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ON THE
FRONT FOOT A UK-based company’s mission to make factories sentient
HOW AUTOMATION IS REWRITING THE RULES
THE IMPORTANCE OF INFRASTRUCTURE
A focus on the sorting industry’s AI-driven transformation
Why infrastructure has become an enabler of electrification
CUSTOM MICRO INGREDIENT SCALES
www.apecusa.com 616.374.1000
CONTENTS
Welcome I am moving on to pastures new and, as such, this will be my last issue of International Process Engineer. I shall miss the breadth of coverage, since so many manufacturing sectors have a processing component. Areas of particular interest have included chemical production, heat management, testing, AI and automation, quality control, water and wastewater management and fire prevention. This issue’s cover story features an interview with the CEO of Matta, a company that looks likely to put Britain on the AI map with a solution that offers a unique brand of factory sentience. Their technology relies on sensor cameras to monitor and report on production lines. It is rumoured that there are currently more than 300 interested factories looking to deploy their technology. Another quite different automation story features on page 12, APEC's Reducing labour dependency looks at how AI and automation can mitigate issues caused by skills or labour shortages. Reinventing processes on page 42 introduces a platform that changes the way chemical molecules are made using machine learning. It claims to reduce CO2 emissions compared with standard processes by more than half. Sticking with a sustainable theme, Scaling CO2 use on page 26 explores a solution that converts carbon into fossil-free fuel using an innovative new method. In a rather belated celebration of INWED (A women in STEM on page 58) we showcase one woman’s enthusiasm for her chosen career. Nicola Brittain Editor
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– SEPTEMBER 2026 – COVER
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On the front foot A very British AI solution
PROCESS EQUIPMENT UPDATE
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Equipment update Four product stories from the process industry
PLANT MANAGEMENT
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Monitoring aluminium production
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Acid cooler protection A phosphate producer’s case study
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Connected cables Designing cable penetrations
Rethinking the wake
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How VE technology eliminates vortex shedding
Scaling CO2 use
A new solution that converts CO2 into fuel
The benefits of monitoring aluminium
Reducing labour dependency How automation can offset skill shortages
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Rewriting the rules AI's impact on factory sorting methods
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CONTENTS
MATERIALS HANDLING
SAFETY IN THE PLANT
RECYCLING
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A new standard
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Insight into a new coriolis measurement tool
The importance of infrastructure Infrastructure as a critical enabler of electrification
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Choosing the future An overview of conveyor belt constructions
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Meeting the challenge Exploring accurate surface temperature measurement
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Beyond the seal
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The mechanics of secondary dust explosions
Dust control The second part of a guide to dust control from Martin Engineering
Some mitigation tactics
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Top tablet How the right tablet can benefit staff on site
INSTRUMENTATION & ELECTRONICS
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SKILLS AND TRAINING
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A women in STEM The benefits of being a female engineer
Open edge optimisation An expert look at industrial production lifecycles
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Clock on a chip A precise clock for satelliteto-cellular operations
A systems approach to pump reliability
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Reinventing processes How one company is making chemical molecules from scratch
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Toll partners Considerations when shipping produce overseas
WATER & WASTEWATER MANAGEMENT
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A flow of finalists A look at the Water Discovery Challenge finalists
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PUBLISHER Jerry Ramsdale EDITOR Nicola Brittain nbrittain@setform.com STAFF WRITER Lydia Arundel larundel@setform.com DESIGN – Dan Bennett, Jill Harris HEAD OF PRODUCTION Luke Wikner production@setform.com HEAD OF SALES & PARTNERSHIPS David Pattison ACCOUNT DIRECTORS John Abey | Peter King SENIOR ACCOUNT MANAGERS John Davis | Darren Ringer | Roy Glasspool
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ON THE FRONT FOOT Matta's factory sentience model
EQUIPMENT UPDATE
MICRO-EPSILON RELEASES 3DINSPECT Precision sensor manufacturer Micro-Epsilon has released 3DInspect, a software tool enabling 3D data capture and evaluation from its 3D sensor portfolio for use on production lines and in quality control. The
product supports the new ScanControl 8x00 Green Laser Profile sensors and includes several key innovations and features, including additional 3D measurement programs such as flatness, sphericality and hole extraction, as well as new 2D functions such as straightness 2D. 3DInspect supports all 3D sensors in the MicroEpsilon portfolio, including SurfaceControl for geometry, shape and surface inspection of matt objects; ReflectControl for measurement of shiny, reflective surfaces, and ScanControl 30xx and 8x00 laser scanners for precise, inline 3D measurements. The 3D Profile Unit from MicroEpsilon will allow users to combine several individual profiles of the ScanControl 30xx sensors in a common coordinate system and evaluate these using the 3DInspect software tool. Operators will benefit from numerous extensions for measurement, data pre-processing, and automated evaluation among other things. For more information visit: www.micro-epsilon.co.uk
SIMSCALE LAUNCHES A SIMULATION AI AGENT AI-native cloud simulation platform SimScale has released an AI agent to its community of over 900,000 engineers, designers, and students. The agent can run complete simulation workflows autonomously, from CAD geometry clean-up, to simulation set-up, through to validated output reports - elements of the broader agentic workflows SimScale claims to have spent the past year proving with enterprise customers. The release follows a good year of community growth for SimScale, with over 160,000 professional engineers, hardware designers and students joining the platform within the last year, and more than 100,000 in the first six months of
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2026 alone. The community spans over 190 countries, with the largest community in the US and significant communities in Germany and the UK. It also covers all sectors of the engineering industry, with the most heavily represented being the built environment and AEC, industrial machinery and equipment, energy, manufacturing, electronics, automotive and aerospace. AI adoption in engineering and simulation workflows has doubled in less than a year, according to some reports. This growth has come with a shift in what engineers are using AI-native cloud simulation to do. Platform data shows that the use of non-linear mechanical simulation used across consumer goods, manufacturing, medical devices and advanced structural work, rose 99% in the past 12 months. For more information visit: www.simscale.com/startup
EQUIPMENT UPDATE
NEW DRIVES FROM APPLIED MOTION PRODUCTS Applied Motion Products Inc. (AMP) has launched the new AK series of drives for machine builders and automation engineers. The drives provide a choice of open-loop stepper, closed-loop stepper, or full closedloop servo motion control in a compact package in combination with NEMA 11 to NEMA 34 frame motors
operating from 24–48 VDC power. The AK series supports EtherCAT, EtherNet/IP, CANopen, and Modbus communication interface options. A battery-less 17-bit multi-turn absolute encoder eliminates the need for homing routines and external position sensors, simplifying machine design. Launched at the same time as the AK StepSERVO series, AMP’s MCA6 PLC and MET2 I/O systems combine to offer complete machine integration for applications ranging from compact benchtop equipment to larger industrial machinery. The AK drive series operates in combination with AMP’s Q-Programming software for basic to advanced motion and machine control while the new Stepper Suite II software covers USB-C setup for online or offline parameter configuration with an integrated oscilloscope providing real-time monitoring, and a smart fault diagnosis feature including corrective actions that aim to minimise commissioning and downtime. For more information visit: www.mclennan.co.uk
ARC INFORMATIQUE TO MARKET PCVUE 17 Publisher of the SCADA/BMS PcVue platform, ARC Informatique, has launched PcVue 17, a building management system that aims to help factory operators and engineers to address energy efficiency, operational performance and cybersecurity across multiple critical systems. The platform actively optimises energy demand through control scenarios that can include AI-driven energy management and forecasting to avoid consumption peaks and reduce energy costs. The product will also enable users to configure workflows and orchestrate complex processes through low-code interfaces. By combining AI processing and real-time data analysis, the PcVue17 automates routine tasks and accelerates decision-making across systems, departments and teams. Backed by IEC 62443-4-1 and IEC 62443-4-2 certifications, designed to ensure secure development processes and robust product security for industrial automation systems, the platform offers high performance and resistant to cyber threats, thus ensuring operational
confidence for critical infrastructures. The platform uses low-code, intuitive interfaces to help users automate routine tasks, configure workflows, and speed up businesscritical decisions. For more information visit: www.pcvue.com
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COVER STORY
Factory operators will be able to liaise with a chat bot to ask business-critical questions
ON THE FRONT FOOT Matta CEO Doug Brion tells Nicola Brittain about his mission to make factories sentient, and that there are limits to what AI can do
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I is forever in the news with many commentators predicting an impact as disruptive as mechanisation during the industrial revolution. Some views are downright dystopian with a focus on US tech companies and their ‘obsolescence’ projects (an aim to completely replace staff with robots). It was therefore refreshing to catch up with Doug Brion, CEO of technology company Matta, who expressed his respect for the manufacturing sector and the skills that its workers have honed over decades.. A University of Cambridge spin out, Matta is currently London based with plans to expand into Germany and the US in 2027. The company has grown rapidly since its inception a couple of years ago, with its current team of 21 up from 10 at the beginning of the year. “We’re basically in full scale-up mode,” Doug explained.
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US$14m in December last year; has several European investors; funding from Silicon Valley; and money from business interests including Jaguar Land Rover and the Peugeot family.
WIDE RANGE OF CLIENTS
The company’s clients are varied and colourful, including but not limited to a chocolate factory, wellie makers, and fighter jet engineers. Matta works with SMEs and global enterprises alike offering solutions of varying complexity, even offering a cloudbased solution for companies that don’t want on-premises AI servers. Co-founder of Matta, Doug Brion, says the firm is in “full scale-up mode”
UK SMEs don’t typically find funding easy to secure, but Matta has faced no problem in this respect. The company raised seed funding of
WHAT SERVICES DOES MATTA PROVIDE
Matta’s services include the provision of industrial AI models that understand manufacturing, and a central platform designed to give factories real-time
COVER STORY
Matta works with process engineering company Cargill
self-awareness or ‘factory sentience’. Practically, this means that after working out what a client is looking for, Matta will place sensors and cameras around a factory floor to watch the production line, then feed data regarding products to a central platform. This platform proceeds to analyse the information to find faulty produce or batches and ascertain where the fault originated, or to understand what is causing a bottleneck. By watching parts on a production line these sensor cameras quickly learn what good looks like. They can also measure, count, and read barcodes. As Doug explained: “If there is a scratch on a part, the cameras will know the serial number and it can easily be retrieved.” The complexity of Matta’s solution will depend on the client’s size and requirements, but every installation helps speed up processes and reduce downtime. Doug says: “Managers can easily get a snapshot of their throughput using this technology. It quickly becomes clear where there are bottlenecks.” Factory managers will also be able to liaise with a chat-bot interface equipped to provide almost immediate answers to business-critical questions
such as: “how does this quarter compare with the last quarter?”, or “what are the biggest issues faced by a particular production line?”.
HOW DOES THE SYSTEM LEARN?
Doug explained that the system learns by watching. “It’s like showing a toddler something it hasn’t seen before. We show the sensors what to look at and they learn patterns over time. If a toddler is shown 10 examples of well painted mechanical parts and there’s one with a scratch, it might say, “Oh, that’s wrong” without having seen it before.
WHERE DO THE PEOPLE COME IN?
The system is a tool like a microscope or hammer and is not designed to replace staff currently employed, Doug explained: “I get pretty angry with all the AI tech bros saying, ‘we want humanoid robots everywhere’. To be honest, I think it comes from them never really visiting factories. They don’t understand the amount of skill involved in manufacturing, particularly with dextrous jobs like leather stitching, linishing, or maybe even icing a cake where each cake has a different shape
and design.” He continued: “There are some jobs in manufacturing where staff have been training for 20 years. They use sight, sound, smell, touch and have done this work for eight hours a day every day. The idea that you’re going to replace these people overnight is crazy.”
WHAT DOES THE FUTURE LOOK LIKE FOR MATTA?
Matta has concrete plans to grow and expand its services, with a move into predictive automation and even correction and fixing of faulty parts. Doug explained that the company has some more eccentric plans too: “The team has decided they’d quite like our headquarters to resemble Bletchley Park; a kind of Bletchley part 2.0 if you like. We imagine a stately home surrounded by boffins in sheds, maybe a cricket pitch outside. The Americans will have their huge buildings in San Franscisco and we’ll have our sheds. We’ve given ourselves eight years to make it happen.”
For more information visit: www.matta.ai
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PLANT MANAGEMENT
MONITORING ALUMINIUM PRODUCTION Bengt Löfstedt from Opsis describes how environmental monitoring at an aluminium industry plant can also aid process optimisation and double as a warning system for issues in production A pot room at an aluminium smelter. Note the ducts leading waste gas from the individual pots to the gas treatment centre
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rimary aluminium is produced from alumina (aluminium oxide), which in its turn is produced from the sedimentary rock bauxite. The production process often gives rise to high levels of very aggressive hydrogen fluoride (HF), as well as sulfur dioxide (SO2) and nitrogen dioxide (NO2). Most of these pollutants are caught as an integral part of the production process but some of them may slip through as emissions to ambient air. The industry is therefore often subject to strict environmental regulations, including active monitoring of the emissions. Such monitoring can in some implementations also be used as tools for production control.
ALUMINIUM PRODUCTION
Pure, metallic aluminium is produced through electrolysis of alumina in a pool of fluoride compounds, primarily cryolite. The electrolysis occurs in pots kept at just under 1,000 degrees
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Celsius. A single industry can house hundreds of pots located in distinct, very large, elongated pot rooms. Typically, each pot in operation always has several tonnes of alumina and several tonnes of cryolite inside.
Differences in density and forces from the electrical field send the molten aluminium metal to the bottom of the pot. It is extracted from there at the same time as new alumina is added from the top.
