. In addition to clogging up, it also didn’t have the capacity, so only half of the tank was being emptied. There was a cage around the old pump to protect it from solids, so it became a very messy and time-consuming drain on manpower to keep sorting it out.” The new setup includes a control panel and a continuous level measurement sensor that alerts the team at Rosemaund when the tanks are nearing time for the wastewater to be tankered away. Prior to the pump and

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sensor, a member of the Rosemaund team had to remain on standby to go to the site, including at weekends and especially during heavy rainfall. “We’re not on site 24/7 of course,” added Will Skinner, “so with the much heavier rainfall we get these days, it was important for us to futureproof the process by investing in a better, all-round automated solution that would also protect local watercourses. With whisky production we don’t have the same level of solids that we had from the potatoes for the vodka, but solids are inevitable in a waste stream, which we know that the Landia Chopper Pump will deal with very efficiently.” Following the purchase of the Chase vodka and gin brand, James Dashwood Chase began experimenting with whisky production and wood ageing in 2012, eventually leading to the eagerly anticipated release of the first Rosemaund 10-year-old single malt. With Herefordshire renowned for its cider production, and the cask warehouse surrounded by orchards, it is perhaps no surprise that apple blossom scent is often one of the first characteristics that people notice and savour when tasting Rosemaund whisky. landia.co.uk

Denmark is known for design icons. Ours is the Chopper Pump. Invented in 1950: Built to Last, easy to maintain. Read more at landia.co.uk

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SUSTAINABILITY

ENGINEERING WASTE OUT OF THE WORKPLACE Tork, a brand of Essity — a global, leading hygiene and health company — explains how considered hygiene and sanitation solutions can effectively reduce workplace waste to support waste-reduction and wider sustainability goals while bettering employee wellbeing.

anufacturers are routinely engineering waste out of production, through efforts to reduce electricity consumption of machinery, procuring packaging containing renewable or recycled materials and reducing impacts across supply chains. Yet the same scrutiny is not always applied to workplace hygiene systems. By examining dispensing, consumption, packaging, replenishment and disposal as one connected system, businesses can uncover opportunities to reduce waste while maintaining hygiene standards and operational efficiency.

BEYOND THE PRODUCTION LINE

With waste reduction already central to manufacturing operational practice, leaders can apply existing streamlining processes to workplace hygiene. Hand towels, toilet tissue, soaps and industrial wiping products are used every day across factories, workshops and communal areas. Individually, these consumables may seem minor, but their repeated use across a site can compound into considerable waste sources that are worth analysing. Naturally, employees use differing amounts of hygiene products when cleaning depending on the task, individual preferences and dispensing rate of the unit. For example, an employee may unintentionally take a cluster of industrial wipes for the sake of efficiency, inadvertently creating unnecessary waste. Intentionally designed dispensers that limit the output of hygiene products help reduce unnecessary consumption and lower product use and replenishment requirements.

HIDDEN WASTE IN WORKPLACE HYGIENE

Total hygiene throughout a workplace exists as a connected system of individual parts. Identifying sources of waste throughout the hygiene ecosystem enables targeted action by employers to reduce costs, not just waste. By applying an engineering mindset to the hygiene process, waste can be managed out where it matters. It may be excessive product being dispensed unnecessarily, inappropriate wiping materials being used for tasks or partially used refills being replaced prematurely. The solutions to these are categorically separate; they are

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achieved through either operational, product or process changes. With 44 per cent of machine operators stating workday interruptions of up to 20 times a shift due to fetching or disposing of wipes, situating dispensers close to workstations can reduce motion and inventory waste significantly1. Equally, training around efficient cleaning processes can prevent excessive waste.

DESIGNING OUT OVERCONSUMPTION

Procurement also plays a pivotal role in minimising waste in the hygiene process, with product selection directly influencing consumption habits. The principle is similar to process control in manufacturing: when the system controls the quantity delivered, there is less scope for unnecessary use. In practice, this can be achieved through one-at-a-time wipe and towel dispensers, controlled dosage soap systems, dispensers that protect unused materials through single-feed, or fully enclosed designs. This applies to both site washrooms and to the production floor, with towels, wipes and soaps used across both environments for different purposes. Tork found through a specialist lab report that switching to a limited towel dispenser reduced consumption by 28 per cent

SUSTAINABILITY

when compared to standard open-basket or basic stacked dispenser tissues2.

REMOVING WASTE FROM PACKAGING AND LOGISTICS

The product packaging components equally matter when assessing a hygiene system, as cores, wrappers and bulky refill packs can all add to waste volume. Industrial wiping and cleaning systems can reduce waste through product and packaging design. For example, packaging from selected Tork industrial cleaning cloths is made from 100 per cent recycled fibres and contains at least 30 per cent recycled plastic, while one-at-a-time dispensing options help operators take only the cloths they need. Some cloths are also suitable for repeated use, helping to reduce overall consumption. These examples demonstrate why product specification informed by verified lifecycle and packaging data should extend beyond using recycled materials alone. Engineers and procurement teams can ask how much packaging a product requires, how efficiently it occupies storage space and how its format affects handling. Any benefit should be assessed against the site’s layout. A compact refill format, for example, only becomes an operational advantage when storage and replenishment practices make use of it.

CONNECTING SUSTAINABILITY WITH OPERATIONAL EFFICIENCY

Maintaining and improving a hygiene system requires effort through checking dispensers, moving supplies, replenishing stock and removing waste. Reviewing these activities alongside consumption can reveal opportunities to simplify facilities operations. High-capacity wiping dispensers with easy-load features can reduce replenishment frequency and maintenance time; while positioning them close to workstations helps operators access the wiping materials they need without unnecessary journeys. This invites a lean-manufacturing perspective. Are staff making unnecessary journeys? Is

stock held where it is needed? Do servicing routines reflect actual demand? The answers will differ between sites depending on workforce size, shift patterns, layout and hygiene requirements. These factors should inform the design rather than adopting a standardised assumption about how often every dispenser needs attention.

