The process industry, like every other manufacturing sector, is knee deep in ‘industry 4.0’ or smart manufacturing technology. The term 'industry 4.0' can be used to describe the use made of a digital infrastructure (including IoT sensors) to improve productivity, flexibility and agility. There is now ample data available to plant managers, but the big question is, what should they do with it? The cover story Augmented Factory (on page 8) looks at how one interesting augmented reality tool transforms raw data into safety advice, inventory information, operator instructions and other guides. It even promises to help with a shortage of skilled engineers, according to the manufacturer. Many operators are moving towards plant electrification in a bid to phase out fossil fuel. However, unexpected downtime is a key worry since electric grids can be temperamental and increased demand may exacerbate this. Meeting your energy needs (page 8) looks at technology from Watlow that can ensure the process runs smoothly and that supply and demand of electricity are not out of sync. As usual the magazine covers a number of verticals, with food and drink featuring heavily. One global producer has significantly reduced emissions at a Polish plant by installing a Bosch steam boiler (page 17); another manufacturer Domino is at the forefront of label-less printing (page 28). Finally, technology company Atlas Copco is working hard to support beer manufacturers and their customers to produce a good tasting product with a little less froth (page 32).
Nicola Brittain Editor
Alleviating leaks
Optimising leak testing of coffee packaging 28
Bottle closure
A solution to support label-less printing 30 Natural aroma
Improving the taste of non-alcoholic beer
32 Reduce the froth
Reducing foam in the beer-filling process
33 A solvent business
A green expansion in solvent recovery
36 Durability compared The benefits of a pump system versus new pipes SAFETY IN THE PLANT 38 Digitising food safety A guide to digitalisation in
PUBLISHER
Jerry Ramsdale
EDITOR
Nicola Brittain nbrittain@setform.com
DESIGN
Dan Bennett, Jill Harris
GROUP HEAD OF MARKETING
Shona Hayes shayes@setform.com
HEAD OF PRODUCTION
Christine Flaxman +44 (0)207 062 2573
BUSINESS MANAGER
John Abey +44 (0)207 062 2559
SALES MANAGER
Darren Ringer +44 (0)207 062 2566
ADVERTISEMENT EXECUTIVES
Paul Maher, Iain Fletcher, Peter King, Adam Croft, Marina Grant Setform Limited, 6, Brownlow Mews, London, WC1N 2LD, United Kingdom
+44 (0)207 253 2545
injection moulding solves industry problems
A 'must attend' show for filtration professionals
Setform’s international magazine for engineers is published quarterly and distributed to senior engineers throughout the world. Other titles in the company portfolio focus on Oil & Gas, Design, Transport, Mining, Energy and Power.
AR technology promises to revolutionise factory processes
HIGH PRECISION VALVES
Global technology giant Emerson has launched the Aventics Series 625 proportional pressure control valves. With a control deviation of less than 0.5%, the new valves are designed to deliver highly accurate, electronic proportional pressure control and provide the flexibility needed to support sophisticated pneumatic control engineering applications.
DATA ACQUISITION SOFTWARE
Data acquisition software (DaS) included with Series 625 Sentronic valves also make it possible to quickly startup, monitor and control valves directly on a PC. “In high-precision equipment, such as that used for flame cutting and laser eye surgery, accuracy and control are critical,” says director of product management for Emerson’s discrete automation business Nicolas Jacquet. “Series 625 Sentronic valves are engineered to precisely control pressure, flow rate, power, speed, distance and angular positions.”
As part of the extensive Aventics portfolio of cylinders, valves, air preparation and pressure regulators, the Series 625 Sentronic is a core technology for factory automation.”
VALVE SPECIFICATIONS
Four valve sizes from 1mm up to 20mm support a comprehensive range of flow rates, from 55 litres per minute to 4,700 l/min. Pressure capabilities range from vacuum levels up to 50 bar, which can reduce the overall number of valves required for a machine design. Housing material is available in brass, aluminium or stainless steel and sealing material is available in nitrile (NBR) or fluoroelastomer (FKM). There are also three sets of connectors, M12 5-pin, M12 8-pin and M16 7-pin.
A
new control valve series comes with PC monitoring and
control capabilities
Series 625 Sentronic valves are engineered to precisely control pressure
As development and manufacturing phases get shorter, fast startup procedures and reliable, controllable manufacturing processes are more important. Using the DaS software, operators can diagnose, control, repair or individually configure valves. They can also perform cascade controls when applications require exceptional precision and other complex control
loops. The expanded range of diagnostic and monitoring functions include input pressure, commanded pressure, internal temperature and ethernet communication.
VD810 Compact Vacuum Meter
On the road to the future.
§ Chemically resistant ceramic sensor
§ Measurement range Absolute pressure 2000 to 1mbar and relative pressure -1060 to +1200 mbar
§ Big data logger for saving measurement series
§ Graphic display with intuitive menu-driven operation
§ USB-C interface and Bluetooth® LE
§ Integrated battery with long performance
MEETING YOUR ENERGY NEEDS
Guillaume Braillard from Watlow discusses how to strike a balance between demand flexibility and supply availability when electrifying a process plant
Questions around electrification are more practical than they once were. For example, one of the first questions asked at the start of an electrification project is whether the local utility grid can handle an increased load. This is not simply a question of power availability, but of balancing power demand and supply.
WILL A GRID MEET A PLANT’S ENERGY NEEDS?
This question is trickier than it first appears because the amount of power supplied by the grid, and the amount of power demanded by the process in question, fluctuate over
time. Issues arise not because the equipment exceeds the grid’s capacity, but because when multiple pieces of equipment run at peak capacity, it passes a threshold at a time when the grid cannot adequately support the demand.
The increasing loads that electrification projects place on the grid have spurred the call for better demand flexibility. On one hand, utility companies can take a much more moderate approach when it comes to adding generation capacity or making expensive upgrades to the grid. On the other hand, facilities reap the benefits of better cost control and more indepth data analysis.
This win-win scenario assumes
that plants are willing to invest in the kind of power control necessary to implement demand flexibility across processes, and throughout the plant as a whole. Specifically, it requires using modern power controllers that have Predictive Load Management (PLM) capabilities across a network.
ADVANCED POWER CONTROL
PLM is one of the key technologies for demand flexibility in process power control and consists of two main functions, load balancing (or load sharing) and load shedding. Load balancing involves equally distributing power of different loads to obtain an overall power consumption that is
The true benefit of PLM can be seen when multiple machines and in use and multiple controllers are connected across a network
as stable and balanced as possible, eliminating instantaneous peaks and as a result ‘smoothing out’ the power consumption curve. Load shedding involves limiting and shifting the overall energy consumption altogether, or within user-defined priorities.
PLM is a feature of many of the SCR power controllers that Watlow manufactures. At the level of a single machine or device, a power controller with PLM can allow an operator to set a power threshold to ensure that the process will never draw power over that threshold. But the true benefit of PLM can be seen when multiple machines are in use and multiple controllers are connected in a network. Then, PLM-equipped controllers can uniformly distribute power loads, ensuring that at any given moment, the overall power is as stable and balanced as possible.
A PLANT’S PROCESS LINES
Take for example, a plant that has ten process lines, each of which has
a thermal array that draws power. Any individual machine has a power draw limit of 200 kw. However, the plant will receive some hefty charges from the utility company if it exceeds 1,000 kw during its peak period. Without any sort of networking or demand management, in the worstcase scenario, all ten lines could run simultaneously and draw peak power. To be safe, each machine would need to be limited to 100 kw.
MANAGING DEMAND AT THE PLANT LEVEL
Alternatively, consider an additional power controller with PLM attached to a network of devices. The controller can set an overall network threshold, which in this case is over 1,000 kw. Now, the individual controllers will synchronise and communicate, providing a level of demand management at the plant level.
