Despite its history as a manufacturing powerhouse, the UK is now very much a de-industrialised nation, with just 8.8% of GDP currently coming from the sector - this compares with 9.8% for the US (also deindustrialised), 27% for China and 20% for Japan.
The UK’s industrial strategy, launched in June, made some bold commitments to put the UK back on the manufacturing map (see ‘Robot Vision’ on page 8) with financial injections and regional support aimed at redressing some of the nation's economic imbalances.
The strategy’s focus on automation, AI and robotics seems to have been widely welcomed by manufacturers and the process industry, but as ‘AI Watershed’ on page 36 explains, artificial intelligence isn’t yet able to deal with many aspects of engineering because of its complexity. That said, the financial promises and training support proposed by the 180-page plan, launched in June, may help shift the UK's heavy reliance on the FIRE sectors (Finance, Insurance and Real Estate) and broaden the nation's skills base.
In keeping with this, we have a big training focus in this issue of International Process Engineer. I interviewed EEMUA (Training with EEMUA on page 46) regarding how its range of courses for process engineers helps organisations prove their credibility with customers and the regulator. In addition, BPMA argues in Pupils for Pumps on page 50, that training is essential for optimising smart pumps; a technology expected to deliver significant energy savings for industry and households in the coming years.
Nicola Brittain Editor
16
Hydraulic drive
A hydraulic motor that increases conveyor belt speed
An overview of the UK's industrial strategy with its focus on AI and automation PROCESS EQUIPMENT UPDATE
6 PEU
A range of recently launched products aimed at the process industry
12 Monitoring food production How computing systems
be designed for hygiene and durability 14 Preventing factory fires
How
conditions
18
Electrification without limits
Electrification’s role in transforming cross sector production
20
Subsea control valve
New valves mark a milestone for this flagship range
Making the case for an integrated
A recent gathering looked at nutraceutical production challenges and solutions
How clean label trends are affecting manufacturing
The benefits of partnering with a specialised provider around the safety certification process
A technology expert provides insight into the company’s centrifugal process pumps
AI watershed
How the engineering sector is catching up with others in the use of AI
PUBLISHER
Jerry Ramsdale
EDITOR
Nicola Brittain nbrittain@setform.com
DESIGN – Dan Bennett, Jill Harris
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Luke Wikner production@setform.com
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John Abey | Darren Ringer
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Control systems and their central role in process engineering
How a SIS management system moves data out of silos
Ensuring fire in recycling plants is controlled
An overview of courses run by this long-standing members body
How training can help smart pumps run optimally
An interview with the organisers of this upcoming show on the expected highlights and talking points
Setform’s international magazine for engineers is published quarterly and distributed to senior engineers throughout the world. Other titles in the company portfolio focus on Oil & Gas, Design, Transport, Mining, Energy and Power.
Robotics, AI and the UK's industrial strategy Setform Limited | 6, Brownlow Mews, London, WC1N 2LD, United Kingdom
INTRODUCING OUR NEW RANGE OF SUBSEA CONTROL VALVES
The Series 1275 Subsea Control Valves are a new and fully qualified range, designed, engineered and tested at our Brighouse facility in the UK.
Key features include:
- Specialist trim technology to suit all applications
- Repeatable and dependable operation
- Enhance wear resistance
- Backlash removal
- Highly accurate
- Power efficient
MANUFACTURING SUBSEA VALVES SINCE 1984
KOSO Kent Introl has over 35 years’ experience in the subsea industry manufacturing a range of Control and Choke Valves for the world’s largest energy companies.
A new remote control promises to help staff manage important tasks CONVENIENT CONTROL
Auma’s new RSTX 100 remote control offers easy and convenient operation of Auma actuators on site, according to the company.
The RSTX 100 is rugged yet ergonomic and easy to use, even with gloves. It has a large, high-resolution colour display with clear menus and self-explanatory text, as well as a Bluetooth range of 20 metres. For potentially explosive atmospheres it is ATEX and IECEx certified intrinsically safe (ex ia).
The remote shows its strength when actuators are mounted in positions that are hard to reach, for example in pits or at height. As its display shows the entire communication, including the actuator’s response, all operations can be performed easily even if the actuator’s own display is out of sight.
The device helps staff intuitively manage all the important tasks related
The RSTX helps staff intuitively manage all the important tasks related to Auma actuators
to Auma actuators. Functions include opening and closing valves, configuring actuator parameters, setting valve end positions, updating actuator firmware, and reading out actuator log data for analysis and diagnostics in Coralink the Auma digital ecosystem.
The RSTX 100 remote control works with a wide range of Auma actuators: Profox, Tigron, and SA and SQ with
AC 01.2 controls. Users can thus operate different Auma actuator types in their plant in the same intuitive way, speeding up daily work and reducing the need for training.
TECHNOLOGY SOLUTIONS PROVIDER EXPANDS REACH
Solutions provider Barnbrook signs distribution contracts for actuators
Hampshire-based technology solutions provider Barnbrook Systems has reported on a successful trade mission to the Asia-Pacific (APAC) region.
Barnbrook MD Andrew Barnett and Richard Dunn from tech firm Flair travelled 26,500 miles on a return trip from the UK to the UAE, China, South Korea and Australia.
The globetrotting duo attended conferences and trade shows, held meetings, made connections, researched new technology, explored potential products for their clients and built business relationships during the odyssey which included stops in Dubai, Seoul, Shanghai and Melbourne. They negotiated breakthrough distribution partnerships in each area for their innovative E:BAG technology which supresses and extinguishes lithium-ion battery fires in devices such
as mobile phones, vapes, tablets, laptops and e-scooters.
Mr Barnett also signed distribution partnerships for the Fareham company’s market leading fire suppression actuators for extinguishers, sprinklers and similar systems.
Barnett said: “Our trip showed that there is no reason to fear collaboration with partners overseas despite some of the current international geopolitics making headlines.
“Much of our trip was dedicated to spreading word about our E:BAG system and the way it can counteract lithium-ion batteries fires which are becoming an increasing threat in multiple sectors worldwide.
Barnett and Dunn struck deals after a trip to the UAE, China, South Korea and Australia
The carbodiimide crosslinkers are low toxicity and CMR-free
Speciality coatings expert Stahl has introduced a new range of highly functional carbodiimide crosslinker products specially designed for packaging coatings.
The product, called Hypac, is a group of patented crosslinkers that enable Stahl customers to manufacture high-performing, durable packaging products.
HOW CROSSLINKERS WORK
Crosslinkers benefit from high levels of reactivity thereby improving a coating’s tensile strength and resistance to cracks, abrasion, chemicals, water and heat, while improving adhesion to the coated material. With the help of crosslinkers, coated products can withstand a variety of climates and experience a much longer life, resulting in lower maintenance costs.
The range includes conventional isocyanate and aziridine-based crosslinkers, as well as more sustainable carbodiimide alternatives, making it versatile for customers’ application requirements.
KEY ATTRIBUTES OF THE CARBODIIMIDE CROSSLINKERS:
• Low toxicity and CMR-free
• Suitable for a wide range of end applications
• Long pot life exceeding 24 hours
• Proven anti-soiling properties
• Contributes to lower carbon emissions
• Non-yellowing
• Very high efficiency (on par with aziridines)
• Low curing temperature
• Strong adhesion properties
THE SUSTAINABILITY BENEFITS
The Hypac range includes a variety of carbodiimide crosslinkers, which maintain the high performance of aziridine and isocyanate crosslinkers without using carcinogenic, mutagenic and reprotoxic (CMR) materials: Carbodiimides are defined as non-hazardous under the Global Harmonised System (GHS).
Many carbodiimide Hypac products cure at room temperature, are waterbased, have a long-lasting pot life and contain no voltatile organic compounds (VOCs), making a sustainable, safe and easy-to-use option for high-performance crosslinking, according to the company.
The product has been developed in Europe but ships globally.
Deloitte recently forecast the UK robotics industry to reach £1.7bn by end of 2025
ROBOT VISION
The UK’s recently launched industrial strategy emphasises the importance of robotics and automation. Nicola Brittain gets insight from key players on whether the strategy will benefit the process industry
The long-awaited UK’s industrial strategy, a 160 page report launched in June 2025, outlined a ten year plan that aims to boost business investment and economic growth. Although a few commentators have argued that the report is too broad, there was considerable emphasis on some specifics, namely the importance of robotics and automation to the UK economy. According to a recent MAKE UK survey, 76% of manufacturers have recently invested in automation, with 59% planning to increase that investment over the next year. Similarly, Deloitte recently forecast the UK robotics market to reach £1.7bn in 2025 and to grow at over 16% compound annual growth rate (CAGR), with a forecast to hit £3.1bn by 2029.
CASH INJECTION FOR ROBOTICS
Oliver Selby sales director at Robotics manufacturer Fanuc and chair of the British Automation and Robotics Association (BARA) opened a recent press event to discuss the impact of the strategy on robotics and automation (the First Friday Club held in July). He said that he welcomed elements of the advanced manufacturing sector plan. For example, the pledge to establish ‘robotics adoption hubs’, a new national network that will support SMEs to integrate robotics and autonomous systems; as well as the promised £4bn injection of industrial strategy growth capital via the British Business Bank to support automation aligned innovation.
Selby explained why he thought this was important. “UK productivity rates
Nikesh
UK productivity rates have to rise if we are to remain a force on the international stage
have to rise if we are to remain a force on the international stage,” he said. “In Q4 2024, productivity was estimated to be 0.8% down year-on-year, and 19% lower than that of the US. However, there is a clear correlation between automation adoption and higher productivity rates, so why aren’t more UK manufacturers investing in robots?” The UK is currently 24th in the world for deployment of robots despite being the 12th largest manufacturer. Selby went on to explain that the idea that robots take people’s jobs is a false one. He said: “It has been proven that robots do not replace people at work. Rather they do the dirty, dull and dangerous jobs
The UK is currently 24th in the world for deployment of robots
meaning that staff can be reskilled and moved into a different role within the business.”
One of the key elements of the industrial strategy is development of the ecosystem around manufacturing, with a key focus on supply chain resilience. This aims to target planning, infrastructure and bottlenecks; coordinate public and private investment across freight corridors, ports and warehousing clusters, and work with devolved governments and industry to align infrastructure with sector needs.
THE BENEFITS OF PARTNERSHIPS
Selby’s presentation was in large part about the benefit of partnerships, in keeping with the strategy’s focus on the manufacturing ecosystem. He said this was essential in a country made up of SMEs since many are currently in a chicken and egg situation where they can’t grow without orders and can’t take volume orders because they are too small. Of all UK businesses, 99.8% are small or medium sized (SMEs) and there are 5.5 million of these in total [source: Finder.com]. These companies need help to move into robotics and automation since the upfront costs are often prohibitive.
Selby explained that the company offers end-users a variety of pricing agreements through these organisations,
Mistry, Gambica
Oliver Selby, Fanuc & BARA
as well as considerable support on agreements with a recognition that cashflow will be limited. “We are aware of cash-flow constraints and are committed to helping small companies become automated,” he said.
Selby also discussed the importance of Fanuc’s horizontal partners. These include trade bodies, universities, distributors, and venture capitalists.
