1
#
PROBLEM SOLVERS
ELIMINATE ENGINEERING HEADACHES
PROBLEM SOLVERS
#2
QUICK WINS FOR EVERYONE... Common problems and inefficiencies occur every day, in all industries. It is these little problems which can cause Engineers some of the biggest headaches, but thankfully there is normally a simple solution. We’ve worked alongside our partner suppliers to create a range of Problem Solvers which showcase some of the latest products and innovations to relieve your everyday engineering headaches. This edition we focus on Food and beverage Automotive Mining and quarrying General Engineering
To view all of the ERIKS Problem Solvers visit eriks.co.uk
ERIKS Industrial Products, Services & Solutions
PROBLEM SOLVERS
FOOD AND BEVERAGE FOOD AND BEVERAGE
#3
CONTENTS Cut corrosion from frequent washdowns
4
A smart way to reduce air consumption
5
Foodline Y-Bearings reduce lubrication
6
Correct alignment reduces energy consumption
7
Speedi-sleeve shaft repair kits
8
Steam audits enable efficiency improvements
9
Waste removal in vegetable processing
10
Accurate dosing and easy calibration
11
TableTop metal chain reduces energy consumption
12
PSX material eliminates external lubrication
13
Production increase with igus chainflex®
14
Automatic lubricators simplify maintenance
15
Combat cross-contamination with OxyBAC®
16
FOOD AND BEVERAGE
CUT CORROSION FROM FREQUENT WASHDOWNS #4
Problem: A large food manufacturer was experiencing frequent issues on part of their mixing line.
Over time, the frequent wash down procedures were corroding the cylinders on the aluminium barrels.
Solution: Following a quick inspection of the application the customer was advised to switch to Festo’s DSBF cylinders.
The DSBF cylinders incorporate Festo’s ‘all clean design’ which eliminates unnecessary cavities reducing potential bug traps whilst providing excellent corrosion protection. In addition the cylinders are resistant to conventional cleaning agents, and perfect for use in splash zones and where frequent wash downs are required.
ERIKS Industrial Products, Services & Solutions
FOOD AND BEVERAGE
A SMART WAY TO REDUCE AIR CONSUMPTION #5
Problem: A well known ice cream manufacturer wanted to increase their energy efficiency levels at a large production plant and as part of this process attention was directed towards compressed air consumption costs. Solution: Following an in depth technical and compressed air audit of the production line a recommendation was made to implement Festo’s Energy efficiency module MSE6-E2M. This module measures the flow rates in the compressed air network, and can also instantly evaluate the information before initiating appropriate measures.
Since it has been introduced it has reduced compressed air consumption to zero during system downtimes and breaks. It has also provided the added benefit of reporting back if the pressure drops too quickly during downtimes, which enabled leak detection.
It has also continuously delivered process relevant data such as flow, pressure and consumption, which it sends to the machine controller via Profibus. The end result is the module has quickly paid for itself through transparency of energy use, and energy savings.
FOOD AND BEVERAGE
FOOD LINE Y-BEARINGS REDUCE LUBRICATION #6
Problem: A soft drinks manufacturer was using industry-standard conveyors for transporting PET containers, cans and glass bottles. After each wash down, maintenance personnel were having to re-lubricate every single bearing unit to ensure the conveyors remained reliable. This was extremely costly, labour-intensive, and risked some lubrication points being missed through human error. It also risked grease spills, potentially violating HACCP requirements and creating personnel safety issues. Solution: By installing SKF Food Line Y-bearing units, lubricant is kept in, water and detergents kept out, even under high pressure, due to a highly efficient multiple-lip seal and rotating flinger arrangement on both sides. This enables the units to withstand wet and humid conditions and the harsh, frequent wash downs required to maintain product safety.
The new units enabled the producer to meet HACCP hygiene requirements and achieve the required reliability. Labour costs and lubricant consumption were significantly reduced, and the risk of unplanned downtime due to missed lubrication points was eliminated.