A PRACTICAL HYGIENE WASTE AUDIT

A focused audit can turn these principles into action: • Map out consumption: identify where wiping and hygiene products are used. • Establish a baseline: record consumption, refill frequency and relevant waste. • Observe use: check for over-dispensing and mismatches between products and tasks. • Review the system: examine dispenser capacity, packaging, storage and servicing. • Compare alternatives: consider performance and lifecycle information alongside cost. • Pilot changes: test in one area and review the results before wider implementation.

HYGIENE AS A SYSTEM

Engineering waste out of workplace hygiene systems is a routine task that requires businesses to examine how products, dispensers, people and servicing routines work together, before making adjustments as necessary. By controlling unnecessary consumption, questioning packaging and using credible lifecycle information, manufacturers can make more informed choices. The same discipline used to improve production can help create workplace hygiene systems that use resources more efficiently while remaining effective and accessible. torkglobal.com 1. tork-images.essity.com/images-c5/338/410338/original/eu-eti2-2022-a-guide-toreducing-motion-waste-a4-gb.pdf 2. torkglobal.com/gb/en/sustainability/use-and-waste

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SUSTAINABILITY

EVIDENCE BEFORE ACTION Sustainability targets are easy to state. The harder task for manufacturers is deciding which projects deserve investment, demonstrating that changes work, and explaining results to finance teams, auditors and senior management. That requires more than estimates: it requires measured data.

ndustrial sites already generate information through utility meters, energy-management systems and equipment controls. Yet site-wide totals rarely explain how an individual compressor, production line or support system behaves. Demand also changes with shifts, throughput, start-up, shutdown and maintenance. Without time-based data at the point of use, avoidable consumption can remain hidden inside an apparently normal monthly figure. This challenge is familiar to Shane Kennedy, Environmental and Sustainability Lead at C&C Group’s Bulmers facility in Clonmel, Ireland. When assessing opportunities across the site, he found “a lot of quick, easy wins”, but also identified a fundamental obstacle: poor metering. His response was to strengthen decisions with measurement and verification. The principle matters because a sustainability proposal must survive scrutiny. A credible baseline helps teams quantify existing performance, compare options and establish what should be checked after implementation. As Kennedy put it, “You can’t ask why without data.” The data does not make the decision, but it gives engineers the evidence needed to ask better questions. At Bulmers, portable Tinytag Energy Loggers have supported investigations involving compressed air, lighting, LED upgrades and electric-vehicle charging infrastructure. When Kennedy compared logger results with the existing energy-management system, the exercise revealed an unexpected power-factor issue on a compressor. Independent measurement did more than confirm a saving; it challenged the reliability of an existing assumption and directed attention towards a specific problem. This is where targeted energy logging adds value. Temporary measurement at equipment or process level can record current, voltage, power, power factor and energy over time. Teams can examine operating patterns, investigate abnormal

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loads and compare performance before and after a change without treating the logger as a permanent billing meter. A useful study still needs a clear question. What asset is being assessed? Which operating conditions must be recorded? Is the baseline representative? What other factors changed during the comparison? Measurement without context can create false confidence, so production schedules, maintenance activity and process demand should be considered alongside the energy trace. For manufacturers, sustainability becomes actionable when ambition is connected to evidence. Measured baselines can strengthen business cases, support verification and help teams prioritise improvements rather than relying on generalised assumptions. Kennedy’s conclusion was simple: “It’s all about the data.” The most productive starting point is therefore not a promised saving, but a well-defined question, an appropriate measurement plan and the willingness to act on what the evidence reveals. That is how sustainability moves from aspiration to accountable, repeatable practical industrial improvement. For more information about energy efficiency in industry and manufacturing, visit: geminidataloggers.com/energy-in-industry

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TRUSTED ENVIRONMENTAL MONITORING EXPERTISE FOR OVER 40 YEARS

SUSTAINABILITY

AUTOMATED LAYUP IN CARBON FIBRE Published figures put production waste in aerospace composites at 20 to 30 per cent. Pravin Luthada, CEO and co-founder, Addcomposites, explains how automated fibre placement (AFP) reduces it, where it falls short, and what that means for manufacturers facing cost and carbon pressures.

ollow a roll of carbon fibre prepreg from the freezer to a cured part and material is lost at almost every step. A research project description from Centexbel1, a Belgian textile research centre, puts production waste in aerospace composites at 20 to 30 per cent. A case study at one aerospace manufacturer identified layup as its main source of prepreg scrap, citing a figure of 35 per cent2.

WHERE THE WASTE GOES

The first loss is in kitting. Plies are cut from a roll 1 to 1.5 metres wide, and even with nesting software, curved, tapered and 45-degree plies rarely fit perfectly on a

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rectangular roll. Every ply also carries a positioning margin that is trimmed off later. Offcuts are often too small, cut at the wrong orientation, or no longer traceable, so they are binned. Out-life is another loss: prepreg keeps curing at room temperature, so a delayed job can expire before it is laid. Then come scrapped parts: wrinkles, misplaced plies and voids found at inspection can write off a whole laminate. In my experience, most manufacturers don’t have a consolidated waste figure, because it is spread across purchasing, the cutting room and quality, and no one function tracks it end-to-end.

SUSTAINABILITY WHAT THE NUMBERS LOOK LIKE

Buy-to-fly is the weight of material bought divided by the weight in the finished part. With a waste fraction w, buy-to-fly is 1 ÷ (1 − w). So, 20 per cent waste gives 1.25, 30 per cent about 1.43 and 35 per cent about 1.54. In my view, that is a realistic range for manual prepreg layup on aerospace parts. For AFP, a Netherlands Aerospace Centre (NLR) paper3 cites scrap rates of 5 to 20 per cent in work from 2008 to 2011. That is a buy-to-fly of roughly 1.05 to 1.25. These are published ranges, not our customer data. Shape matters most. On a flat rectangular panel, a good ply cutter wastes little and the gap is small. On curved parts with tapers, cut-outs and many ply drops, the gap opens up.

DRAWING EACH PLY INSTEAD OF CUTTING IT

I describe AFP as drawing each ply with a pen instead of cutting it out with scissors. The head feeds narrow tows, typically 6 to 25 millimetres wide on aerospace machines, heats them and presses them onto the tool with a compaction roller. Tows have cutters, so a course starts and stops at the ply boundary and cut-outs are left empty. At angled edges, square-cut tows end in a staircase. A coverage setting decides whether tows stop early, leaving small gaps, or late, leaving overlaps; many programmes use around 50 per cent as a compromise. The process has its own defects, including gaps, twisted tows and tows bridging concave corners. Fix them on the ply being laid, rather than finding them after cure when the whole part is lost. Simulating the layup first catches most geometric mistakes on screen.