“It takes an entire ecosystem to bring robots and automated products to market,” he concluded.
One of the trade bodies Fanuc works with is Gambica, a trade association for instrumentation, control, automation and laboratory technology in the UK. Nikesh Mistry, Gambica sector head for industrial automation and test and measurement also gave his take on the new industrial strategy at the event.
“With a £22.6bn commitment to research and development and £600m aimed at strategic sites, the strategy sets a bold course for nextgeneration manufacturing,” he added, “key initiatives like the Made Smarter expansion, Robotics Adoption Hubs,
and a £2bn AI Action Plan highlight the important role of automation and ethical tech innovation.
He concluded: “Industry and policymakers must work together. Our sector has been so resilient in the face of recent geopolitical unrest, and the industrial strategy’s focus on partnerships will help bolster this.”
Some organisations argue that the strategy doesn’t go far enough, however. A release from trade body ICHEME said: “Although the report recognises the transformative potential of AI and digitalisation for improving efficiency and innovation across industry, more targeted action will be needed to equip engineers from sectors like chemicals, manufacturing and process engineering with the tools and expertise required to fully exploit these technologies.”
THE
INDUSTRIAL
STRATEGY:
HIGHLIGHTS MANUFACTURING SECTOR PLAN
The ‘made smarter’ programme aims to support development of robotics and automation
The strategy pledges to double annual business investment in advanced manufacturing by 2035 to £39bn
A new national network will support SMEs in integrating robotics and autonomous systems via ‘robotics adoption hubs’
A £2bn AI action plan will scale responsible AI and automation across sectors including manufacturing
Industry strategy growth capital of £4bn to support automation will be made available via the British Business Bank
SUPPLY CHAIN RESILIENCE
A strategic site accelerator of £600m will unlock land for logistics and advanced manufacturing hubs and target planning, infrastructure and grid bottlenecks
SUPPLY CHAIN CENTRE
The new centre will observe vulnerabilities, dependencies and critical inputs (eg semiconductors and rare earths)
The centre will inform future interventions and trade policy
SKILLS DEVELOPMENT
The government will contribute £1.2bn a year by 2028-29 focused on IS-8 sectors (advanced manufacturing, clean energy and digital)
A body called Skills England will replace IfATE with a broader remit, and align training with industrial needs and migration policy
ICHEME wants to see more action to equip process engineers with digital skills
MONITORING FOOD PRODUCTION
Today’s food and beverage plants require computing systems engineered for hygiene, durability, and seamless operator interaction
As today’s food and beverage plants embrace greater automation and data-driven control, rugged industrialgrade monitors are emerging as vital tools on the production floor. These displays provide operators with immediate access to critical process information and controls within a demanding environment. They must withstand repeated cleaning and moisture exposure without corroding, along with a seamless, sanitary surface that prevents the buildup of contaminants.
To meet these challenges, touchscreens are often housed in enclosures rated for washdown environments, typically NEMA 4X. Stainless steel is often chosen because it resists corrosion. In certain cases, anodised aluminum may be used. Without such protection, ordinary monitors would quickly fail or become contamination risks.
Within such facilities, these displays serve as vital interfaces for operators to view, monitor, and control every stage of the process. Critical production information must be visible in real time to maintain product consistency and regulatory compliance. Operators also rely on these monitors to respond to system alarms, manage equipment settings, and record data for traceability. Without this constant visibility, efficiency and quality control can deteriorate, leading to potentially serious production and even food safety problems.
In this environment, Human Machine Interfaces (HMI) offer a visual summary of process systems that simplifies- the monitoring of crucial status and control data. An effectively designed graphical user interface strengthens situational awareness, eases the demands placed on operators, and enables consistent oversight of the full production process. As a result, operators are better prepared to recognise and respond
promptly to any unexpected conditions.
Through the HMI, the monitor continuously displays operational data from equipment and production lines, providing clear visibility into essential variables such as temperature, flow levels, and mixing durations. This setup helps operators respond more quickly to any abnormal process conditions.
Using the HMI, the monitor presents live data from machinery and production systems, giving operators access to key metrics like temperature, flow rate, and mixing time. Operators interact with the HMI using a touchscreen to adjust settings, start or stop equipment, and respond to system alerts.
To withstand the harsh production environment, ARISTA’s ADM series of industrial monitors are fully waterproof and feature sealed construction to prevent moisture ingress. Stainless steel or aluminum bezels provide corrosion resistance and structural durability in sanitary settings.
One example is the ADM-2124AP, a 24-inch panel-mount touch LCD display, which enables precise multitouch control (even when operators wear gloves), supporting seamless interaction with process control systems and quality management tools.
For larger production areas, the 42inch ADM-5842AX integrates a KVM (keyboard, video, mouse) extender, allowing the display to connect with remote computing systems. This setup keeps sensitive electronics away from washdown zones while providing operators with clear visibility of critical process data.
In addition to durable construction, flexible mounting options—such as pendant arms, walls, pedestals, ceilings, and VESA mounts—ensure the monitors can be installed wherever operators need fast, reliable access to HMI data.
As food and beverage manufacturing continues to adopt more advanced automation and data-driven processes, the role of reliable, hygienic control and monitoring displays on the plant floor will grow. Purpose-built systems such as the ADM series help ensure that critical production data remains visible and accessible - thereby supporting quality, efficiency, and compliance in sanitary production environments, according to the company
For more information visit: www.arista.com
The HMI presents live data from machinery and production systems
PREVENTING FACTORY FIRES
This article explores how manufacturers can use testing equipment to mitigate fire-prone production conditions
Kett’s portable lab-quality instruments help keep factories safe
Supply chain issues for factories producing essential materials and goods have accelerated since 2020. However, factory plant managers and production line workers may not realise that the industry experienced even greater disruptions in 2024 than in previous years. By one account, there was a 38% increase in supply chain disruption last year.
And the leading cause of these recent disruptions? Factory fires. Factory fires threaten the facility, disrupt productivity, and endanger the entire workforce. Consequently, taking
the necessary precautions, which includes using equipment capable of detecting and preventing fire prone conditions, is essential to mitigate the growing risk of fire and ensure a safe working environment.
THE URGENT NEED TO MINIMISE FIRE RISK
In 2024, there were 2,299 recorded factory fires worldwide. The majority of these occurred in facilities within the US, followed by incidents in India and Germany. Many fires took place in manufacturing-focused factories.
A range of operational and supply
Manufacturers need to be aware that combustible dust can contribute to fires when sparking occurs – and that almost every material can be combustible in dust form
to the increased fire risk. In recent years, global disruptions have led to labor shortages, regulatory delays, and reduced oversight in some facilities. As a result, many factories operated with fewer skilled workers on-site, while employees were often required to take on additional responsibilities with limited support.
At the same time, some factories quickly adapted their operations – such as introducing new chemical processes or expanding existing production lines – without fully assessing the associated risks. This often resulted in gaps in critical safety protocols, driven by short staffing or shifting priorities, which in turn increased the likelihood of undetected hazards.
In some cases, insufficient training resulted in the mishandling of chemicals, posing serious safety risks to both workers and the facility. Additionally, delays in maintaining critical equipment or systems increased the risk of operational failures, safety
incidents, and costly disruptions.
Machinery issues were a significant factor in factory fires in 2021 as well.
According to Resilinc, a supply chain risk management company, 59% of the factory fires analysed that year were linked to faulty equipment. Common causes included improper installation, operation, or maintenance; inadequate safety and cleaning procedures; and failure to replace outdated or wornout equipment on time. Additionally, insufficient employee training, particularly a lack of awareness of key risks, was often a contributing factor.
Specific conditions on or around the production line can also increase the risk of a fire.
ALMOST EVERY MATERIAL CAN BE COMBUSTIBLE
“Manufacturers need to be aware that combustible dust can contribute to fires when sparking occurs – and that almost every material can be combustible in dust form, including wood, metal, dyes, food, and chemicals,” says John Bogart, managing director of Kett US, a manufacturer of a full range of moisture and organic composition analysers.
Bogart adds that chemical plants face an increased fire risk when excessive friction occurs. Similarly, mechanical equipment can become a fire hazard if it is not properly cleaned, maintained, and lubricated, leading to overheating and, in some cases, ignition.
Since many of these issues are largely preventable, industry professionals emphasise the importance of awareness and proactive measures.
“By prioritising equipment maintenance, providing comprehensive training, and conducting regular safety inspections – even during periods of disruption – factories can significantly reduce the risk of fires and safeguard both employees and assets,” says Bogart.
Bogart also recommends equipping factories with instruments that can detect hazardous conditions on the production line, essential for preventing fires and improving overall safety.
To address this need, industry OEMs have developed a variety of types of equipment specifically designed to prevent the conditions that can lead to factory fires. For example, Kett’s pulp and paper moisture meters line can
prevent over drying, leading to higher fire risk, when producing paperrelated products.
To keep friction, overheating and sparking from causing machineryrelated fires, the OEM’s line of friction testers like the H94 Handheld Portable Friction Tester can evaluate machinery for friction and wear on-site.
The OEM’s engineers assist manufacturers in selecting portable and in-line laboratory-quality instruments to enhance factory safety and reduce fire risk. These instruments are designed for fast, efficient operation and are userfriendly, ensuring effective monitoring by any operator, regardless of who is on-site.
Factory fires pose a serious risk to workers, equipment, and overall
operations, yet many are preventable with the right precautions. Equipping facilities with advanced monitoring instruments ensures early detection of hazardous conditions, allowing for quick intervention before a fire can start.
By investing in reliable safety equipment, manufacturers can reduce fire risks, maintain productivity, and protect both personnel and assets. Proactive safety measures, including proper training and routine maintenance, combined with the right detection tools, are essential for ensuring a safer, more resilient production environment.
Kett’s KB30 Smart Incline NIR Moisture Meter can prevent grain overdrying
HYDRAULIC DRIVE
Hydraulic drive motors for conveyor belts have traditionally operated in the lower speed range, a new efficient motor from Hagglunds promises to change this
Compact and lightweight, hydraulic direct drive systems are well suited to machines like belt conveyors. The hydraulic motor mounts directly on the pulley shaft, while the rest of the system can be placed where it fits best, without foundations or alignment issues. Still more important are the operational advantages, many of which extend conveyor lifetime, these include the following:
Soft starts that help reduce belt stretching and extend belt life
Perfect process feed rate control through fully variable speed
Unlimited starts and stops with no risk of overheating
100% load sharing that reduces shaft and pulley stresses
Possibility to drive both head and tail
Hägglunds, a specialist in hydraulic direct drive systems, has supplied a variety of industries with conveyor belt drives. Most have employed the Hägglunds CB hydraulic motor, which was recently renamed Hägglunds Quantum. Today, that motor is joined by the Hägglunds Quantum Power, which shares the original motor’s DNA but also creates new, efficient opportunities.
EFFICIENCY CHALLENGES AT HIGHER SPEEDS
Until now, hydraulic direct drive systems have been most competitive for specific types of belt conveyors. They have excelled on slow-moving conveyors, typically operating below 50 rpm, or on faster conveyors that start and stop frequently – where electromechanical drive systems are usually overdimensioned to avoid overheating.