ERIKS Industrial Products, Services & Solutions
FOOD AND BEVERAGE
CORRECT ALIGNMENT REDUCES ENERGY CONSUMPTION #7
Problem: A beverage plant was experiencing excessive vibration in 12 of its pumps. This was resulting in excessive energy consumption and the premature wear of parts, leading to unplanned downtime, increased maintenance costs and lost production. Solution: A SKF condition monitoring programme showed that the high vibration levels were due to misalignment. Using an SKF Shaft Alignment Tool TKSA series, technicians were able to quickly and accurately realign the pumps. The TKSA series are highly accurate, quick and simple to operate. In addition, some models can be used in conjunction with your own tablet or smart-phone to produce and store alignment reports. These give an instant overview of the alignment process and results, and are easily shareable via email or cloud services.
By correctly aligning its shafts, vibration was reduced, improving the reliability of the pumps, and the company reduced the energy consumption of its pumps by 20%; a total reduction of 180 MWh per year.
FOOD AND BEVERAGE
SPEEDI-SLEEVE SHAFT REPAIR KIT #8
Problem: A food and beverage manufacturer was experiencing problems in their distribution centre. Very fine dust from corrugated cartons covered much of the equipment.
After discovering an oil leak, the dust was found to be working its way past the sealing lips on both the input and output shafts of the conveyor drive. The seals were subsequently replaced, but oil leaks continued, risking product contamination. Further investigation showed that dust ingress had caused the shaft to wear underneath the sealing lip, leading to premature seal failure and leakage.
Solution: The company was recommended to install SKF Speedi-Sleeve. Made from a proprietary stainless steel material, these are a wellproven solution to the problem of worn shafts.
Instead of removing and re-machining the shaft, which can be incredibly time-consuming and costly, an SKF Speedi-Sleeve can simply be fitted over the worn section. This can be done in a matter of minutes, instantly providing a wear-resistant, highlyfinished surface that creates an optimised seal counterface, minimising seal wear and protecting the shaft.
ERIKS Industrial Products, Services & Solutions
FOOD AND BEVERAGE
STEAM AUDITS ENABLE EFFICIENCY IMPROVEMENTS #9
Problem: When acquiring a new boiler house the opportunity to review steam equipment arises. One brewer did exactly this since upon acquisition and review of their new boiler house they identified a number of older-style steam traps which weren’t in the best shape.
However, even after the inspection the steam traps were still failing. Since they had been so thorough it became apparent their testing system was not reliable enough for their requirements.
Solution: TLV were contacted to conduct a steam audit, which identified 8 faulty steam traps out of the 30 in the boiler house. These faults had cost ÂŁ3000 in wasted energy.
The accuracy of the audits undertaken by TLV has given the brewer confidence in their new boiler house and can be assured when future audits are undertaken by TLV efficiency improvements can be made.
FOOD AND BEVERAGE
WASTE REMOVAL IN VEGETABLE PROCESSING #10
Problem: A salad vegetable processor in England was removing processing waste from lettuce, broccoli, carrots etc., using horizontal grinders over wide throat pumps. This was problematical as they were not hygienic and product bridged above the cutters of the grinder, resulting in serious production downtime and excessive repair costs to the pump. Solution: SEEPEX open hopper pumps with integral knives (BTM range) were designed to fit into the production area. They are made from stainless steel and comprise an auger inside the hopper to feed product into the knives. Once chopped the product is pumped away in enclosed pipework to a dewatering device before disposal to compost.
In this case the standard design was adapted to eliminated bridging and to incorporate a stone trap to remove contaminants before pumping the waste away, all designed and installed by SEEPEX engineers. SEEPEX BTM pumps also remove waste chickens, fish, mixed food and fruit peel from many processing sites.
ERIKS Industrial Products, Services & Solutions
FOOD AND BEVERAGE
ACCURATE DOSING AND EASY CALIBRATION #11
Problem: Heineken at Hereford, who make Bulmers cider, were having problems with their diaphragm pumps which dosed sweeteners, colours and other minor ingredients into their cider. The pumps needed frequent maintenance which was expensive and time consuming. Additionally, due of the pulsating nature of the flow a lengthy re-recalibration had to be done after each overhaul. Solution: SEEPEX progressive cavity pumps, from the dosing range D were chosen to replace these due to the very low pulsation flow characteristics. The flow rate is directly proportional to pump speed and accurate to +/-1%. Calibration is straightforward – speed up for more flow and slow down for less and installation is also streamlined with no need for ball valves or pulsation dampeners.