Open-path, real-time gas concentration monitoring close to the roof of a pot room. In this case, the pot room is covered by two light beams. The tubes in the foreground are two light receivers aimed in opposing directions. The light emitter for the rear receiver is barely visible as a white spot at the far end of the pot room
PLANT MANAGEMENT
Pot room gas monitoring may be implemented as point measurements where pumps force air through a filter
The key components of an Opsis gas concentration monitoring system, in this case with two open-path light beams. Multiplexing the light allows cost-effective coverage of very long and/or multiple pot rooms
In addition to the alumina, the carbon anode which leads the current into the electrolyte is a major consumable. The manufacturing of one ton of aluminium requires about two tons of alumina and half a ton of carbon anode, and on top of that close to 15 MWh electrical energy. This makes production of primary aluminium extremely energy consuming, explaining why most production facilities are located where energy is readily available and cheap.
WASTE GAS TREATMENT
The cryolite (Na3AlF6) which is present in the electrolyte is not any major consumable but kept at constant level in a semi-closed loop. Gaseous fluoride compounds originating from the cryolite evaporates from the pots, but the pots are enclosed under normal operations, and the emissions are caught and conveyed to a gas treatment centre (GTC) where alumina is added for adsorption of the fluoride compounds and subsequent feedback to the pots. The alumina mixture added to the pot also contains some sodium and the pot itself therefore produces the cryolite which to some extent is consumed. The GTC typically also captures the sulfur dioxide present in the flue gas through a scrubber process.
POT ROOM MONITORING The pot rooms are often equipped with gas concentration measurement
systems for HF but sometimes also covering SO2, NO2, and possibly other compounds. The systems are crucial for compliance with environmental regulations including the monitoring of emissions to the ambient air. Pot room gas monitoring may be implemented as point measurements where pumps force air through a filter. The filters are exchanged regularly, and the used filters are sent to a laboratory for analysis. Such approaches may meet the environmental monitoring requirements, but they provide very poor time resolution and there is a substantial delay between sampling and seeing the analysis result. Monitoring data will probably be of limited use from a production perspective. Also, the filter handling is labour intensive.
OPEN PATH, REAL-TIME MONITORING
However, there are also monitoring systems providing real-time data. They can provide excellent information from ongoing production. The effects of a change in production process settings can be seen immediately. This can give valuable insight into both production efficiency and environmental effects. The data can also be linked to alarm systems, for example alerting the operators in case the waste gas feed to the GTC is disturbed. Opsis offers such real-time monitoring systems. There are several variants available, but they
are all based on optical detection with a central analyser and with light emitters and receivers. The gas sensing takes place in open light paths, typically aimed along the pot room stretching for several hundreds of metres. In addition to providing real-time data, the light path also means that all pots can be monitored at once. A change in the performance at any of the pots can be seen immediately. This contrasts with point sampling, whether filter-based or real-time, where the instruments only monitor the situation at the pots closest to the sampling point.
FILTER SAMPLING AS A SUPPLEMENT
Filter-based point sampling can be in operation in parallel with real-time, open-path monitors. Although they have poor time resolution, filters still allow detection of parameters such as dust composition, a parameter not readily available using optical techniques. However, detection of gas concentrations in real time have quickly formed the base for both environmental compliance and production process monitoring at those aluminium producers that have acquired optical, open-path gas monitoring systems.
For more information visit: www.opsis.se
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PLANT MANAGEMENT
REDUCING LABOUR DEPENDENCY Keith Wilcox president of APEC explores how automated systems can help where recruitment and retainment are difficult
Automation can help plant managers where there are skills shortages
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PLANT MANAGEMENT
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abor availability has become an increasingly important consideration in processing plant design. When experienced operators are difficult to recruit or retain, facilities must find ways to maintain production without allowing workforce constraints to compromise consistency, safety, or throughput. For plants handling powders, bulk solids, and other ingredients, one area worth examining is the materialhandling and batching process. These operations can involve repetitive weighing, transferring, conveying, and sequencing tasks that require both physical effort and careful attention to detail. Automating those activities can reduce dependence on manual intervention while creating a more controlled and repeatable process.
LOOK BEYOND HEADCOUNT
The value of ingredient-handling automation is not simply that fewer people may be required to perform a particular task. A more important engineering consideration is how automation changes the process itself. Manual batching depends heavily on operator execution. An employee must identify the correct ingredient, determine the required quantity, move the material, verify the measurement, and complete the sequence correctly. Each additional manual step introduces another opportunity for variation. An automated system can instead coordinate storage, conveying, weighing, and batching according to defined process parameters. This shifts critical activities from individual operator judgment toward repeatable, system-controlled procedures. That distinction becomes particularly important when production runs across multiple shifts or when lessexperienced personnel must be brought into the operation. Standardising the process can reduce the extent to which product consistency depends on individual experience.
MATERIAL CHARACTERISTICS DRIVE THE DESIGN
Automation does not eliminate the need for process engineering. In many cases, it makes proper system design
even more important. Bulk ingredients can differ substantially in particle size, density, moisture content, flow characteristics, and tendency to bridge or compact. A conveying or feeding method that performs well with one material may not provide the same results with another. Engineers therefore need to consider material behavior when specifying storage vessels, feeders, conveyors, weighing equipment, and controls. The objective is not simply to automate a manual procedure, but to develop a material-flow system that reliably delivers the required ingredients at the required rates and quantities. This is especially important for micro ingredients, where relatively small quantities can have a significant effect on the final formulation. Accurate weighing and controlled sequencing can help minimise variability between batches.
AUTOMATION CAN REDUCE PROCESS VARIABILITY
Consistency is one of the primary engineering benefits of automating ingredient handling. When materials are manually measured and transferred, differences in technique, timing, and interpretation can affect batch-to-batch performance. Automated weighing and batching provide a repeatable framework for executing recipes. The control system can manage ingredient sequencing and quantities while reducing the amount of manual intervention required. The resulting benefit extends beyond formulation accuracy. More consistent material flow can also make downstream processes easier to control. When upstream inputs are more predictable, mixers, coating systems, packaging equipment, and other process stages have a more stable starting point.
SAFETY IS ANOTHER CONSIDERATION
Reducing manual material handling can also affect worker safety. Ingredient handling may expose employees to dust, allergens, repetitive lifting, and other physical demands. Moving more of the process into enclosed or controlled material-
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PLANT MANAGEMENT
The APEC micro-ingredient system is a six bin batching set up
handling pathways can reduce some of these exposures. However, automation should not be viewed as a substitute for appropriate engineering controls, guarding, dust management, sanitation procedures, or operator training. Instead, it can be one component of a broader approach to designing safer processes.
manually measuring and moving ingredients, operators can increasingly focus on monitoring equipment, responding to exceptions, performing quality checks, and maintaining overall process performance.
INTEGRATION MATTERS
Not every ingredient-handling operation requires the same level of automation. The appropriate solution depends on production volume, recipe complexity, ingredient characteristics, labor requirements, quality objectives, and the existing plant infrastructure. A useful starting point is to identify where manual intervention creates the greatest operational risk or consumes the most labor. Repetitive weighing, frequent material transfers, inconsistent batching, and production bottlenecks are potential candidates for automation. From there, engineers can evaluate whether automating individual steps or integrating multiple operations
An automated ingredient system should be considered as part of the overall production process rather than an isolated piece of equipment. Integration between storage, conveying, weighing, batching, controls, and downstream processing can determine whether automation actually removes bottlenecks or simply relocates them. Engineers should examine the complete material path, including ingredient replenishment, equipment access, cleaning, maintenance, changeovers, and process data. The human role also changes. Instead of spending most of a shift
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A PRACTICAL APPROACH TO AUTOMATION
would provide the greatest benefit. The broader objective is resilience. A well-designed process should be capable of maintaining consistent performance despite changes in staffing, production demand, or operator experience. For facilities handling ingredients, automation can contribute to that resilience by making material movement, measurement, and batching more predictable. As workforce challenges continue, process engineers have an opportunity to address labor dependency as a system-design issue rather than simply a staffing problem. By combining appropriate materialhandling technology with sound process controls and thoughtful system integration, plants can build operations that are more repeatable, scalable, and less dependent on manual execution.
For more information, visit: www.apecusa.com
PLANT MANAGEMENT
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PLANT MANAGEMENT
Gainnext separates food-grade PET trays from non-food packaging with over 95% purity
REWRITING THE RULES Lars Enge, EVP and head of Tomra Recycling explains how deep learning is rewriting the sorting industry’s rules
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here is a common misconception that AI is new to the sorting industry, but AI has always been part of
Tomra’s DNA. Even the company’s first Autosort systems, dating back some 30 years, used basic AI principles to make intelligent decisions about which materials to keep or reject. The ability to make decisions like a human is the very definition of AI. This type of technology is not just a trend. What has changed is the use and scale of deep learning, a subset of machine learning that allows sorting systems to move beyond the physical limits of traditional sensors.
A POWERFUL EXTENSION, NOT A REPLACEMENT Lars Enge said: “AI is not new for Tomra. The change though is in the use and scale of deep learning.”
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Deep learning is a specialised branch of machine learning, built on neural networks trained on huge volumes of raw data to recognise intricate patterns and apply them to new
material. It is a powerful extension of proven sensor-based sorting, such as near-infrared (NIR) and colour-sensor systems. It adds value through visual classification that conventional sensors cannot achieve alone. Its strength lies in object recognition using full-colour cameras, meaning these systems see what the human eye can see. The Gainnext ecosystem is a great example, solving previously impossible tasks such as distinguishing between food-grade and non-food-grade PET. These materials can share an identical composition and spectral signature, making them invisible to conventional optical sorting. The Gainnext PET Cleaner application, combined with Autosort, delivers purity levels exceeding today’s industry standards, eliminating hard-
PLANT MANAGEMENT
to-detect items such as opaque white packaging, textiles and foils from PET bottle streams. This produces recycled material that closely resembles virgin raw materials, ensuring PET is not merely downcycled but recovered for the most demanding high-end applications, such as food-grade packaging and high-quality textiles. The same principle now extends to food-grade PET trays, historically inseparable from non-food trays using conventional optical sorting as they share the same material composition and spectral signature. Gainnext overcomes this by distinguishing takeaway or supermarket trays from non-food trays, including consumer goods and medical packaging, achieving purity levels above 95% without manual sorting, according to the company. As demand for foodgrade rPET grows, PET trays are becoming a critical new feedstock alongside bottles. Regulatory pressure is intensifying, and the EU’s Packaging and Packaging Waste Regulation (PPWR) introduces stricter requirements for recyclability and recycled content. By enabling tray-to-tray recycling, Gainnext supports the transition to closed-loop plastic packaging systems, helping recyclers secure feedstock, meet regulatory requirements and remain competitive.
FROM REACTIVE TO PROACTIVE PROCESS OPTIMISATION IN SORTING
AI-powered sorting systems generate data on material composition, sorting efficiency and equipment performance. Intelligent camera systems can also monitor material flows throughout the plant, tracking purity, flagging losses and supporting regulatory compliance. Historically, operators relied on retrospective, manual analysis to fix today’s problems with yesterday’s data. The industry is now moving toward continuous, data-driven optimisation, where decisions are based on live material composition trends, allowing for far more stable output, the primary requirement for bottle-to-bottle applications. Tomra expects greater integration through systems like Tomra Local Control,
Deep learning solutions can see what the human eye sees, thanks to their object recognition capabilities enabled by full-colour cameras
which enables operators to manage multiple sorters centrally and react faster to changing conditions on the plant floor. This keeps sorting stable even when infeed material is highly variable, allowing the entire line to be adjusted as one cohesive system. Complementing Tomra Local Control, the PolyPerception Waste Analyser acts as an automated, continuous quality auditor, using cameras to track material composition from infeed to output and provide instant visibility into material loss and purity at strategic points across the sorting circuit. PolyPerception has introduced an AI-native platform that enables operators to interact with plant data through a conversational AI interface. Similar to using a digital assistant, users can ask questions in natural language, generate bespoke quality reports, investigate process deviations and receive insights tailored to their sorting processes and goals, without the need to manually analyse complex datasets or dashboards. Users can also explore performance trends and process behaviour by asking questions such as why purity levels have changed, where material losses are occurring or which sorting line is underperforming, receiving immediate, data-backed insights. The platform also addresses one of the industry’s fastest-growing risks: fire hazards from items such
as vapes and batteries. Using a similarity search, operators can flag one problematic object and instantly locate every visually similar item, triggering automated alerts without retraining any models. For compliance, it automates sampling at the infeed and key outputs, replacing manual reporting with documented, real-time evidence for audits.
DATA AS INFRASTRUCTURE FOR THE GREEN TRANSITION
As global regulations tighten, the ability to provide a digital birth certificate for recycled material through data will be just as critical as the physical sorting process itself. This data will help manufacturers prove, for example, that less than 5% of the input material consists of nonfood-grade PET. This is why AI-driven analytics and plant-wide data intelligence will play an increasing role in waste analysis, extending transparency throughout the sorting process, not just at the sorter itself. As both regulatory and consumer pressures build, deep learning offers a powerful solution to advance the circular economy. By unlocking its potential, Tomra aims to create new markets for higher-value products, further stimulating growth and sustainability.
For more information visit: www.tomra.com/waste-metal-recycling
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PLANT MANAGEMENT
ACID COOLER PROTECTION How Omniflex helped phosphate producer Foskor modernise its acid cooler protection without disrupting production
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emote monitoring specialist Omniflex has supplied an advanced anodic protection control system to South African phosphate producer Foskor, helping modernise the company’s acid cooler infrastructure while maintaining continuous operation during the upgrade.