Higher speeds require more hydraulic fluid to pass through the
motor, which has meant increased pressure and efficiency losses. Thus, on fast-moving conveyors where operations are smooth, electromechanical systems have often had the upper hand.
NEW DESIGN THAT MINIMISES LOSSES
With the new Hägglunds Quantum Power motor, Hägglunds has changed the equation substantially – not only for belt conveyors but also for other equipment, such as mills, crushers and kilns. Built upon the Hägglunds
Hägglunds Quauntum Power Belt Conveyor
With the new Hägglunds Quantum Power motor, the equation has changed substantially
Quantum concept, the Hägglunds Quantum Power has the same interfaces and small frame sizes as its sister motor, but it features an innovative internal design and a range of other enhancements.
A new connection block, which has eight main ports of 2” in diameter, combines with an optimised distributor and refined internal channels to provide more flow to the radial pistons – with minimal losses, which reduces operating pressure.
The result is a hydraulic motor whose efficiency at higher speeds aligns with that of an electromechanical solution, which brings the other advantages of a hydraulic direct drive back into play.
CALCULATING THE EFFICIENCY IMPROVEMENT
To exemplify the difference, one can compare motors of equivalent size in a high-power belt conveyor application, requiring 75 kNm of torque while running at 65 rpm. Both the Hägglunds Quantum 400 and the Hägglunds Quantum Power 400 could supply the necessary torque, but their energy consumption at this higher speed would differ significantly.
Over one year of continuous operation, calculated as 8,000 hours (accounting for planned maintenance), the Hägglunds Quantum Power would save around 312 MWh compared with the Hägglunds Quantum. This equates to 138 metric tons of CO2* – or the energy used by 127 electric cars with an annual mileage of 12,000 km.**
Looking at it another way, the input energy saved would be roughly 7% of the shaft output in same time frame.
EXTENDED LIFETIME AS WELL AS ENERGY SAVINGS
While the Hägglunds Quantum motor remains the appropriate choice for many belt conveyors, the Hägglunds Quantum Power makes a long-lasting hydraulic direct drive system feasible for many more. At higher speeds, its minimised losses and the resulting reduction in operating pressure mean an even longer motor lifetime.
In fact, there are further aspects of the Hägglunds Quantum Power that enhance its lifespan. These include reinforcements, such as a diamondbased piston coating and an improved cam roller design, but also monitoring and service aspects, including a builtin temperature sensor and separate seal retainers that allow easy seal changes from the outside. All these features are standard, as is the motor’s ability to work with Environmentally Friendly Lubricants.
Between higher efficiency, extended motor lifetime and the overall ability of a hydraulic direct drive system to safeguard the belt conveyor it drives, the Hägglunds Quantum Power gives sustainabilityconscious mining customers reason to consider a hydraulic solution –even at higher speeds.
* Source: ember-climate.org (calculated at a world average grid carbon intensity of 442 g CO2e per MWh)
** Source: bmuv.de/en/
Quantum Power 280 – back
Quantum Power 280 – front right
Quantum Power 280 – front
ELECTRIFICATION WITHOUT LIMITS
Simon Farnfield director at Advanced Engineering explores how electrification is transforming cross-sector production
Electrification is gathering pace, moving from a mobility-focused trend into a catalyst for broader engineering and manufacturing change. As manufacturers, systems integrators and designers are looking beyond combustion and hydraulic technologies and how they bring fresh demands on supply chains, productivity and design principles. Here, Simon Farnfield, event director at Advanced Engineering, explores the impact of electrification and the challenges facing the engineering community during this transition.
When we think of electrification, it’s easy to jump to electric vehicles (EVs). However, electrification is now prominent in sectors such as aerospace, logistics and manufacturing. Many manufacturers are now using electric motors to power machinery in their plants, replacing older hydraulic systems. It’s the same in aerospace, where electric actuators are increasingly used for flight control to help simplify and lighten structures.
However, these sectors share many of the challenges faced by EVs, like efficiently storing, converting and controlling electric power, and ensuring long-term battery reliability. Meeting these challenges requires a collaborative approach spanning supply chains, sectors and disciplines.
SUPPLY CHAIN PRESSURES
For many engineering and production firms, the most obvious impact of the electrification transition will be the
strain it puts on their supply chains.
According to a survey by Make UK, increases in cost of raw material, transport and energy are all driving supply chain disruption, with almost half of those surveyed having increased investment in supply-chain resilience.
The disruption caused by electrification is almost inevitable since the transition requires a shift in components – from hydraulic cylinders to electric actuators, and from internal combustion components to power electronics. These demand new sourcing strategies and supplier relationships. Just to illustrate this, the same survey by Make UK found that four-fifths of companies are diversifying their supply chains by increasing or reducing suppliers, and electrification will only exacerbate this trend.
THE SKILLS AND KNOWLEDGE GAP
By 2026, it is estimated that 91,000 engineers – nearly 20 per cent of the UK’s current engineering workforce — will have retired or be about to. This is problematic, not just for our electrification hopes but for the engineering industry in general.
As systems become more electrified and connected, the skills required to design, install and maintain them are shifting. Today, mechanical engineers are expected to understand electric drives and how they work. Similarly, control engineers must integrate energy monitoring and safety protocols for high-voltage systems.
We now face an upskilling challenge that impacts everyone from OEMs and system integrators to end users.
We must focus on bridging these knowledge gaps, and initiatives such as Advanced Engineering UK’s ongoing #MINDTHEskillsGAP will be crucial. This campaign calls for closer collaboration between industry leaders and policymakers to develop solutions that will secure the next generation of engineering talent.
A SHARED CHALLENGE
To harness the benefits of electrification, we must realise that no individual sector has all the answers. For example, battery thermal management techniques used in aerospace could help guide automotive production. Meanwhile, material science advances in robotics could shape EV motor design.
We can expect electrification to continue transforming the UK’s engineering and manufacturing industry, but this also poses several challenges that we must address.
The impact on supply chains is one thing, but we must futureproof the skills and knowledge powering our industry, and this means creating a cross-sector collaborative space where ideas can be shared and innovation encouraged. Advanced Engineering UK provides such a platform, bringing together over 9,000 of the brightest engineering minds each year to explore cuttingedge innovations and uncover pioneering solutions.
OPTIMASS with sensors and electronics MFC 400 for Safety Instrumented Systems
• Using the new OPTICHECK Flow Mobile app on mobile devices or FDT/DTM on laptops commissioning, parameterisation, verification, performance monitoring and application parameters can be managed on-site via a secure Bluetooth® connection (<20 m/65.6 ft) –ideal for inaccessible areas or EX Zone 1
SUBSEA CONTROL VALVE
Completion of a comprehensive development and qualification programme for subsea control valves marks a milestone for Koso Kent Introl’s flagship range
KKI leveraged decades of experience in manufacturing specialised topside process control valves, to ‘marinise’ proven design features into a robust subsea solution
Subsea valve manufacturer KOSO Kent Introl (KKI) has announced the successful completion of a comprehensive development and qualification programme for a brandnew range of subsea control valves. This milestone marks a significant leap forward for subsea processing, carbon capture, utilisation and storage (CCUS), as well as hydrogen storage applications. These are sectors where precise, reliable control has historically been difficult to achieve.
The 8in SPCV 4A control valve
SPECIFICATIONS AT A GLANCE
The newly qualified range covers a broad spectrum of operational requirements:
• Size range: 1” to 9”
• Pressure rating: Up to API 6A 10K
• Material class: API 6A ‘HH’ (corrosion-resistant alloys)
• Temperature range: -46°C to +140°C (-50°F to +284°F)
• Water depth capability: Qualified to 3,048 metres (10,000 feet)
• Operation: Bespoke low-friction MOIPRS – ROV or electrically operated
CLOSING A LONGSTANDING GAP
Until recently, subsea systems often relied on relatively crude choke mechanisms to regulate process flows. While functional, these solutions lacked the accuracy and control necessary for optimised subsea processing, resulting in system-wide compromises and reduced operational efficiency.
In critical applications – such as subsea separation, boosting, CCUS injection, and hydrogen storage –this lack of precision could limit the overall effectiveness of the subsea infrastructure.
The answer to that challenge is the Series 1275 Dynamic Subsea Control Valve Range.
FROM TOPSIDE EXPERTISE TO SUBSEA INNOVATION
KKI leveraged decades of experience in manufacturing specialised topside process control valves, to ‘marinise’ proven design features into a robust subsea solution. This approach meant that each element – from the mechanical operator to the sealing system – was engineered to withstand the extreme demands of subsea environments.
The qualification testing process involved input from some of the world’s leading oil and gas operators, ensuring the final product met or exceeded real-world expectations. In fact, the Series 1275 underwent one of the most extensive endurance testing programmes ever conducted on a subsea control valve.
A RIGOROUS TESTING PROGRAMME
The development team adopted a conservative, safety-first philosophy, recognising that reliability is paramount in subsea systems where maintenance can be costly and complex.
General testing included hydrostatic pressure trials, seat leakage checks, and API 6A PSL 3G gas testing. More specialised qualification tests included:
• API 6A PR2F
• Hyperbaric testing in accordance with API 17D / ISO 13628
• Flow performance testing.
• Endurance testing as defined jointly by client and KKI
To support the programme without disrupting ongoing production, KKI invested heavily in upgrading its inhouse test facilities. This capability not only accelerated the project but also positions KKI for future subsea developments.
BREAKTHROUGHS ACHIEVED DURING DEVELOPMENT
The Series 1275 range incorporates several industry-leading innovations:
• Low-friction mechanical operator featuring an Inverted Planetary Roller Screw (IPRS) for enhanced accuracy and positioning.
o Operating torque reduced to less than 25% of typical subsea choke operators.
• Advanced stem hard coating for superior wear and corrosion resistance.
• New gland seal packing system designed to accommodate the extensive stem movement typical in subsea operations, ensuring long-term sealing integrity.
These features combine to deliver exceptional control accuracy, reliability, and operational lifespan – all essential for high-value subsea infrastructure.
A LEGACY OF SUBSEA EXPERTISE
Founded in 1967, KKI has built a global reputation for manufacturing severe service control valves across upstream, midstream, and downstream applications. While its core subsea choke valve technology dates back to the early 1980s, the company’s first subsea control valve project was delivered in 1986 for the Argyll field
in UK waters.
That pioneering scope included subsea control, butterfly, and choke valves for a prototype subsea separation and pumping unit (SSPU), supplied via British Offshore Engineering Technology (BOET). Since then, KKI’s subsea capabilities have steadily evolved alongside the offshore industry’s growing interest in the “subsea factory” concept –where entire processing systems are deployed on the seabed.
INDUSTRY FIRSTS FROM KKI
Over the decades, KKI has introduced several subsea valve innovations:
• 1986: First range of subsea control and choke valves for subsea processing.
• 1992: Deep-water retrievable chokes using collet-type connectors.
• 1997: Lightweight choke insert weighing under 200 kg.
• 2001: First choke valve to complete a 1-million-step endurance test (now an industry recommended practice).
• 2006: 8-inch deep-water insert retrievable control valve.
To date, the company has supplied more than 1,000 subsea choke valves worldwide.