Hygienic dosing pumps were fitted in stages to all the ingredient dosing stations and have resulted in accurate dosing with reduced costs, maintenance is less frequent and, when it does occur, less costly.
FOOD AND BEVERAGE
TABLETOP METAL CHAIN REDUCES ENERGY CONSUMPTION #12
Problem: A large beer brewery was experiencing high noise levels and high energy consumption of drives on their 60,000 bottles per hour returnable beer bottling line. Solution: RexnordÂŽ 661 Series TableTopÂŽ Metal Chain was installed at the discharge section of the labeling machine and the complete section between the filler and the pasteuriser. The chain combines a lightweight stainless steel one-inch pitch - straight running and side-flexing - with reduced side-flexing gaps to provide smooth and efficient conveying ideal for beverage fill lines.
The customer acknowledged the benefit of the Rexnord 661 Series TableTop Metal Chain in combination with rubbercovered return rollers. The noise level of the conveyors dropped significantly which means a better working environment for the line personnel.
Besides noise level reductions, we were able to reduce energy consumption. As a result of the 25% reduced weight of the Rexnord 661 Series TableTop Metal Chain, power consumption of the drive motors has been reduced by more than 14%.
ERIKS Industrial Products, Services & Solutions
FOOD AND BEVERAGE
PSX MATERIAL ELIMINATES EXTERNAL LUBRICATION #13
Problem: A large beer brewery is operating a 90.000 c/h can filling line. They were looking for a solution to completely eliminate the need for external lubrication without making any concessions to can filling speed and line efficiency. Solution: The complete can filling line has been equipped with Rexnord® Flush Grid TableTop® Chain in PSX® Material in combination with Rexnord ULFTM Combi-X corner tracks. The Rexnord PSX Material selected for this project resulted in large savings on water usage and lubrication costs plus dry production floors improved worker safety in the production hall. The friction level of Rexnord PSX Material on the dry running conveyors is low and constant, which is important to maintain the optimal product flow and have minimal backline pressure on the delicate cans.
The chains in Rexnord PSX Material and Rexnord ULF Combi-X corner tracks show minimal wear after more than two years of continuous use. Ensuring maintenance costs for the conveyors are minimal, giving them the full benefit of the dry running solution.
FOOD AND BEVERAGE
PRODUCTION INCREASE WITH IGUS CHAINFLEX® #14
Problem: A confectionary production facility in Yorkshire was experiencing high control cable failures on its Sorting Beds, resulting in frequent downtime for the company which were reducing production volumes drastically.
The standard cables used were subject to constant flexing motion for which they were not designed, therefore were failing approximately every 5 weeks.
Solution: igus chainflex® cables were the perfect solution! Using their range of CF130 chainflex® cables the downtime experienced by the customer could be reduced significantly – Since installation in 2016 there have been no registered failures!
igus PVC Control Cables were designed to be a cost effective solution for indoor applications, which proved perfect for the environment at this factory. It also resulted in minimal cost increases to switch to a product designed to cope with continuous flexing motion, increasing uptime and production throughput.
ERIKS Industrial Products, Services & Solutions
FOOD AND BEVERAGE
AUTOMATIC LUBRICATORS SIMPLIFY MAINTENANCE #15
Problem: A brewery in the North of England had a manual lubrication schedule in place on their bottling line. However, this was proving to be a time consuming practice for the engineers, and resulted in concerns being raised about whether the lubrication points where being lubricated correctly. Solution: Following a demonstration of Simatec’s Simalube Automatic Lubricators the brewery decided to change their lubrication maintenance routine. They installed thirteen lubricators to meet the demands of the bottling line.
As a result they found grease usage is easier to monitor as each Simalube can be set to an individual dispensing rate, ensuring that each bearings lubrication requirements are exactly met. The improved lubrication control has increased the reliability of the bottling line whilst reducing the overall cost of maintenance.