REPLACING A LEGACY TRANSFORMER
The project involved replacing a long-serving legacy transformer rectifier (T/R) system used to protect acid coolers in Foskor’s phosphoric acid production process. Rather than replicating the existing installation, Omniflex delivered a distributed PowerView CP solution that combines programmable transformer rectifiers with distributed control system (DCS) integration and comprehensive remote monitoring capabilities. Acid production environments place significant demands on plant equipment, making reliable anodic protection essential for extending asset life and maintaining efficient production. However, upgrading these systems can be challenging, particularly where production cannot be interrupted and new equipment must integrate seamlessly with existing infrastructure. This system allows for remote monitoring of the entire system, enabling the project team to track the system’s performance during integration. This ensures that potential issues are identified early, allowing for rapid troubleshooting without major disruptions to operations. Furthermore, the DCS system’s remote monitoring capability means that experts and technical staff can access system data from anywhere, offering unparalleled flexibility and efficiency. Whether working from a central control room, on-site, or remotely from another location, team members now have the ability to diagnose problems, adjust parameters, and perform troubleshooting without the need
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Modernising systems without disrupting production is a challenge
for on-the-ground intervention. This significantly reduces response times, cuts travel costs, and minimises the need for scheduled maintenance windows, all of which contribute to improved system reliability and cost-effectiveness. “Many industrial facilities rely on legacy protection systems that continue to perform an essential role, but modernising them without disrupting production can be a significant challenge,” said Ian Loudon, international sales manager at Omniflex. “This project demonstrates how distributed control and remote monitoring can provide a practical upgrade path, giving operators greater visibility of system performance while reducing maintenance requirements and extending the life of critical process assets.”
THE DISTRIBUTED ARCHITECTURE
The distributed architecture positions T/R units close to the acid cooler tanks, reducing installation costs and cabling requirements while
allowing engineers to monitor performance remotely. Engineers can securely access operational data from anywhere, enabling faster fault diagnosis, simplified troubleshooting and reduced maintenance costs. Lebo Vries, instrumentation engineering manager at Foskor, said: “Omniflex delivers an excellent product helping us to cost effectively upgrade our acid cooler transformer rectifiers with programmable control.” Following careful planning, phased implementation and comprehensive testing, the upgraded system now provides reliable anodic protection while supporting uninterrupted plant operations. The installation incorporates dual transformer rectifiers per panel. PowerView CP control and both manual and DCScontrolled operation, creating a flexible platform that supports long-term operational reliability.
For more information visit: www.omniflex.com
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At HILCO®, we specialize in providing comprehensive filtration systems designed to address industrial fluid challenges. Our expertise spans across Engineering, Design, Manufacturing, Lab Analysis, and Field Services, delivering cutting-edge solutions to optimize performance and extend the life of industrial systems.
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Quality | Innovation | Excellance Established 1905
PLANT MANAGEMENT
CONNECTED CABLES An expert from MCT Brattberg explores how to design cable penetrations for changing plant demands
A modern SMR facility
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rocess plants are becoming more connected, more instrumented and more dependent on electrical and data infrastructure. Across sectors such as chemicals, pharmaceuticals, food processing, energy and water treatment, operators are adding sensors, control systems, monitoring equipment and automation platforms to improve safety, efficiency and reliability. This shift creates a practical engineering challenge. The physical routes that allow cables and pipes to pass through walls, floors, cabinets and structural barriers must be able to support change without compromising safety. A penetration
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2 x multi-cable and pipe transits
that is suitable at commissioning may need to accommodate additional services years later. If that future need is not considered at the design stage, upgrades can become slower, more expensive and potentially more difficult to manage safely. Cable and pipe penetrations are sometimes treated as secondary details compared with the major process equipment, control systems and structural design. However, they can have a direct influence on fire safety, water tightness, gas tightness, environmental separation and the integrity of hazardous or controlled areas. In many facilities, the barrier is only as effective as the sealing system
used where services pass through it. The growing complexity of process plants means engineers should consider service penetrations as part of the wider lifecycle strategy, not only as a construction-phase requirement.
PLANNING FOR FUTURE MODIFICATIONS Plant layouts rarely remain unchanged. New production lines, updated control systems, condition monitoring equipment and safety upgrades often require additional cables to be routed through existing structures. In older facilities, documentation may be incomplete, and space within penetrations may already be limited.
PLANT MANAGEMENT
When spare capacity has not been planned, site teams may be forced to find improvised routes. These can include drilling new openings, overfilling existing penetrations or using temporary sealing methods that remain in place longer than intended. Each of these actions can increase risk, particularly in areas where fire resistance, pressure resistance, hygiene, water ingress protection or gas containment is required. A more resilient approach is to consider future modification at the design stage. This includes assessing expected cable growth, allowing spare capacity where appropriate, and ensuring that sealing arrangements can be inspected, reopened and resealed without unnecessary damage to the surrounding structure. This is especially important where process plants are being modernised. Digitalisation projects often begin with relatively small additions, such as new sensors or monitoring points, but can expand over time. The physical infrastructure must be able to keep pace with these changes.
MAINTAINING BARRIER PERFORMANCE
The main purpose of a sealed penetration is to maintain the performance of the barrier it passes through. Depending on the application, that may involve resistance to fire, smoke, gas, water, dust, pests or pressure. In hazardous environments, poor sealing can contribute to the spread of fire or hazardous substances. In controlled production areas, it can affect hygiene, cleanliness or environmental separation. Performance depends not only on the sealing system selected, but also on correct installation and longterm maintenance. A penetration may be correctly installed during construction, but later altered during maintenance or upgrade work. If the changes are not properly recorded and resealed, the original safety function can be weakened. For this reason, inspection and documentation should form part of the engineering process. Plant operators should know where penetrations are located, what services pass through them, what level of protection is required, and whether any spare
Robot grinding a multi-cable and pipe frame
capacity remains. This information is valuable during audits, shutdown planning and emergency repairs.
COORDINATING DISCIPLINES EARLY
Cable and pipe penetrations sit at the intersection of several disciplines. Electrical engineers, process engineers, mechanical engineers, civil designers, fire safety specialists and installation contractors may all have an interest in the same opening. Without coordination, conflicts can appear late in the project, when changes are more expensive and harder to resolve. Early coordination helps determine the size, position and protection requirements of each penetration. It also reduces the likelihood of overcrowding, poor access or incompatible installation methods. In modular construction or prefabricated plant sections, this becomes even more important, as late changes can disrupt manufacturing schedules or require rework on site. Digital planning can support this process by giving project teams a clearer view of cable schedules, penetration layouts and available capacity. Used properly, planning data can help reduce uncertainty between
design, installation and maintenance teams. It also creates a stronger basis for future modifications, because the operator has a record of what was installed and why.
DESIGNING FOR LIFECYCLE VALUE
The cost of a cable or pipe penetration is small compared with the cost of production downtime, emergency rework or loss of barrier integrity. Yet the consequences of poor planning can be significant. A plant upgrade that should be straightforward may require additional permits, hot work, structural modification or extended shutdown time simply because service routes were not designed for change. A lifecycle approach considers not only the initial installation, but also the future need to inspect, modify and reseal. It asks whether the penetration can be accessed safely, whether additional services can be added without compromising performance, and whether maintenance teams can verify that the barrier remains compliant.
For more information visit: www.mctbrattberg.com
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PLANT MANAGEMENT
RETHINKING
THE WAKE How VE Technology eliminates vortex shedding and solves the insertion probe paradox
Daily Thermetics is deploying the VE TEchnology solution to break the traditional insertion probe paradox
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or decades, process engineers have operated under an unwritten compromise when instrumenting critical velocity fluid streams. To achieve highly accurate, representative samples or to capture rapid temperature responses, measurement probes must extend deep into the process stream, ideally into the centre third of the piping cross-section. However, placing a standard cylindrical probe into critical velocity flows subjects the structure to severe high-velocity impingement and wake forces. The primary culprit is Vortex Induced Vibration (VIV). As fluid flows past a rigid cylinder, it creates an alternating wake known as a Von Kármán Vortex Street. When the shedding frequency of these
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vortices matches the natural resonant frequency of the probe, the resulting lock-in condition causes violent oscillation, rapid fatigue failure, and catastrophic mechanical shear. To prevent these failures, engineers traditionally use the ASME PTC 19.3 TW standard to guide thermowell and probe design. The standard often forces a defensive engineering compromise: making the probe shorter, which sacrifices process representation, or making it thicker, which drastically slows down response times and chokes flow lines. Having recently secured the exclusive intellectual property and global brand rights for VE Technology, temperature measurement solutions specialist Daily Thermetrics is now deploying this proprietary solution to break the
traditional insertion probe paradox. Rather than relying on oversized mechanical dimensions to withstand fluid forces, VE Technology reengineers the fluid dynamics of the wake itself—suppressing vortex shedding frequency before it can induce structural resonance.
VE Technology reengineers the fluid dynamics of the wake itself – suppressing vortex shedding frequency before it can induce structural resonance
PLANT MANAGEMENT
An engineer operating the VE Technology solution
Nozzle measurement
THE PHYSICS OF COMPLETE VORTEX SUPRESSION
The patented VE Technology design solves the insertion probe paradox by eliminating the root cause of cyclic stress: the correlated wake. Rather than attempting to withstand the destructive energy of vortex shedding through increased mass or wall thickness, VE Technology utilises a proprietary, precisely engineered helical profile along the probe body. As the process fluid encounters this unique helical geometry, the strakes force the fluid into a complex, threedimensional flow regime. The uniform correlation of vortex shedding along the length of the probe is completely broken. Because the vortices cannot synchronize, the alternating lift and
drag forces drop to near-zero levels. This revolutionary aerodynamic compliance allows long, low-mass probes to operate safely in high-velocity processes where traditional straightsided cylinders would fail within hours.
TRANSFORMING ANALYTICAL PRECISION, VE TECHNOLOGY SAMPLING PROBES
In process analytical sampling, accuracy is entirely dependent on sample representativeness and lag time. In high-velocity gas lines or dense liquid streams, traditional sampling probes must be built with thick, heavy walls to survive flow conditions. This added mass creates a large internal volume, leading to slow
sample refresh rates and significant analytical lag. By mitigating VIV at the fluid level, VE Technology Sampling Probes are engineered with optimised, small-bore internal volumes without compromising mechanical safety. This ensures rapid sample transport to downstream analysers, providing real-time data for tight process control loops.
TWO PRIMARY OPERATIONAL CONFIGURATIONS
Daily Thermetrics delivers this technology across two primary operational configurations. Fixed VE Technology Probes FVE: these are engineered for permanent, critical loops where process conditions remain steady and continuous,
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PLANT MANAGEMENT
Process engineers must eliminate known failure mechanisms
representative sampling is required. Retractable VE Technology Probes RVE: These are designed for highpressure, high-velocity processes where online maintenance is nonnegotiable. Utilising integrated isolation valves and robust drive mechanisms, these probes can be safely extracted and serviced under full process conditions, eliminating the need to wait for a unit turnaround or force a costly plant shutdown.
REDEFINING TEMPERATURE MEASUREMENT
Temperature loops face a parallel challenge. When a standard thermowell fails the stringent wake frequency calculations of ASME PTC 19.3 TW, traditional engineering remedies often force a severe compromise. To survive high-velocity flows, conventional designs require significantly shortening the insertion length or drastically increasing the root and tip diameters. However, short wells fail to reach the true process stream centerline, introducing significant boundary-layer thermal errors. Conversely, thickening the thermowell wall vastly increases its thermal mass, causing sluggish response times that can cripple tight process control loops and mask critical thermal transients.
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The DHTW Thermowell, incorporating proprietary VE Technology, removes these operational constraints entirely. By integrating vortex suppression geometry directly into the machined body of the well, the DHTW suppresses the destructive cyclic forces of the wake at the fluid level. It passes ASME PTC 19.3 TW requirements effortlessly without forcing engineers to choose between mechanical safety and instrument responsiveness. Process engineers can confidently specify the optimal insertion depth for true representative measurement while maintaining a low-mass, fast-responding thermal profile that ensures total mechanical integrity.
EXTENDING THE PRINCIPLE TO INJECTION QUILLS
The vulnerabilities of sampling probes and thermowells apply equally to injection quills. Used to introduce chemical inhibitors, wash water, or catalysts into a stream, traditional quills are highly susceptible to fatigue from VIV. When an injection quill vibrates or shears, the consequences extend far beyond a broken instrument. A failing quill often results in poor chemical atomisation and distribution, leading to localised droplets impinging on
the internal pipe wall. In applications like neutralising amine or wash water injection, this localised concentration leads to aggressive, accelerated corrosion cells that threaten the pressure envelope of the piping asset. Implementing VE Technology on injection infrastructure ensures the fluid is introduced exactly at the centerline of the stream, achieving homogenous mixing while guaranteeing the structural survival of the injection tip.
CONCLUSION
Maximising plant availability and safety requires process engineers to eliminate known failure mechanisms. Traditional, straight-sided insertion devices treat the symptoms of vortex-induced vibration rather than the cause. As a fully integrated, proprietary solution from Daily Thermetrics, VE Technology bridges the gap between mechanical survival and process data accuracy. Transitioning from brute-force mass to fully engineered compliance allows modern plants to achieve faster thermal response, faster sampling times, and uncompromised mechanical safety.
For more information visit: www.dailyinst.com
PLANT MANAGEMENT
SCALING CO₂ USE How a new solution from green technology provider GKT converts CO2 into chemical base materials and fuels
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arbon capture is becoming an established part of industrial decarbonisation and a key area of focus for many process engineers. But capturing C02 is only the first step. The real opportunity lies in converting it into valuable products that can replace fossil-based raw materials thereby improving a company’s environmental footprint.
ECO2CELL TECHNOLOGY
Austrian technology provider GKT has therefore developed ECO2CELL, a solution that converts captured CO2 electrochemically into chemical base materials and fuels, creating value where emissions previously occurred. The technology transforms CO2 into valuable chemical products using electricity and water. The electrochemical process operates under mild conditions at ambient temperature and atmospheric pressure. Unlike many alternative processes, no external hydrogen supply is required, which reduces infrastructure complexity and improves operational safety. When powered by renewable electricity, the conversion can significantly reduce the carbon footprint.