Without this kind of network capability, engineers are forced to make very cautious and conservative guesses as to what the peak power
demands of each machine is separately, and this can effectively limit what the plant is capable of overall. But with networking, it is possible to measure power supply and demand dynamically, allocating power in the most efficient way possible. This helps to achieve the demand flexibility needed, resolving the issue of whether the grid can sustain electrification without decreasing throughput or creating downtime.
Electrification is not as simple as replacing fossil fuels with electric alternatives. In fact, the electrification of processes and process heating requires a change in power management. The issue is not just about power availability, it’s also about finding a balance between power demands and supply availability to enable a smooth transition.
Watlow’s ASPYRE group of SCR power controllers
NEW BEARINGS FOR ROBOTS
A high performance bearing will prevent emission of particles such as grease and oil
Bearings play an important role in maintaining the good function of servomotors.
A servomotor is a piece of equipment that decodes a control signal to ensure that a motor output shaft is in the right position. In short, it is used to drive a machine’s joints, and these are particularly common in industrial robots.
Bearings specialist NSK has launched a high-performance bearing for servomotors that reduces the emission of particles such as grease and oil.
OVERCOMING THE ISSUE OF EMISSIONS
To identify a potential way of overcoming the issue of particle emissions from bearings, NSK undertook research into the mechanism behind this long-standing industry problem.
Alongside the implementation of a higher-precision evaluation and test machine with a configuration and environment similar to an actual servomotor, the company was able to design an entirely new bearing structure featuring advanced design elements.
Using its experience in tribology (controlling friction and wear via lubricants and material surfaces), NSK succeeded in developing a bearing with new grease and seal technology that offers twice the low-particle-emission performance of conventional products. The grease also provides double the conventional lifespan, while the rubber seal delivers lower torque, particularly useful for servometers.
The bearing has been designed for use inside robot joint servometers
The new NSK grease restrains evaporation in high-temperature environments such as servomotors
THE TRANSITION TO MANUAL ROBOTS
With many countries facing a shrinking labour pool, the market for industrial robots continues to grow. However, robots require high levels of reliability if they are to transition from manual to automated operations. Robot reliability is beholden to its major components. A typical articulated arm robot, for example, might feature up to six servomotors to facilitate robot positioning and speed in its various axes. Each servomotor houses two bearings: a load-side bearing supporting the shaft where it exits the servomotor; and a counter loadside bearing located between the brake disc and encoder disc.
HIGH TEMPERATURE ENVIRONMENTS
In high-temperature environments such as servomotors, bearings tend to scatter tiny particles of grease and oil as they rotate. These emissions
stick to the discs and cause issues such as encoder read errors and brake slippage. The need for bearings with low particle-emission performance is clear in applications of this type, which is why NSK set about developing antiscatter grease and seals that provide a high level of hermeticity.
The new NSK grease restrains evaporation in high-temperature environments such as servomotors and uses thermally resistant components to ensure low particle emissions and better resistance to seizing. NSK’s new rubber seal features a redesigned lip shape that again supports low particle emissions as well as 10% lower torque.
NSK’s new bearing is also suitable for other products that require low-particle-emission performance, contributing to stable operation in a wide range of industrial machinery.
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
(0) 25 22 / 76 - 0 pp@hammelmann.de
D-59302 Oelde www.hammelmann-process.com
Renquip flange spreader weighs just five kilograms
A PERFECT SPREAD
A new flange spreading wedge will help with a wide range of applications
Hydraulic and mechanical equipment supplier Renquip has launched the Viper-28, a flange spreading wedge that, it argues, sets a new benchmark for the global flange tool market. Flange spreaders are tools used in industrial operations to safely and efficiently separate flange joints. These tools help to create a necessary gap between flanges to facilitate maintenance, inspection, repair, or replacement of equipment.
SPREADING FORCE
The Viper-28 is a powerful
flange spreader, boasting a spreading force of 28 tonnes and a precision tip measuring just 5 millimetres. This tool can be used with a wide range of applications for flanged joint maintenance, installation, and commissioning.
A LIGHTWEIGHT DESIGN
Despite its power, the Viper-28 weighs only five kilograms, combining lightweight design with strength. Its single-pin mechanism means the tool can be disassembled by hand for easy maintenance. The Viper-28 is durable, has undergone extensive field trials and been rigorously tested for endurance and overload.
Marc Gerrard, managing director of Renquip, says of the company: “our team has dedicated thousands of hours of engineering, design, and testing to the product. The launch of the Viper-28 represents our commitment to innovation.”
ESG PRINCIPLES
The Viper-28 aligns with Environmental, Social, and
Governance (ESG) principles and is designed to assist in flange maintenance and prevent leakages. It is easy to transport and has a long operational life. Additionally, it can run on biodegradable oil for environmentally conscious applications. The tool’s certification and regulatory compliance highlights “Renquip’s dedication to safety and sustainability”, according to Gerrard.
AN EXPANDING INTERNATIONAL FOOTPRINT
Renquip is expanding its international footprint through key distributors, as well as experiencing growth and capturing an increasing share in both local and international markets. Despite being a relatively young company, Renquip recently invested over £1m in stock and secured distributorships for well known UK brands such as Norbar, Atlas Copco, Festec, and Climax H&S Tool.
The company employs a team with a proven track record and a reputation for being experienced, reliable, and professional, according to the company
The
The Renquip flange spreader has a spreading force of 28 tonnes
Precision Craf ted Performance
The Future of Nonwoven Filtration
AUGMENTED FACTORIES
New AR software will help process engineers with commissioning, maintenance, inventory and more, as Nicola Brittain discovers
SARA can help staff operate LiDAR devices in factories
AR uses IoT sensors and computer vision to overlay the real world with digital information
Augmented reality was the stuff of science fiction for decades – The Terminator had visual access to swathes of data, as did the cyborgs in Bladerunner 2049. Augmented (AR) tools in the process and manufacturing industry now very much resemble these early sci-fi representations.
AR technology relies on IoT sensors and computer vision to overlay the real world with digital information, thereby enhancing the viewer’s perception of their surroundings. Now that so many elements of a factory
infrastructure contain IoT sensors, AR is fast becoming the next step towards digitalising industry.
The World Economic Forum issued a white paper in 2022 that identified the manufacturer’s relationship with technology as one that had moved on from automation to augmenting the capabilities of the workforce. Similarly Gartner, in its group outlook for 2024, identified the ‘augmented connected workforce’ as one of ten key strategic trends of note.
AR is just one element of the digital revolution (along with robotics, automation and more) that will help
factory operators and engineers streamline their processes.
SICK’S MOVE INTO AR
Germany-headquartered technology company SICK recently launched an augmented reality assistant called SARA (the SICK Augmented Reality Assistant) that it expects to be particularly useful for process engineers and manufacturing plant operators. Originally a hardware manufacturer, the company moved into sensors then digitalisation, and now AR, as digital solutions consultant for SICK Charlie Walker explains.
SARA EXPLAINED
SARA is the company’s first augmented reality tool. It is a programmable software package that retrieves data from sensors or PLC gateways and presents it to operators in a readable format. The sensor might be a Siemens PLC, a Rockwell PLC or an app detailing weather channel information for example.
All factories or warehouses now contain intelligent sensors systems and analysers that provide raw data to gateways. This data is converted to smart information via the cloud and on premises digital solutions.
As Walker explains, “getting data is no longer an issue, it’s how best to use it that has many engineers and operators thinking.”
And SICK’s engineers and operators thought very hard about how make factory data available to its customers.
As such, the SARA engine converts raw data into the standard OASIS IoT MQTT format which Walker describes as “a very manageable protocol” then provides information where it’s needed via tablets and smart phones as long as they have an Android or Apple operating system and camera.
A DEVICE AGNOSTIC TOOL
Walker makes it very clear that the data doesn’t need to come from IoTenabled SICK devices, “although of course it can,” he says.
Once installed, an operator will use their device to view information related to a factory’s IoT connected inventory (pipes, robots, valves or stock) via diagnostic information that will appear as lines, arrows
and labelled lines; a 3D point cloud; warning triangles; images; cubic volumes; or hyperlinks to sites and documents.