POSITIONING KENT INTROL’S PRODUCTS FOR THE FUTURE
By launching the Series 1275
Dynamic Subsea Control Valve range, Koso Kent Introl has reinforced its position at the forefront of subsea flow control technology. With the energy industry accelerating towards subsea processing, CCUS deployment, and hydrogen storage infrastructure, the need for precision-engineered, reliable subsea control valves will only grow.
This new range not only fills a historic technology gap but also offers operators a proven, qualified solution that enhances efficiency, reduces operating torque, and withstands the harshest subsea conditions.
For more information visit: www.kentintrol.com
PERFECT PINTS
Nick Beeson from Ebar explains how the company’s patented technology reduces froth and waste when pouring beer
Two Brighton & Hove Albion fans make use of an on-site Beerwall
The West Yorkshire company behind a fast growing automated self-serve drink solutions, Ebar, is ramping up production after extending its manufacturing partnership with PP Control & Automation (PP C&A).
EBar has developed patented pour technology capable of delivering 200 pints per hour and has sealed a number of new contracts with sporting venues for its Beerwall technology (a wall of beer dispensers for use at venues) the company expects to see the number of units in operation rise to 100 by the end of 2025. In short, the company is deploying high-speed bottling plant technology in a retail environment.
International Process Engineer caught up with Ebar’s founder Nick
Beeson to find out some more about the technology itself.
Nick explained that at its core Ebar has patented a pouring method by which a seal is made across the rim of a plastic cup, pressure is applied inside and the beer is injected into the cup. The pressure inside the cup is kept above the bubble point of the beer, preventing foaming during the dispense.
Foaming is a major problem for non-pressurised automated solutions, which can only try to contain it by slowing down the speed of serve. At the end of the dispense, the EBar releases the pressure in the cup and the beer ‘head’ forms, in exactly the same way that it appears when a beer bottle is opened. The result is a cold, fresh and fizzy pint.
TIME TO DEVELOP
Development started in 2017, with a Scottish Enterprise SMART Feasibility grant supporting the design and construction of the first prototype EBar in 2018. This was successfully trialled at Twickenham Stadium in 2019 and further funding was then raised to develop a commercial prototype.
Product development continued during the Covid-19 pandemic and the first commercial mobile EBars were deployed in August 2021. The company’s built-in Beerwall solution was launched in September 2023 with the first units deployed at The Den, the home of Millwall FC.
PROBLEM SOLVING
EBars were developed to reduce queues, improve customer experience and increase the profitability of venues. Traditional venue bars rely on old-fashioned bar equipment that is operated by casual staff who may have little experience of serving beer. This can make service slow and inefficient, frustrating venue customers who often decide to not bother buying a drink, particularly if they know that the quality may be poor.
The venue then loses out on high margin sales. The industry also traditionally suffers from high levels of beer waste, with margins further squeezed by increasing staff costs.
SIMPLE USER INTERFACE
EBars have a simple user interface that allows a customer to order, pay and pour two pints in under 30 seconds. This requires no user skill, unlike manual self-service options available in the market. Each EBar can serve up to 200 keg-fresh pints per hour, reducing queues and increasing
bar sales. With one member of staff able to supervise up to six EBar units, staffing costs are slashed, and our pressure pour system means that waste is negligible.
PLANNED UPDATES
The company has a roadmap of hardware and software development for both its core large venue market and the wider traditional pubs and bars sector. First in line is an automated cup feeding system, which will increase service rates to over 300 pints per hour per Ebar, according to the company. Digital ID verification technology will soon be opening up further opportunities with faster and more effective age verification.
To cope with this increase in volumes the company has collaborated with outsourcing specialist PP C&A which took over the complete electronics and mechanical build and full assembly earlier this year.
A dedicated team of eight engineers at EBar’s West Midlands factory has created a specialist production cell that has the potential to build up to
The best inventions are often born out of necessity and that is certainly true of EBar. The technology is transforming bar service at live venues across the UK
five units every week, a 200% increase on the previous capacity.
Nick said: “The best inventions are often born out of necessity and that is certainly true of EBar, which is transforming bar service at live venues and sporting events across the UK.”
Two units per week were built by PP Control & Automation during the initial production phase but six months into the ‘outsourcing partnership’, with systems and processes in place, production of the Beerwall is hitting the target of five units per week.
Build time has been cut in half and right first-time rates have improved significantly meaning EBar has full confidence in the performance of its technology when it rolls into a commercial setting.
Supply-chain management concerns have been minimised by giving full responsibility to PP C&A, with new components identified for future builds that could save money and time.
Engineers from both teams continue to work together to identify other assembly improvements and to explore how the latest technology addition such as the automatic cup feeder which can be integrated into new Beerwalls at venue outlets.
For more information visit: www.ebar.co.uk
EBar technology prevents venues losing out on sales
Each EBar can serve up to 200 keg-fresh pints per hour
RETHINKING THERMAL MANAGEMENT
This is the first of two articles in which Johann Lainer from Watlow makes the case for the integrated thermal loop in process engineering
The industrial landscape is undergoing a profound transformation. Increasing manufacturing complexity, stringent regulatory standards, and escalating sustainability demands are compelling industries to rethink how they manage thermal processes. Traditional systems, where heaters, controllers, sensors, and power units do not operate in full synergy, are no longer sufficient to meet these challenges. Enter the Integrated Thermal Loop: a data-driven, unified approach that redefines thermal management.
INTEGRATING KEY THERMAL COMPONENTS
This transformative system integrates all key thermal components and system data into a cohesive ecosystem, enabling real-time feedback, enhanced precision, and actionable insights. Unlike traditional setups, where elements are not
fully integrated, the concept of an Integrated Thermal Loop creates a seamless synergy, unlocking new levels of efficiency and control. It isn’t just an innovation; it’s an essential framework for meeting the demands of modern industry while laying the groundwork for future advancements. The adoption of such systems is not just about keeping pace with technology. It’s about future-proofing operations, ensuring compliance with increasingly strict regulations, and contributing to global sustainability goals. This holistic approach addresses the complexities of today’s manufacturing environments and prepares industries for a connected, data-driven future.
A NEW ERA OF CONTROL
In industries such as aerospace, automotive, pharmaceuticals, semiconductor, oil & gas and energy, thermal processes are critical to achieving operational excellence.
Six elememts that make up the Integrated Thermal Loop
Yet, inefficiencies, inconsistent performance, process drift, and unplanned downtime often hinder productivity and drive up costs. In highly regulated industries, these issues are exacerbated by the need to comply with rigorous standards like AMS2750, CQI-9, and ISO 20431:2023, which require detailed process documentation and precise temperature control.
The Integrated Thermal Loop addresses these challenges by combining sensors, controllers, and power systems with robust data analytics and predictive maintenance capabilities. One example is Watlow’s Thermalwatch system, which leverages IoT-enabled gateways to collect and analyse data from thermal systems and adjacent subsystems. By identifying early warning signs like sensor drift, insulation degradation, or control instability, predictive maintenance can occur to minimise unplanned downtime, reduce the risk of scrap or poor quality products, and extend the thermal equipment lifespan.
SEMICONDUCTOR MANUFACTURING CASE STUDY
Consider a semiconductor manufacturing facility as a case in point: While the primary challenge for this manufacturer was frequent downtime every two weeks, the root cause was identified through detailed thermal system analysis. By collecting and analysing data, the team discovered multiple cold spots along the exhaust lines, which led to condensation of process gases and, ultimately, clogged lines. Operators would only detect the issue when a pressure spike occurred at the vacuum pump - at which point downtime was unavoidable. Leveraging data insights and thermal loop expertise through the Thermalwatch solution, the system was optimised by introducing additional control zones to eliminate cold spots. This refinement significantly reduced clogging, extended the preventive maintenance cycle, and ensured a more stable manufacturing process. The result meant that the facility extended its maintenance intervals from two
weeks to 26 weeks. This change not only saved millions of dollars annually but also ensured continuous operation in an industry where downtime can cost up to $16,000 per minute.
Take another example of a process that is running well. After carrying out planned maintenance, although the process temperature remains constant, the percent power increases by 20% when the system comes back online. Something has changed! The legacy thermal loop cannot “see” this change because it is just trying to maintain a temperature set point, and that set point is still being achieved. Maybe the insulation had not been put back on or was not installed correctly. The result of such undetected mistakes would mean higher energy consumption, possible safety issues, reduced heater reliability, unplanned downtime and potential additional replacement equipment costs. By collecting and understanding more data from across the entire integrated thermal loop, we can understand the cause of the process drift, flag where the issue lies, and take corrective action.
Another example is a combined temperature and power controller with a two-zone ceramic pedestal, such as the Watlow Powerglide controller, used in semiconductor manufacturing. Such systems operate differently than traditional controls. While these are technically ‘closed loop’ systems, they can only see one temperature sensor point in the center of the pedestal. If the two element temperatures are also not kept close to each other, this can cause nonuniformity, resulting in poor chip yield on the wafer. Furthermore, the variance in actual temperature between the center of the pedestal to the edge can result in the pedestal cracking, causing very expensive downtime and replacement costs. Systems such as Powerglide integrate the actual heating element temperature measurements individually and turn the power up and down to keep them balanced, thereby increasing overall thermal uniformity and reliability.
The E-Power controller
The PowerGlide controller
EXPLORING NUTRACEUTICALS
A recent gathering in Cologne explored the challenges and opportunities when manufacturing nutraceuticals
The demand for nutraceuticals – a whole food that is repackaged and concentrated in a non-food format – is growing exponentially. A boom in sales of beets, spinach and garlic capsules in recent years demonstrates that these products have struck a cord with consumers struggling to fit the full range of nutrients into their diet. Despite this growing demand there are well documented issues with the manufacture of such products. A recent gathering of around 20 guests from six European countries aimed to examine these from a variety of perspectives. The event was hosted by packaging specialist Romaco Kilian in collaboration with coating specialist Biogrund, AI tablet design company TaBlitz and the Romaco sister companies Innojet and Tecpharm.
COMPANY INVOLVEMENT
Nutraceutical production presents an array of challenges. In most cases, only a limited choice of ingredients is available for the formulation, as chemical additives need to be avoided as far as possible. Moreover, the authorised natural ingredients are often very complex to process: plantbased raw materials, for instance, tend to be sticky and poorly flowing, making them difficult to compress. They also have a reputation for high chemical and physical instability. Minerals, on the other hand, exhibit highly abrasive properties and attack the tooling.
PRODUCTION CHALLENGES
As such, the event looked at potential solutions for granulating, tableting and coating nutraceuticals via seven expert lectures. Novel concepts for lubricant usage and an AI supported platform for tablet design were likewise featured in this context.
A hands-on session at the KiTech tableting laboratory concluded the event. Here, participants carried out
compression tests using the KTP 1X compaction simulator from Romaco Kilian. In addition, granulation of a placebo mixture was demonstrated on the Ventilus Lab fluid bed processor from Romaco Innojet.
Gallmann, sales director at Romaco Kilian said: “Our objective was to share practical know-how and provide a clear picture of the diverse ways we can support the industry – from machines and tools to ingredients and data-analysis techniques.”