PROBLEM SOLVERS
COMBAT CROSS-CONTAMINATION WITH OXYBAC #16
Problem: 5.5million people are affected by food poisoning in the UK each year, according to the Food Standards Agency (FSA).
A foodborne illness can originate from several sources but it is clear that robust hand hygiene is vital for safe food production. Poor personal hygiene accounts for up to 40% of food related outbreaks,*1 yet only 47% of staff wash their hands before preparing food*2
Solution: Food sector specialists, Deb, provide a comprehensive hand hygiene package for the workplace incorporating, specialist advice and surveys, training resources and high performance products. OxyBAC® is their HACCP certified antimicrobial hand wash, effective against bacteria and many common viruses. An enhanced formulation is now available – the faster-acting OxyBAC® works in half the time, just 30 seconds of contact time delivers a 99.999% kill rate.
Gentle on the skin and with no toxic residue, it’s safer for the environment too. OxyBAC® forms part of Deb’s specialist range for the Food industry. Source: *1 Journal of Extension, 2009, Vol 47, No. 1.
*2 Food Standards Agency (FSA)
ERIKS Industrial Products, Services & Solutions
PROBLEM SOLVERS
AUTOMOTIVE
#17
FOOD AND BEVERAGE
CONTENTS ISOLineâ„¢ makes cylinder installation easier
18
New OLED display increases visibility
19
Boron cutter makes short work of spot welds
20
AUTOMOTIVE
ISOLINE™ MAKES CYLINDER INSTALLATION EVEN EASIER 135 #18
many years and in some of the most harshest and challenging environments. ustry leading 2-year warranty.
Problem: The specialist knowledge needed for cylinder installation in the harsh conditions of commercial vehicle sector.
anges include names such as IMI Norgren, Pneufit, Enots, IMI Herion, Martonair, t.
Solution: IMI Norgren’s ISOLine™ offers customers a ‘fit and forget’ SIMPLE MODs AVAILABLE system that simplifies installation, increases service life and Ext’d piston rod (/IU), M/50 series reduces maintenance costs. The range introduces the IMI different rod thread, end caps turned Norgren Adaptive Cushioning System (ACS) which automatically Ext’d piston rod (/IU), M/50 series plus bracket adapts application without the need for any manual different rod to thread,an end caps turned adjustment of the cushion screw. SWITCHES
M/50 series plus bracket
M/50 series plus bracket
M/50 series plus bracket
M/50 series plus bracket
M/50 series
PNEUMATICS
M/50 series
Ext’d piston rod (/IU), different rod thread
This removes the need for any specialist knowledge for setNone up and simplifies the installation process, for safer, smoother operation making it easier for customers to fit to a machine. Also, the ACS None will adjust to any changes in the application, such as varying loads, which could occur over a cylinder cycle, a working None shift or the life of the machine. This helps ensure the application always runs efficiently. Conforming to ISO standard 15552, the None product range is up to 20% lighter than previous pneumatic cylinders,Noneproviding improved performance.
M/50 series (up to 4")
None
N/A
None
N/A
None
ERIKS Industrial Products, Services & Solutions
AUTOMOTIVE
NEW OLED DISPLAY INCREASES VISIBILITY #19
Problem: A UK based firm specialising in the maintenance and repair of Porsche motor vehicles required a solution that would enable their mechanics to accurately set a torque wrench in fairly subdued and dimly lit environments. There was a problem with inaccurate setting of traditional torque wrenches due to lack of light. In dimly lit environments, such as working underneath a vehicle, it can be difficult to clearly see the scale and accurately set the torque. Solution: The Norbar ClickTronic® does not require the user to set a cursor on a graduated scale, something that is problematic in poor light. Instead ClickTronic® uses a bright and easy to read OLED display, providing the user with clear torque information which is clearly visible in dimly lit conditions.
With several models, covering from 10 to 340N·m, to choose from there is a ClickTronic® that will meet your requirements. The display will indicate the exact torque value set by the mechanic and can be seen from any angle. All tools are accurate to ±3% of reading.