Technicians will be immediately alerted to any issues within their plant or factory as well as what is causing them via an easy-to-read display.
Walker argues that the provision of data in a real environment will lead to reduced downtime and make equipment more available leading to cost savings. “The service will also provide a better understanding of the machines and general infrastructure,” he explains.
THE MQTT FORMAT EXPLAINED
MQTT is an OASIS standard messaging protocol for IoT-connected devices. A deliberately lightweight publish/subscribe messaging transport system, it is ideal for connecting remote devices with a small code footprint and minimal network bandwidth. MQTT is used in a variety of industries, such as automotive, manufacturing, telecommunications and oil and gas.
HOW WILL THE TOOL HELP PROCESS ENGINEERS?
As Walker explained the product was originally designed as a LiDAR (light detection and ranging tool) for autonomous vehicles since it can help to make these sometimes complex, error prone systems accessible to the workforce without
the need for robotics experts. However, the SICK engineers quickly realised that the technology’s application was broader than this.
For example the tool can help plug skill shortages. “If there is one engineer and lots of technicians, as well as software and a little bit of programming, a senior engineer can pour their understanding into the software to make it available for the whole team,” Walker explains. “The skills shortage has been particularly acute in the UK since Brexit and so we expect this to be a key driver for uptake of our product.”
INACCESSIBLE OR UNSAFE AREAS
SARA can also be useful for checking inaccessible, unsafe or restricted areas or equipment since a phone or tablet can be pointed at a sensor
from a distance. More specifically SARA might be used to test a motor’s temperature, to check a PLC load, to analyse vibration, or to measure liquid/gas levels and flow. In addition, an array of drives, motors, and pumps can be inspected in a short period of time.
SARA will also help with maintenance and commissioning since it can link to URLs or PDFs providing pictorial or step-by-step guides. It can also be used to order new stock when there is a fault.
AVOIDING COSTLY MISTAKES
Manufacturing processes require precision and attention to detail, and even a small mistake can result in significant losses for the company. The technology can help operators avoid this by providing easy to follow instructions to employees without the need for additional explanatatory material.
Inventory feedback is another potential use case for the product. As long as a high shelf containing stock can be pointed at, the operator doing so can easily collate stock data.
Walker concludes: “Wherever equipment or stock is IoT enabled, SARA can provide insight. The number of potential use cases mean we expect to see a wide range of industries making use of the technology in the near future.”
The SARA engine was demonstrated at Smart Factory Expo 2024
The SARA engine can be used via any Android or Apple-enabled device
FULL STEAM AHEAD
FHighly efficient boilers heat the buildings and production halls
How a Bosch steam boiler is being used in one Polish factory to reduce carbon emissions
ood and beverage manufacturer PepsiCo began producing tortilla chips and potato crisps on three production lines in Środa Śląska, Poland, last summer. The plant is special in that it is one of PepsiCo’s most environmentally friendly facilities in Europe. With its own energy infrastructure and the continuous expansion of this, the company is pursuing a net zero vision, and a hybrid boiler system from Bosch is helping the company achieve this goal.
PepsiCo’s 55,000-square-metre greenfield plant was built in 20 months, and sustainable, innovative technology is the centrepiece of the new production landscape. The
The technology has an efficiency level of 99%, enabling energy savings and low-emission operations
plant uses environmentally friendly energy sources such as waste heat, biogas and solar energy. The production volume is up to 130 tons per day. Process heat is provided by a hybrid Bosch steam boiler system that is designed for different energy sources. The system primarily uses surplus green electricity via the ELSB electric steam boiler. With an electrical output of 3.6 MW, the ELSB generates 5 t/h of steam at 184°C and 10 bar which produces no carbon emissions at all. There are further advantages from an economic point of view: the electric boiler achieves an outstanding efficiency rating of over 99% and, by utilising surplus electricity, makes steam generation profitable. PepsiCo also generates
part of its green electricity using an on-site photovoltaic system. There are plans for further expansion in the future, and a wind turbine will also support electric power generation at a later date. If there are fluctuations in the amount of electricity produced owing to the weather, or when there are peak loads, a reliable back-up is needed. The solution to this is a highly efficient, gas-fired UL-S steam boiler, which supplements the Bosch system by producing another 5 t/h of steam. The convertibility of such boiler systems will offer flexibility if, in the future, other renewable energy sources become available in the infrastructure.
The generated steam is used in the corn cooking process to heat huge containers. Corn is the main ingredient in tortilla chips and up to 15,000 tonnes are processed every year. This makes the reliable supply of process heat all the more important. The different systems and types of energy need to be combined in a way that works holistically and the control system, produced and configured by Bosch for this project, has been set
PepsiCo generates part of its green electricity from its on-site photovoltaic system
up accordingly. The incorporated software not only controls the complex steam processes, but also ensures intelligent communication between the systems. This is made possible by the smart multi-boiler control. In addition to the hybrid steam boiler system, Bosch also supplied two gas-fired UT-L boilers for heating the buildings and production halls. The total heat output is around 6 MW and the technology has an efficiency
The electric boiler uses 3.6 MW of green electricity to generate up to 5 t/h of steam without producing any carbon emissions
level of 99%, enabling energy savings and low-emission operations. With its multivalent approach, Bosch succeeded in finding a flexible solution for PepsiCo that meets the company’s current and future sustainability goals.
SAFETY LIGHTS
Stuart Head, technical and certification manager at Petrel, explores lighting in explosive areas
The advancement of technology has led to significant changes in the lighting industry
Ensuring safety while maintaining operational efficiency in explosive atmospheres poses a significant challenge. Flammable gases, vapours, and combustible dusts create high-risk environments where a single ignition can lead to disastrous consequences. Strict safety regulation requirements add complexity to daily operations.
Additionally, the need for specialised equipment, such as explosion-proof lighting, increases cost of ownership and maintenance. The harsh conditions and strict regulations in these environments also demand regular maintenance to prevent accidents.
The advancement of technology has led to significant changes in the lighting industry. With the phase-out of fluorescent lamps, Light Emitting Diodes (LEDs) have emerged as the primary lighting solution. This shift to LED technology presents both benefits and challenges that must be considered to ensure safe and efficient operations in explosive atmospheres.
THE LEGAL SITUATION
Hazardous area lighting must comply with UK, European and international regulations. This legislation currently requires UK sites to meet the ATEX Directive (2014/34/ EU), ensuring they’re designed and manufactured to prevent ignitions in explosive environments. To comply, manufacturers must: Design products for explosion protection.
Have certain products third-party approved by a notified/ approved body.
Undergo site assessments by a notified/approved body.
Provide technical documentation. Apply correct markings.
Maintain quality management systems.
Conduct regular audits. These working practices ensure
Light Emitting Diodes (LEDs) have emerged as the primary lighting solution
adherence to essential safety requirements for equipment in potentially explosive atmospheres.
ADVANTAGES OF LED IN EXPLOSIVE ENVIRONMENTS
LED lighting is highly energy-efficient and consumes significantly less power than traditional, older lighting systems. This efficiency results in reduced energy costs, an important factor for industries relying on extensive lighting. Using energy-efficient LEDs will not only save up to 50% per year in energy costs, but also contribute towards a carbon net-zero journey.
Additionally, the longevity of LEDs translates to lower maintenance costs and fewer operational disruptions. While fluorescent lamps are relatively inexpensive, the costs associated with obtaining permits, powering down circuits and conducting the work, can become very costly. By contrast, LEDs minimise the need for maintenance and lamp replacements. This is especially true when these are bespoke modules designed to work within the luminaire, and not just a LED lamp.
LED lighting also provides improved visual acuity in the most hazardous areas, offering better colour rendering and directional light control. Enhanced visual acuity is critical in these environments, where accurate visual cues and colour perception can
significantly impact safety.