THE LECTURES
The Romaco Innojet lecture dealt with the production of free flowing granulates with a precisely defined particle size as well as hot melt coatings to mask the taste of bitter plant extracts. Romaco Kilian summed up the requirements a tablet press must meet in order to reliably process sticky and poorly flowing powders. The host company outlined the numerous possibilities for digital data analysis and evaluation using a smart compaction simulator for tablet development. Biogrund gave a rundown of the individual lubricants and how they work, then went on to talk about alternatives for magnesium
stearate. Finally, the specialist for solid oral dosage forms offered detailed insights into tablet disintegration behavior and described the effects that can be realised with selected excipients.
NEW AI PLATFORM
With this in mind, TaBlitz introduced its new AI platform, which simplifies feasibility studies for optimised tablet design as well as digital testing of tablet tooling. In addition, the AI checks whether tablets are shaped to be easy to swallow and coat.
The Romaco Tecpharm presentation focused on the extensive options for coating nutraceuticals, examining the widespread use of film coatings as well as the application of sugar coatings in a drum coater. Dr. Carola Hanl, KiTech laboratory manager at Romaco Kilian said: Our industry meet-up demonstrated very impressively the importance of sharing ideas, it also demonstrated what can be achieved through industry cooperation.”
Romanco Kilian summed up the requirements of a tablet press at the event
CLEAN-LABEL CONSUMING
Chris Johnson managing director of SMB Bearings explores how clean label trends are affecting the type of equipment used in food processing
Reuters recently reported that nearly half of global consumers had purchased more fresh, unprocessed foods over the past year. Today’s consumers are not only checking ingredient lists, they’re scrutinising how food is made –a considerable 75 per cent say they’re willing to pay more for clean-label products, according to NielsenIQ.
These shifting expectations mean food manufacturers must adapt not only their formulations, but their equipment too. Here Chris Johnson from SMB Bearings explains why the smallest components, such as industrial bearings, are playing a bigger role in food safety and compliance.
The clean-label movement (built on transparency, traceability and minimal processing) is accelerating demand
for hygienically engineered machinery and manufacturing processes.
For manufacturers, this means re-evaluating the materials and maintenance requirements of every part of their equipment, which brings us to bearings. These ofteninvisible components are critical to food processing equipment, from rotary slicers and conveyor systems to packaging and mixing machines. But as the sector evolves, bearings must now meet much more than performance metrics.
In clean-label facilities, for example, they must resist corrosion, endure aggressive washdowns and eliminate contamination risk – all while complying with food safety standards like European Union Regulation (EC)
No 1935/2004 and the US Food and Drug Administration (FDA)’s FDA CFR Title 21.
However, traditional bearings often fall short under these demands, which is why manufacturers must embrace alternatives.
STAINLESS STEEL AND HYBRID BEARINGS
Manufacturers are shifting to stainless steel bearings or hybrid bearings with sealed, lubricated-for-life designs. These options are not only mechanically robust but are easier to sanitise and less likely to introduce contaminants.
Stainless steel and hybrid bearings are particularly well-suited to food and beverage environments because
The clean-label movement is accelerating demand for hygienically engineered machinery
of their superior corrosion resistance, mechanical strength and cleanability. Stainless steel offers high resistance to rust and chemical damage, making it ideal for machinery that must endure daily washdowns with caustic or chlorinated cleaning agents.
Hybrid bearings, with stainless steel races and ceramic balls, offer superior wear resistance, lower friction, and enhanced reliability in harsh conditions. Their sealed, lubricatedfor-life design reduces maintenance and downtime – a key advantage in food production, where bearing failure can disrupt operations and risk contamination, according to the company. By choosing stainless steel or hybrid options, manufacturers not only meet strict hygiene standards but also safeguard production uptime and product integrity.
Lubrication for bearings is another critical part of the equation, as leaking or degrading grease can contaminate food. To mitigate this risk, foodsafe lubricants compliant with UK Food Safety Act 1990 or National Sanitation Foundation (NSF) H1 or H3 standards in the US are now a baseline requirement. Solid or lifetime lubrication is increasingly specified, especially in allergen-free or vegan facilities where even minor crosscontact can trigger costly recalls. Take a salad processing line. Equipment here faces water, vibration and sanitising chemicals – often several times a day. Bearings in these environments must be sealed against ingress, made from corrosion-resistant materials, and pre-lubricated with food-grade grease that won’t degrade under pressure. Bearings that meet these standards don’t just protect consumers, they reduce downtime, extend service life and support compliance with regulations and retailer audit schemes.
GREATER TRANSPARENCY
Hygiene is just one piece of the puzzle. Traceability is now a central requirement too. Food processors must demonstrate full component traceability, especially when supplying large retailers or exporting internationally. That means knowing where each bearing came from, what materials it’s made of, and how it
meets relevant safety standards.
That’s why specialty bearing suppliers like SMB Bearings offer stainless steel and hybrid units designed for food and beverage use – complete with food-safe lubricants and compliance documentation. Costconscious manufacturers may wonder about the return on investment (ROI) of upgrading to food-safe bearing systems, but benefits like reduced downtime, fewer recalls, and extended maintenance intervals often far outweigh the initial cost.
As consumers demand greater transparency and cleaner labels, food manufacturers must respond with more than just new recipes – they
need smarter, safer machinery built for compliance and hygiene. Bearings may be small, but their impact on food safety, equipment reliability and regulatory compliance is significant. Stainless steel and hybrid designs with food-safe lubrication are no longer optional upgrades – they’re essential components of a clean-label strategy.
To explore how hygienic, food-grade bearings can support clean-label and compliance goals, visit SMB Bearings’ website or speak to one of its experts.
For more information visit: www.smbbearings.com
Hybrid bearings offer superior wear resistance and lower friction
SAFETY CERTIFICATION
Leigh Picton, product safety certification provider from Kiwa, outlines the benefits for manufacturers of partnering with a specialised provider around the safety certification process for electronics
Speed to market is a key consideration for manufacturers introducing new IT, audio/visual, and laboratory measurement/control electronic products for both domestic and professional applications.
Any new electrical product introduced in the UK and beyond must be fully certified to ensure it complies with national and international safety standards. Therefore, securing the correct safety certification under the internationally recognised IECEE CB scheme is a key milestone in any successful electronic product’s development and launch journey. Getting safety certification right is critical, but the process can be complex. Global and regional safety standards are increasingly rigorous, and each target market often has its own unique requirements.
But streamlining the certification process by collaborating with a reputable, independent safety certification provider can help deliver market competiveness and practical and commercial benefits as manufacturers look to get their new innovations into the hands of consumers and stocked by retailers quickly and efficiently.
ADOPT A SINGLE SOLUTION APPROACH
The best strategy is to opt for a single program of testing under the CB safety scheme; one that will cover all the requirements demanded by a wide range of global target markets. It includes full product evaluation, rigorous expert-led testing and assessment, collaborative feedback and tangible time and cost-saving advantages - all under one roof. This approach to achieving the necessary safety certification will get the manufacturer to a position to launch quicker and with less expense when compared with deploying a less integrated certification solution.
FREEING UP INTERNAL RESOURCE NEED
Product safety certification providers will oversee the entire process from start to finish, leaving manufacturing time and resources free to work on other product elements. The provider begins by defining the exact scope of testing needed and identifying the target countries or regions for launch. From there, once they are in receipt of necessary product details and documentation – including information for all associated product components – safety testing against International Electrotechnical Commission (IEC) standards, as well as the national requirements of target countries, takes place.
Dedicated laboratory resource and experienced engineers provide high quality testing at pace, raising issues with clients if needed so they can be rectified without undue delay to the overall launch process.
Addressing product-related issues spotted as part of the in-depth testing program in a prompt manner, helps keep momentum on track and ensures the product will meet all safety standards ahead of the certification issue.
TIME AND COST BENEFITS
Once the product complies with all relevant standards, the certification body issues the CB Test Certificate and Report. These documents are critical for securing access into global target markets. They include the products test results against the international standard as well as any test characteristics specific to the target countries.
This approach allows manufacturers to apply for certifications in multiple countries without duplicating laboratory testing commitments through a strategy that can save both time and costs.
As an example, some regions, like the US, may require additional certifications such as the NRTL mark. In such instances, Kiwa works with local partners to ensure the CB Test Certificate is leveraged effectively and ultimately it streamlines all the required national certification processes.
The Kiwa CB test certificate and report will help secure global market access
Explosion venting devices limit the overpressure and mitigate damage to process equipment by controlled venting of the excess pressure with or without flame to a safe area. ATEX explosion venting systems offer an economical, cost-effective means for explosion protection. We have the latest and best in explosion venting technology, over 50 years of practical design knowledge and up to date computer modelling.
Explosion Suppression
Safety
Cement Industry
Most processes involve interconnection with associated vessels. To prevent propagation to other vessels, it is essential to apply appropriate explosion isolation devices to prevent flame, spark and/or pressure from transmitting to the other vessels. For the very best in explosion isolation solutions, view our full range.
Atex CO ACOM Systems www explosionhazards co uk
Explosion Suppression Systems are fast fire extinguishing systems that detect the explosion pressure in a protected plant and then mitigates the flame/pressure damage to an acceptable level. For the very best in explosion suppression solutions, view our full range of ATEX solutions.
The Atex CO detection system uses advanced carbon monoxide (CO) sensors to detect early stages of powder combustion before a fire or explosion can be ignited.
Email: info@explosionhazards.com
CENTRIFUGAL CAPABILITY
Technology expert Dirk Hinze from Egger Pumps, provides insight into the company’s centrifugal process pumps
The single-stage centrifugal process pumps of the EO series from Egger are widely recognised in the chemical and petrochemical industries for their ability to handle fluids containing solids and gas fractions of up to 25% GVF.
This robust capability is achieved through a semi-open impeller design, which incorporates a geometry optimised to maintain stable flow even under gas-laden and/or abrasive conditions. This feature is particularly valued in reactor loops with external heat exchangers or circuits, where mixtures often include catalysts and gaseous reaction products.
Whether operated in batch or continuous mode, EO pumps ensure reliable circulation with stable pressure condtitions. The result is shorter production cycles and consistently high system availability, key factors in modern process plants.
STANDARD EO PUMP
The standard EO pump casing is rated
for 16 bar and 25 bar (230 and 365 psi) and handles process temperatures up to 180 °C (355 °F).
For more demanding applications, OH2-compliant casings are available in several configurations, including 25 bar/235 °C (363 psi/455 °F), 45 bar/235–280 °C (655 psi/455–535 °F), and 100 bar/280 °C (1450 psi/535 °F). Egger typically manufactures these casings using duplex stainless steel to ensure corrosion resistance and mechanical strength.
Where required, martensitic or austenitic materials extend this thermal range to 450 °C (840 °F). For highly aggressive or corrosive media, material options such as nickel-based alloys or zirconium are available.
The precise pressure/temperature design values depend on the selected material but can be reliably calculated using finite element (FE–) analysis.
Depending on customer requirements, the EO series meets or approximates the specifications of ISO 5199 and API 610, providing engineering reliability to international standards.