THE MATERIAL COST QUESTION

Slit tape costs more than wide prepreg, because it is slit, spooled and held to tight width tolerances. Depending on material, supplier and tolerance, the premium can range from modest to roughly double. The break-even is simple: divide your manual buy-to-fly by your AFP buy-to-fly. At 1.5 and 1.1 the ratio is about 1.36, so the saving covers a tow premium up to 36 per cent. Above that, the case must come from labour, scrap and quality. With illustrative round numbers, finished parts containing 1,000 kilograms of prepreg, laid by hand at a buy-to-fly of 1.5 and €80 a kilogram, need €120,000 of material. With AFP at a buy-to-fly of 1.1 and a 30 per cent tow premium, they need about €114,000. On expensive parts, avoiding even a few scrapped parts a year can outweigh that offcut saving.

WHERE AFP FITS, AND WHERE TO START

The biggest difference comes on the parts hardest to lay by hand: doubly curved shells, variable thickness, many ply drops and expensive aerospace-grade material. In my view, geometry matters more than volume. Because AFP needs no ply kits or cutting templates, a change to the ply layout means a new program rather than new ply kits. That makes small batches practical, especially with a single-tow

head such as our AFP-XS on an existing industrial robot. Hand layup remains the better choice for small flat parts that nest well, features the roller cannot reach, and woven fabric designs. AFP is still not zero waste. Tow restarts, trim allowances, spool ends and process trials all consume material. Studies cited by University of Nottingham4 researchers put virgin carbon fibre production at roughly 200 to 600 MJ/kg. An earlier Oak Ridge National Laboratory5 assessment estimated that making carbon fibre takes around 14 times the energy needed for steel. Recycling helps, but I see reducing waste upfront as the bigger lever. If you can do only one thing this year: measure. Weigh what you buy and what ends up in finished parts for your top five parts by material cost. Take the one with the worst buy-to-fly and the most expensive material. Ask any automation supplier to simulate that part and show you its predicted material use, not brochure figures. addcomposites.com 1. centexbel.be/en/innovation/research/reprec 2. wsg.washington.edu/wordpress/wp-content/uploads/SEKISUI_CaseStudy_ Dec2023.pdf 3. reports.nlr.nl/bitstreams/d427c6f0-1508-45bb-96d4-578a53cf6e57/download 4. nottingham-repository.worktribe.com/OutputFile/880172 5. ornl.gov/publication/life-cycle-assessment-carbon-fiber-reinforced-polymercomposites

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DRIVES, MOTORS & CONTROLS

MOTOR CONTROL FOR MODERN AUTOMATION Ahead of Invertek Drives exhibiting the next-generation Optidrive E4 at SPS in Germany, learn how the drive delivers smarter motor control for modern automation.

he Optidrive E4 is the latest general-purpose variable frequency drive (VFD) from Invertek Drives, part of the Sumitomo Heavy Industries, Ltd. (SHI) group. Engineered for modern automation systems, the Optidrive E4 builds on the global success of the Optidrive E3, delivering enhanced diagnostics, improved connectivity and advanced motor control while retaining Invertek’s renowned ease of use. Rhydian Welson, Sales & Marketing Director at Invertek Drives explains: ‘’The E4 platform provides a strengthened technical foundation for future development and wider application coverage. It has been designed to support the evolving needs of OEMs, machine builders and industrial users who require efficient, flexible and reliable motor control solutions. As automation systems become more advanced, customers demand greater functionality, easier integration and improved performance.’’ The Optidrive E4 features embedded diagnostics, built-in flight recorder, dual-channel SIL3 Safe Torque Off (STO), USB-C Bluetooth and Industrial Ethernet communications for live system integration. The E4 has been designed to support a wide range of motors, including IE2 and IE3 induction, AC PM, brushless DC, SynRM, LSPM and hybrid permanent magnet assisted reluctance (PMAREL) motors, delivering future-proof compatibility with high-efficiency motor technologies. Invertek’s precise current control algorithms make this possible, ensuring optimum torque production, superior thermal management, reduced electromagnetic interference (EMI) and a built-in C1 EMC filter. The Optidrive E4 includes a dualchannel Safe Torque Off (STO) system, certified to SIL3 and PL e/Cat 3. STO provides robust protection in safetycritical applications.

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E4 is ideal for applications such as CNC machining, automated cells, materials handling and high-speed packaging lines. Integrating the stop function into the drive simplifies safety-circuit design, removes the need for external contactors and speeds up emergency stops. The drive’s communication platform has been improved. With Industrial Ethernet interfaces, including PROFINET, EtherCAT, and Modbus TCP, allowing real-time data exchange for precision control and diagnostics. This supports predictive maintenance strategies and integration with Industry 4.0 and IIoT systems. The flight recorder provides key operational parameters, delivering real-time data for diagnostics and minimised downtime. The USB-C connectivity allows for in-box programming without mains power or removing the drive from its packaging. Bluetooth also provides remote commissioning and monitoring using a smartphone and Invertek’s OptiTools Mobile App, making it a great feature for when drives are installed in confined or difficult to access locations. Every E4 drive has a unique QR code, offering instant access to the Digital Optidrive Passport. This online resource brings together drive data including datasheets, ecodesign information, factory test certificates and product documentation. It allows engineers, OEMs and installers to easily find everything they need, making commissioning, traceability, and lifecycle support much easier. Invertek will be exhibiting its latest Optidrive E4 alongside its core product range at SPS in Germany. Find them at Hall 3A stand 455, or visit the company’s website. invertekdrives.com

Invertek 2026 E4 Overview @ SPS 1.01 MEPCA (210mm x 297mm) 3mm Bleed.indd 1

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INDUSTRIAL AUCTIONS

PLAN MACHINERY DISPOSAL EARLIER When the time comes to replace assets, investment in new machinery takes centre place. But what about the equipment being replaced? Commercial asset disposal specialist BPI says manufacturers should plan machinery disposal alongside their next investment.