AUTOMOTIVE
BORON CUTTER MAKE SHORT WORK OF SPOT WELDS #20
Problem: A large fabrication workshop were experiencing problems, when drilling Boron spot welding on cages. It’s resistance to conventional cutting tools, such as spot weld drills, and standard cutters etc. were ineffective. Solution: A new three cutting edged Boron Cutter was developed with multilayer alloy coating technology. This gives the drill bit the ability to cleanly cut through these new materials. Extreme high heat insulation and dispersion characteristics, offer excellent wear, prolonging tool life.
This technically advanced drill is more effective and cost efficient when drilling through these new high strength materials. Correct cutting fluid will also extend the life of the drill bit.
ERIKS Industrial Products, Services & Solutions
AUTOMOTIVE
MINING AND QUARRYING
#21
FOOD AND BEVERAGE
CONTENTS Keeping mills operating and revenue rolling
22
Exceptional protection in every environment
23
Bearing inserts for harsh environments
24
Don’t throw away the old belt just yet...
25
Easy installation with Fenner Taper-Grip
26
PROBLEM SOLVERS
KEEPING MILLS OPERATING AND REVENUE ROLLING #22
Problem: A large cement mill operator was experiencing problems in the rotary kiln and cooling system. The flexible coupling connecting the motor to the pump was causing distress. Solution: Three fundamental factors need to be considered to maximise production rates and in turn to reduce total cost of ownership, safety, reliability and ease of maintenance. In order to achieve this, the equipment needed to be upgraded. The Falk® Wrapflex® Elastomeric Coupling is an innovative ‘Replace in place’ coupling that allows quick, easy installation and replacement without needing to move driven or driver equipment. The flexible element is retained after failure, helping minimize the potential for damage or personal injury.
Next to this, Wrapflex Couplings are non-lubricated material couplings featuring tough polyurethane elements with excellent wear and chemical resistance. Advanced manufacturing methods and innovative material offer higher capacity ratings at a more competitive price than ever before possible.
ERIKS Industrial Products, Services & Solutions
PROBLEM SOLVERS
EXCEPTIONAL PROTECTION IN EVERY ENVIRONMENT #23
Problem: A quarry was suffering major issues with the availability and reliability of a critical conveyor. The quarry’s remote location meant that maintenance work was challenging, costly and potentially dangerous. A catastrophic failure of a bearing on the conveyor’s head pulley resulted in the entire facility being shut down for six days, costing tens of millions in lost production. Solution: The company decided to install the SKF Three Barrier Solution. This innovative system is perfect for heavily contaminated environments such as quarries and construction sites.
Incorporating a standard SNL housing, a sealed SKF Explorer spherical roller bearing, SKF Taconite Seals and SKF Biodegradable Bearing Grease LGGB 2 in the housing which acts as a contamination barrier. This cost-effective solution creates three barriers to prevent the ingress of contaminants such as dust and grit, and ensure continuous smooth running.
As a result of installing the SKF Three Barrier Solution, the conveyor pulley’s meantime between failures increased from two years to more than four, bringing greater reliability and significantly reducing maintenance costs, downtime and lost production.
PROBLEM SOLVERS
BEARING INSERTS FOR HARSH ENVIRONMENTS #24
Problem: A major aggregate producer was experiencing regular failures of the housed bearing units on their stone conveyors. Ingress of dust and dirt, as well as impacts to the seals was identified as the route cause of failure. Solution: A NTN/SNR AGR insert was supplied to replace the existing bearing insert, providing enhanced sealing for such an aggressive environments along with a more robust shield against flying debris.
The heavy-duty zinc-plated shield provides protection against impacts, and the internal triple lip seal provides excellent resistance to the ingress of contamination.
As a lubricated for life bearing, the customer no longer needed to consider re-lubrication intervals, particularly beneficial where access to bearings was difficult.