An EO-pump integrated into a reactor loop for the American market in its final stages of the production process in the Swiss manufacturing site of Cressier, Neuchâtel
The Egger Process Pump EO handles process temperatures up to 180 °C
THE PLUS VARIANT
The ‘plus’ variant of the EO pump is used for pressures up to 45 bar (655 psi), featuring an oil-lubricated bearing housing with labyrinth seals.
On the impeller side, a cylindrical roller bearing ensures smooth running, while the coupling side is supported by two angular contact bearings. For applications above 45 bar, a spherical roller bearing is added to absorb high axial loads.
If necessary, the bearing housing can be fitted with an integrated cooling coil. When high thermal expansion is expected, the baseplate can also be mounted on spring-loaded supports to preserve alignment and structural integrity.
Shaft sealing is typically handled by double-acting mechanical cartridge seals that are fully integrated into the seal chamber. For more complex media or hazardous fluids, triple mechanical seals are also used. For applications that require hermetic separation of pump and atmosphere, magnetic coupling systems have been successfully implemented.
As mentioned, a core feature of EO hydraulic design is its ability to maintain performance when handling fluids with significant gas content. In reactor systems with external heat exchangers, EO pumps can manage large volumes of reaction gas-laden catalysts without pressure instability or performance drop.
This ensures process continuity and helps operators maintain efficient reaction control even under variable process conditions.
Over decades of development, Egger has built the EO range into a flexible and robust process pump programme. In response to evolving market needs, particularly the demand for low-flow, low-specific-speed solutions, Egger has extended the EO series to include two new sizes: DN 50 (2 inch) and DN 80 (3 inch).
These models were specifically engineered to maintain the hallmark EO features even at low nq values. The development challenge was to preserve the ability to handle gas and solid fractions within this more compact hydraulic design while maintaining high operating stability and reliability.
These new sizes extend the low flow
Illustrated performance field for the Egger EO series, including the newly developed EO8-50 and EO10-80 models. The extended range fills a low-flow application gap while maintaining solids and gas-handling capabilities.
Performance map highlighting the EO8-50 at higher rotational speed (2900 min-¹). This version addresses compact system designs requiring higher heads at low flow rates, while preserving the hydraulic stability characteristic of the EO range.
range from 25 to 90 cubic metres per hour at heads between 70 and 140 metres, and 25 to 190 cubic metres per hour at heads between 40 and 100 metres. In imperial terms, this equates to flow rates from 110 to 395 gallons per minute (gpm) at heads of 230 to 460 feet, and 110 to 835 gpm at 130 to 330 feet. These smallersize pumps open new opportunities in compact process systems, pilot units, or decentralised modules where controlled flow and tight process windows are required.
The range of the entire EO-series reaches a maximum capacity of up to 4,500 cubic meters per hour, or 19,800 gallons per minute.
The expanded EO product line offers operators more flexibility across all flow classes while preserving the robust design principles for which Egger process technology is known.
As customers continue to seek improvements in uptime, process stability, and energy efficiency, Egger EO pumps remain the benchmark for reliability, adaptability, and long-term performance.
A Full UI AutoReview user interface
AN AI WATERSHED
The engineering sector has lagged others in the use of AI to check and approve projects, but this is changing with exciting results. Nicola Brittain reports
There are a host of reasons why the engineering sector has been slow to take up AI. With this in mind, International Process Engineer caught up with the CEO of CoLab Software Adam Keating, to find out more about the company’s new AI technology AutoReview; as well as why engineering lags other sectors in the take up of AI, and how we might break down this generic charactarisation of the technology in a more granular and useful way.
Although enterprise technology spend has fallen over the last six to 12 months, there has actually been a significant increase in AI spend, according to Adam. “Every boardroom we talk to has a major initiative around the technology.”
CoLab, a US-based agile technology company recently launched its checking tool AutoReview six months ahead of schedule. The technology automatically reviews 2D drawings and 3D models against a checklist, promising to ensure quality standards, boost productivity and reduce errors and costs.
As is often the promise with AI, this product will help remove some
An illustration of AutoReview finding some design flaws in a drawing
of the grunt work currently done by engineers (engineering teams spend nearly a quarter of their time on administrative tasks). Users of the product include Techtronic Industries and TPI Composites, and both report reduced Bill of Materials (BOM) costs of up to 50% and design
cycles accelerated by 100% according to CoLab.
AutoReview works by scanning documents and identifying common issues, including errors in drawings and design for manufacturing (DFM) optimisations. For example, it will find missing or incorrect countersinks
CoLab CEO Adam Keating
The illustration shows an ambiguous configuration picked up by AutoReview within drawings - these are the measurements responsible for ensuring the head of a screw sits flush or just below a surface. It also checks molding measurements in designs to make sure wall thickness dimensions will work and that molds are easy to remove for manufacturing.
TWO PARTS TO AUTOREVIEW
The two key elements to the technology are an AI peer checker and an AI lessons learnt tool.
The peer checker checks a file, drawing schematic or a 3D model. It red lines the file just like a human checker would. The tool then creates markups on a drawing or highlights on a 3D model.
AI lessons learnt is similar except it takes an already conducted human level review and looks for similarities in terms of models and designs in a new file using a machine learning model (built in house). The tool is then able to bring up problems previously encountered, preventing engineers from making the same mistake twice.
An October release will merge these properties together (they’re currently two separate streams) and allow users to look at new and ‘worked on’ files.
WHY ENGINEERING LAGS OTHER SECTORS LIKE LAW
Engineering lags the legal and other sectors in terms of its uptake of AI because, as Adam explained, engineering data sets are not publically available to train LLMs. There is also considerable complexity in engineering data, since it’s not just text. “You need to understand a lot about how the data in a file is constructed to provide a context for what it means,” Adam says.. “In addition, 3D and simulation data is very unstructured and could mean many different things without the appropriate background information”. Similarly, a lot of engineering takes a big-system approach with 3D file simulation and requirements attached. Engineering as a whole hasn’t figured out systems engineering - it is still an evolving field - meaning there isn’t a complete set of rules or data sets to upload to an LLM. “There is a lot to encompass and we need to understand most of that before we can provide useful multi-step AI agents to industry,” Adam said. Other challenges include the fact that engineers are sensitive about their IP, however Adam asserts that this seems to be changing.
DIFFERENT PHASES OF AI ADOPTION BY ENGINEERS
1) Co-pilot phase: Use of co-pilot or ChatGPT to ask general knowledge questions. During a recent CoLabs led keynote most people in the audience were using Microsoft co-pilot or ChatGPT.
2) Peer-checking partner phase: This is the type of AI that checks things humans would normally look at – it’s the ‘low-hanging fruit’ work. Peer checking is really beginning to take off for engineers.
3) Multi modal / multi step phase: These tools help people manage complex workflows operating several disciplines using many different tools.
4) Generative AI: Underpinned by machine learning generative AI tends to produce original output. Such a tool would spit out an object such as a CAD file. Engineering does not yet use this most advanced form of AI - the technology simply isn’t there yet.
WATERSHED FOR COLABS
Adam reported that recent interest in AI for administrative tasks in the engineering sector has increased exponentially. At the time of writing more than 20,000 people were currently on the waitlist for Autoreview. “When we started up, half the people we talked to were excited, half were nervous. Things are different now. and there is a huge early adopter bucket,” he said, adding: “it reminds me of the move to Microsoft Teams during the Covid 19 pandemic, Within a month or so the whole world was using Microsoft Teams when just weeks earlier nobody had heard of it.”
For more information visit: www.colabsoftware.com
HEART OF THE MATTER
Control systems sit right at the heart of complex processing equipment. Keith Wilcox from APEC explores how such a system can integrate seamlessly with existing machinery and support production goals
In every industry that relies on complex processing equipment –whether that’s food production, chemical manufacturing, bulk materials handling, or another specialty – the controls system is the heart of the operation. It starts machinery in the right sequence, runs equipment at precise speeds, ensures accurate dosing, and stops processes safely when needed.
For process engineers, the challenge isn’t just to keep equipment running. It’s ensuring the control system integrates seamlessly with existing machinery, supports production goals, and can adapt as requirements change. These goals are not always achievable with a standard off-the-
shelf control panel or a one-size-fitsall software package. In many cases, a tailored approach provides the precision, flexibility, and reliability that complex operations demand.
THE LIMITS OF STANDARD CONTROLS
Standard controls are designed to meet the most common requirements across industries. While they may be suitable for straightforward systems, they can struggle in environments with unusual equipment layouts, specialised sensors, or unique safety interlocks.
When mismatches occur, engineers often face costly workarounds –rewiring panels, adding extra I/O
modules, or rewriting sections of code just to get the system to function as needed. These compromises can make troubleshooting more difficult, slow future upgrades, and increase the risk of downtime.
A process that’s been adapted to fit a control system – rather than the other way around – may also lose efficiency or accuracy. For high-stakes operations where precision matters, that’s a trade-off most engineers would prefer to avoid.
DESIGNING CONTROLS AROUND THE PROCESS
A more effective strategy is to design the controls around the process itself. This begins with a deep
understanding of the process flow –how materials are moved, measured, combined, and finished.
From there, the engineering team can determine the most effective control architecture, whether that’s a single panel controlling one machine or a distributed system managing multiple production lines. Early considerations typically include:
• Input/Output (I/O) requirements –Determining the quantity and type of field devices, from sensors and actuators to drives and load cells.
• Integration points – Ensuring the new control system communicates with existing machinery, plant networks, or supervisory systems.
Controls projects are most successful when they’re built on collaboration between the controls team and the plant’s engineering staff
The control system is at the centre of many complex processing plants
• Environmental factors – Specifying enclosure ratings for dust, moisture, washdown, or temperature extremes, and designing for vibration resistance where needed.
• Operator interface – Developing HMIs that present information clearly, allow quick adjustments, and support safe, intuitive operation.
• Safety and compliance –Incorporating lockout/tagout procedures, e-stops, guarding interlocks, and other safety measures to meet applicable regulations and standards.
By addressing these factors early in the design phase, engineers create systems that are efficient to build,
straightforward to maintain, and capable of supporting consistent, longterm production.
THE ROLE OF COLLABORATION
Controls projects are most successful when they’re built on collaboration between the controls team and the plant’s engineering staff. This cooperation starts well before fabrication begins and continues through installation and commissioning.
Key collaborative stages might include:
• Initial scope definition – Sharing process diagrams, equipment specifications, and operational
requirements to ensure mutual understanding.
• Functional design review –Confirming control sequences, safety protocols, and interface layouts before hardware is built or code is written.
• Factory acceptance testing –Verifying system performance in a controlled environment before it arrives on-site.
• On-site commissioning – Finetuning parameters, verifying safety systems, and adjusting programming to match real-world operating conditions.
Clear, consistent communication through these stages helps prevent delays, reduces the risk of costly changes, and ensures the final system reflects the realities of plant operations.
ENGINEERING DEPTH AND PRACTICAL EXPERIENCE
Technical capability is essential, but experience often determines whether a system will perform reliably under real-world conditions. Experienced control engineers understand how hardware and software interact under load, how to anticipate operational challenges, and how to design systems that are serviceable over time.
For process engineers, working with an experienced controls team can mean fewer surprises during commissioning, faster problem resolution, and a final product that reflects the way equipment is actually used – not just how it appears in a schematic.