A well-designed LED luminaire will also contribute to higher energy savings owing to their increased compatibility with the use of controls. The lifespan of older technologies is negatively affected by users turning them on and off frequently. Some try to reduce maintenance costs by leaving lights illuminated continuously. LED luminaires are not affected by users turning them on and off many times a day, since they consume no power when off, and strike instantly with 100% light output.
CHALLENGES OF USING LED LIGHTING IN EXPLOSIVE ENVIRONMENTS
Despite the benefits, implementing LED technology in explosive environments presents challenges. One such issue is ensuring compliance with stringent safety regulations. Explosive atmospheres demand lighting systems that minimise the risk of ignition, requiring the development and certification of LED luminaires that are specially designed for hazardous locations. This adds complexity and cost to the transition process.
Another challenge is managing heat dissipation. LEDs generate heat during operation, and effective thermal management is crucial in hazardous areas. The good news is that a welldesigned LED system can run cooler
than its equivalent in legacy products. This lower temperature translates to better T ratings and ultimately a safer product and working environment.
Lastly, maintaining consistent performance under extreme conditions is an ongoing concern for LED lighting. These harsh environments often expose systems to vibration, shock, and extreme temperatures, impacting the reliability and longevity of luminaires. To address this issue, manufacturers must design thermally managed, robust products that can withstand these harsh environments.
EMBRACING THE INEVITABLE TRANSITION
The phase-out of fluorescent lighting has made the transition to LED technology an inevitable step, but manufacturers and end-users can collaborate to ensure a successful, safe and efficient transition.
Design software can aid in the compliance process supporting good lighting practices and standards. These simulations can demonstrate the lighting required for an area, and provide vital information regarding uniformity, colour rendering (CRI) and levels when emergency luminaires are needed.
THE FUTURE OF LIGHTING IN EXPLOSIVE ENVIRONMENTS
As industries continue to evolve and adopt new technologies, embracing LED lighting in hazardous areas is a vital step towards enhancing safety, efficiency, and operational performance. Although challenges can be present, ongoing innovation and collaboration between manufacturers and end-users will pave the way for the widespread adoption of LED technology in critical environments. By embracing the inevitable transition and addressing the key hurdles, hazardous area lighting can move forward into a more sustainable, costeffective, and safer future.
The transition to LED lighting is an inevitable step
A GUIDE TO PROCESSING EQUIPMENT INSTALLATION
How to ensure proper equipment integration, calibration and training
During the installation process, operators should consider hiring a third-party installation company
Investing in processing equipment is a significant decision, and plant operators must understand the entire process of equipment integration, calibration, and testing for a successful installation and smooth startup. This guide provides a step-bystep approach to installing processing equipment in your plant, covering all the above stages.
1. PROCESSING EQUIPMENT INTEGRATION
EVALUATE SPACE AND COMPATIBILITY
The first step when integrating new processing equipment is to assess the available space within your production line. This involves detailed planning and layout evaluation to ensure that the new equipment fits seamlessly with existing systems. Collaborating with a reputable equipment manufacturer can be invaluable. These manufacturers often offer comprehensive services, guiding you from initial concept to final installation. They will meticulously
analyse your production area, ensuring there is ample room for the new equipment and that all control system components are compatible.
HIRE INSTALLATION EXPERTS
During the installation process, operators should consider hiring a third-party installation company. These experts will ensure that all aspects of the installation, including wiring and plumbing connections, are executed smoothly. Additionally, having a technician from the equipment manufacturer on-site can provide an extra layer of oversight, ensuring that the equipment is installed correctly and efficiently. This technician can address any issues that arise during the installation process, minimising downtime and ensuring a smooth transition.
ENSURE CONTROL SYSTEM COMPATIBILITY
A crucial aspect of equipment integration is ensuring that the new equipment communicates seamlessly with your existing control
systems. Detailed knowledge of the controls used in your facility is essential. Collaborate with the company that supplied your controls to guarantee compatibility. This partnership ensures that the new equipment can be integrated without communication issues, enhancing overall efficiency and productivity.
2. EQUIPMENT CALIBRATION
PARTNER WITH KNOWLEDGEABLE TECHNICIANS
Calibration is a critical step to ensuring that your equipment operates at optimal performance. Partnering with a company that employs knowledgeable technicians is essential. These technicians provide comprehensive support, guiding you through the calibration process with precision and attention to detail. A thorough calibration process guarantees that the equipment is adjusted to meet specifications, ensuring incredibly efficient and reliable operation.
IMPLEMENT REGULAR CALIBRATION SCHEDULES
To maintain optimal performance, implementing regular calibration schedules is essential. Consistent calibration checks help identify any deviations from the standard specifications, allowing for timely adjustments. This proactive approach minimises downtime and ensures that your equipment continues to operate at peak efficiency.
3. EQUIPMENT TRAINING PROVIDE COMPREHENSIVE SERVICE MANUALS
When you purchase processing equipment, ensure that you receive a complete set of service manuals. These manuals are invaluable resources for your team, providing detailed instructions on operation, maintenance, and troubleshooting. Some companies also offer video tutorials and other training tools, which can further assist your maintenance crews.
OFFER HANDS-ON TRAINING
In addition to providing manuals, arranging on-site training from the equipment manufacturer will be highly beneficial. Hands-on training sessions will equip your operations and maintenance staff with the
APEC’s batch mixer has been installed and used in a variety of industrial applications
knowledge and skills needed to handle any operational challenges. A well-trained team is essential for maximising the potential of your processing equipment, ensuring smooth and efficient operations.
CONTINUOUS TRAINING AND DEVELOPMENT
Investing in continuous training and development for your team is a wise decision. Regular training updates will keep your staff informed about the latest advancements and best practices in equipment operation and maintenance. This ongoing education empowers your workforce, enabling them to utilise the processing equipment to its full potential and adapt to any changes in the production process.
Careful installation will ensure products like APEC’s Proflow mixer are optimised
4. PROCESSING EQUIPMENT TESTING
CONDUCT RIGOROUS PRE-SHIPMENT TESTING
Conducting rigorous testing is crucial before any processing equipment leaves the manufacturer’s facility. This step ensures that the equipment meets the highest quality standards. Experienced technicians should evaluate the equipment under various parameters and meticulously document the results. This testing phase is vital for identifying and addressing any potential issues before the equipment is shipped to your location.
PERFORM ON-SITE TESTING
Upon arrival at your facility, conduct further on-site testing before production begins. This additional testing phase provides an opportunity to verify that the equipment has been transported and installed correctly. On-site testing guarantees a seamless transition into your production line, minimising disruptions and ensuring efficient operation. Having a manufacturer’s technician present during this phase can be highly beneficial. The technician can oversee the testing process and assist with troubleshooting any unforeseen issues.
EXPLORE PROCESSING EQUIPMENT SOLUTIONS
Successful processing equipment installation involves careful integration, precise calibration, thorough training, and comprehensive testing. By following these steps, you can ensure a smooth and efficient installation process, maximising the potential of your investment. When choosing equipment manufacturers, consider their reputation and ask for references. Learning from previous customers’ experiences can help you find reliable partners who meet your specific needs. Taking these factors into account will enable you to make informed decisions and achieve optimal results for your production line.
For more information visit: www.apecusa.com
Coffee is affected by environmental influences: oxygen, moisture or light can lead to a loss of aroma and quality
Bialetti tests product quality with devices from Infinicon’s Contura S400 series
ALLEVIATING LEAKS
Technology that optimises leak testing of coffee packaging
The food and packaging market is facing major challenges including longer transport routes and pressure to extend shelf life. In addition, there are increased demands in terms of environmental compatibility, legal requirements and consumer wishes. In order to fulfil these criteria, coffee producers must carry out leak tests on packaging during production to prevent damage.
