PDATE May 2022
Reducing your off-grid carbon footprint
Fulton’s Leigh Bryan looks at the options for hitting the magic net zero target by 2030
See page 66
PDATE May 2022
Reducing your off-grid carbon footprint
Fulton’s Leigh Bryan looks at the options for hitting the magic net zero target by 2030
See page 66
At the forefront of digital marketing, Engineering Update strives to bring its readers the latest in industrial engineering, in a format that provides the best usability and ease of use for it’s readers.
Publication Director Kane Weller 01843 580 460 Kane@engineering-update.co.uk
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Kane’s Notes The Engineering sector continues to be squeezed by supply chain disruptions across Europe and the UK. Political factors, the covid crisis and the war in Ukraine mean that innovation is not just the key to thriving, but now surviving in the sector. As many businesses look to localize their procurement and streamline their operations, this has gone hand in hand with the need for companies to intensify their message and keep themselves in the conversation. Events and publications are becoming increasingly important for both buyers and sellers, (we ourselves have seen a 32% percent increase in monthly impressions since January!,) and in this issue, we highlight a number of upcoming events. We also look at innovative software and how certain companies are employing agile manufacturing to stay relevant and keep ahead of the competition. We hope you find it useful!
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SME Manufacturers Call For Supply Chain Support THE LARGEST UK EVENT DEDICATED TO DESIGN ENGINEERING
Modern-Day Supply Chain Resilience
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Railtex / Infrarail
30% Growth After Implementing MRP System During Pandemic
27-28 APRIL 2022
12-13 October 2022
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Stay up-to-date with all the opportunities and challenges facing the sector through inspirational keynotes, case study led presentations and interactive panel sessions. Browse the latest cutting-edge technology, projects and innovations spanning the length and breadth of UK engineering. The best part... you can join us wherever you are and it’s all free to attend.
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Sector Can Reduce Carbon Emissions
SME Manufacturers Call For Supply Chain Support As Government Eyes New Business Support Landscape Supply chain support and longer-term assistance are at the top of the wish list for UK manufacturing SMEs if they are to make the most of the post-pandemic recovery and the long-anticipated UK Shared Prosperity Fund. Over three quarters of the 335 firms questioned by the Manufacturing Growth Programme (MGP) in its latest report indicated that supply chain improvement would make them more profitable, while grants to help them buy new equipment and invest in new technologies to support digitalisation would make the biggest difference to their ongoing performance. The survey - the largest ever undertaken on the future of industrial business support - showed that management teams wanted access to specialist external advice and funding to drive profitability (68%), increase
sales (62%) and to boost productivity (58%). 75% felt that leadership and management training is beneficial, whilst 83% said they wanted business support to be delivered by experts with significant industry experience, such as the MGP Growth Managers. Unsurprisingly considering the growing environmental agenda, just over a quarter said they want to use assistance to help them move towards Net Zero to meet new sustainability targets and make the most of the green economy.
ENGINEERING PDATE “We are operating in unique times, with companies looking to recover from the aftereffects of the pandemic but against a volatile backdrop of supply chain disruption and rising inflationary pressures. It is critical that Manufacturing bosses continue to receive specialist support to rebuild their growth strategies,” explained Dean Barnes, Regional Director of the Manufacturing Growth Programme. “Manufacturing is responsible for 10% of national GDP and still accounts for half of the UK’s goods exported and nearly two thirds of all R&D activity in this country. These reasons alone mean we need to understand what industry wants and needs to grow.” He continued: “The report clearly underlines some common themes and the need for assistance to be longer-term to deliver the most benefit and, importantly, for in-depth supply chain support alongside more grants to be available to spend on capital purchases. “These are important messages to be sending out to Government as they look to reshape the business support landscape.” The recent Levelling Up White Paper released earlier this year laid out plans to ensure that manufacturers, from across all sub-sectors, are automating, decarbonising and building resilience by 2030. This will be achieved by maximising existing spending and nonspending policy levers and strategic investments to attract, anchor and grow supply chains, working closely with local leaders, industry and academia. The Manufacturing Growth Programme continues to contribute to achieving this strategic vision. Funded by the European Regional Development Fund (ERDF) and delivered by Oxford Innovation Advice, the initiative was launched in 2016 to create a targeted service to support manufacturing SMEs by delivering business improvement projects in strategic planning, productivity and process
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improvement, competitiveness, innovation and leadership and management. It has assisted more than 4000 companies to date, providing over £12m of grants and helping to create or safeguard 9200+ jobs, with nearly £20m of private sector investment also leveraged. Digital marketing and e-commerce, productivity strategies, quality standards, business and growth plans and new product development have been the most popular forms of help.
She went on to add: “With funding due to change, it’s now time for Government to build on this good work, whilst also listening to what firms are telling us – most noticeably to make it easier to access capital grants and for the support to be longer-term and strategic.” Like many businesses, The Manufacturing Growth Programme had to pivot during the pandemic, developing a ‘Crisis Management Framework’ as an engagement tool for SMEs.