Practical considerations, such as how wiring is routed for maintenance access or how components are arranged for cooling and service, can make a big difference in a plant’s dayto-day operation.
DESIGNING FOR ACCURACY AND EFFICIENCY
In many processes, accuracy is just as important as throughput. A batching line might need to dose materials within tight tolerances to maintain quality, while a material handling system may require precise timing to avoid blockages or product loss. Custom controls can improve both accuracy and efficiency by integrating:
• Feedback loops – Real-time measurements used to make immediate process adjustments.
• Scaling and calibration tools –Built-in procedures to maintain accuracy over time and equipment wear.
• Data logging and analysis –Performance tracking that allows engineers to identify inefficiencies and refine processes.
These elements help reduce waste, maintain product consistency, and optimise equipment performance, contributing directly to both quality and profitability.
SCALABILITY AND FUTURE PROOFING
Few plants operate in a static environment. Product lines change, capacity requirements grow, and technology evolves. A control system
designed with scalability in mind can help plants adapt without starting over from scratch.
Scalability might involve leaving physical space in panels for future components, using modular software that can be expanded, or selecting communication protocols that support integration with systems that are due to come on line.
By designing for change from the outset, process engineers can protect their investment and respond quickly to new demands.
CONCLUSION: ENGINEERING CONTROLS WITH PURPOSE
For process engineers, the most effective control systems are those designed with a clear understanding of the process, built to withstand the demands of real-world operations, and adaptable enough to handle future changes.
By focusing on process-driven design, fostering collaboration between engineering teams, and applying practical experience to every stage of the project, control solutions can become more than just a means of automation. They can serve as a foundation for reliability, efficiency, and quality—key factors in the long-term success of any processing operation.
APEC’s control centre panel
TRANSFORMING SIS MANAGEMENT
A process engineer from oil and gas giant Philips explains how SIS management helps the processing industry move data out of digital silos to improve safety, operations and uptime
When it comes to digital transformation, refining and processing operators face unique challenges. Unlike other industries already leveraging digital twins to improve design, enable predictive maintenance, and boost operational efficiency, the refining and processing sectors often struggle with data management.
Many facilities have accumulated vast quantities of data over decades, that is often scattered across departments, locked in outdated formats, and managed by tools from different generations. Such fragmentation makes digital transformation complex, as updating one document can render others outdated, creating uncertainty about which version is accurate.
“Everyone is looking to digitalisation, but in refining, it is not that simple,” says Nagappan Muthiah, Phillips 66 safety instrumented systems lead, Industrial Control Systems.
Muthiah and his team at Phillips 66 were tasked with leading the digital transformation of the company’s Safety Instrumented Systems (SIS). Their mission: identify the best way to consolidate decades of dispersed and inconsistent safety data into a smarter, more practical system.
THE REALITY OF DIGITALISATION IN REFINING
Phillips 66, headquartered in Houston, operates nine refineries and initially set out to pursue full lifecycle digitalisation when it began its digital journey over five years ago. This would allow it to replicate its entire safety system digitally from front-end design through to commissioning.
Phillips 66 made a strategic decision to reorient its efforts around SIS during the operations and maintenance (O&M) phase—where proactive decisions directly impact reliability, uptime, and safety.
This approach aligned with guidance from the American Petroleum Institute’s (API) Recommended Practice 754 —revealing that a safety protection system was activated to prevent a potential event.
FROM DOCUMENTATION TO REAL-TIME DECISION SUPPORT
Phillips 66 used a safety lifecycle tool, SIL Solver Enterprise, developed by Dr. Angela Summers, a professional engineer with over 30 years of experience in SIS.
The secure, cloud-based architecture from SIS-Tech allowed Phillips 66 to centralise all SIS data across its refining assets. Rather than managing static reports in disconnected systems, teams now work within a dynamic environment where safety data can be filtered, analysed, and compared across units and facilities.
For more about this project read the extended version on Engineerlive.com.
Philips 66 is using a safety lifecycle tool from SIL Solver Enterprise
RECYCLING THE FLAMES
Conveyor belt specialist Les Williams explores the problem of fires in recycling plants
In the UK in 2024, six billion lithium-ion batteries were discarded, causing an estimated 700 fires in dustcarts and waste-processing centres
Two major fires at Hündgen Entsorgungs’ SwisttalOllheim waste sorting facility in Germany in April and July of this year caused immense damage. The fire in July lasted for four days with damage estimated to cost at least €2m. These fires were just two more examples of the many thousands that are occurring around the world and serve as yet another stark reminder of the huge fire safety challenges facing the waste recycling industry.
According to fire safety experts, the primary cause of waste sorting and recycling plant fires is lithiumion batteries found in modern-day battery-powered products, which can explode if damaged or crushed. They are found in a diverse range of products including greeting cards that light up or play music, electronic kitchen appliances, toothbrushes, razors; power banks for smartphones or tablets; headphones and hearing aids; e-cigarettes and vape products and even children’s toys and light-up shoes.
BREATHTAKING GROWTH
The scale of the problem is quite breathtaking. For example, in the UK in 2024, six billion lithium-ion batteries were discarded, causing an estimated 700 fires in dustcarts and waste-processing centres. The Environmental Services Association in the UK says the resulting fires cost fire services and waste operators some £158m a year. The US and Canada is estimated to have incurred losses worth more than $1.2bn because of lithium-ion battery fires.
Although the problem is making headline news, what appears to be escaping the attention of plant operators and insurers alike is the role of rubber conveyor belts in all of this and how they can potentially reduce the extent of the fire.
The majority of conveyor belts used in recycling are rubber multi-ply construction and the first thing to bear in mind is that they can never be totally fireproof. Rubber is flammable and the fabrics used in the carcass of multi-ply belts are mostly polyester and nylon, which have virtually no resistance to fire. Once alight, they can
be remarkably efficient at conveying flames at a frightening speed. Fortunately, they can be engineered so that their ability to do so is dramatically reduced.
WHAT IS MEANT BY ‘FIRE-RESISTANT’?
A more accurate description rather than the commonly used term “fire resistant” would be “selfextinguishing”. This is because the ability of a rubber conveyor belt to ‘resist’ fire is achieved by adding special chemicals and additives such as antimony trioxide, decabromodiphenyl, alumina trihydrate and magnesium hydroxide to the rubber compound during the mixing process. The actual amounts depend on the level (international
standard) of fire resistance required. Once fire-resistant rubber has been vulcanised and is ignited it emits gases that effectively suffocate (extinguish) the fire by starving the flames of oxygen.
PRIORITISING A COMPETITIVE PRICE
The special additives are costly so if low grade or insufficient quantities are used in order to keep the selling price sufficiently attractive to win orders then the ability of the belt to self-extinguish will be slower (and sometimes non-existent) and therefore much less safe. Especially in the past twenty years or so, the conveyor belt market, particularly in Europe, has been inundated by ‘cheap’ imports from South East Asia, primarily
Lithium-ion battery fires are costing the industry billion
Low price fire resistant belts can prove deadly
China. Performance, longevity and ultimately safety, have all become sacrificial lambs in the effort to win greater market share and force out the competition.
The reality is that ‘economy’ versions of high-quality fire-resistant belts simply do not exist. The biggest single influence on the ability to resist fire is the quality of the rubber. Unfortunately, because it typically constitutes around 50% of the material cost of a conveyor belt, it is the prime cost saving target for manufacturers who want to compete on price, even though they will claim to meet the same safety specification as the premium brand versions without hesitation.
ADDING FUEL TO THE FIRE
Fire-safety experts describe the ignition of a lithium-ion battery as having the intensity of a blow torch that will continue to burn until the battery cell is exhausted. The duration is therefore very much dependant on the size of the battery. Although the duration and intensity cannot be influenced, the speed at which the flames spread along the conveyor belt is very much influenced by the ability of the rubber to inhibit the flames by starving them of oxygen. Without this, the belt can rapidly become a moving, burning mass, effectively adding fuel to the original source of the fire. Burning rubber and synthetic materials such as polyester and nylon release a dangerous thick smoke that contains cyanide, carbon monoxide, sulfur dioxide and products of butadiene and styrene. With most recycling conveyors housed indoors, the danger is exacerbated.
EVERY SECOND COUNTS
There are international and national standards relating to conveyor belt fire safety performance and separate standards that specify the test methods that measure that performance. The EN12882 standard is for safety requirements for conveyor belts for general-purpose, above ground applications and describes a range of classes from ‘1’, ‘2A’’, ‘2B’ up to ‘5C’. The most basic safety requirement is EN 12882 Class 1,
Rubber conveyor belts can never be totally fireproof
which simply demands that the belt is anti-static. Class 2A (K grade) and Class 2B (S grade) make the distinction between fire resistance with covers and fire resistance with and without covers and are tested according to EN ISO 340 specified methods. The testing is very much about the speed and effectiveness of the self-extinguishing process because in the event of a belt being ignited, every second counts.
The relevance of testing ‘without covers’ is that wear gradually reduces the amount of fire-resistant rubber protecting the internal flammable carcass. Testing without covers therefore determines that the remaining rubber, especially the ‘skim’ rubber used between the plies, is sufficiently fire resistant. For the majority of recycling applications, a premium brand EN 12882 Class 2A or Class 2B belt is most probably perfectly adequate but if you are at all unsure then seek expert advice.
EN ISO 340 TESTING
The tests involve exposing six individual samples of belt to a naked flame causing them to burn. The source of the flame is then removed, and the combustion time (duration of flame) recorded. A current of air is applied to the test piece for a specified time after the removal of the flame. The flame should not re-ignite.
The time it takes for the belt sample to self-extinguish after the flame has been removed is a maximum of 15
seconds for any individual sample with a maximum cumulative duration for each group of six samples of 45 seconds. This means that the maximum allowable average time per sample is 7.5 seconds. This factor is of paramount importance because it effectively determines the distance that the fire can be carried by belt when in motion.
Even if a manufacturer states that their fire-resistant belt has passed the ISO 340 test, caution must still be exercised. A typical conveyor belt will easily travel several meters within the 15 seconds allowed for a belt sample to pass the test, which is a potentially very dangerous distance.
SEEK ADVICE
Fire resistant conveyor belts really can be a matter of life and death so never hesitate to seek expert advice. In my professional opinion, the safest option is to use one of the leading European manufacturers who have well-founded reputations for higher quality and safety standards and are much more able to provide expert technical support and advice. Although almost certainly higher priced, the cost of a fire-resistant conveyor belt that does not self-extinguish fast enough when ignited by an exploding lithium-ion battery pales into insignificance.
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TRAINING WITH EEMUA
EEMUA offers training courses for engineers at various competency levels. Nicola Brittain provides an overview of their services
EEMUA (the Engineering Equipment and Materials Users Association), a not for profit trade organisation, has been running for an impressive 75 years. The organisation was originally established to share information with members that needed common approaches to working in heavy industry - its modus operandi has changed very little since then.
CHANGING TOPICS AROUND THE SAME FUNDAMENTALS
As John Lilley operations director at the organisation explains, the topics explored by EEMUA change over time but the fundamentals tend to remain the same. He said: “If you’re working with steel, the structures and processes might evolve but each generation of engineers will be using the same basic materials as the last.”