or most manufacturers, the decision to invest in new machinery is carefully considered. Budgets are approved, production requirements assessed and installation planned. But what happens to the equipment being replaced can often be an afterthought. That can be costly. Machinery that is still operational, well maintained and in demand can attract significantly more interest than equipment that has been disconnected, left idle or moved into storage. Planning disposal alongside investment gives manufacturers more options. Equipment can be marketed while it is still in production, helping businesses maximise its value while continuing to use it until replacement machinery is ready. It can also free up valuable floor space and reduce the costs associated with storing, maintaining and securing equipment that is no longer required. This is where BPI helps manufacturers. BPI specialises in the disposal of commercial and industrial machinery through online auctions, connecting sellers with a broad market of buyers looking for used equipment. The auction model gives manufacturers access to multiple potential buyers rather than relying on a single private sale or trade-in. Assets are professionally catalogued with detailed specifications, photography and video, then

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promoted through targeted marketing to reach relevant industries and buyers. The process also needs to work around production. For many manufacturers, machinery cannot simply be switched off and removed because a sale has been agreed. BPI can market equipment while it remains operational, with collection then planned around the installation of replacement machinery, scheduled shutdowns or other operational requirements. A recent example is BPI’s work with H+K International, where more than 200 engineering and fabrication assets were sold from the company’s Rugby facility. BPI managed the marketing, buyer open day, decommissioning, lifting and collection programme, completing the disposal within six weeks. For manufacturers investing in new equipment, considering the resale value of the machinery being replaced at the same time can make good commercial sense. Planning disposal early can help maximise the value of existing assets, minimise disruption and give productive machinery a second life with another business. For more information, visit BPI’s website. bpiauctions.com

Investing in new machinery? Make sure your old equipment works hard for you too. When it’s time to upgrade your machinery, BPI provides an auction solution for existing equipment, helping manufacturers maximise asset value while minimising disruption to their operation. Minimise operational disruption Maximise asset value Flexible around your schedule Fast, hassle-free service

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TEST & MEASUREMENT

COMPACT, HIGH-SPEED SPECTROSCOPY Optical spectroscopy provides precise, real-time analysis across industries such as pharmaceutical manufacturing, food processing, and biotechnology. Hamamatsu Photonics recently released the FTIR Engine C16511-01, a compact, high-speed nearinfrared spectrometer explicitly designed for robust industrial environments.

ptical spectroscopy is a technique that analyses how light interacts with matter to determine its physical, chemical, or structural properties, using light in the UV, visible, or infrared wavelengths. Traditional spectrometers often lack the compactness and speed needed for effective integration into real-time, inline industrial processes. USB connectivity, commonly used in portable devices, limits communication speed and reliability, impeding seamless integration into industrial automation.2 Additionally, traditional diffractive spectrometers must compromise between spectral resolution and speed, a compromise not required by FTIR spectrometers.

INTRODUCING THE FTIR ENGINE C16511-01

The FTIR Engine C16511-01 integrates advanced Fourier Transform Infrared (FTIR) technology within a compact, rugged enclosure. Its design significantly advances industrial spectroscopy by overcoming traditional limitations through improved connectivity, speed, and reliability. The optical interferometer in the C16511-01 features a built-in light input section, beam splitter, fixed mirror, movable mirror (ϕ3 mm), and photodetector. The photodetector precisely captures light intensity signals varying with the position of the movable mirror. These signals undergo a Fourier transformation to generate accurate optical spectra. The built-in semiconductor laser (VCSEL: vertical cavity surface emitting laser) continuously monitors the movable mirror’s position, ensuring consistently high wavelength accuracy.

VERSATILE INDUSTRIAL APPLICATIONS

The FTIR Engine C16511-01 addresses diverse analytical needs: • Industrial Quality Control: Real-time inline process analysis. • Pharmaceutical Inspection: Rapid, non-destructive medicinal product analysis. • Food and Agricultural Testing: Immediate contamination detection and quality assurance on production lines.

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• Bioprocess Analysis: Continuous monitoring of biological reactions in biotech industries. • Material Identification and Plastic Sorting: Efficient sorting and recycling of materials, enhancing sustainability. The FTIR engine comes equipped with intuitive evaluation software for data acquisition, measurement condition configuration, and result visualisation. Disclosed DLL specifications allow custom software solutions tailored to specific analytical processes and integration requirements. Supporting accessories such as vibration isolation tables, specialised optical fibre cables, a fibre coupled diffused reflection light source (the L16462-01) and flexible power solutions (12 or 24 V) further simplify integration and enhance performance.

CUSTOMER BENEFITS

The FTIR Engine C16511-01 delivers clear operational advantages: • High precision and speed enabling quick decisionmaking and improved quality assurance. • Rapid and reliable data transmission via Ethernet. • Improved robustness reducing downtime and maintenance requirements. • Simplified integration, enhancing flexibility across various industrial setups. Hamamatsu’s FTIR Engine C16511-01 sets new standards in industrial spectroscopy, delivering significant improvements over previous models. Visit Hamamatsu at stand J123 at Advanced Engineering 2026 to discover how this advanced solution can enhance your analytical capabilities. bit.ly/4jogqS9

EMAIL: info@hamamatsu.co.uk TEL: (+44) 1707 294888

Advanced Engineering Visit Hamamatsu Photonics at Stand J123 to discover high-performance optical solutions for manufacturing.