THE CONTAINER BASED ECO2CELL CUBE SYSTEM
The new ECO2CELL Cube brings GKT’s patented electrochemical CO2 conversion technology to pilot scale. Installed in two 20-foot containers, the mobile system enables process development under near-industrial conditions – directly at industrial sites if required. With an electrolysis power of up to 15 kW and a CO2 conversion rate of up to 5.34 kg/h, the Cube provides a flexible platform for developing and validating CCU and Power-to-X applications. Adjustable operating parameters allow targeted product formation and catalyst optimisation. Closed-loop CO2 recycling, an
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Dr. Mohammad Rezaei, MBA head of business unit environmental technology, GKT
industrial safety architecture and integrated laboratory facilities provide the basis for reliable process evaluation and scale-up.
FROM PILOT TO INDUSTRIAL SCALE
Insights gained with the ECO2CELL Cube provide the foundation for complete industrial process solutions. GKT covers downstream separation and plant integration as well as engineering, manufacturing and commissioning. By combining ECO2CELL technology with decades of expertise in thermal separation and plant engineering, GKT bridges the gap between electrochemical innovation and industrial application.
For more information visit: https://gkt-solutions.com
The ECO2CELL Cube enables process development under near-industrial conditions
FURTHER INSIGHTS ON C02 UTILISATION For a more detailed perspective on C02 utilisation, GKT has developed an Insights Series (see QR code) that examines the topic from different angles – from the role of CO2 as a recyclable raw material to emerging conversion technologies and the economics of CO2 electrolysis in addition to the broader potential of CCU in a low-carbon economy. The whitepaper brings together the key findings from the series and provides a concise overview of CO2 utilisation and its potential for industrial applications.
Explore GKT Insights >
Your system is only as protected as its openings. Fire, water, gas and pressure find the weakest point. MCT Brattberg cable and pipe transits help maintain the integrity of critical safety barriers - protecting people, assets and continuous operations.
Spareblock The compression unit Placed anywhere in the frame. The PTG-120 compresses the system and completing the penetration steel.
The transit frame Can be bolted or welded. Hardware and material in the highest quality for the toughest of applications.
Stayplates Placed between each row blocks, they ensure even blasts can’t make it through the penetration seal.
The unused space in the frame is filled with solid spare blocks. This allows for the option of fitting new cables/ pipes in the future.
HandiBlock Available in four sizes to fit cables/pipes or tubing from 4 to 54 mm (0.16” to 2.13”), inserts marked with designated cable/pipe dimensions. A safe, flexible and easy-to-install block module.
Standard Block Each block consists of two halves and can seal cables/ pipes with diameters from 3.5 – 110 mm. (0.14–4.33”).
MATERIALS HANDLING
The Optimass 5000 Coriolis meter
A NEW STANDARD
David Hopper from Krohne explores what the release of the Optimass 5000 Coriolis meter means for the measurement sector
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oriolis specialist Krohne has launched the OPTIMASS 5000, a new generation of Coriolis mass flow sensors. Following the successful limited-sales readiness phase, this milestone marks the introduction of the Optimass 5000 to the Krohne portfolio. The Optimass 5000 extends and strengthens Krohne’s Coriolis offering, positioning the company competitively in a demanding market environment while providing customers with an optimised balance of performance, reliability and cost efficiency, according to the company.
The golden rule is to always size a Coriolis meter using process conditions and take into account all factors and customers’ process requirements
WHY OPTIMASS 5000?
This product is the new standard Coriolis meter. The Optimass 5000 directly addresses ongoing challenges and market developments: continued global pressure on Coriolis competitiveness, lead times and ecological approach from all industries. This is a meter that was
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David Hopper provides mass flow support for Krohne customers
MATERIALS HANDLING
SILVER = C0.M0.Y0.K30 For use in layouts where the logo will be placed on a dark color field such as technical services gray. SILVER = C0.M0.Y0.K30
DARK BLUE = C90.M50.Y5.K40 LIGHT BLUE = PMS285 or C91.M53.Y0.K0 Orange = C0.M56.Y92.K0
LIGHT BLUE = PMS285 or C91.M53.Y0.K0
ROTATING SHAFT SEALING EXPERTS
PATENTED TECHNOLOGY
AGITATOR SEALS THAT WORK. PATENTED TECHNOLOGY
PREMIUM MECHANICAL INTRODUCING THE PACKING
DURAPACK® System
Innovative hybrid bearing and lantern ring sealing system.
Servistar Industrial Way | Westfield, MA 01085 | Phone: 413-564-5202 | Fax: 413-564-5203 • PackRyt® BRG Bearing for shaft stabilization
• SealRyt’s patented MA SLR® (Structural Lantern Ring) | Fax: 413-564-5203 Servistar Industrial Way | Westfield, 01085 | Phone: 413-564-5202 • Resists clogging and is removable for easy cleaning and maintenance
Servistar Industrial Way | Westfield, MA 01085 | Phone: 413-564-5202 | Fax: 413-564-5203 • Non-collapsible design won’t crush or shift inside the stuffing box
Servistar Industrial Way | Westfield, MA 01085 | Phone: 413-564-5202 | Fax: 413-564-5203
SCAN to learn more.
ROTATING SHAFT SEALING EXPERTS
Call us to find out why reliability and maintenance managers are moving to our patented solutions! Our Patented Parts are
Phone: 413-564-5202
white url Designed and Manufactured in Westfield, MA
MADE IN THE U.S.A.
PACKRYT® BRG and STRUCTURAL LANTERN RING (SLR®) with PACKING
Patented Product
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MATERIALS HANDLING
The Optimass range
KEY FEATURES • 6 sizes: S10 to S80 • Wetted parts: Stainless Steel 316L • Temperature range: -50°C to +180°C (-58°F to +356°F) born optimising the sensor itself and the manufacturing process, using state-of-the-art, high-level automation and robotics throughout the complete process from storing and parts collection, CNC, to robotic welding, blasting, testing and calibration. The Optimass 5000 has been specifically developed to respond to these dynamics, offering improved performance compared with entrylevel devices, eco-friendly and strong positioning against competitors´ standard meters. This enables the end users to regain competitiveness in key application segments without compromising on quality or reliability.
COMPLETING THE RANGE
Krohne is a Coriolis specialist making mass flow meters since 1986. Coriolis meters come in different shapes and sizes. Selecting the best one for an application can be complex. Each tube design has its strengths and weaknesses. Coriolis meters seem ideal for a wide range of applications, but some models are suited to certain applications. How do I select the perfect meter? It can be a balance between many factors: accuracy, flow rate, pressure drop, installation envelope, and, of course, price. Compared to other technologies, the working principles of Coriolis meters offer several distinct advantages. With no moving parts that come in
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• Pressure rating: up to PN100 / ASME Class 600 • Typical case burst pressure: > 200 barg / 2900 psig • Mass flow uncertainty: o Standard: 0.15% (liquids) o Optional: 0.1% • Zero stability: 0.01% of nominal flow rate • Compatible with MFC400 and future converters • Installation length compatible with OPTIMASS 1000 direct contact with the measured fluid, whether liquid or gas, they require little maintenance. Coriolis meters are also a true multiple variable device, offering more than just mass flow measurement, such as density, temperature and concentration. Advanced diagnostics can also provide an insight into the fluid which can be helpful in determining process issues. Tube design is of extreme importance. Straight tubes offer a more compact installation envelope and fit the pipeline perfectly, so the installation won’t require elevating the entire pipeline or digging a hole in the ground. The pressure drop of a single straight tube meter is comparable to that of the pipeline, and they are easy to clean and inspect. They can handle abrasive fluids (following the recommended guidelines) and are available in many materials, such as Titanium, Hastelloy, Duplex, and Tantalum. The availability of these materials is especially important in the chemical industry, where various
types of acids are handled. On the other hand, bent tube designs excel in applications up to 400°C or cryogenic down to -200°C and for high pressures. They are also particularly suited for gas applications, for applications with complex flow conditions such as entrained gas, and where very high accuracies are required. The golden rule is to always size a Coriolis meter from the process conditions and take into account all factors and customers’ process requirements. Purchasing a Coriolis meter from a manufacturer that offers a wide range of designs will help customers find possible solution. Whether this is a single, double, or four-tube design or whether it is a straight or a bent design. Experience also matters when making Coriolis; some of us have been making them for over 40 years.
For more information visit: www.krohne.com
MATERIALS HANDLING
THE IMPORTANCE OF
INFRASTRUCTURE Domenico Marzocchi from Watlow explores how infrastructure is becoming a critical enabler of the electrifcation of process heating
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s industrial facilities seek to improve energy efficiency, enhance process control, and modernise thermal operations, electrification of process heating is attracting growing attention. While early discussions focused largely on emissions reduction, the conversation among engineers has increasingly shifted toward implementation, infrastructure readiness, and operational performance. The technical capability of electric process heating is no longer in question. Modern electric heating systems can reliably deliver multimegawatt thermal duties across a wide range of industrial applications. However, as projects move from feasibility studies into detailed engineering, many organisations discover that the heater itself is rarely the primary challenge. Instead, electrical infrastructure often becomes the critical factor determining project feasibility, cost, and long-term success.
REPLACING A FIRED REBOILER
Consider a refinery evaluating the replacement of a 12 MW fired reboiler with an electric heating system. Replicating the thermal duty is generally achievable using existing electric heating technology. The engineering challenge quickly expands beyond heater selection, however. Project teams must assess available grid capacity, substation loading, transformer capability, cable routing, protection systems, power quality requirements, and future
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Infrastructure often determines the feasability of an electrification transition
expansion plans. In many cases, these considerations become the dominant factors influencing project economics and implementation schedules. This situation is increasingly common across refining, petrochemical processing, hydrogen production, LNG facilities, and chemical manufacturing. Applications such as charge heating, process reboilers, regeneration systems, vaporizers, and thermal fluid heating frequently require several megawatts of continuous thermal energy. Historically, these duties have been supplied through fired equipment, steam systems, or thermal fluid loops. Electrification fundamentally changes how energy enters the process, transferring significant thermal demand onto the plant electrical network. For smaller heating applications, conventional low-voltage electric systems can provide an effective solution. However, as power requirements increase, infrastructure complexity often grows rapidly. Delivering large amounts of power at low voltage requires higher current
levels, resulting in larger conductors, increased cabling requirements, larger switchgear assemblies, and greater heat dissipation within electrical rooms. These factors can significantly affect project economics, particularly in brownfield facilities where space is limited. Existing cable trays may have insufficient capacity, electrical rooms may be fully utilised, and available transformer loading may already be constrained. Consequently, infrastructure modifications can represent a substantial proportion of total project cost.
ADDRESSING CHALLENGES
To address these challenges, many facilities are evaluating mediumvoltage electrification strategies. By increasing operating voltage, current requirements can be significantly reduced while maintaining the same power output. Lower current levels reduce conductor sizes, simplify cable routing, decrease installation complexity, and reduce the overall electrical footprint of the project.
MATERIALS HANDLING
Diagram showing thermal loop stages
For high-power process heating applications, medium-voltage systems offer several practical advantages. Reduced cabling requirements can simplify installation and improve maintainability. Electrical distribution equipment may occupy less space, and in some cases the need for additional stepdown transformers can be minimised. These benefits become increasingly valuable as electrification projects scale into the multi-megawatt range. However, infrastructure alone does not determine project success. The Watlow Powersafe integrated heating and control system
Experience from early electrification projects demonstrates that process heating should be approached as a complete system rather than an isolated equipment replacement exercise. Modern thermal systems increasingly integrate heaters, sensors, power management, process controls, and digital monitoring platforms into a unified architecture. This integration enables improved operational visibility and more precise process control. Rather than simply delivering thermal energy, electrified systems can provide continuous insight into equipment condition, power consumption, and process performance. For plant operators, this visibility creates opportunities to improve reliability and reduce maintenance costs. Real-time monitoring of electrical load, temperature profiles, and operating conditions allows engineers to identify inefficiencies and optimise system performance. In many facilities, predictive maintenance strategies are being developed using operational data to identify emerging issues before they result in unplanned downtime.
LESSONS LEARNED
Lessons learned from early projects have highlighted the importance of evaluating infrastructure requirements during the earliest stages of project development. Common challenges identified during front-end engineering studies include insufficient transformer capacity, overloaded cable routes, underestimated electrical demand, protection coordination issues, and integration challenges between new and existing control systems. Facilities that address these considerations early typically experience smoother implementation and reduced project risk. For this reason, many organisations are adopting phased electrification strategies. Rather than pursuing full-scale conversion immediately, facilities often begin with selected thermal duties where the technical and economic case is strongest. Applications such as reboilers, regeneration systems, and thermal fluid heaters frequently serve as initial projects, allowing organisations to gain operational experience while developing a better understanding of infrastructure requirements. As industrial electrification continues to mature, success will increasingly depend on multidisciplinary engineering collaboration. Process engineers, electrical engineers, automation specialists, maintenance teams, and operations personnel must work together to ensure that heating systems, electrical infrastructure, and control architectures are fully aligned. Ultimately, the future of large-scale process heat electrification will be determined not only by advances in heating technology but by the ability to engineer complete thermal systems that integrate power delivery, process control, operational intelligence, and long-term reliability. Facilities that approach electrification as a comprehensive engineering challenge rather than a simple equipment replacement project will be best positioned to achieve reliable, scalable, and cost-effective implementation.
For more information, visit: www.watlow.com
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MATERIALS HANDLING
CHOOSING
THE FUTURE Conveyor specialist Jan Willems from Fenner Dunlop explores how innovative single and dual-ply conveyor belt constructions are helping processing plants to optimise efficiency 34
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MATERIALS HANDLING
T
he basic construction of industrial conveyor belts has not really changed for over 120 years. True, the rubber and the cotton inner ply layers are now synthetic, but the basic construction and application principles have not. The heavier, more aggressive the materials are then the more layers and thicker outer covers that are required. In multi-ply conveyor belts manufactured in accordance with ISO 14890, the declared longitudinal tensile strength is the combined result of the individual fabric plies working together under tension. For example, a belt designated as an EP 800/4 contains four layers of polyester/ nylon (EP) fabric reinforcement with a nominal overall tensile strength of 800 N/mm. Each ply has its own breaking strength, typically around 200 N/mm. When bonded together to form the belt’s carcass, their individual strengths effectively ‘join forces’. However, the greatest influence on the strength of a conveyor belt is not the number of plies but the design of the weave pattern and the physical properties of the ply fabric such as its longitudinal strength. The number of plies needed to achieve a specific tensile strength needs to allow for the splice method. The step splice is the most commonly used method. This requires the removal of the length of the step of subsequent layers of fabric plies so that the two belt ends can be overlapped and either glued or hot vulcanised together. The disadvantage is that this creates a proportional loss of tensile strength equivalent to the strength of one ply. This means for example, that a step splice used to join a 3-ply 630 N/mm-ply belt will only retain a maximum of 67% of the tensile strength.