ERIKS Industrial Products, Services & Solutions
PROBLEM SOLVERS
DON’T THROW AWAY THE OLD BELT JUST YET . . . #25
Problem: If you are operating equipment using a conveyor belt you will experience the belt cover wears through in some parts over time and might face the renewal of the whole system. At best, the conveyor will have to be removed from service long before its time. At worst, the damage could lead to catastrophic failure, loss of production, unscheduled maintenance downtime and even injury. Solution: The LOCTITE Conveyor Belt Repair offers the solution. A US mining company uses this system on its stone conveyors, and has restored belts to full working order within just two hours. An Australian manufacturer has achieved repairs in the same time-scale – in a ship-loading application that had been losing up to £7,000 per hour through delays caused by belt damage. But it’s not just cost savings from quick and timely repairs that make this LOCTITE solution so effective. A quality repair can even extend belt life too – by up to 70% in most cases.
PROBLEM SOLVERS
EASY INSTALLATION WITH FENNER TAPER-GRIP™ #26
Problem: The stone-washer drive at a local quarry had broken down. Following an inspection it was noted that the current shaft mounted gearbox was under-rated for the application. Solution: After calculating the exact power requirements for the application a Fenner SMSR gearbox was selected. However, the larger gearbox has a 125mm hub and would not fit the existing 120mm shaft, so the ERIKS Drives team set to work converting a standard bore gearbox to the innovative Fenner Taper-Grip™ bush locking system, which when supplied with a 120mm Taper-Grip™ bush could be easily fitted without any additional modification required to the machine.
The unique Taper-Grip bush locking system allows Fenner SMSR’s to be secured to the driven shaft thus overcoming the difficulties that can be experienced with other methods of mounting - particularly in corrosive environments.
ERIKS Industrial Products, Services & Solutions
PROBLEM SOLVERS
GENERAL ENGINEERING
#27
FOOD AND BEVERAGE
CONTENTS Quick and easy fast bonding
28
Teeth strippage eliminated with versatix blades
29
Storage solutions built to last
30
400% increase in productivity with Rocol RTD
32
Get up and running in minutes with PowerTwist
33
Flexpak high bay luminares light the way
34
Just the ticket for extreme applications
35
Unplanned stoppages stooped by WEG
36
Laser aids belt drive alignment
37
Ensuring machine safety
38 39
GENERAL ENGINEERING
QUICK AND EASY FAST BONDING #28
Problem: A manufacturer of plastic moulds was experiencing failures and damage of inlet and outlet tubes on their moulds. This was costing time and money in drilling out and replacing the water inlet ports which are subject to temperatures of 100°C. Solution: Using the new LOCTITE Hybrid adhesive technology, LOCTITE 4070, a new design for the inlet and outlet ports on the mould was possible. LOCTITE 4070 is a 2-part, cyanoacrylate/ acrylic hybrid gel adhesive that provides a fast fixture at room temperature, bonding gaps up to 5 mm. Suiting various substrates including most plastics, rubbers and metals.
The solution provided the fast bond strength required for the design of the mould, high temperature resistance, durability and was quick and easy to apply. Thus the time and cost wasted in repairing the ports on an ongoing basis, was eliminated.
ERIKS Industrial Products, Services & Solutions
GENERAL ENGINEERING
TEETH STRIPPAGE ELIMINATED WITH VERSATIX BLADES #29
Problem: A well known fabrication company were experiencing major teeth strippage of their band saw blades when cutting tubes, structural beams and other types of intermittent cutting.
This wasn’t the only issue, this was becoming a common fault with interrupted cuts, Starrett R&D decided to find a solution to the ongoing problem.
Solution: Starrett designed, developed and patented a new revolutionary tooth profile which set new standards in intermittent cutting. The Starrett Versatix MP Band Saw Blade is ideal for cutting structural steels, sections, tubes and solids and can easily cope with shock loading conditions associated with manual pull down machines on interrupted cutting.
GENERAL ENGINEERING
STORAGE SOLUTIONS BUILT TO LAST #30
Problem: A customer had been on the same site for 15 years, they are a successful business and as such had outgrown their existing premises and invested in a new building. Planning the move, and focusing on LEAN production, the engineering manager assessed current issues:
Time wasting - Organic growth meant that there was no recognised storage location for specific tools, operators were having to walk between cells searching for tooling and components.