USING NONDESTRUCTIVE LEAK TESTING
Instrumentation specialist Infinicon has been developing packaging for coffee producers for some time - this is an industry vertical where quality requirements are particularly high. Arman Khazali, operations manager at Italian coffee manufacturer and Infinicon customer Bialetti, estimates that Bialetti’s annual output is 180 million coffee capsules and 2.9 million soft packs. Because these products are exposed to high water pressure during the brewing process in the coffee machine, a leak would impair the delivery into the cup and therefore the quality of the coffee. According
to Khazali, the main focus of an intelligent leak test must therefore be accuracy and the ability to provide a numerical quantification for each test in order to carry out a statistical analysis. “Non-destructive testing offers added value compared with a destructive test,” says Khazali. “Other advantages are the significant reduction in testing time and the fact that we are autonomous in terms of personnel and can therefore produce without downtime.”
A FAST, RELIABLE METHOD
Bialetti, situated in the province of Brescia, Italy, has only recently switched from destructive water bath testing to the non-destructive method. It has been ensuring product quality with leak testers from Inficon’s Contura S series. With the help of an applied pressure increase method [see boxout] in the flexible test chamber, both the smallest and largest leaks are detected quickly, reliably and without test gases. “The Infinicon system makes a decent contribution
to the consistent quality of our capsules and packs,” says Khazali.
LONGER MINIMUM SHELF LIFE
The testing process with the mobile Contura S products can be easily integrated into production. During evacuation of the test chamber, two flexible membranes enclose the test objects so that they remain intact. If there is a leak, gas from the packaging penetrates into the evacuated test chamber causing a measurable increase in pressure in the vacuum of the chamber. Gross leaks and micro leaks of less than 10 μm are detected in seconds. The Pressure Increase Method extends the minimum shelf life significantly.
USER-FRIENDLY DISPLAY
The Contura S products come with a user friendly touch display and these are a major benefit for Bialetti:
“The screen shows the relevant test results and information in color - it also provides an acoustic signal,” says Khazali. In addition, the display provides the exact leakage rates for the set time interval, giving users a quick overview of the quality of the coffee packaging.
FULL SUPPORT FROM INFINICON
“Infinicon, provided full support with the implementation of the Contura S product, it also made staff available to answer our technical queries,” says Khazali. In addition, the company demonstrated its technical expertise and reliability with tests, results reports and analyses.
“Building on this, we expect to work with Infinicon on future projects. We might even expand our production capacity as a result,” he concludes.
For more information visit: www.inficon.com
THE PRESSURE INCREASE METHOD
Various methods can be employed to test leaks in packaging including bubble bath or CO2 testing. These methods use the common principle of creating a pressure difference between the test object and the surrounding environment. This pressure difference forces any contained gas to escape through leaks. The higher the pressure difference, the smaller the detectable leaks. However, high pressure can damage the seals and packaging, which may lead to misinterpretation of results, as intact packaging might rupture and be mistakenly identified as leaking.
Additionally, traditional testing systems like bubble baths are highly dependent on the user’s expertise and must be adjusted for each volume and type of packaging. The results are recorded manually, and all tested samples, whether intact or leaking, must be disposed of after testing. This practice is unpopular with manufacturers owing to high write-offs. The food waste and additional unavoidable waste also harms the environment.
By contrast, the Contura system measures leaks using a pressure increase method within a flexible film chamber. It is very easy and quick to operate, according to the company. A technician will place a test item in the chamber and close it. The system automatically evacuates to 30 mbar while the membrane protects the packaging from expansion and seal stress. The system then uses highly precise, self-developed and produced pressure sensors to detect potential leaks, providing the manufacturer with a non-destructive and reproducible result in less than 15 seconds. The Contura system calculates a quantifiable and reproducible leak rate in mbar*l/s from the pressure increase and the time. The device therefore not only shows whether something is leaking or not, but exactly how tight it is. This happens regardless of the type or number of leaks.
BOTTLE CLOSURE
An efficient printing solution to support label-less bottles
Beverage manufacturers are moving away from labels on bottles for environmental and legislative reasons.
As such, UK-based printing specialist Domino Printing Sciences has launched a range of high-speed product handling and printing solutions designed to support this move. Domino’s range of Bottle Closure Printing Stations (pictured) is able to print variable data and machinereadable codes, including QR codes, onto high-density polyethylene (HDPE) bottle caps and closures.
The solution features a product handling system capable of stabilising filled water bottles, alongside highresolution printing of 300–900dpi variable data codes at speeds of up to 44,000 bottles per hour from Domino’s K300 monochrome digital printer. The stations also feature pre- and post-treatment of the printed codes to ensure code adhesion and longevity, as well as integrated machine vision for automated code inspection and verification.
INSTALLATION IN KOREA
Domino recently completed the installation of its first in-line Bottle Closure Printing Station for a prominant Korean beverage manufacturer. The installation was the first of its kind in the region, with the
Domino’s in-line printing station prints QR codes onto HDPE bottle caps
customer reporting that Domino’s quick response time, and ability to provide a complete solution were instrumental in their choosing to partner with Domino. Several additional installations have followed as more brands realise the benefits of bottle cap printing in the move to label-less PET bottles.
“There is growing interest in labelless bottles and the role they can play in supporting the bottling industry’s move towards a circular economy,” says Nigel Allen, marketing manager 2D Codes & High-Resolution Inkjet, Domino. “Although plastic labels are often recyclable, they typically need
Domino’s K300 digital printer runs at speeds of up to 44,000 bottles per hour
to be removed prior to disposal to ensure that both labels and bottles can be recycled.”
Removing the need for labels not only helps to simplify the recycling process and reduce the total quantity of plastic required but can also save manufacturers up to 5% on their production costs, as well reducing the financial burden in regions with plastic taxation.
The addition of variable data codes on bottle closures, the most common being QR codes, including GS1 QR codes, can provide a link to all the data usually required on product labels, supporting applications including product traceability, provision of product recycling information, and consumer engagement.
The Bottle Closure Printing Stations can be customised to suit different beverage sector production environments. Options are available for high-speed printing of loose bottle caps and closures near line and in-line coding of filled bottles.
For more information visit: www.domino-printing.com
The EvodiaBio fermentation process harnesses the power of yeast cells to produce aroma molecules
SUSTAINABLE SCENT
How one bio-solutions company uses a unique fermentation process to create an environmentally-friendly product
Appealing flavours and scents are central to the success of food and drinks manufacturers, as is the use of sustainable produce. One Danish bio-solutions start-up, EvodiaBio, has developed a product that meets these needs, an aroma for non-alcoholic beer called Yops. The product is created via a precision fermentation process that also reduces the impact on the environment.
The company recently raised €7m that will be used for commercialisation and the expansion of its business. With this extra backing, the company aims to develop its role as a global leader in sustainable aroma development.
On hearing news of this cash injection, International Process Engineer contacted EvodiaBio’s CEO,
Camille Fenneberg, to find out what exactly makes the company’s product unique.
HOPS IS THREATENED BY CLIMATE CHANGE
Hops, one of the key ingredients of beer, is being threatened by climate change with production declining, and quality deteriorating. A paper published in Nature Communications last autumn predicted a decline in European hop yield and alpha content of between 4% and 18% and 20% and 31% by 2050, respectively.
In response to these concerns, EvodiaBio began developing a technology using yeast and precision fermentation to produce sustainable aromas to create the hops taste.
The production process is sustainable and scalable, according
to the company, and has moved away from traditional extraction methods requiring significant plant material. Instead it uses precision fermentation meaning it can produce natural flavors with a much lower environmental footprint.
Camille says: “We’ve just finished an LCA analysis showing that water usage, energy consumption, and CO2 emissions are reduced by more than 80% if aroma hops are replaced with Yops.” She continues: “Our technology is also based on breakthrough and patented research from the University of Copenhagen, enabling us to produce aroma molecules more efficiently. Our method is 20-100 times more productive than has been reported with conventional techniques, allowing us to meet growing market demand sustainably.”
IMPROVING THE TASTE OF NONALCOHOLIC BEER
The product has already seen considerable uptake from the beer industry since Yops improves the taste of non-alcoholic beer. “Our aromas are already meeting a need within the drinks industry since they significantly improve the taste of non-alcoholic beer and partially replace aromatic hops, which are currently under threat.”