The strength of the inner fabric ply and design of the weave pattern is key
It was the ‘less is more’ principle that technicians working for Michelin-owned Fenner Dunlop Conveyor Belting in the Netherlands and North Americas used to defy old conventions by developing single and dual-ply belts that were not only thinner and lighter but stronger and more robust than their thicker, heavier multi-ply counterparts.
The greatest influence on the strength of a conveyor belt is not MARKET INUNDATED the number of plies WITH LOW GRADE IMPORTS but the design of the Fenner Dunlop saw the development weave pattern and the of single and dual-ply belting worthy of considerable investment because, physical properties of especially in the past twenty years or so, the market had become inundated by the ply fabric low grade imports from South and East
THE ‘LESS IS MORE’ PRINCIPLE
The history of technological advancement provides countless examples of the principle that ‘Less is more’. One of the best examples are the mobile phones we use today compared with just 20 years ago. Originally the size of a house brick, who could ever have imagined what the ‘fit in the pocket’ device can do now?
The way mobile phones have developed is beyond original predictions
Asia, primarily China. To win market share, performance and operational lifetime were routinely sacrificed to achieve prices consistently more than 50% lower than the premium quality brands such as Fenner Dunlop and Continental in Germany could ever achieve without sacrificing their hardwon reputations for quality, nor their strict adherence to European health and environmental safety regulation. Having a long-established brand with a globally trusted reputation for quality, they decided to continue competing for market share based on lower lifetime cost rather than headline price by producing belts that could withstand even tougher demands, achieve even longer operational lifetimes while requiring even less running maintenance and fewer stoppages for repairs in order to further widen the gap in ‘total cost of ownership’ value for money.
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MATERIALS HANDLING
UsFlex was already successful for Fenner Dunlop
SINGLE AND DUAL-PLY REPLACE MULTI-PLY BELTS
Having first introduced their hugely successful ‘extreme conditions’ single and dual-ply UsFlex belt more than two decades previously, Fenner Dunlop decided to build on the concept of replacing multi-ply belts with single and dual-ply versions by taking advantage of what they saw as having two more aces up its sleeve.
If its first ace was having already developed UsFlex, their second lay with benefits of their long history of innovative rubber compound technology. For example, a recent laboratory test survey revealed that their rubber has significantly greater abrasive wear resistance than their competitors, according to the company. Their third Ace was having their own R&D teams and weaving facilities in the US for the
Advantage of in house weaving facilities in North America
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further development of the important synthetic ply fabrics.
THE MAKEUP OF FIBRES AND YARNS
Its first priority was to ensure that the individual fibres and yarns were strong and of high quality. Next came the design of the weave pattern. To add to the ‘Straight warp’ UsFlex carcass made of hightenacity polyester fibres protected by polyamide weft lines used for the very toughest applications, two additional versions of fabric were developed. First was Ultra X, launched six years ago featuring a specially woven ‘crimped warp’ carcass, creating outstanding strength, stability, and impact resistance, according to the company. Ultra X1 replaces multibelts up to and including 400/3 while the X3 version is designed to replace up to 630/4. With the demands of the lower end and top end fulfilled, then came the higher tensile strength Nova-X, which uses an even stronger crimped warp fabric, providing excellent rip, tear, and impact resistance under load. Nova X4 is designed to replace up to 800/4 and
MATERIALS HANDLING
Weft strands bundle together to stop the belt or expel the penetrating object
Nova X6 can replace up to 1250/4 multi-ply belts. The common denominator between the fabrics is that they all consist of longitudinal strands lengthwise and heavy strands running crosswise, held in position by a strong yarn. The UsFlex strands are completely straight in both directions and not interlocked as in conventional fabric, allowing the weft to float free from the warp. This creates up to 300% greater impact resistance by using a shock absorber effect that dissipates impact energy over a larger area,
allowing the belt to withstand the kind of punishment that would destroy a conventional belt. The special carcasses also possess a longitudinal rip resistance that significantly greater than conventional multi-ply belts of equivalent tensile strength rating, according to the company. When penetrated and being pulled through a trapped object such as a sharp rock, the strands in the uniquely woven fabric gather in a bundle that eventually become strong enough to stop the belt or even expel the object altogether.
GREATER SPLICE EFFICIENCY
A single or dual-ply belt can possess the necessary tensile strength because of a combination of the strength of the fabrics supported by a much higher level of splice efficiency. Single-ply belt constructions require a finger-splice joint, which are stronger, longerlasting and less prone to damage. However, their biggest advantage is that they retain considerably more of the belt’s original tensile strength compared with the conventional step splice, which proportionally loses the tensile strength equivalent to the strength of one ply.
COMPETITORS
The growing success of single and dual ply on both sides of the atlantic appears to have been monitored by Fenner Dunlop’s nearest premium quality competitor, Continental, a company that recently announced their own plans to introduce the single ply construction, effectively validating Dunlop’s innovation.
For more information, visit: www.fennerdunlopemea.com A finger splice retains considerably more tensile strength
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MATERIALS HANDLING
MEETING THE CHALLENGE Exploring accurate surface temperature measurement
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he challenges of accurate surface temperature measurement will vary depending on whether it is the temperature of a liquid, gas or process medium that is being measured. In many industrial applications, permanently modifying pipework, vessels or machinery to accommodate a sensor may be unnecessary or impractical, particularly when measurements are required temporarily or at several different locations. Thermocouples are widely used throughout industry, but conventional sheathed assemblies are primarily designed for tip sensing. When applied directly to a surface, the physical construction of a probe can make good thermal contact difficult, while heat conduction along the probe stem can contribute to measurement errors. For reliable surface measurement, the sensing junction needs to make effective and repeatable contact with the surface being monitored. Several attachment methods can achieve this, including adhesive patches, washer and stud arrangements, pipe clips and magnetic mounting. For ferrous surfaces, magnetic thermocouples provide an alternative that does not require drilling, welding or permanent mechanical fixing. The sensor can be positioned directly on the measurement point and subsequently removed or relocated. This can be particularly useful during equipment commissioning, maintenance, testing and fault-finding, where engineers may need to compare temperatures at several locations.
MAGNETIC THERMOCOUPLE CONFIGURATIONS
UK temperature sensor manufacturer Labfacility has developed magnetic thermocouple configurations with pull strengths ranging from 0.7kg to 11.8kg, providing different attachment options according to the requirements of the application.
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Labfacility has developed magnetic thermocouple configurations with pull strengths ranging from 0.7kg to 11.8kg
Lower pull strengths can be suitable for lightweight assemblies and accessible measurement positions. Greater holding forces may be required where cable weight, movement, orientation or vibration places additional load on the sensor. Button-style and higher-pull magnet constructions can therefore address different installation requirements, while flexible magnetic-strip designs provide another option where a larger contact area is advantageous. Pull strength alone, however, does not determine measurement performance. Surface condition is an important consideration. Paint, coatings, corrosion, contamination and surface geometry can influence both magnetic adhesion and thermal contact. The sensor should be positioned on a clean, suitable ferrous surface with consideration given to both mechanical security and thermal contact. Sensor construction must also
reflect the surrounding environment. Cable insulation such as PTFE or PFA can be selected according to operating conditions, while stainless-steel overbraid can provide additional mechanical protection where required. The operating limits of the magnet itself must also be considered alongside those of the thermocouple and cable. Magnetic thermocouples will not replace permanently installed sensors where continuous process measurement or control is required. They do, however, provide engineers with a practical method of obtaining temporary or repositionable surface temperature measurements without permanently altering the equipment being monitored.
For more information, visit: www.labfacility.com
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Free OPTICHECK Flow Mobile app for iOS and Android: krohne.link/opticheck-mobile
products
solutions
services
MATERIALS HANDLING
BEYOND THE SEAL Peter Chilton from Sealryt provides a systems approach to pump reliability
Many pumps in the process industry are more than 40 years old
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rocess engineers are accustomed to looking at systems. Flow, pressure, temperature, solids content, equipment condition and operating practices are interconnected, and changing one variable can affect the entire process. Yet when it comes to pump sealing, that systems thinking is sometimes abandoned. A seal fails, so the seal is replaced. When it fails again, a more advanced seal may be specified. But what if the sealing device was never the root cause? Modern mechanical seals are remarkable pieces of engineering. Materials, manufacturing techniques and tolerances have improved dramatically. The challenge is that
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many of these highly engineered products are being installed on equipment that has been operating for decades. Across process industries, pumps that are 30, 40 or even 50 years old remain in service. During that time, foundations move, bearings wear, shafts deflect, alignment changes and piping introduces strain. The pump may still perform its basic process function, but the mechanical environment surrounding the sealing area can be far from ideal.
ENSURING MECHANICAL STABILITY
Precision sealing technology cannot compensate indefinitely for
mechanical instability. This is particularly important as plants lose experienced maintenance personnel. The mechanic or engineer who understood a pump’s history— and recognised that repeated seal failures were actually symptoms of vibration, shaft movement or process conditions—is increasingly difficult to replace. Without that institutional knowledge, maintenance can become transactional: remove the failed component and install another. Process engineers can help change that approach by treating sealing as part of the larger equipment system. Before selecting a sealing technology, examine the conditions surrounding it. Is shaft runout acceptable? Are bearings providing
MATERIALS HANDLING
Peter Chilton is a marketing manager at Sealryt
Process engineers can treat sealing as a part of the larger equipment system
adequate support? Is the equipment properly aligned? Is pipe strain contributing to movement? What is actually happening inside the stuffing box? Then consider the process itself. Temperature and pressure matter, but so do solids concentration, abrasiveness, shaft speed, flush-water availability, operating cycles and maintenance capabilities.
SEALING STRATEGY
Once those variables are understood, the sealing strategy can follow.
Sometimes a mechanical seal will unquestionably be the right solution. In other applications, modern braided packing, stabilisation systems or hybrid approaches may better accommodate the realities of the equipment and process. Packing technologies can offer greater tolerance for shaft movement and abrasive media, while bearing and stabilisation technologies can improve the environment in which the sealing system operates. The objective should not be to promote one technology over another. It should be to create the conditions necessary for whichever technology is selected to succeed. For process engineers, this represents a familiar principle:
optimise the system rather than an isolated component. A recurring seal failure should therefore be treated as process information. Instead of simply asking, “What seal should replace this one?”, ask “Why is this sealing system failing?” That distinction can lead to longer equipment life, reduced water consumption, fewer maintenance interventions and lower total operating costs. Better sealing does not necessarily begin with a better seal. It begins with a better understanding of the system.
For more information visit: www.sealryt.com
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MATERIALS HANDLING
REINVENTING PROCESSES How one innovative start-up is making chemical molecules from scratch
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or decades, the chemical industry has steadily improved its processes. But that incremental approach is now reaching its limits. A large share of industrial processes still relies on technologies developed several decades ago. They often require high temperatures, high pressures, metal catalysts, or solvents whose economic and environmental costs are becoming increasingly difficult to justify. Optimising what already exists is no longer enough. Chemical specialist Plaskimia is not developing a new molecule, rather it is developing a new way to make all the others. The startup has developed a platform capable of designing, testing, optimising, and industrialising new processes through a modular, electrified, data-driven architecture. Laurent Boitard, CEO of Plaskimia, said: “For decades, innovation in chemistry has focused on discovering new molecules. We believe the next revolution will be about how they are made. That is what we are building at Plaskimia: an industrial platform capable of accelerating the design of more resource-efficient, safer, and more competitive processes. Europe’s industrial sovereignty will also depend on its ability to invent the processes that will make the molecules of tomorrow.”
The Plaskimia team are accelerating the design of molecules
The second, PlasmAI, is the platform’s learning engine. Each experiment feeds a proprietary database that brings together reaction parameters, analytical results, and the performance achieved. These data then feed artificial intelligence models capable of proposing new experimental conditions, optimising existing reactions, and
For more information visit: www.plaskimia.com
A PLATFORM THAT LEARNS
The platform is based on two complementary technology components. The first, PlasmaFlow, utilises continuous-flow plasma chemistry which circulates gases and liquids through reactors. Within these reactors, cold plasma generates reactive chemical species capable of triggering the desired reaction. Depending on the application, this approach makes it possible, at ambient pressure, to limit the use of certain metal catalysts and facilitate scale-up, from the laboratory to initial industrial pilots.
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exploring new synthetic routes. Each experiment enriches the platform and each new reaction improves those that follow. Basically the platform learns to improve the reactions. This architecture turns laboratory know-how into a reproducible, controllable process ready for industrialisation.
Each new experience enriches the Plaskimia platform
MATERIALS HANDLING
TOLL PARTNERS Ben Beattie from toll company Forbeats looks at considerations for overcoming bottlenecks and disruptions
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or manufacturers in industry, toll processor partnerships can play a vital role in overcoming bottlenecks and disruption. Ben Beattie, manager of Forbeats, explains why the delivery of end-to-end solutions and the provision of expertise, capacity, safety and compliance are key considerations when choosing a partner. The UK processing industry has faced years of constant disruption. Despite recent attempts to improve EU-UK trade relations, Brexit still creates additional regulations, paperwork, costs, border checks
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and transport delays. Meanwhile, the ongoing Ukraine- Russia war has impacted the supply of raw materials and disrupted transport, while the attacks on shipping in the Red Sea and the closure of the Straits of Hormuz have brought vital international supply routes to a complete standstill. In addition, manufacturers have had to contend with the slow pandemic recovery and, more recently, with the tariffs and counter-tariffs that have brought continuous volatility and uncertainty. The impact of these disruptions
Ben Beattie explains how toll managers can help process engineers
on the processing industry is considerable. Products and materials are harder to procure, take longer to arrive and invariably cost more to purchase and transport. The lack of stability in the market also means things can change overnight. The resulting bottlenecks make it increasingly challenging for manufacturers to complete orders and meet deadlines.