Find out more about our solutions Light sources

Optical sensors

• LEDs (UV – IR) • Excimer Sources • Quantum Cascade Lasers (QCLs) • Deuterium and Xenon Lamps • Extreme Ultraviolet (EUV) Light Sources • Laser-Driven Light Sources (LDLS) • Supercontinuum White Light Lasers

• Mini-Spectrometers • Photodiodes and Avalanche Photodiodes (APDs) • Multi Pixel Photon Counters (MPPCs or SiPMs) • Infrared Detectors • X-Ray Flat Panel Sensors • Photomultiplier Tubes (PMTs) • VIS/NIR/X-ray Cameras

4th- 5th November 2026 Find us at - NEC, Birmingham – J123

TEST & MEASUREMENT

CURE MONITORING WITH THAT PHOENIX FACTOR When it comes to coating quality, the ability to monitor product temperature through the cure oven is crucial for achieving the cure schedule recommended by the coating supplier. PhoenixTM Thru-process temperature profiling systems are designed for the demands of busy coating operations.

o suit different applications, PhoenixTM offers a range of data loggers, measuring 6 to 20 thermocouples and offering an accuracy of ±0.3 °C that guarantees data quality. Powered with userreplaceable AA batteries, the data logger offers 1000 hours of logging time. No charging or battery replacement delays means it’s ready when needed. The silicone-free, 113 mm high aluminium thermal barrier provides two hours of protection at 200 °C and weighs just 3.7 kg, making lifting making transfer to and lifting on the line simple. In addition, a comprehensive range of thermocouples, designed specifically for coating applications, offer easy, accurate and economic measurement. Real-time monitoring options are available with an RF Radio Telemetry communication link. With this function, measured temperature data is transmitted direct from the data logger via a thermally insulated RF antenna, which exits the thermal barrier with the thermocouple cables. The RF signal transmitted out of the oven is then passed along a series of repeater units (‘LWMesh’ networking protocol), if needed, back to the main coordinator connected to the monitoring PC. This enables process issues to be identified immediately and process optimisation can be performed live with the system in situ.

PHOENIX FACTOR

To make cure analysis easier and more accurate, the Phoenix Factor cure analysis calculation is available in the Thermal View Finishing Software package. The analysis calculation generates a single Cure Index value, which is accurate, yet easy to set-up and interpret. The Phoenix Factor not only allows instant QA, but also accurate optimisation of the process settings and direct comparison of different processes.

OPTICAL PROFILING

The PhoenixTM Optic system allows thru-process paint defect detection using Optical Profiling. The highresolution video camera can safely travel through the paint oven with an independent torch recording video footage of the product transfer through the oven. The TS64 thermal barrier permits thermal performance of 3 hours at 200 °C. In practice, airborne dust/dirt particulates appear

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PhoenixTM Optic System as streaks across the video image. Such signs of contamination indicate a major paint inclusion quality concern. The high-resolution video allows process engineers to locate the contamination source and apply quick corrective action. By providing visibility of the cure oven under production conditions, oven damage or conveyor product transfer issues can also be identified. For more information on how to find, fix and forget paint cure problems, visit PheonixTM’s website. phoenixtm.com

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TEST & MEASUREMENT

SEE ADVANCED INSPECTION IN ACTION Vision Engineering brings its full 2026 launch line-up to Advanced Engineering for the first time at Stand Q164, NEC Birmingham, 4–5 November 2026.

ision Engineering will show its full 2026 range of inspection and measurement systems on Stand Q164 at Advanced Engineering 2026. This is the first time the new EVO Cam AURA and PicoZoom digital inspection systems, and the EDGE Series benchtop zoom metrology systems, will be seen at the show. Aerospace, automotive, medical device, electronics and precision engineering manufacturers are all under pressure to prove quality without slowing production. The Vision Engineering stand is aimed at the engineers and quality managers who deal with that every day. Visitors are invited to bring their own parts and samples, and Vision Engineering’s applications team will inspect or measure them live on the stand.

THE FULL LINE-UP ON STAND Q164

• EVO Cam AURA: this is the next generation of Vision Engineering’s digital microscope range. It combines 4K imaging with optical zoom, autofocus and focus stacking, so detail such as hairline cracks, burrs and contamination stays sharp even on uneven or complex parts. The AURA software brings zoom, lighting, capture, calibrated measurement and golden-sample comparison into one interface. Customisable go/no-go overlays and a Supervisor Mode that locks down settings help keep inspection consistent between operators and shifts. • PicoZoom: a compact, cost-effective autofocus digital inspection system. It brings fast, repeatable inspection to production lines and goods-in areas. • EDGE APEX and EDGE VISTA: these two models from the new EDGE Series of benchtop zoom video metrology systems are built to move measurement out of the lab and onto the shop floor. APEX, the flagship, is a 3-axis CNC system with motorised 6.5:1 zoom for high-throughput batch inspection. VISTA is suited to flat and turned parts. Both have a 200 × 100 mm measurement envelope, and image stitching lets them measure features larger than the field of view. Both fit where space on the production floor is tight. • Mantis PIXO, Lynx EVO, ProteQ VISO and LVC 400: a complete a range that runs from ergonomic optical inspection through to non-contact measurement. Phillip Townend, Group Marketing Communications Manager, Vision Engineering, said: “Advanced Engineering

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brings together the people who design and build the UK’s most demanding components, so it’s the right place to show our new 2026 range for the first time. “The best way to judge an inspection or measurement system is on your own parts. We’re asking visitors to bring their toughest samples to Stand Q164 and see what the new systems can do with them.” Advanced Engineering takes place at the NEC, Birmingham, on 4–5 November 2026. Entry for visitors is free. visioneng.com

QUALITY FOCUSED

INSPECT. MEASURE. REPORT. Flagship 4K digital inspection for confident quality control. EVO Cam AURA is digital inspection upgraded. • See the detail that matters. 4K image quality shows the fine detail your inspection demands. • Handle challenging parts with ease. A range of integrated tools brings uneven, reflective or hard-to-see samples into clear view. • Consistency built into every inspection. Auto-recognition, presets and Supervisor Mode keep settings controlled and traceable across your operation. • Document as you inspect. Annotate, measure and capture metadata directly on AURA. No separate PC required. Available in 4K and HD, with touch screen or buttons, and in standard and secure variants. Designed to suit your task and environment.

NEW EVO Cam AURA. Available now. Tel: +44 (0) 1483 248300 Email: enquiries@visioneng.co.uk

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DIGITALISATION

MATERIALS PRODUCER TAKES THE JUMP TO ERP Scottish insulation products manufacturer IndiNature gained control of orders, inventory, purchasing, production and costs within a few months of implementing ERP. The company’s Supply Chain Manager recommends making the jump to other small manufacturers.

ounded in 2016, IndiNature is a Scottish manufacturer of natural fiber insulation products. The company’s products are made using natural fibers, including UK-grown industrial hemp. In the beginning, IndiNature’s production setup was relatively straightforward. As volumes started increasing, however, managing individual parts of the operation with spreadsheets was no longer enough. Supply Chain Manager Nina McKeown explained, “It was all being done in Excel, and we realised that wasn’t going to work.”