OVER 60 DOCUMENTS IN USE
The engine of EEMUA is its weighty guidance documents, there are currently over 60 of these in use. The documents set out what is needed in terms of safety, compliance and efficiency across a swathe of heavy industry.
The documents are provided free of charge to member companies from sectors including chemicals, oil and gas, power generation, renewables, maritime and defence, although they are also suitable for any heavy industry sector or one involving hazardous activity, substances or processes.
THE ROLE OF MEMBER COMPANIES
The guidance documents are generated by member companies that sit on technical committees. There are
EEMUA currently has more than 60 guidance documents in circulation
The EEMUA annual conference is a space for members to discuss topical issues and regulations
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Process safety
█ Hazard identification and risk analysis techniques (including HAZOP and LOPA)
█ Process safety management
█ Understanding different hazards (eg hydrogen)
█ Human factors in the chemical and process industries
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█ Engineering project management
█ Applying the IChemE Forms of Contract
Process and plant operations
█ Chemical engineering core concepts
█ Distillation technology
█ Plant and production management
█ Scale-up of chemical processes
█ Introduction to sustainable process engineering
█ Sustainability leadership
█ Sustainability measurement
█ Material resource management and the circular economy
approximately ten of these operating at any one time and they cover specific topic areas - the resulting documents are often accepted as good practice by national regulators. The organisation also hosts looser groups called technical forums that may produce some guidance, as well as exchanging ideas and getting updates.
Examples of guidance include EEMUA 159 on the inspection of above ground storage tanks, or EEMUA 191, a guide to design, management and procurement of alarm systems.
In addition to forums and technical groups, EEMUA also holds an annual conference for its members to discuss topical issues and regulations (pictured).
The organisation also offers several ways for engineers to test themselves on their competencies, and for employers to demonstrate that their staff are knowledgeable and competent.
The competency schemes are broken down into three levels:
1) AWARENESS: E-LEARNING
E-learning is at the awareness level where people gain an introduction to a particular topic. No previous knowledge or experience of the subject is required. The e-learning modules take between 30 and 90 minutes. It is a pass or fail certificate but it is designed to be open, so people can retake the test if they fail.
2) BASIC APPLICATION
The next competency level is for people involved in a particular type of operation on a day-to-day basis and tests knowledge of storage tanks, for example. The storage tank test would look at corrosion, how tanks work and the different valves involved. There are a basic series of courses at this level providing insight and background to help engineers get to grips with procedures and policies on site.
3) PRACTITIONER LEVEL COURSES
The next step up is the practitioner level courses for folk in companies that either contribute to key decisions or are making them. This level of test would start looking at integrity questions to ensure a person was making good decisions. Engineers might be tested on the results of an inspection for example. The practitioner courses will encourage consideration of commercial pressures, regulatory demands and legal requirements as well as consideration of regional and global standards. A practitioner will look at basic engineering data as well as data coming from inspections. The courses also examine the asset integrity life cycle from design to decommissioning. Typically practitioner courses are assessed by a two-part exam – a multiple choice and a far-reaching scenario-based test. John said: “As an
organisation we make sure all our tests are challenging. They need to reflect the fact that somebody is going to be in a hazardous site and they’re going to have to make important decisions.”
ASSET INTEGRITY LEADERSHIP CERTIFICATE
There is also a course called the Asset Integrity Leadership Certificate which teaches and tests a portfolio of submitted work. It comprises a scenario-based test and a multiplechoice exam aimed at people in leadership positions. The course guides and tests them on making important decisions in response to a specific scenario. The format resembles law exams or Prince 2 for project management. These tests encourage the examinee to digest a scenario and then think what are my next steps? Who should I involve? What are the most appropriate things to be considering? What am I going to do immediately? What will the next 30 days look like? And who do I need to communicate with regarding the scenario?
This is the first in a series of articles exploring the EEMUA’s work with and for the engineering community.
PUPILS FOR PUMPS
How training can help optimise the performance of pump systems
The British Pump Manufacturers Association (BPMA) is campaigning to reinforce the importance of ongoing skills development for all engineers, contractors, and operatives involved in the selection, installation, operation, and maintenance of pump systems across UK industry.
With pump systems playing a critical role in sectors ranging from construction and water management to energy, manufacturing, and processing, the BPMA is calling on employers to prioritise technical training as a route to improved efficiency, compliance, and sustainability.
Pumps account for over 20% of the world’s electrical energy consumption,
and the potential for energy savings through correct system design, operation, and maintenance is significant. The BPMA’s suite of independent training programmes provides professionals with the up-todate knowledge required to optimise system performance and reduce environmental impact.
INDUSTRY-RECOGNISED TRAINING
Designed to serve all specialisms within the pump industry and its wider user base, BPMA training courses cover a range of technical, operational, and regulatory topics. These include pump fundamentals, system design, energy efficiency,
As pump systems become more advanced and energy performance targets more demanding, the need for qualified, knowledgeable personnel has also increased
Wayne Rose CEO of the BPMA
condition monitoring, and legislative compliance. Courses are designed to be delivered in accessible formats and lead to industry-recognised qualifications that competence and business performance.
A STRATEGIC INVESTMENT FOR EMPLOYERS
For employers, investing in structured training supports greater technical competency, fewer system failures, reduced downtime, and enhanced sustainability credentials, according to the BPMA. It also helps organisations align with tightening environmental regulations and standards.
Wayne Rose, CEO of the BPMA, said: “As pump systems become more advanced and energy performance targets more demanding, the need for qualified, knowledgeable personnel has never been greater. Our training programmes are independently developed and quality assured to provide engineers, contractors and plant operatives with the expertise required to make the right decisions across a pump system’s lifecycle. The benefits to employers and the wider economy are clear— better skills improved commercial and environmental outcomes.”
A CALL TO ACTION ACROSS ALL INDUSTRIES
BPMA training is open to individuals and organisations across all sectors that use pump systems—including building services, utilities, oil & gas, pharmaceuticals, and food production. It represents a strategic opportunity to upskill teams, drive operational improvements, and contribute meaningfully to the UK’s sustainability goals.
For more information, visit: www.bpma.org.uk
APEC
Specializing in the design and manufacturing of ingredient automation equipment and controls for liquid coating and handling, continuous feeding, mixing and blending, weighing, batching, material handling and automation controls.
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HILLIARD
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PACKING IT ALL IN P
PPMA, to take place in the last week of September, is one of the packing industry’s best known events. Here we ask the organiser what they expect will be the highlights at this year’s show
The event will feature over 350 exhibitors
PMA (Process and Packaging Machine Association) will take place on the 23rd to the 25th September at the NEC in Birmingham. The show brings together technology and people from the packaging industry together to discuss ongoing innovations and developments in the sector. We took the opportunity to ask a few questions of the show’s organiser Automate UK.
HOW HAS THE PPMA SHOW DEVELOPED OVER THE YEARS?
PPMA Total Show 2025 aims to build on the success of last year’s event by introducing enhanced live technology demonstrations, expert-led innovation tours, and a broadcast element via ‘Total Show TV’ to extend the reach of content beyond the exhibition floor. We’re offering visitors unique opportunities to see new machinery and automation systems in action. As well as learn from leaders in the field, and network with peers. The event will feature over 350 exhibitors and 1,500 brands, each showcasing innovations designed to improve performance, reduce costs, improve sustainability, and future-proof businesses.
WHAT DO YOU EXPECT WILL BE THE KEY THEMES / HIGHLIGHTS OF THE SHOW?
Key themes will include sustainability, smart manufacturing, operational efficiency, automation, and the integration of new technologies such as AI and advanced robotics. Highlights include keynote speeches from Priya Lakhani OBE on AI adoption, Mike Coupe on retail transformation, and Levi Roots on entrepreneurial resilience. In addition, a live demo theatre; ‘Innovations Eleven’ will showcase eleven brand-new product launches and feature daily innovation tours to help visitors identify solutions that suit their specific operational needs.
TELL ME ABOUT ANY TECHNOLOGY SHOWING AT PMMA THAT MIGHT INTEREST TO INTERNATIONAL PROCESS ENGINEER READERS
Attendees will see groundbreaking machinery such as Sew-Eurodrive’s sustainable Hugo Beck Flow Pack R packaging system and Gary the Gantry 2 multi-axis automation. They can also view Fortress Technology’s Vyper Vision System for automated label inspection and quality control; and Shemesh Automation UK’s Alantra P+ high-performance fillercapper. Many of these systems combine automation, advanced vision systems, and intelligent control to minimise waste, meet quality assurance, and increase line efficiency.
ARE THERE ANY REGULATIONS THAT YOU EXPECT PROCESS AND PACKAGING COMPANIES TO BE DISCUSSING AT THE SHOW?
Yes. We have a seminar dedicated to next-generation barcodes, a development with significant regulatory and operational implications for retail packaging: Title: The Future of Retail Packaging Starts With Data Accuracy, & it Depends on You!
Time: Tuesday 23rd September, 2:30pm – 3:00pm
The ISO lab fire test at last year’s show
Location: Seminar Theatre (A100)
The GS1 Digital Link QR code represents the biggest change in retail packaging for 50 years, offering benefits such as food waste reduction and increased consumer engagement – but only if data is correct and codes are readable. Speakers Camilla Young (GS1 UK) and Dr. Russell Sion (AIPIA) will outline benefits, regulatory drivers, and data/ machinery considerations for companies wanting to comply with the regulations.
AI IS SHAKING UP SO MANY SECTORS, HOW IS IT AFFECTING THE
PROCESS AND PACKAGING INDUSTRY?
AI is increasingly embedded in inspection systems, predictive maintenance tools, and supply chain
Seminars will form a big part of PPMA Total Show 2025
optimisation into process engineering and packaging. At PPMA Total Show 2025, Priya Lakhani OBE will address how businesses can move from AI curiosity to AI confidence, covering real world examples, strategic questions for adoption, and how AI enhanced decision making can provide operational benefits. AI is also enhancing vision systems, enabling faster defect detection, adaptive control in production lines, and better integration of automation with quality control.
WHAT MAKES THE SHOW DIFFERENT FROM OTHER PROCESS AND PACKAGING SHOWS?
PPMA Total Show is the UK’s largest and most comprehensive event dedicated to processing and packaging machinery, robotics, and industrial vision. Now in its 38th year, it offers the widest crosssection of manufacturing sectors under one roof, combining largescale equipment demonstrations with thought-leadership from high-profile keynote speakers. Unique features include the Innovations Eleven live demo theatre, daily innovation tours, real-time broadcast via PPMA Total Show TV, and a rich mix of networking opportunities – all of which are free to attend.
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From day one, each Learner on EEMUA MIPC® training builds a unique 'how to' workbook of mechanical integrity know how tailored to each Learner, site and company.
EEMUA's MIPC course helps practitioner-level engineers to be where they are needed – on-site and on top of the latest industry developments and good practice in primary containment of hazardous substances.
* Equipment Design Elements * Inspection and Test Techniques * Asset Condition * Reporting * Legislative Environment * WSE * Risk and ALARP * Audit * User Responsibilities and Competencies * Postponement * Feedback * and more.
www.eemua.org
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