TOLL PROCESSING KEEPS PRODUCTION GOING
Experienced toll processors help mitigate shortages and delays, enabling manufacturers to overcome bottlenecks and fulfil orders even during periods of disruption. Able to deliver full-service, end-toend solutions for either ongoing or
MATERIALS HANDLING
one-off operations, they can provide the gamut of processing and chemical handling requirements, including handling hazardous chemicals. With a wide range of other key services also available, they are an important consideration for manufacturers seeking a partner that has the capacity and flexibility to tackle bottlenecks or cope swiftly with increased demand. With properly equipped facilities and a highly skilled workforce, toll processors can operate independently to streamline processes, minimise risk and implement robust quality control. This ensures safety, cuts waste and eradicates inadequate processing. Furthermore, with a focus on stock control, order forecasting, and cost and process optimisation, a toll processor can react promptly to demand and plan production schedules effectively.
Forbeats can meet chemical handling requirements
THE IMPORTANCE OF PARTNER NETWORKS
Experienced toll processors are also problem solvers. Having learnt from historical disruptions, forward-thinking contractors have now developed extended partner networks. These networks are an invaluable source of contingency services, while up-to-date partner surplus databases mean scarce or delayed materials can be sourced at speed, ensuring that production can be maintained despite disruption. The wide range of additional services offered by partner networks includes warehousing and logistics, labelling, custom packing and repacking, batch traceability, paperwork, import and export clearance, and full contract manufacturing services. These extend a toll processor’s capabilities and capacity, enabling them to provide true end-to-end solutions. This is an important consideration for manufacturers as it gives them access to an effective, comprehensive and cost-efficient outsourcing solution.
PUTTING SAFETY AND COMPLIANCE FIRST
Safety and compliance are critical considerations when choosing a toll processing partner. Manufacturers need assurance that their contractor has an up-to-date knowledge of regulations, can operate compliantly
Forbeats focuses on stock control, order forecasting and cost optimisation
and handle, process, store, label, pack and transport goods safely. Toll processing partners should have ISO9001 accreditation as well as a detailed understanding of regulations, such as UK REACH. They must also have the know-how to handle the spectrum of ingredients and materials across viscosities and hazard classes. Besides expertise, toll processors also require the dedicated COMAH facilities needed to store, process and transport materials properly, together with the capability to provide sample analysis, batch traceability and the associated administration. Having these requirements in place ensures a contractor is not only able to guarantee quality and safety, but that they also have the facilities to scale operations at pace and provide scalerelated efficiencies.
For manufacturers within the processing sector, an experienced toll processing company with a wide and trusted network of partners offers a practical and effective way to mitigate the ongoing challenges and disruption in today’s market. The key consideration when choosing a company to work with is whether they have the experience and facilities to deliver agile, full-service, end-to-end solutions. At the same time, they should also be able to provide a smooth supply chain that can overcome bottlenecks and meet deadlines, while ensuring safety, costefficiency and high quality.
For more information visit: www.forbeats.co.uk
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WATER AND WASTEWATER
A FLOW OF FINALISTS The finalists for Ofwat’s most recent Water Discovery Challenge impress the judges with their innovations
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he finalists of Ofwat’s second Water Discovery Challenge were announced earlier this summer, with innovations that include water cleaning fleas and flies, smart sewage batteries, and chemical busting bubbles. The winner will be announced in April 2027, but each of the 20 finalists has already received a bursary of up to £100,000 with a total of £7.5m to be awarded over 20 months, in addition to a comprehensive package of support. This includes seven months of mentorship to help teams convert ideas into successful business opportunities; with a focus on data and commercial development. They will also receive expert guidance from water companies. The Water Innovation Fund aims to accelerate the development and adoption of innovations to support challenges in the water sector. Innovators come from a range of sectors including academia, energy, agriculture, farming and environmental services. The finalists include: • DWS: Nature-based tertiary wastewater treatment for safe water reuse - led by Daphne Water Solutions Limited, in partnership with ATG Group. The project uses tiny water fleas called Daphnia to remove forever chemicals, pharmaceuticals and microplastics from wastewater. Daphnia are about the size of a grain of rice, and capable of naturally capturing these contaminants, removing the need for chemical treatment or energy input. This helps water companies to meet tightening regulations while reducing costs and environmental impact. • Rheya Labs: Smart batteries to eliminate sewage pumping station spills - led by Rheya Labs Limited. The group is developing back-up batteries for pumping stations to prevent raw sewage
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DWS are using water fleas to remove forever chemicals from water
from spilling into the environment during power failures. In the event of an outage, the battery instantly takes over to keep the pumps running and prevent pollution leaking into the water system. • Lunasonic: Ultrasound for catalyst-free destruction of persistent organic pollutants - led by University of Glasgow. The innovators are developing ultrasonic treatment technology to destroy organic pollutants in water. Using only sound as an input, the technology creates microscopic bubbles that break down forever chemicals and other contaminants into carbon dioxide and naturallyoccurring minerals. • Entoremediation: Utilising black soldier fly larvae to clean sewage sludge and screenings the project is led by Entocycle Ltd. The team has developed a process that uses larvae from black soldier flies to remove contaminants from sewage sludge and wastewater.
These larvae are known to be able to efficiently convert organic waste into nutrient-rich fertiliser, and so this project will test whether they can break down contaminants more effectively and at less cost than methods currently being used. Director of innovation at Ofwat, Jo Jolly said: “With our rapidly changing climate, it is more vital more than ever that we double down on our efforts to create a water system that is able to support lives and livelihoodsnow and in the future. By opening our doors to innovators outside the water sector, we have invited fresh perspectives to tackle some of our greatest challenges. With this line-up of finalist projects, we are reminded that tackling the climate and nature crises isn’t limited to any one sector. The array of ideas from new players is astounding. The challenge now is funding and supporting them so that they can become realised solutions within a practical and useful time frame.”
For more information visit: www.waterinnovation.challenges.org/water-discovery-challenge
HAMPRO® HIGH-PRESSURE PROCESS TECHNOLOGY The high-pressure pumps of the HAMPRO® series are used in the Oil and Gas Industries to pump a very wide range of fluids, meet the stringent requirements of the relevant safety and reliability regulations and are characterized by a robust design and careful use of resources. Our experienced team of experts will be happy to help configure the perfect solution for your individual application.
RECIPROCATING PUMPS TO API 674 - Glycol pumps - Leak test pumps - Methanol pumps - Produced water injection pumps - Sea water injection pumps Pressure: 50 – 4000 bar Flow rate: 0,1 – 256 m³/h
Hammelmann GmbH Carl-Zeiss-Straße 6-8 D-59302 Oelde
(0) 25 22 / 76 - 0 pp@hammelmann.de www.hammelmann-process.com
TAILOR-MADE RATED & FULLY INTEG
SAFETY
THE MECHANICS OF SECONDARY
DUST EXPLOSIONS Exploring the way secondary dust explosions develop and how to offset the process
I
ndustrial facilities ranging from chemical processing plants and grain elevators to pharmaceutical factories and advanced metalworking shops routinely handle materials that present severe fire and explosion hazards. While standard fire safety practices focus primarily on preventing thermal events and localised fires, the physics and dynamics of an industrial explosion are significantly more complex, rapid and destructive. An explosion is rarely a single, instantaneous event; rather, it is a rapid, multi-staged thermodynamic process that can evolve from a minor localised spark into an all-encompassing, facility-wide catastrophe.
THE GENESIS OF AN EXPLOSION: THE COMBUSTION FUNDAMENTALS
To understand how an explosion develops and escalates, one must look beyond the traditional fire triangle of fuel, oxygen and heat. In industrial settings, explosions require two additional elements, fuel dispersion and containment, completing what is commonly called the Explosion Pentagon. These five required elements are: FUEL: Flammable gases, volatile liquid vapors or mist, or combustible solid dusts. OXIDANT: Typically atmospheric oxygen, though other oxidising agents can suffice, but are less common. IGNITION SOURCE: Mechanical sparks, electrostatic discharge, hot surfaces, electric arcs or open flames,. DISPERSION: The fuel must be suspended and thoroughly mixed with the air to form a cloud.
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CONFINEMENT: An enclosure, vessel, pipe, or congested room that traps expanding gases. EXPLOSION PENTAGON PRINCIPLE: If any one of the five elements of the Explosion Pentagon is successfully removed or neutralised, an explosion cannot occur. While fire prevention targets the traditional three elements (fuel, oxygen, ignition), industrial explosion prevention and mitigation frequently focuses on eliminating dispersion (e.g. preventing dust clouds, limiting gas concentrations) and removing confinement (explosion venting). When a combustible fuel is suspended in air at a concentration within its lower and upper explosive limits (LEL and UEL) and encounters an ignition source, combustion begins. Initially, this combustion takes the form of a deflagration, which is the foundational phase of most accidental industrial explosions.
THE COMPOUNDING THREAT: SECONDARY DUST EXPLOSIONS
In facilities that handle combustible solid particulates such as sugar, grain, flour, plastics, wood, or light metals like aluminum and magnesium, the initial deflagration is frequently just the trigger for a far more devastating phenomenon: the secondary dust explosion. The anatomy of a secondary dust explosion follows a tragic, compounding sequence that regularly catches uneducated operators off guard. In many industrial facilities, daily operations generate ultrafine dust particles. If housekeeping is inadequate, this dust escapes
containment and gradually settles over time onto horizontal surfaces throughout the plant. It accumulates on overhead rafters, structural steel beams, light fixtures, cable trays, and the flat tops of heavy machinery. This settled dust is known as ‘fugitive dust’ and represents a massive, dormant fuel source spread across the facility. When a primary explosion occurs, which could be a small gas deflagration inside a piece of processing equipment, a mechanical bearing failure igniting a dust cloud inside a bucket elevator, or an electrical arc in an unrated enclosure, it creates two distinct physical waves: THE PRIMARY SHOCK/PRESSURE WAVE: A high-speed blast wave that travels outward from the epicentre of the primary explosion at the speed of sound. THE PRIMARY FLAME FRONT: A slower-moving thermal wave of combustion that trails behind the initial pressure wave. As the fast-moving primary pressure wave travels outward from the primary explosion, it shakes the structural elements of the building. This structural vibration dislodges the accumulated fugitive dust from the rafters, beams and equipment. As the dust falls due to gravity and is buffeted by the turbulent air currents, it becomes suspended and dispersed into the air, creating a dense, highly combustible dust cloud that spans a vast volume of the facility. Moments later, the slower-moving flame front arrives at this newly formed, facility-wide dust cloud. The flame ignites the dispersed dust, causing a massive secondary explosion. Because the secondary explosion involves a vastly larger volume of fuel distributed over a wider spatial area, the fireball generated is often orders of magnitude larger than the primary event. It is
SAFETY
Preventing the escalation of industrial explosions requires a comprehensive, multi-layered approach centered on the principles of inherent safety
almost always the secondary dust explosion, rather than the primary event, that causes total structural collapse, widespread fatalities, and the complete leveling of industrial complexes. Image 1: The beginning of an explosion
Image 2: A more advanced explosion
Image 3: An explosion that has the potential to be a structural event
ENGINEERING MITIGATIONS AND PROCESS SAFETY MANAGEMENT
Preventing the escalation of industrial explosions requires a comprehensive, multi-layered approach centered on the principles of inherent safety, rigorous engineering design, and active mitigation. To control dust hazards and prevent secondary explosions, facilities must enforce stringent housekeeping protocols using specialised, certified industrial explosion-proof vacuums rather than compressed air utility lines (which would inadvertently create a hazardous dust cloud). Furthermore, dust collection systems must be designed with effective containment and self-cleaning mechanisms to minimise fugitive emissions. Industrial explosions are highly dynamic, non-linear phenomena that scale rapidly from minor thermal ignitions to catastrophic, facility-wide structural events. The progression from a localised, subsonic deflagration to an all-encompassing secondary dust explosion highlights the dangerous nature of handling combustible materials in industrial settings. By fully understanding the mechanical triggers of the dispersal of fugitive dust by primary pressure waves, the industrial sector can implement robust engineering designs, rigorous housekeeping and explosion prevention systems to effectively neutralise these hazards before they culminate in disaster.
For more information visit: www.fike.com
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SAFETY
The IS945.x is made for environments that require consistency and dependabiiity
TOP TABLET
Jan Rieks Zonderman, product manager of automation from i.safe Mobile, explores how the right tablet can make every plant walk count
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rocess work demands more than rugged hardware, it requires a device that helps engineers move faster, stay focused, and keep information flowing without friction. The i.safe Mobile IS945.x is built to do exactly that. Instead of forcing users to adapt to a new mobile ecosystem, it brings the familiar Windows experience into the plant environment. That means less time learning, less time troubleshooting, and more time getting the job done.
BETTER MOBILITY
Many industrial teams already rely on Windows-based software for daily operations, maintenance, and compliance. With the IS945.x, users can bring that familiar environment directly into the field, making it easier to access the tools they already know and trust. The result is a smoother workflow from control room to plant floor. For end users, this translates into
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faster adoption, fewer interruptions, and a more intuitive way of working, according to the company. The device fits naturally into existing processes instead of creating new ones.