“Typically, non-alcoholic beer lacks aroma and contain off-notes. It is technically more challenging to create than a regular beer. Our aromas can improve the scent while also masking some of the off-notes.” Yops is customisable and so can be used for proprietary brands.
THE CEO’S BACKGROUND
Camille has a background in commercial leadership across industries that include life sciences, MedTech, and renewable energy.
Before joining EvodiaBio, she was the CEO of a renewable energy startup. and spent many years in a large international life-sciences company. She explains that the common thread has been a focus on bringing innovative solutions to market. “I’ve always been driven by a desire to develop solutions that make a difference,” she says.
PRODUCT CREATION
The Yops flavor is produced using a process that harnesses the power of yeast cells to produce specific aroma molecules called monoterpenes, these are naturally found in plants but are difficult and resource-intensive to extract.
The fermentation conditions are then carefully controlled to ensure consistency and quality, so the flavor remains stable even during largescale production. By refining the production parameters, the company claims to have developed a reliable method that maintains the purity and
integrity of the flavor throughout the manufacturing process.
A SYNDICATE OF INVESTORS
Founded just three years ago, EvodiaBio is supported by an international syndicate of investors consisting of Nordic Foodtech VC, the German flavour house Symrise, PINC (the venture arm of Paulig), Thia Ventures VC, Newtree Impact, Ananke Ventures Limited, EIFO, and The March Group.
The company is already experiencing high interest from breweries, and as Camille says the possibilities extend beyond nonalcoholic products.
“This funding round is an important step towards our vision,” Camille says. “We are ready to make an impact on the global stage.”
REDUCE THE FROTH
A new product promises to reduce excess foam in the beer-filling process, by Jake Holmes
Leading brewery customers have long complained about excess foam causing issues in the beer-filling process. At the end of filling, the foam created typically enters the vacuum line, clogs the pipes filling the bottles and reduces the volume of beer produced. The foam volume also causes a reduction in the quality of the product as well as excessive waste and high costs.
Technology manufacturer Atlas Copco has responded to these complaints with a new technology for beer bottling processing, the Beer Foam Separator (BFS 900), a product that aims to provide better quality and more consistency to the beer bottling industry.
The vacuum pump in the vacuum line is fully protected by the beer foam separator’s smart features and easy to clean design. The product has been rigorously tested.
Alesandro Villa, applications manager, Atlas Copco says: “We spent a lot of time perfecting this particular component for the beer industry because we wanted to design a system that would not only protect the pump but offer a higher level of energy efficiency and savings for our customers.”
HOW THE SEPARATOR WORKS
The beer foam separator is made from stainless steel which provides durability. This has been coupled with an auto-draining tank and an associated logic control system. Foam collapses the foam separator because of a calming section which has a large diameter for foam settling. Sensors detect the rise and fall in liquid levels, then activate the automatic separation process once the liquid reaches a certain level. An airlock consisting of electro-pneumatic actuators as well as a receiver tank allows drain in continuous operation.
Pamela Cateland, marketing manager west, Atlas Copco Vacuum said: “We provide not just products, but solutions. Our new beer foam separator is an example of this. Our vacuum pumps and the systems we build, help maintain quality, shelf life and ultimately, customer satisfaction.”
The separator is also fitted with cleaning technology. This is achieved via a shower ball mechanism ensuring reach to all internal parts that makes the beer foam separator compliant with mandatory hygiene standards.
Villa added: “Addressing process concerns for the beer industry using our applied engineer expertise is a key area of focus for us.“
Being more efficient and sustainable, the beer foam separator includes features such as zero water wastage, an auto-drain function, durable
design, energy savings, reliable sensors, and easy maintenance, according to the company.
The system requires very little water giving it an added advantage over others. It also has automatic drain, vent and isolation system components that are activated by control valves. The integrated cleaning cycle means the product is easy to maintain and clean. Two sets of sensors, level and radar, measure the amount of beer collected in the drain tank and foam level respectively. Finally, this new system reduced energy used by 40% compared with previous systems owing to its use of GHS VSD efficient technology.
The Atlas Copco Beer Foam Seperator aims to improve beer quality
A SOLVENT BUSINESS
Demand for sustainable recycled products has kick-started a growth in solvent recovery capacity
The push for emission reduction and recycled products has led waste treatment specialist Veolia to increase its capacity for recycling of used solvents, waste paint thinners and solvent based paint to 86,000 tonnes a year to meet the growing demand for more sustainable industrial products.
The company has expanded its facility, at Garston in Liverpool to create new products as an alternative to virgin solvents, to enable reuse in industries like pharmaceuticals, semiconductors, paint, agrochemicals and cement manufacture.
WHAT IS SOLVENT RECYCLING?
Solvent recycling is the process of recovering and reusing processed solvents. It is used for a variety of products including hand sanitiser,
alcohol, and other solvent-based solutions. Solvent waste can be altered back into a virgin-like solvent and the process reduces the volume of hazardous waste.
SOLVENT RECOVERY METHODS
There are various distillation processes used to recover solvents. Distillation involves the conversion of a liquid into a vapor through boiling and condensing the substance back into liquid form through cooling. The following are the best known methods:
1) Simple distillation – the separation of a liquid from a solid-liquid solution. The process, used for mixtures containing one volatile component, is energy efficient and cheaper than other options.
2) Fractional distillation – a popular method that separates a liquid from a solution of two or more mixable
liquids. Fractional distillation is able to separate mixtures into high-quality recycled solvents.
3) Flash distillation – this heats liquids to the same boiling point and separates the solvent from residue, for use in paint manufacture. Veolia uses this method then transports organic residues to a specialist facility to be blended into secondary liquid fuel, used as an alternative to fossil fuels for cement and lime kilns.
4) Steam and vacuum distillation – these are other techniques used within the solvent recovery process. Steam can generate organic solvent-free products and vacuum distillation helps distil heavier objects and volatile compounds. Veolia uses a combination of methods including flash and fractional in a multi-stage operation. All loads are sampled and
analysed on site as they arrive to check compliance, followed by the distillation process which transforms the liquids into new products for industry use depending on the liquid type.
THIN FILM EVAPORATOR
The company also uses a ‘thin film evaporator’ to separate the components of a process liquid based on volatility. The basic method involves applying heat to a liquid which causes it to evaporate, thereby leaving the less volatile substance behind. The more volatile, and now gaseous, substance is then condensed and collected at a separate location.
Traditionally, batch or continuous processes such as natural/forced circulation, falling and rising film, and climbing and falling plate evaporators have been used successfully with a range of process liquids. However, these evaporators have proven to be inefficient with high-boiling, viscous, fouling, and heat sensitive liquids.
The company claims that this solvent recovery process will save an estimated 172,000 tonnes of CO2e in greenhouse gas emissions each year, equivalent to taking 78,000 diesel cars off the road annually.
The energy centre in Garston uses a distilled product fuel, produced on site, to power the steam boilers, reducing the energy required from gas by 10,000 MWh per year, equivalent to the gas usage of 1,000 homes per year.
VEOLIA’S STRATEGIC PLAN
The expansion is part of the facility’s new strategic plan called GreenUP which aims to make Veolia a champion of decarbonisation, de-pollution and regeneration of natural resources.
The site processes waste materials to regenerate them into high-quality
recycled products that can be reused, thereby displacing virgin materials in the supply chain.
FUELLED BY RECYCLED MATERIALS
As well as generating recycled products, the plant also produces several types of fuel. As mentioned, a distilled product fuel is used instead of natural gas to power the site’s steam boilers. Other by-products from the process are sent to Veolia facilities to be manufactured into alternative fuels for use in the cement industry, helping to decarbonise this industry and reduce the reliance on fossil fuels.
The increased processing capacity has been achieved by installing new distillation columns to separate liquids, and 17 tanks to store or transfer the solvents. Transport is handled through two new high throughput tanker loading bays which manage logistics for processing and loading the recycled solvents ready for customer delivery.