Efficiency – tooling and components stored were not stored relative to the area and the process required within that area.
Security - some components were being ‘lost’ due to the unrecognised set location and unsecured storage especially for higher value tooling.
The old workplace storage system was mismatched and worktops, internal components, locks and divider kits were not suitable for the job at hand.
ERIKS Industrial Products, Services & Solutions
GENERAL ENGINEERING
#31
Solution: Bott arranged a site visit to understand the operations performed in this new area. Drawings were prepared showing the necessary storage for each cell to optimise production. The result was a fully functional workshop that offered:
Shadow boards for easy access to tooling, and immediate visibility of missing items. Drawer cabinets with specific divider systems to suit components per area, and drawer labelling for identification. The drawer configuration within each cabinet was tailored to suit the customer who needed higher drawers at the bottom for larger components. Worktops to suit each different area, lino covered tops for working with oil and grease and steel clad worktops for heavy engineering use with hot components.
All cupboards and cabinets were lockable, with the engineering manager having a master key to ensure security and access to storage on both day and night shifts. The customer was delighted in the professional appearance of their new workshop
All Bott products come with a 10 year guarantee, so they can rest assured that their investment is truly Built to Last.
GENERAL ENGINEERING
400% INCREASE IN PRODUCTIVITY WITH ROCOL RTD® #32
Problem: A well-known Precision Engineering company were experiencing difficulties due to a competitor’s fluid failing under pressure, incurring unsatisfactory surface finish, broken taps and reworked/scrap components. Solution: The RTD® range of hand applied cutting lubricants were the ideal solution for this issue. RTD is still the world’s leading hand applied lubricant for Reaming, Tapping and Drilling. Offering 9 different variants of the product from liquids, compounds and sprays.
For this application RTD compound applied directly by brush, did not break down and delivered an improved surface finish on threads, producing over 1000 threads without a failure. Furthermore, this resulted in a 400% increase in productivity.
When investing time and money into complex components, manufacturers cannot cut corners on tapping or reaming those final holes due to the high risks associated. Therefore in production processes where damage and breakages can mean significant cost increases, using RTD helps to minimise these risks and provides the ability to…Cut with confidence.
ERIKS Industrial Products, Services & Solutions
GENERAL ENGINEERING
UP AND RUNNING IN MINUTES WITH POWERTWIST #33
Problem: A large engineering company in the North of England were experiencing problems with regular belt failures, however they carried little or no stock on site and required urgent assistance each time. Solution: Whilst the customer investigated the root cause of the failures, ERIKS suggested the customer stocked Z, A and B sections of Fenner PowerTwist.
This emergency belt can be made to any length in minutes with no special tools, getting your plant up and running immediately, whilst the replacement rubber belts are in transit. In this instance saving the customer 4-6 hours on downtime.
GENERAL ENGINEERING
FLEXPAK HIGH BAY LUMINARES LIGHT THE WAY #34
Problem: To provide a lighting solution that would provide good uniform light distribution for a busy warehouse facility that could be mounted at a high level. Solution: Quick and easy to install and commission, Thorn FlexPak LED high bay luminaire comes with wireless control and provides all of the advantages you would expect from the latest LED technology, including maximum energy savings.
The luminaire is available in 8000, 13,000, 17,000, 23,000 and 31,000 lm, all with a constant lumen output feature and a choice of wide beam and very wide beam optic. With single-suspension mounting especially suitable for refurbishment, the luminaire offers features and performance for flexible use in a classic round high-bay shape.
A chain suspension clip can be ordered separately, alternatively, a cord suspension is available in 3 different lengths. For ceiling mounting, stirrups are available including tilt adjustment. They are also available with an innovative radio frequency node to connect with remote IP65 sensors.
ERIKS Industrial Products, Services & Solutions
GENERAL ENGINEERING
JUST THE TICKET FOR EXTREME APPLICATIONS #35
Problem: A manufacturer of outdoor ticket dispensers was experiencing problems when the machines were installed outside with selfservice use. The existing adhesive solutions used bonding Ferrite magnets to a cast aluminium, and were not withstanding the extremes of temperature and vandalism. Solution: LOCTITE HY 4090 adhesive technology was successfully used to bond the magnets to the disc in the ticket machine.