BUILT FOR THE PACE OF THE PLANT
A long shift in demanding conditions calls for a device that is dependable, and easy to carry. The IS945.x is designed to remain lightweight and efficient, helping reduce fatigue during inspections, maintenance rounds, and plant walkdowns. It supports productive work without adding unnecessary bulk or heat. That will make a real difference in daily use. When the device is easier to handle, workers can stay focused on the task instead of the technology.
CONFIDENCE IN CRITICAL ENVIRONMENTS
In hazardous industrial areas, reliability is not optional. The IS945.x
is made for environments where safety, stability, and consistency matter every day. Its long-term platform approach helps ensure a familiar user experience that remains dependable over time. This gives teams confidence in the field. They can rely on a device that supports their work without constant changes, re-learning, or disruption.
A PRODUCTIVITY TOOL
The IS945.x is more than a rugged tablet. It is a productivity tool that helps make industrial work simpler, smoother, and more efficient. By combining familiar software access with mobile usability and hazardousarea suitability, it helps users work with less friction and more confidence.
For more information visit: www.isafe-mobile.com
Come and visit us at: Solids Antwerp - Stand: 4323 Powtech - Hall 7 Booth 7-780
INSTRUMENTATION & ELECTRONICS
Open edge vision architectures decouple model development from runtime execution
OPEN EDGE OPTIMISATION
Decentralising the model training lifecycle will improve efficiency
An expert from LMI Technologies explores how to optimise industrial production lifecycles through open edge vision architectures
M
odern industrial automation increasingly depends on separating computationally intensive artificial intelligence development from deterministic, real-time execution on the factory floor. While artificial intelligence has significantly expanded machine vision capabilities, traditional deployments often introduce infrastructure complexity by relying on industrial PCs or centralised servers for inference. As manufacturers scale inspection across multiple production lines, these architectures become more costly to deploy and maintain. Open edge vision architectures address this challenge by decoupling model development from runtime execution, enabling manufacturers to optimise computing resources while maintaining fast, reliable inline inspection.
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DECENTRALISATING THE MODEL TRAINING LIFECYCLE
Training deep learning models requires substantial graphics processing unit resources to process large image datasets and perform iterative optimisation
Training deep learning models requires substantial graphics processing unit resources to process large image datasets and perform iterative optimisation. These workloads are best handled on engineering workstations, dedicated servers, or external hardware accelerators rather than active production equipment, where they can consume valuable processing resources and impact deterministic performance. Once trained and validated, neural networks can be exported directly to production hardware for deployment. This separation allows engineers to continuously improve inspection models without interrupting manufacturing operations. For organisations requiring greater flexibility, advanced smart vision
INSTRUMENTATION & ELECTRONICS
platforms can also provide sufficient onboard computing resources to train, refine, and deploy models directly at the edge when needed, reducing development cycles for localised applications.
development kits, middleware, or extensive scripting. This open workflow gives manufacturers greater flexibility to adopt evolving technologies while reducing deployment complexity and recurring software licensing costs.
OPEN ‘BRING YOUR OWN MODEL’ INTEGRATION INFERENCE OPTIMISED EDGE EXECUTION A major advancement in edge artificial intelligence is the emergence of open ‘bring your own model’ architectures. Instead of restricting manufacturers to proprietary development ecosystems, open platforms such as LMI Technologies’ GoPxL (version 1.6 and up) enable engineers to build datasets, label images, and train models using industry-standard tools such as Roboflow and Label Studio. Pre-trained models – including popular Ultralytics YOLO architectures – can then be imported directly into compatible smart vision devices through a standard browser interface. The embedded processor executes inference natively without requiring custom software
Production environments demand predictable, low-latency performance. Rather than dedicating edge hardware to model development, inference-optimised smart vision systems allocate their computing resources exclusively to executing trained neural networks in real time. Combining efficient multicore processors with dedicated acceleration enables continuous inline inspection with response times measured in milliseconds. Modern edge platforms also unify artificial intelligence and traditional machine vision tools within a single inspection pipeline. Geometric measurement, optical character recognition, barcode reading, and
anomaly detection can operate simultaneously without requiring separate software environments. This hybrid approach combines the repeatability of rules-based inspection with the adaptability of deep learning, improving accuracy while simplifying deployment. Deploying such a solution will result in a scalable inspection architecture capable of supporting applications across automotive manufacturing, electronics assembly, packaging, battery production, consumer goods inspection and more. By embracing open edge vision architectures, manufacturers can reduce infrastructure complexity, preserve development flexibility, and deploy inspection systems that scale efficiently from a single production cell to enterprise-wide manufacturing operations efficiency
For more information visit: www.lmi3d.com
Windows® Tablet
IS945.1
Bridging mobility with desktop-grade performance and enterprise integration in the field. Windows 11 IoT Enterprise LTSC – Long-term support until 2034 Enterprise security built-in – BitLocker, TPM, Windows Defender ATP Familiar environment – Accelerated deployment, reduced training costs Arm64 efficiency – 5G-enabled edge computing with AI (and minimal heat generation)
ISM_MA0339_260812
Maximum compatibility – Seamless integration into Windows infrastructure
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INSTRUMENTATION & ELECTRONICS
CLOCK
ON A CHIP How a new atomic clock will deliver precise timing for space systems
The device can offer shorter lead times and lower overall costs
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he New Space market is growing, as is the demand for related electronics including smaller, reduced cost hardware to support short duration missions for applications such as satellite-to-cellular communications, alternative navigation and Earth imaging. Microchip Technology has expanded its atomic clock portfolio with the radiation-tolerant Space CSACSA65, a Chip Scale Atomic Clock designed to deliver precise timing for space systems. The device provides a compact, low-power alternative to traditional radiation-hardened timing solutions, helping developers reduce size, weight, power and cost while maintaining accuracy. Building on the heritage of Microchip’s Space CSAC-SA45, the Space CSAC-SA65 extends radiation tolerance to at least 30 kRad and operates in extended temperature ranges from –40°C to +80°C. Consuming less than 120 mW and occupying less than 17 cc of volume, the device is optimised for size-, weight- and power-constrained satellite designs. Its built-in 1 PPS input and output capabilities support synchronisation for satellite systems, while its atomic stability
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enables extended operation without continuous reliance on external timing references such as Global Navigation Satellite System (GNSS) signals. “By enabling one of the lowest power atomic clocks to thrive in extreme conditions, even the smallest CubeSat can now fly with atomic accuracy,” said Randy Brudzinski, corporate vice president of Microchip’s frequency and time systems business unit. “The Space CSAC-SA65 brings atomicclock performance to applications where size, weight, power and cost are tightly constrained, helping developers maintain synchronisation and timing accuracy even when external timing references are unavailable.” Manufactured as a Commercial Off-The-Shelf (COTS) product using radiation-tolerant commercial electronic components, the device can offer shorter lead times and lower overall costs compared to traditional space-grade oscillators. Designed for Low Earth Orbit (LEO) missions, the CSAC-SA65 is well suited for applications including satellite timing and frequency control, satellite clock reference, assured positioning, navigation and timing (PNT), and satellite cross-linking. The clock might also be used in the following environments:
• Tactical military communications: Securing ultra-high-frequency (UHF) radio synchronisation and frequency hopping in environments where adversaries actively jam electronic signals. • GPS-denied navigation: Enabling precise dead-reckoning and assured positioning, navigation, and timing (PNT) for ground vehicles, aircraft, or infantry units operating underground, underwater, or under heavy electronic jamming. • Financial and telecom networks: Maintaining precise timing holdover for cellular base stations and highfrequency financial trading servers if primary GPS timing references drop out. • Unmanned and autonomous systems: Providing reliable, independent navigation clocks for drones and autonomous remote vehicles where external connectivity is unstable.
For more information visit: www.microchip.com
INSTRUMENTATION & ELECTRONICS
Minimise Risk, Maximise Uptime, DRIVE EFFICIENCY Subsea, Topside & Hybrid Valve Solutions J B Valves Ltd Majestic House, 29 Green Street, Huddersfield, West Yorkshire, HD1 5DQ, United Kingdom www.jbv.co.uk - enquiries@jbv.co.uk - Tel: +44 1484 509 888 - Registered in England No. 8994615
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RECYCLING
Figure 1: Materials in the recycling process can contain a significant proportion of fines. Copyright © 2026 Martin Engineering
DUST CONTROL The second part of a guide to dust control in materials recycling by Oliver Kampfer from Martin Engineering
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ecycling is now firmly at the heart of the raw material supply chain, especially across Europe where companies specialising in materials management – commercial wastes, industrial byproducts, metals, electronics, biomass, cardboard, paper and plastics – are maximising the value of their feedstocks, while simultaneously improving production efficiency. Within these waste streams, fine materials can account for a substantial share of the total output, necessitating measures to control and contain spillage and emissions for engineers and managers. Difficult and costly to dispose of, fine particulates can also cause problems throughout materials-processing operations. [Fig.1] In this, the second of a series of two articles exploring dust control in materials recycling, Oliver Kampfer from Martin Engineering provides several solutions for controlling dust in recycling (the first article, published in June, looked at how problematic dust is created).
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SKIRT AROUND THE SUBJECT
The length of a conveyor belt loading zone is ley to managing dust, and the entire enclosure needs to be wellsealed with belt skirting. • Single skirting should be cut to match the belt’s trough angle for a tighter seal. The best designs can be mounted externally for easy and safe adjustment. • Dual skirting is an engineered design that incorporates a primary and secondary seal, providing an additional layer of protection against spillage and fugitive dust. Dual skirting is available in urethane and rubber. • Self-adjusting skirting systems use gravity to apply light downward pressure, minimizing maintenance needs and making them the right solution in some situations. [Fig.2]
CRADLING THE IMPACT The weight of material landing onto a conveyor can cause the belt to sag between the skirting and idlers. The efficiency and performance of a
transfer point can be greatly improved by installing cradle support beneath the belt. Impact cradles absorb the force of falling material to prevent damage to the belt and structure. The shock-absorbing bars help seal the environment and mitigate spillage. In addition, fitted under the belt, slider cradles with abrasion-resistant polyurethane bars retain the seal along the entire length of the skirtboard, producing an air-tight settling zone.
CURTAIN CALL
After the initial impact, turbulent air can be stabilised by extending the transfer chute enclosure along a specified length of the conveyor, providing more space for larger particulates to drop back onto the belt. While some airflow will still be present, the key is to slow it to under 1 meter/second (m/s) (approximately 200 feet per minute), slow enough for particulates to settle. Adding a tail panel and dust curtains is essential for slowing airflow but simply adding them at the ends does not necessarily create the proper stilling environment.
RECYCLING
Understanding the air flow and then strategic curtain placement is the key to increasing the length of travel for the dust particles giving them more time to agglomerate and settle onto the belt. Chutes that are properly sealed and retrofitted with three curtain zones recirculate the airflow and allow dust to settle. Field tests show a drastic reduction in emissions of both nuisance and respirable dust with the correct curtain set-up.
DISCHARGE DEBRIS
Fugitive material at the discharge zone can also be problematic. Carryback from inadequate belt cleaning can lead to spillage and cause airborne material along the entire length of the belt return. Besides the build-up of material beneath the system, conveyors exposed to wind and weather can spread fugitive dust across a wider area. To prevent carryback the optimum cleaning solution requires technologies that reduce the need for regular maintenance and inspection help to prevent unscheduled downtime. When it comes to the types of materials being recycled, leading manufacturers of belt cleaners have devised durable solutions capable of cleaning belts from the most abrasive, corrosive, acidic, or liquid substances without damaging the belt. [Fig.3]
Figure 2: Skirting is the only solution to ensure a well-sealed loading zone, whilst a series of dust curtains act as a brake to slow air speed. Copyright © 2026 Martin Engineering
CONCLUSION
The diversity of waste feedstocks and the processes of crushing, shredding, and grinding invariably generate large quantities of particulates, which can easily become airborne if not tightly controlled. While conveyor transfer points are not the only source of dust, they are among the most prevalent generators of particulate emissions. Dust is one of the fastest-growing industrial health issues, and solutions to control it are available. Beyond health and safety, eliminating airborne dust delivers numerous benefits, including better housekeeping, improved environmental management, less maintenance, process efficiency, greater productivity and whole-life cost reduction.
For more information visit: www.martin-eng.com
Figure 3: Keeping conveyors clean is vital to prevent fugitive material from being carried back along the return side of the belt. Copyright © 2026 Martin Engineering
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SKILLS AND TRAINING
Johanna Abrahamsson says: “As a woman I bring a different perspective to my engineering team”
A WOMAN IN STEM A recent graduate and product developer for Assa Abbloy Johanna Abrahamsson explains how a love of problem-solving led to a career in engineering and sustainability
T
he annual International Women in Engineering Day (INWED#26), which took place in June, is a global celebration of women engineers - past, present and future. In this article, a recent graduate, Johanna Abrahamsson explains how a childhood love of building things has unlocked a career designing everyday products. She says: “When people think about engineering, they often picture technical drawings, calculations and manufacturing assembly lines. What attracted me was much simpler. I like building things and I like solving problems.
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Today, I work in product development at Assa Abloy, a global leader in access solutions. I’m based in Eskilstuna, about an hour and a half’s drive west of Stockholm. This is the company’s key production hub. “This is our innovation centre and its where I work on products that combine usability, safety, and design in ways most people never even notice. “When you think about it, these products, including handles, escutcheons, and lock cases are everywhere, in every country. Most people never give them a second thought, but we all use them all the time.”
GOOD DESIGN SHOULD FEEL SEAMLESS
“I think that’s a key part of what makes good design – the interaction with an object is so seamless that you don’t register using it. Of course, getting a product to that stage takes a lot of work. “My master’s thesis focused on improving the user experience of smart locks, specifically around inclusive design on physical keypads. As well as examining common usability issues, we also made sustainability a key part of the process. “Obviously, environmental sustainability means using green and recycled materials where possible,
SKILLS AND TRAINING
as well as designing products to be modular so they can be easily repaired rather than replaced. “But for me, as a product developer, design is as much about social sustainability – designing products that are easy and ergonomic to assemble in production, while also ensuring they are inclusive and accessible for end users.”