FLEXIBILITY AND COST TIPPED THE SCALES IndiNature evaluated several solutions while comparing the systems in terms of cost, efficiency and flexibility. The company ultimately decided that MRPeasy offered the best combination for its requirements. With relatively little legacy data to migrate, implementation took only a couple of months. “It was quite a quick implementation,” McKeown recalled.

ONE SYSTEM FOR MANAGING EVERYTHING MRPeasy is now used across much of IndiNature’s operation, with each customer order running through the system from quote to delivery. For McKeown, three areas stand out as particularly important: production tracking, control over raw material inventory, and order processing. Bringing these processes together gives the company a clearer picture of what is happening across the operation without having to manually consolidate information from different spreadsheets. Cost tracking has also become an important part of IndiNature’s everyday use of MRPeasy. Having manufacturing, purchasing, and inventory information in a single system helps the company remain profitable. “MRPeasy helps us keep an eye on production costs and make sure our margins are healthy,” McKeown said.

ACCESSIBLE INFORMATION BENEFITS CUSTOMERS

The centralised order information also benefits customer service. When customers contact IndiNature about an

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order, the team can quickly check its status instead of looking through separate spreadsheets or asking different departments for an update. “I can very quickly see where the order is in the system and when it’s going to be delivered,” McKeown said.

LOT TRACKING FOR TRACEABILITY

Traceability is another part of IndiNature’s manufacturing workflow. The company uses barcodes and lot numbers to carry the relevant information from material lots through production and ultimately to product labels. “MRPeasy provides us with end-to-end traceability,” McKeown said. “We don’t have issues very often, but if something occurs, we know exactly which batch it was.”

SUPPORTS A SCALING COMPANY

For a scaling company like IndiNature, McKeown rates MRPeasy extremely highly for its ability to support the manufacturing operation. “I would say MRPeasy is easily a nine or a ten,” she said. “At the level we are right now, as we scale up, it’s the perfect system.” McKeown’s advice to other small manufacturers considering the same move is straightforward: “Don’t be scared to use it; it’s so easy. Take the jump. Don’t wait.” mrpeasy.com

CONVEYORS

A FLEXIBLE PACKAGING CONVEYOR SOLUTION AdaptTech Manufacturing Solutions, the sole UK and Ireland distributor for mk products, shares how an efficient conveyor with turning technology enabled an office supply manufacturer to achieve a flexible packaging process.

manufacturer of office supplies required a flexible conveyor system to transport packs of cardboard folders efficiently and reliably from production and packing through to the shipping facility. The packs, supplied in quantities of three or five and weighing up to 2.5 kg, needed to be handled gently while maintaining a consistent production flow. The system also needed to accommodate two packaging processes. Packs could either be transferred directly into cardboard boxes, or diverted to an automatic filmwrapping machine before being returned to the main conveyor line. With cycle outputs of up to 14 packs per minute and continuous three-shift operation, reliable product handling and safe integration were essential.

FLEXIBLE CONVEYOR SOLUTION

To meet these requirements, mk supplied a conveyor system incorporating belt conveyors, timing belt conveyors, roller conveyors, guarding and customised automation. For direct packaging, the folder packs are transported upright along an approximately five-metre-long belt conveyor. Lateral roller guides maintain the correct product position as the packs travel towards the downstream packaging station. For film packaging, the packs are diverted from the main conveyor flow and transferred to an automatic packing machine. An integrated turning station uses a turning star to pick up each vertically positioned pack, rotate it through 270 degrees and place it flat onto a timing belt conveyor equipped with cams. The packs are then transferred via a roller conveyor with pusher onto a further belt conveyor, which feeds them accurately into the automatic packing machine. Following shrink-wrapping, the products are discharged onto a belt conveyor incorporating a lift-gate conveyor, providing convenient operator access. The wrapped packs are then returned to the main conveyor route. A roller conveyor and timing belt conveyor transfer the products to a second turning station, where another turning star rotates the packs back into their original vertical orientation before returning them to the main conveyor.

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INTEGRATED AND SAFE

The complete system, including the control cabinet and controller, was supplied as a solution ready for connection to the customer’s production environment. Safety was also a key consideration in the design. The turning stations and feeders are fully enclosed, with safetymonitored access doors providing controlled access for maintenance. The inclusion of a lift-gate conveyor also provides easy access to the automatic packing machine without compromising the overall conveyor layout. By combining automated conveying, product positioning and turning technology, the system enables two different packaging processes to be accommodated within a single production flow. The result is a reliable and flexible material-handling solution capable of supporting continuous three-shift operation while maintaining gentle product handling and efficient material flow. For more information about the mk conveyor range or to discuss a conveyor application, contact AdaptTech Manufacturing Solutions, the sole UK and Ireland distributor for mk products. adapt-tech.co.uk

INDUSTRIAL LABELS

NEW, NO WASTE RFID LABEL PRINTER Introducing Brady Corporation’s new i7500 RFID label printer. Underpinned by patentpending technology, it does not waste a single label in calibration and prints and encodes RFID labels correctly first time.

he new BradyPrinter i7500 Industrial RFID Label Printer prints and encodes the first RFID label right. Tested competitive models waste 10 to 30 labels after each consumable change. The printer also automatically locates label RFID chips to select the right internal antenna and power level that optimally encode UHF RFID labels currently loaded in the printer. In most RFID printers this input needs to be provided manually. The Brady printer’s unique technology reduces label waste even further, limits void labels, avoids time loss in production environments and adds great practicality for non-expert RFID printer users. Brady claims the technology accurately recognises RFID chips, even on labels as small as 15 mm width. The patent-pending print and encoding technologies included in Brady’s new i7500 RFID make the printer extremely easy to use in a wide range of industrial contexts. They enable industries to easily switch UHF RFID label types on a single printer, without suffering label waste with each consumable change.