LOCTITE HY 4090 can withstand temperatures from -40 to +150°C and therefore the ideal product to withstand the temperature extremes. It also has very good humidity resistance, an added bonus as the units can accumulate condensation. The company also since used the adhesive to bond plastic and metal fixtures that were previously been detached due to vandalism.
LOCTITE HY 4090 is one of a range of Hybrid technology products from Henkel extending the limits where adhesives can be used.
GENERAL ENGINEERING
UNPLANNED STOPPAGES STOPPED BY WEG #36
Problem: Due to the high mechanical stress on the V-Belts at start up, a well known company was having to change belts in its HVAC system at regular intervals. This not only cost money for replacement belts but also down time due to maintenance stoppages. Solution: The WEG SSW900 soft starter provided the solution to this problem.
Not only did this product reduce the shock loading at start up, it also acted as a protective device for the motor.
The number of belts being used has been drastically reduced and stoppages are now a thing of the past.
ERIKS Industrial Products, Services & Solutions
GENERAL ENGINEERING
LASER AIDS BELT DRIVE ALIGNMENT #37
Problem: A large OEM customer who manufactures blower units were having problems installing belts and pulleys accurately under tight time constraints. Each drive package was taking up to 3 hours to install and tension correctly. Solution: It was suggested that using the Fenner Drive Alignment Laser Tool would aid quick and accurate alignment.
The old method meant that any adjustment needed to tension the belts could alter the other elements of the drives alignment due to its design.
The use of the Fenner Drive Alignment Laser meant there was a visual guide from the laser light so you could see what effect any adjustments had with regard to alignment, therefore fine adjustments could be made either axially or angularly dependant on the movement of the laser.
Belts could now be tensioned in minutes, rather than in hours.
GENERAL ENGINEERING
THE QUICK EXHAUST WAY TO INCREASE SERVICE LIFE #38
Problem: A large machine builder wanted to increase their service life of its central components and safety level for a new pilot installation. Solution: After careful consideration the customer decided to opt for Festo’s MS9-SV-C soft start/quick exhaust valves.
The MS9-SV-C caught the customers attention as it sets itself apart from other air service units, the combination of a pressure build up function with an on-off and exhaust valve so that devices can be fully exhausted and there is no residual pressure. Having these two functions in a single housing not only saved them valuable space, but also ensured greater operating safety during commissioning and maintenance and protected central locking pneumatic components, axes and shock absorbers in their engineered application.
Due to the success of the trial of the MS9-SV-C the customer is now well positioned to deliver greater security and performance as well as reduced costs. The machine builder now uses the MS9-SV-C as standard in their engineered solution.
ERIKS Industrial Products, Services & Solutions
GENERAL ENGINEERING
THEY’RE NOT BIG . . . BUT THEY ARE CLEVER #39
Problem: After undertaking research with professional technicians, Carl Kammerling identified that over 85% of them carry a non-insulated stubby screwdriver. Despite understanding the importance of using insulated tools, they were putting their lives at risk when working with electricity in confined spaces, there was simply no other solution when their usual VDE screwdrivers would not fit. Solution: The C.K Stubby VDE Slim Screwdrivers filled this gap in the market perfectly, by featuring a shorter length (ideal for use in confined spaces) and full VDE approval, providing the assurance that each product is individually tested to 10,000V for safe working up to 1,000V.
The Slim shafted insulated blades allow access to recessed screws and fixings and their short length makes them ideal for use in confined spaces. The set has 4 tip types that cover the majority of requirements and are made from premium quality chrome vanadium steel which are 100% German manufactured to ensure exceptional quality, strength and durability.
EB251/0818© ERIKS Industrial Services, all rights reserved.
ERIKS UK & Ireland Amber Way, Halesowen, West Midlands, B62 8WG
0121 508 6000
ERIKS Dublin
ERIKS Cork
ERIKS Belfast
00353 1856 8540
00353 21 4232204
02890 612416
www.eriks.co.uk UNREGISTERED