DESIGNING PRODUCTS FOR LIFE
“In my role with Assa Abloy, I focus heavily on testing and verification, especially in terms of meeting compliance and security standards. I’m also fascinated by ergonomics, however. “For example, if something is springloaded and too hard to push or turn, it might pose a security risk making it difficult for senior citizens to open their windows, for example. “Working for a company like Assa Abloy has really opened my eyes to what’s possible in terms of a career. “There’s a real focus on young talent, exciting projects, inclusivity, and design. What’s more, I have people on hand to provide support throughout my journey.
“Not only am I the only woman on the team, but I’m also the youngest. I know that engineering is still a maledominated industry, but things are changing for women in the industry.”
BRINGING A FRESH PERSPECTIVE TO AN ENGINEERING TEAM
“As a woman and young person, I bring a different perspective to my team. I’m collaborative and competent and I have knowledge of new areas, such as artificial intelligence (AI). “My advice to anyone considering a role in engineering is this: If you like hands-on work, product development, and design, then you should certainly consider the profession. “Engineering is immensely rewarding. You can work across a variety of areas and disciplines and the skills gained will open many personal and professional doors.“
For more information visit: www.inwed.org.uk
Consultancy Services and Short Courses for Process Engineers
My advice to anyone considering a role in engineering is this: If you like hands-on work, product development, and design, then you should certainly consider the profession
Pneumatic Conveying......System or Equipment Design...... Characterisation of Materials....Discharge from Hoppers and Silos.... Plant Wear....Storage of Bulk Materials.......Particle Breakage...Additive Manufacturing...Caking, Segregation or Degradation of Materials...Powder Flow...Expert Witness Services
SHORT COURSES CAN BE DELIVERED AT OUR PREMISES, ON SITE, ONLINE OR IN THE FORM OF A WORKSHOP Consultancy services begin with a Teams call at no cost. Contact us with your bulk materials handling problem. Contact the Wolfson Centre experts wolfson-enquiries@gre.ac.uk +44 20 8331 8646 www.bulksolids.com
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SKILLS AND TRAINING
BULK MATERIAL BEHAVIOUR Why a material’s unique properties need to be given thorough consideration
Fig 1: A ‘rat hole’ flow stoppage inside a hopper
M
any industrial processes are formed from assemblies of ‘standard’ equipment types that offer an economical route to obtaining a functional production system. Invariably, the specifications that are drawn up, and against which equipment is supplied, are stringent in the process requirements that must be met. The definition of feed rates, operating pressures and spatial constraints are well within the capabilities of plant engineers to distil into a well written set of requirements. However, the properties of the powders or granular materials that will be handled through such a plant are seldom given the thorough consideration that they are due, and as a result references to material properties range from sparse to virtually non-existent in many sets of documentation against which, in many cases, considerable expenditure is planned or undertaken. The usual result is an element of a plant that can only achieve its planned level of
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efficiency with a certain sub-group of bulk materials out of the full range handled on site. Bottle necks formed in the process by these situations are known to lead to significant direct losses to the bottom line of the plant’s profitability (Fig 1). The financial or contractual losses that are often incurred are typically many magnitudes higher than the initial investment or resources required to adequately define the storage and handling behaviour of bulk materials in either raw material or final blend forms.
FLOWABILITY
One of the most useful measurements for many types of process operation is that of the flowability of powders or granular materials. If the flow behaviour of a range of materials or material conditions can be determined at the design stage of a project, then the construction of vessels utilising this information can deliver equipment that will not only operate without flow irregularities or stoppages, but
Fig 2: Determining flow behaviour is key to successful equipment design
will also have the capability to reduce segregation effects. The importance of characterisation tests for bulk materials that will be used in new build or upgraded processes cannot be over emphasised. Using this information, a reliable and consistent process operation can be achieved without the need for manual intervention.
For more information visit: www.bulksolids.com
SKILLS AND TRAINING
PRIORITISING TECHNICAL EDUCATION
I
n this abbreviated article, James Sopwith a director from engineering firm Adi Group, argues that the government’s commitment to placing technical education on an equal footing with academic learning is an important and overdue step. He said: “At Adi Group, we have been delivering technical education to 14 to 16-year-olds since 2016 through our Pre-Apprentice Programme, first run in partnership with King Edward VI school and later with King’s Norton School for Boys in Birmingham. “Year 10 and 11 pupils attend our Birmingham headquarters for half a day a week alongside their GCSE studies. They work in a genuine engineering environment, learn from experienced professionals and complete an Engineering and Manufacturing Technologies qualification accredited by Excellence, Achievement and Learning Ltd, better known as EAL. “The programme gives students the chance to understand what
Sopwith welcomes the government’s commitment to technical education
engineering involves and learn handson before they make major decisions about their futures.”
For more information visit: www.adiltd.co.uk
TRAINING LIVE ONLINE ON-DEMAND FACE-TO-FACE IN-COMPANY
Supporting professional development Whether you have competency gaps to close on the path to becoming a Chartered Member, want to maintain and enhance your skills to meet new challenges, or are supporting a team with their skills development, IChemE has training to help.
www.icheme.org/training-calendar
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SHOW PREVIEW
A
POWTECH TECHNOPHARM
leading biennial international trade exhibition, Powtech Technopharm, is dedicated to technologies for processing powders, granules, bulk solids, fluids, and liquids. The show will take place between September 29 and October 1, 2026 at the massive NürnbergMesse GmbH exhibition centre in Nuremberg, Germany. Powtech Technopharm showcases mechanical, thermal, and analytical processing technologies including practical machinery for crushing, sieving, mixing, conveying, dosing, and granulation, among other things. Originally launched in Nuremberg in 1984 as ‘Powtech’ the exhibition spent
decades specialising in mechanical process engineering for solids and bulk materials. However the recent convergence of manufacturing disciplines has seen the event undergo some major structural changes.
RECENT CHANGES TO THE SHOW
Perhaps the most notable are its recent rebranding into Powtech Technopharm and a significant expansion of its footprint, moving from a narrow focus on dry solids to a framework that handles liquids, pastes, and complex fluids. Crucially, this added an entirely new dimension centered on GxP-compliant pharmaceutical production ranging
from cleanroom environments to the manufacturing of sterile liquid, solid, and semi-solid medications. To accommodate this influx of sectors, the show has physically expanded into new exhibition halls across the Nuremberg grounds.
CORE THEMES AND HIGHLIGHTS
The trade show revolves around several thematic pillars: • Pharma & life sciences processing: Will take place at the Pharma-inFocus Pavilion, this theme dives deep into biotechnology, aseptic filling, and the regulatory demands of drug manufacturing. • The circular economy and sustainable manufacturing: Could can find this in the Recycling-in-Focus Pavilion. Exhibitors will demonstrate green processing technologies, material flow optimisation, and energy-efficient plant operations. • Smart industry and digitisation: Seminar sessions will look at the transition into Industry 4.0, featuring AI-assisted machine diagnosis and digitalised process management. • Industrial safety: A major crowdpleaser will be the Index Explosion Safety Forum, featuring highly practical, live demonstrations of dust explosions performed on the exhibition grounds.
THE SHOW IN NUMBERS Powtech Technopharm showcases mechanical, thermal, and analytical processing technologies
The event typically draws roughly 10,000 delegates. However, when co-located with the FACHPACK packaging expo, the combined venue footprint draws upward of 72,000 industry professionals. Between 37% and 40% of delegates travel from outside Germany, meaning most attendees are from the host country. Other nationalities that are likely to attend include Italians, Dutch, British and Austrians.
For more information visit: www.powtech-technopharm.com
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YOUR GUIDE TO DISTRIBUTORS, SUPPLIERS AND MANUFACTURERS IN THE INDUSTRY
APEC
Gas Clip Technologies
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.
Gas Clip Technologies provides a comprehensive range of gas detection solutions engineered to protect personnel in the most demanding environments worldwide, including oil and gas, chemical processing, manufacturing, and other high-risk sectors.
GKT GKT is a globally active Austrian systems partner for thermal separation and environmental technologies, specializing in evaporation, distillation, drying, CO₂ valorization, waste heat recovery, and IIoT-enabled process optimization. T +43 2662 42780
T +1 (616) 374-1000
E office@gkt-solutions.com
E terrys@apecusa.com
E sales@gascliptech.com
W www.apecusa.com
W www.gascliptech.com
W gkt-solutions.com
HILLIARD
LabFacility
Rotork
Hilliard offers a diversified product line for industrial applications in a wide variety of industries. Hilliard products are designed, manufactured and sold according to our customers’ applications.
The UK’s leading ISO 9001-accredited manufacturer and supplier for the complete temperature chain. From Temperature Sensors, Thermocouple Connectors and Cabling to supporting instrumentation and components, we are the GO-TO people.
A market-leading global provider of mission-critical flow control and instrumentation solutions for oil and gas, water and wastewater, power, chemical, process and industrial applications.
T +1 607 733 7121
T +44 (0) 1243 871280
T +44 (0) 1225 733200
E sales@hilliardcorp.com
E Sales@labfacility.com
E mail@rotork.com
W www.hilliardcorp.com
W www.labfacility.com
W www.rotork.com
Starlinger & Co Gesellschaft m.b.H
Unifire AB
Greenwich University Wolfson Centre
Sustainability in the bag: From polypropylene tape production to the woven plastic bag back to recycled plastics for packaging production – Austrian machinery manufacturer Starlinger offers the technology to close the loop for plastic packaging. W www.starlinger.com/en
Unifire AB is a Swedish manufacturer of fully autonomous robotic fire suppression systems and advanced robotic nozzles, protecting high-risk facilities worldwide – from waste plants and warehouses to aircraft hangars, ships and industrial sites.
Providing cost-effective solutions to industrial problems: Consultancy services and training for industries that handle powder or granular materials as part of their processes. T +44 20 8331 8646
E contact@unifire.com
E wolfson-enquiries@gre.ac.uk
W unifire.com
W www.bulksolids.com
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SHOW PREVIEW
PPMA 2026
T
he PPMA Show 2026 will take place between 22 and 24 September at the NEC in Birmingham. The organisers expect to welcome over 350 exhibitors and 7,500 delegates and the show will feature the latest innovations in liquid, solid, and powder handling, with a view to ensuring strict hygienic compliance, and boosting efficiency. The show will also feature live machinery demonstrations of packaging lines, coding equipment
and inspection systems. A robotics and automation section will allow delegates to explore high-speed sorting, articulated arms, and cabinet-free automation architecture from the trade flow floor. Industrial vision systems will include state of the art optical verification and quality control technology. Finally there will be a sustainability and materials section allowing delegates to review eco-friendly containers, recyclable pouches, and waste-reducing printing technologies.
PPMA will teature live machinery demonstrations of packaging lines, coding equipment and inspection systems
KEY FEATURES AND HIGHLIGHTS
• Expert-led seminars: Visitors will receive insights on smart manufacturing, operational efficiency, and overcoming labour or regulatory pressures. • Keynote speakers: Industry leaders and guest speakers pepper the seminar programme and include former Dyson CEO Martin McCourt. • Digital tools: Delegates will be encouraged to use the official PPMA show website and mobile app features like SmartScan to plan their visit and network with exhibitors. The seminar programme will run in the newly revamped Seminar Theatre. The programme aims to deliver “actionable, non-promotional educational insights,” according to the organisers. Sessions focus heavily on solving modern production challenges like rising costs, labour shortages, and evolving sustainability regulations. All sessions run for 30 minutes, including a dedicated 5 to 10-minute slot for audience Q&As. Digital networking tools include the PPMA Matchmaker: A digital tool that generates a personalised list of suppliers based on specific manufacturing challenges, allowing them to pre-book meetings before the show starts. They also include the Smartscan and ContentCapture: Integrated into the official PPMA Show App, these tools let delegates scan QR codes at stands to instantly exchange contact info. The event is owned and organised by Automate UK (formerly known as the PPMA Group of Associations). It is a leading trade association for automation suppliers and those working in manufacturing technology. The organisation operates as an umbrella body representing several member associations.
For more information visit: www.ppma.org.uk
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International Exhibition for Process Operations
YOUR DESTINATION FOR PROCESSING TECHNOLOGY. 29.9. – 1.1O.2O26 | NÜRNBERG, GERMANY Erleben Sie hautnah die neuesten Trends und Technologien für die Verarbeitung von Pulvern, Feststoffen und Flüssigkeiten! Nutzen Sie das branchenübergreifende Know-how und Netzwerk für Ihren Geschäftserfolg. Hier gestalten Branchenprofis gemeinsam die Zukunft.
powtech-technopharm.com
Ideelle Träger
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DECODING
DENSITY The importance of density measurement for process applications
MANAGING MATERIALS
IT AND OT INTEGRATION
How material properties impact feeding system performance
How integrating performance stacks improves system safety
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ON THE
FRONT FOOT A UK-based company’s mission to make factories sentient
HOW AUTOMATION IS REWRITING THE RULES
THE IMPORTANCE OF INFRASTRUCTURE
A focus on the sorting industry’s AI-driven transformation
Why infrastructure has become an enabler of electrification
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Index to advertisers
66
GKT
15
LAB FACILITY
29
Gas Clip Technologies
IBC
LMI Technologies
55
Hägglunds
OBC
MCT Brattberg
27
Hammelmann
47
OPSIS
25
HILCO Filtration
19
POWTECH Technopharm
65
APEC
IFC
IChemE
66
SealRyt
29
Daily Thermetrics
31
i.safe Mobile
53
STUVEX
5
ECO PHYSICS
15
JB Valves
55
The Wolfson Centre
59
Fike
51
KROHNE
39
Watlow
43
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Confidence Starts Before the Shift Begins
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That’s more than a sound you hear. It’s expectations being shaken. One small change that sets the stage for so much more. When the new Hägglunds Thunder resonates with your needs, the result is electrifying. Learn what a difference a single difference can make at www.hagglunds.com.
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