FAST, AUTOMATED SETUP

With setup time for large, small, on-metal (up to 2mm thick) and off-metal UHF RFID labels under 3 minutes, the i7500 RFID is 25 to 2 times faster than most competitive models. The printer’s exceptional material setup and calibration speed strengthens its ability to protect industrial operational throughput. Designed to keep the line moving, Brady’s new RFID printer reduces support interventions, UHF RFID tag scrap, component scrap, unplanned downtime and production bottlenecks, all at a print & encode speed of 3 seconds per label.

HIGH ACCURACY DATA

From large pallet labels to small component tags, the i7500 RFID printer includes automated UHF RFID label encoding verification. At the same time, it can add human legibles and tiny machine-readable QR-codes and barcodes for legacy applications, in both 300 and 600 dpi. The printer connects to company systems via Ethernet, USB, Wi-Fi and Bluetooth and supports common data standards, including GS1.

NEXT LEVEL TRACK & TRACE

The new i7500 RFID label printer is part of Brady’s complete industrial RFID solution that also includes reliable RFID labels, RFID readers and RFID software. Together, these solution components enable next level track & trace advantages. The printer can also trigger IoT- events and automations when scanning a label or a specific volume of labels; enable home-in applications on tagged assets; improve just-in-time tracking, automated inventory and cargo control; strengthen compliance in advanced industrial supply chains; and link products to their digital passports with RFID. The BradyPrinter i7500 RFID can give any asset, item and product a unique digital identity that can be read from a distance, without needing line of sight. The new RFID printer completes Brady’s quality traceability offer that enables reliable track and trace in any industry, with barcodes and/or RFID. bradyeurope.com/i7500rfid

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LUBRICATION

FROM SCHEDULED TO CONDITION BASED Here, Klüber Lubrication details how a combination of technologies are transforming lubrication management, shifting away from fixed lubrication schedules to datadriven maintenance.

ondition Based Lubrication (CBL) is a proactive approach that applies lubrication based on actual equipment needs rather than fixed schedules. By monitoring factors such as vibration and temperature, it helps reduce reliance on fixed schedules and manual estimation, supports the prevention of under- and over-lubrication, can contribute to extending equipment life, and may improve overall reliability and operational efficiency. This approach brings greater consistency and can reduce the risk of some failures compared with reactive maintenance. However, because lubrication is carried out according to a timetable rather than actual equipment condition, maintenance teams may have limited visibility of an asset’s actual lubrication requirements, potentially leading to over- or under-lubrication. Automated lubrication systems can provide more accurate and consistent lubrication, helping reduce the risk of human error and lubricant starvation. They can also improve coverage of critical lubrication points and may offer insights into system performance through monitoring features such as counter-pressure measurement. Condition-based lubrication uses equipment and lubricant monitoring to align maintenance activities with actual operating conditions. This can enable earlier detection of potential issues, help optimise lubrication intervals, and support improvements in equipment reliability while contributing to longer asset life. Predictive lubrication uses data and analytics to forecast lubricant and equipment condition, helping maintenance teams identify potential issues earlier. This supports more effective maintenance planning, resource allocation and lubrication management while helping reduce the risk of unplanned downtime. Prescriptive lubrication uses AI and advanced analytics to recommend maintenance actions based on available equipment and lubrication data. This can help optimise lubricant selection, quantity and application timing. Through continuous feedback and analysis, recommendations may become more refined over time, supporting improvements in equipment reliability, performance and maintenance efficiency. Automated lubrication systems can further support these efforts by delivering consistent lubrication, reducing the

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potential for human error and providing additional insights into system performance. Condition monitoring provides information about equipment and lubricant condition by tracking factors such as vibration, temperature and lubricant performance. These data can help maintenance teams identify trends, detect potential issues earlier and develop a better understanding of asset behaviour. Automated lubrication systems are designed to deliver lubricant at controlled rates and intervals, helping to promote consistency while reducing reliance on manual application. When used as part of a condition-based maintenance strategy, lubrication activities can be aligned more closely with operating conditions. Predictive technologies analyse operational data to estimate lubricant life and identify potential maintenance requirements. Some systems also use artificial intelligence to support decision-making through recommendations based on equipment condition and performance trends. Together, these technologies support a more connected and data-informed approach to lubrication management and maintenance planning. For more information on Klüber’s Monitoring Platform where all solutions are integrated visit the company website and submit a contact form. klueber.com/uk/en

EVENTS

THE PPMA SHOW® 2026 HAILED AS A HIT The PPMA Show® 2026 has closed to superb feedback from visitors, while organisers Automate UK have reported an enthusiastic response to the comprehensive, colocated event taking its place next year. Bookings are now underway for the brandnew, reimagined 2027 event.

he UK’s biggest processing and packaging machinery, robotics and industrial vision event took place at the NEC, Birmingham, from 22-24 September, showcasing more than 350 exhibitors and 1,500 brands alongside an extensive programme of innovation and expertise from guest speakers. Automate UK Chief Operating Officer Scott McKenna said the team was thrilled with feedback from exhibitors and visitors during the Show’s 39th year, and proud to have created an environment that inspired new generations, engaged industry professionals and showcased the next phase of innovation. As expected, keynote addresses from Dr Kevin Fong, Jeremy Schwartz and Martin McCourt generated record attendance, while the seminar programme also attracted strong visitor engagement throughout the three-day event. The Show also provided the official platform to launch Automate UK Week, the organisation’s first combined exhibition, taking place from 28-30 September 2027. Marking 40 years of Automate UK hosting leading industrial automation events, Automate UK Week will bring its award-winning PPMA and UK Automation Shows together under one roof, creating an integrated, futurefocused event reflecting the industry’s evolving needs. Taking place across two halls at the NEC, the event

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will cover every aspect influencing the industry, from traditional manufacturing, processing and packaging applications to AMRs, warehouse automation, logistics systems and the enabling technologies surrounding them, supporting Automate UK’s commitment to showcasing innovation, developing connections and supporting growth across the sector. Scott said Automate UK Week had been in development for a long time and that discussions with exhibitors and visitors during PPMA Show® 2026 had generated an extremely positive response. A significant number of exhibitors have already taken advantage of early-bird booking rates to secure prime positions at the new event, demonstrating early industry support for the reimagined format. By co-locating its flagship shows to create a ‘supershow’, Automate UK aims to establish a one-stop shop for industrial automation in the UK, enabling exhibitors and visitors to maximise their experience and achieve the best possible return on investment. Automate UK Week will take place in Halls 1 and 5 at the NEC, Birmingham, from 28-30 September 2027. For further details and to book, visit Automate UK’s website. automate-uk.com

Automate UK Week 2027 | 28 - 30 September | NEC, Birmingham

Get ready for a landmark showcase of advancement and ambition as two of the UK’s leading industry events come together.