Nicola Henshaw, managing director Hazardous Waste at Veolia UK said:
“This latest expansion of our solvent treatment capabilities demonstrates our commitment to deliver high quality recycled products derived from advanced waste treatment. By preserving resources, reducing reliance on virgin materials, and delivering sustainable products to support manufacturers, we can also create major carbon savings.”
The Garston site turns waste materials into high-quality recycled products
Veolia has built new distillation columns at the Garston energy centre
DURABILITY COMPARED
An overview of the benefits of installing a sewer pumping system compared with the complete renewal of underground pipes
Aquarter of a century has passed since the PCK Refinery in Schwedt/Oder, Germany (PCK Raffinerie GmbH) renovated its sewer systems, the so-called main sluice. In 1997, two approaches were pursued and compared.
The conventional approach consisted of renewing the underground pipe systems. The second solution was to install a pumping station at each plant. The slop products from the production plant and the rainwater and surface water produced are pumped into the
central wastewater treatment plant via an existing pipe network on the pipe bridges. The contract was awarded to the second solution.
The PCK Refinery entered into discussions with various pump manufacturers. The composition of industrial wastewater can vary greatly, and corrosive substances can also enter the pits. For this reason, the minimum requirement for the material of the wetted parts was defined as Duplex 1.4462. The design temperature of 80°C ruled out the use of submersible motor pumps. Ultimately, PCK chose sump pumps
with a dry-installed IEC standard motor. The switch-on level for the pumps had to be selected in such a way as to prevent backflow into the inlet channels. This resulted in installation lengths of 2.5 to 5 metres.
EMILE EGGER WON THE TECHNICAL CONTRACT
The Swiss pump manufacturer Emile Egger was one of these potential suppliers. As a pump manufacturer specialising in liquids containing solids, Egger was able to win the technical contract. The patented Turo Vortex hydraulics has an impeller that is
Egger Turo Vortex sump pumps for slop tanks at the PCK refinery
completely retracted into the housing with a free ball passage the size of the discharge diameter. Blockages can be virtually ruled out and coarse solids such as stones, branches, screws or other solid materials can pass through the pump without any failure. The pump is also self-sufficient and does not require any external supply such as sealing liquid. The shaft seal is a single acting mechanical seal located directly behind the impeller. The intermediate journal bearings above it are lubricated with a clean liquid and do not come into contact with the pumped liquid. The pumps are also frost-proof, and the journal bearings are protected against corrosion by a water-glycol mixture.
In addition to these technical
advantages, the very positive operating experience with pit pumps already in use contributed to the order for a total of 48 pumps of this type with Egger in 1998. Two pumps were installed per sewage pumping station. The base load pump is operated via variable speed drive controlled by the liquid level. The second pump with a fixed speed serves as a reserve and as an overload pump, which is switched on in parallel during heavy rainfall.
After more than 25 years of operation, it can be said that the Egger sump pumps of the SG design have proven their worth. Subsequently, Egger submersible pumps were also installed at other locations, including pits and tanks classified as Zone 0. Other very
The Turo sump pumps handle abrasive and corrosive industrial wastewater up to 80 °C
Egger dry mounted pit pumps in redundant design allow single or parallel operation (overload pump during heavy rainfall)
The presence of hydrocarbons requires a complete pump set including dry mounted standard motor in flame proofed design
demanding applications followed, so that more than 100 Egger products are currently in use at the refinery.
This success story was crowned ten years ago with the establishment of the service support centre on the PCK refinery site. The service centre now consists of four people. As the availability of Egger products is very high and the failure rate very low, the Egger service centre also repairs third-party products and supports the company’s main service base in Mannheim with repairs from northern Germany.
For more information visit: www.eggerpumps.com
Slop tank with vertical Egger pit pump, in operation at PCK Schwedt for more than 25 years
DIGITISING FOOD SAFETY
A guide for food manufacturers looking to digitise their systems
The food industry is facing a digital transformation. It will soon be necessary to fully digitise processes and procedures for food safety to enable auditing and monitoring online. Ian Scott-Mance, technology manager at Mettler-Toledo Product Inspection explains that these measures can no longer be put on the back burner since US-based Initiatives such as the ‘New Era of Smarter Food Safety’ by the Food and Drug Administration (FDA) and ‘Race to the Top’ by the Global Food Safety Initiative (GFSI) place such importance on digital auditability. Full traceability is already a prerequisite for certain products to access some Asian markets. China, for example, requires products to be fully traceable before they can be sold inside its domestic market. In addition, the big players
in the food retail sector are imposing stricter requirements for farm-tofork traceability, which must be embedded in digital supply chain management. Food manufacturers must therefore focus on data collection, the essential starting point for any project looking to improve food safety through careful
The digitisation of food safety does not normally mean a complete system replacement. A simple device upgrade or the purchase of a software option is often sufficient
tracking. In this article, Ian ScottMance details the four key steps they should take:
STEP 1: CONDUCT A THOROUGH DATA AUDIT
Data should be made available across the entire supply chain, in an accessible, digital form. Therefore, a comprehensive audit must be carried out to determine how viable this is. Many of the required food safety data and processes should already be available and well documented, as they should already have been created when applying for food safety certifications. For example, production line critical control points ought to have been identified through earlier HACCP certification and appropriate inspection systems should already be installed there. Nevertheless, the audit often proves
Data must be made available across the whole supply chain
challenging since data can be highly fragmented. It is common to find that it is already highly networked in part and is also often still gathered using tools such as USB sticks, or manually with pen and paper. From a technological point of view, the complexity is demanding, particularly since the systems on the shop floor were bought at different times and use a wide variety of protocols, network infrastructures and management processes. Older software solutions and devices were not originally designed for open IoT / industry 4.0 communication, as is standard today.
Manufacturers will need to migrate a colourful hodgepodge of hardware and software into a unified digital food safety program. Global standards and communication protocols, uniform ID coding and standardised transformation events will significantly reduce the level of complexity.
STEP 2: DEVELOP YOUR DIGITALISATION STRATEGY
The key strategic questions are, which specific applications need to be mapped, and what are the company’s long-term digitisation goals? Is the company seeking merely regulatory and market compliance, is the focus optimising production processes, or is the company looking to move into IoT usage and industry 4.0? Each will require a different plan, schedule, and capital cost.
In this phase of strategic development, a manufacturer should consult with suppliers and manufacturers of the systems installed on the shop floor.
Many companies will be surprised at what they are already capable of doing in terms of data acquisition and provision. The digitisation of food safety does not mean a complete system replacement as a rule. A simple device upgrade or the purchase of a software option is often sufficient. When selecting a suitable cloud data management provider, it is important to ensure that it is very familiar with the food safety landscape.
STEP 3: SECURE AND BUILD UP EXPERTISE
All internal and external stakeholders who participate in the process must be identified. It is important to determine how much knowledge and know-how is available across the business and where it is available. In addition to evaluating your own company, a corresponding assessment and evaluation must also be conducted for all partners in the network who are involved in the applications and likely to be accessing them. Talking to the stakeholders in the value chain is an important part of the process. Based on this, an overview of the existing expertise and the knowledge gaps that have yet to be closed must be created.
STEP 4: INSTITUTIONALISE CHANGE MANAGEMENT
The digitisation of food safety is a process that entails changes to working practices – it will impact a wide variety of departments including purchasing, production, procurement and marketing. The cultural change associated with this transformation process must be managed proactively and carefully. Employees must understand and accept that the higher level of data transparency required also includes those involved outside of their own company.
Leadership quality and demonstrated commitment to the project are required here in order to drive the changes forward. Operators are advised to put together a multi-stakeholder group to work out the common advantages of digitisation, while formulating common reservations and concerns. Senior executive sponsorship and a continuous exchange of information with the management teams on the progress of the transformation programs are essential to keep the change process on track and under control. A road-map with manageable, incremental and intermediate goals must be formulated.