Scan to learn more.

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EVENTS

SOUTHERN MANUFACTURING & ELECTRONICS 2027 From aerospace and automotive to medical technology and semiconductors, Southern Manufacturing & Electronics 2027 offers a free opportunity to compare suppliers and solutions across the manufacturing supply chain. Free visitor registration is now open.

isitor registration is now open for Southern Manufacturing & Electronics 2027, taking place from 2–4 February 2027 at Farnborough International Exhibition Centre. The free-toattend event brings suppliers and buyers together across the manufacturing and electronics supply chains, offering a practical start to the year for engineers, production teams and procurement professionals.

DISCOVER THE HEART OF BRITISH MANUFACTURING & ELECTRONICS

For professionals focused on improving plant performance, the manufacturing side of the floorplan will offer opportunities to assess automation, robotics, CNC machining, control systems, materials and Industry 4.0 technologies. Live demonstrations will help visitors move beyond specifications to see how equipment and processes could fit their operations. Components, subcontractors and design and production partners will also be represented, making the event a place to review both immediate purchasing needs and longer-term supply-chain plans. Returning manufacturing exhibitors include Yamazaki Mazak, XYZ Machine Tools, Renishaw, HAAS Automation and igus UK. Their presence, alongside many new exhibitors and smaller specialist suppliers, gives visitors scope to compare established equipment with targeted solutions for challenges such as machining capacity, measurement, automation and component sourcing. The full exhibitor list can be viewed on both the Southern website and the comprehensive show app. The electronics offering extends that conversation from the factory floor to product development and assembly. Exhibitors will cover semiconductors, circuit design, embedded systems, test and measurement, PCB manufacturing and electronic components. Sony UK Technology Centre and Hexagon are among the many exhibitors, giving visitors further opportunities to explore high-precision manufacturing and smart manufacturing technologies. The event is relevant to businesses working across aerospace, automotive, electronics, medical technology and mechanical engineering. For visitors managing cross-

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disciplinary projects, its combined format creates a chance to speak with electronics specialists, machinery suppliers and manufacturing partners during one visit. That breadth is useful when choices about components, inspection, production equipment and suppliers must work together in practice. Learning is also an integral part of the event. Visitors can expect expert-led, CPD-accredited sessions through both its Manufacturing Conference and Electronics & Semiconductors Conference, with topics spanning manufacturing, automation and design engineering. Visitors can combine those sessions with supplier meetings and demonstrations to take away ideas they can evaluate within their own businesses. The previous edition welcomed 10,722 attendees and 571 exhibitors, demonstrating the scale of the community that gathers at Farnborough International. For 2027, visitors can start planning early by reviewing exhibitors and registering for their free pass. Register for free below. southern-manufacturing-electronics.com

EVENTS

PRACTICAL INSIGHT AT UK METALS EXPO 2026 On the 4-5 November 2026, UK Metals Expo returns to the NEC Birmingham, bringing together the people, technology and ideas helping industry turn today’s pressure points into tomorrow’s advantage.

eset by rising costs, fragile supply chains, changing trade rules and tougher carbon targets, standing still is not an option for UK manufacturers. Whether they are responsible for production, operations, quality, maintenance, procurement, tooling, processing or engineering, UK Metals Expo is an opportunity for manufacturers to get closer to the materials, suppliers and expertise that keep manufacturing moving. UK Metals Expo is the UK’s dedicated event for the full metals supply chain, from primary production and stockholding to processing, fabrication, finishing, recycling, reuse, technology and specialist services. For the first time, it will be co-located with Advanced Engineering and Lab Innovations. That means one free registration opens the door to a powerful meeting point for metals, manufacturing, engineering and laboratory technology. More than 15,000 attendees and 750 exhibitors are expected across the three-event cluster. Instead of vague future promises, UK Metals Expo is about practical conversations, relevant solutions and connections that can make a difference to a manufacturing operation. Need to strengthen material security? Explore the latest thinking on critical materials, procurement and supplychain resilience. Looking to improve productivity or process control? Meet technology providers and specialists working in automation, processing and manufacturing innovation. Under pressure to reduce emissions and waste? Discover developments in recycling, circularity, low-carbon materials

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and electric arc furnace technology. At the heart of the event is a free-to-attend conference programme, with more than 100 speakers across four theatres: Big Issues; Supply Chain, Trade & Policy; Sustainability & Circular Economy; and Innovation & Technology. Expect straight-talking discussion on the issues that matter: CBAM readiness, tariffs and quotas, steel pricing, trade policy, decarbonisation, recycling, material availability, process innovation and the skills needed to keep UK manufacturing competitive. The speaker line-up includes major voices from across industry and policy, including Rajesh Nair, CEO of Tata Steel UK; Gareth Stace, Director General of UK Steel; Carles Rovira, CEO of 7 Steel UK; Jonathan Clemens, CEO of the British Constructional Steelwork Association; and Steve Morley, President of the Confederation of British Metalforming. Experts from Hydro Aluminium, Jaguar Land Rover, the Henry Royce Institute, Great British Energy, the International Steel Trade Association and HM Treasury will also contribute. Supported by Tata Steel, Hydro Aluminium UK Ltd, Countrywide Metals Ltd and MEPS International, UK Metals Expo is where the metals community meets to share intelligence, source solutions and build the partnerships that will shape the next phase of UK manufacturing. UK Metals Expo takes place 4-5 November 2026 at NEC Birmingham. Register now for free. ukmetalsexpo.com

COMING UP IN THE DECEMBER ISSUE INDUSTRIAL DATA & AI Also featured in the December issue: CABLING & CONNECTORS PUMPS & PUMPING SYSTEMS ADDITIVE MANUFACTURING MANUFACTURING CHAMPION INDUSTRY NEWS EXPERT OPINIONS Events covered in the December issue:

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