Audits can prove challenging since data can be highly fragmented
INTELLIGENT POWER DEVICE
A new intelligent power device includes safety features such as under-voltage and thermal shutdown
Toshiba Electronics has launched a new intelligent power device (IPD) for space-constrained brushless DC (BLDC) motor drive applications such as air conditioners, air purifiers, and pumps. The product comes fitted with a range of safety features including over-current, under-voltage and thermal shutdown. Additionally, an external signal can be applied to the SD pin to control the behaviour of the output stage. The DIAG output pin provides the status of the safety conditions.
The new IPD (TPD4165K) has an increased maximum output current of 3A, compared with the 2A rating of Toshiba’s existing products like TPD4163K, or TPD4164K. This extends the range of supported
The IPD has a maximum output of 3A
equipment and allows use in higher power applications. The device is suitable for sine-wave drive.
As power supply voltage may fluctuate significantly in some regions where the IP could be used, the absolute maximum voltage rating (VBB) has been increased to 600V to enhance long-term reliability.
This represents a 20% increase over Toshiba’s previous products (TPD4123K, TPD4123AK, TPD4144K, TPD4144AK, TPD4135K, TPD4135AK).
The new TPD4165K is housed in a through-hole HDIP30 package. This has a 21% smaller footprint than the DIP26 package used for many of Toshiba’s previous products, simplifying the design process for challenging spaceconstrained applications. The new device measures just 32.8mm x 13.5mm x 3.525mm. It supports either a threeshunt or single-shunt resistor circuit for current sensing. Shipments of the new device are starting immediately.
For more information visit:
PAPER PROTECTION
A paper electrostatic discharge product will help to protect electronic equipment and the environment
Electrostatic discharge (ESD) is of ongoing concern to electronics engineers since it can so easily damage their components. Although corrosion protection is typically a lower priority this should also be on the radar for manufacturers who want their electronics to reach the end user in good condition, according to corrosion protection specialist, Cortec.
A new product from the company called Ecosonic ESD paper, offers a two-in-one packaging solution that meets both these needs.
CORROSION AND ESD PROTECTION FOR ELECTRONICS
Shipping is a vulnerable time for electronics as they pass through a variety of climates and temperature fluctuations that can cause condensation on sub-assemblies inside a package. Any corrosion or even
staining will call the integrity of an electronic company into question when the end user unwraps it. Cortec therefore coats its Ecosonic ESD Paper with vapor phase corrosion inhibitors (VCI/VpCI) to protect multi-metals from oxidizing. VpCI molecules in the coating vaporize and diffuse throughout a packaging enclosure, adsorb on metal surfaces, and form a protective molecular layer that does not need to be cleaned off when the module is installed.
To address ESD concerns, the Ecosonic ESD Paper also has a static-dissipative coating to eliminate static electricity buildup. With this coating, the ESD properties of the product meet the requirements of ANSI/ESD STM11.11 for surface resistance and MIL-STD 3010C Method 4046 for static decay rate. The final result is a two-in-one recyclable VCI/ESD paper.
REPLACING PLASTIC BAGS
Although Cortec has been creating dual corrosion inhibiting / staticdissipative packaging for electronics for some time, plastic bags have remained the main packaging format for a variety of reasons.
ESD Paper from Ecosonic is an important departure from this standard since its paper is sourced from trees, a renewable resource. This answers the call for paper packaging options from electronics manufacturers in Europe and Asia. The company’s ESD Paper is easily applied by wrapping it around an electronic product and taping the folds to hold them in place, creating an enclosure. The product can also be used to create an instant static-dissipative workspace by laying the paper onto a work bench where employees assemble or inspect sensitive electronic parts.
The pros of plastic INJECTION MOULDING
Katie Reed from BEC dives into the world of filter manufacturing to explore how injection moulding solves several industry problems
Filtration devices are commonly implemented across automotive, biomedical, marine and domestic appliances, keeping air and water clean, and machinery and appliances functioning smoothly. In industry, the quality and cost of each filter is vital, and injection moulding provides an ideal manufacturing method that keeps costs low and quality high.
THE INJECTION MOULDING FILTRATION PROCESS
Injection moulded filter parts begin life as a 3D CAD drawing. Optimised for injection mould tooling, these become the guide for creating the mould tool. Designing out high-cost areas such as non-uniform draft angles, undercuts and inserts at the design stage reduces timescales and additional costs for toolmaking.
Next, material selection is crucial to the longevity and properties of the part, as well as the quality and price. Available materials for both the mesh and the encapsulation framework are wide ranging in origin, application, and cost. Steel and plastic mesh, recycled content, environmental resilience and tensile strength can all be incorporated into injection moulded filters.
Bespoke depth-media, woven and non-woven meshes can be fabricated for filters to provide exactly the level and types of filtration required to ensure their longevity. Nylon is often selected over other engineering plastics owing to its strength and chemical resistance, ensuring that the tough environment’s filters endure.
A Moldflow analysis simulates the material filling the part, allowing for potential quality issues such as weld lines, sinkage or shrinkage to be rectified. Once the design is agreed, a steel tool is produced. Robotically or
manually, a filter mesh is loaded onto the core of the mould tool, the tool closes and clamps around the mesh, and molten plastic is injected through a sprue. The plastic flows through into the mould tool, surrounding the mesh. After a swift cooling process, the tool separates and the filter is ejected from the tool, to be trimmed or undergo further assembly.
THE BENEFITS OF INJECTION MOULDED FILTERS
Once made, a steel mould tool can produce up to millions of identical filter mouldings. This high-volume repeatability and precision help ensure that filter manufacturer’s products are made to a high quality. Stringent inspection, testing and documentation throughout the manufacturing process ensure these are maintained.
Aside from the initial cost of tooling, injection moulded filters present a very low cost-per-part solution. In particular, for large-scale production, this costper-part decreases even further.
Any waste plastic or rejected mouldings used in injection moulding filter production can be re-ground for recycling or immediate use. Injection moulding machines are increasingly energy efficiency, particularly hybrid and all-electric models.
Katie Reed from Bec says: “Injection moulding as a filter manufacturing process allows for cost savings (particularly at scale), while it incorporates flexibility over design and material selection. Repeatability and strict control of process variables ensure tight quality control.” For
Injection moulding allows for significant cost savings
FILTECH: A PLATFORM FOR THE GLOBAL FILTRATION INDUSTRY
The Filtech trade show will run in Cologne, Germany between 12-14 November 2024 and is a global event and platform that focuses on the filtration industry and adjacent sectors.
It claims to be the largest and most significant event of its kind, showcasing new technological advancements and innovations in the field of filtration and separation.
Filtech attracts experts, researchers, and industry professionals from various sectors to address pressing issues such as air pollution, climate change, health hazards posed by germs, and optimising efficiency in the solid and liquid separation processes.
The show aims to offer solutions to meet the diverse needs of the many industries facing filtration challenges and using separation technologies.
The conference programme includes sessions on bio-based polymers as alternatives for fossil based
polymers; adsorption; measurement techniques; particle and solid structure characterisation; steam pressure filtration, water treatment and energy efficient air filtration.
Two short courses on solid / liquid seperation, and air cleaning and dust seperation will run a day before the show, on the 11th November. The other aspects of the conference will run for the length of the show.
Filtech 2024 currently has 574
exhibitors from 42 countries booked proving a testament to the show’s international appeal.
The organisers believe the international aspect of the show is a key draw that develops on the 2023 show when 53.9% of participants came from outside Germany. A substantial increase in visitors from the USA, Asia and Northern Africa attended last year, with experts and speakers coming from 80 nations and all continents.
In 2023, companies reported excellent contact with decision makers as well as a marked willingness among trade visitors to invest, promising new business contacts from all over the world as well as specific contract negotiations and concrete business deals.
Reliable Gas Detection
At Gas Clip Technologies, we believe that quality and budget-friendly should go hand-in-hand, which is why we create top-of-the-line gas detection solutions that have a low cost of ownership. Each detector is compliance-based and designed to withstand the roughest treatment in the harshest environments.
All of our products are available through distributors worldwide.