This meant that firms knew the route to market to access essential support during Covid-19 and this helped them make the necessary changes and business strategy adaptations to remain operational and in a good position to maximise the recovery. Jane concluded: “We’re at an exciting stage of development with the race for electrification gathering pace and digital manufacturing starting to play a bigger role in industry. Now is the time to help SMEs join this journey and contribute to the Government’s overarching ‘levelling up’ agenda.”
“Levelling up is one of the Government’s key commitments and MGP has been doing exactly that since 2016, with more support and activity undertaken in transitional regions across the country to help them ‘level up’ against the more developed areas outside of London,” added Jane Galsworthy, Managing Director of Oxford Innovation Advice. “We have given the powers that be a blueprint for how they deliver industryspecific support that tackles low levels of productivity, failure of SMEs to seek assistance and lack of innovation in our smaller manufacturers. For further information, please visit www.manufacturinggrowthprogramme.co.uk or follow @mfggrowthp on twitter.
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Lamonde Automation Limited Quality Products: Expert Advice
Safe for use in hazardous areas, ATEX certified installed LED lighting is now available from Wolf Safety
Wolf Safety have introduced a powerful new range of ATEX certified LED installed lighting, designed for permanent use in potentially explosive atmospheres. The world’s leading manufacturer of portable and temporary ATEX and IECEx certified hazardous area safety lighting, Wolf have been keeping people safe for more than 110 years. The company’s designers and production engineers have now brought their vast knowledge and expertise to bear on a new range of highly effective LED installed lighting, which is safe to use in Zones 1 and 21 hazardous areas.
DLO directs light exactly where it’s needed and is ideal for use in specific, close-up workspaces, reducing glare to avoid people being ‘blinded’ by the emitted light, while its excellent colour definition facilitates safety critical hazardous area tasks. Forward Facing Array (FFA) technology can be preferable for safely illuminating large hazardous areas which need wide, even and bright light coverage, where lights are mounted away from people or at heights where glare and intensity can’t have an adverse effect on the working environment. Says Miles Jackson, Wolf Safety’s Sales and Marketing Director:
The range includes: •
Linear luminaires featuring the new, revolutionary Directional Linear Optics (DLO) or standard Forward Facing Array LED configurations (with battery back-up emergency versions also available); • Floodlights with a market leading maximum light output of up to 25,932 lumens; • Bulkhead lighting, also featuring DLO (with battery back-up emergency versions also available); • High bay lighting.
“We know that users of Wolf products trust us to keep them safe, especially when they need to work in highly volatile atmospheres and other hazardous workplaces. “All the values people expect from Wolf - and are seen in our portable and temporary lighting ranges - can now be found in this new installed lighting range, which we are proud to introduce.” For detailed technical information visit: www.wolfsafety.com
Snap-on’s Level 5™ asset management system is network ready As engineering managers cope with relentless pressure to deliver improved productivity, often with fewer skilled hands and tighter budgets, the benefits of professional tool storage and management become stronger than ever. Snap-on Industrial’s Level 5™ automated total asset management system brings order to any workplace, enabling engineers and technicians to know exactly where to find every tool they need, when they need it, saving time and easing stress.
How useful would it be if all your workshop’s valuable tools could be tracked from one central point? Snap-on’s Level 5™ system makes that possible. It provides complete reports on everything managers or supervisors need to keep an eye on. They are even informed when a tool needs to be refilled or ordered. And then there’s FOD. The threat of foreign object damage is a real and present danger in many engineering workplaces. Using Snap-on Level 5™ minimises the risk of human error, as automated tool control constantly tracks every tool and detects which tools have been removed or returned, ensuring greater protection against FOD. Engineered to track individual tools by user, without bar codes, scanners, RFID tags or other add-ons, the system works at the speed its users demand. Other systems require additional steps to scan or log activity. The Snap-on system does this automatically so users save time and don’t have to depend on other steps to ensure accurate results. Snap-on’s Level 5™ ATC boxes are network ready, using either Ethernet or wireless connection. That enables users to review activity at all Level 5 boxes in their location from one central computer, avoiding the time consuming need to inspect each box.
Major benefits of the system include: • No individual tool scanning required; • No RFID tags to install or replace; • No limitations on tool size: from ¼” screwdriver bit to just less than the size of the drawer; • Intuitive interface, with an easy to use touchscreen • Audible voice confirmation of tool removal and replacement • Automatic locking for maximum security • Errors announced and displayed to indicate incorrect tool position or advise when a drawer is not closed. Says Richard Packham, Director UK & Europe for Snap-on Industrial: “Snapon’s automated system takes asset management to an entirely new level. The ability to monitor several boxes from one central computer offers a huge advantage to engineering managers.”
For technical details visit: www.snapon-industrial.co.uk, call (01536) 413904 or e-mail: firstname.lastname@example.org
AZM150 SOLENOID INTERLOCK: SLIMLINE DESIGN WITH 360 ROTATING HEAD AND 1400 NEWTON CLAMPING FORCE O
The AZM150 solenoid interlock can be combined with three different actuators for different installation situations: a straight actuator for sliding doors, an angled actuator for large revolving doors and a movable actuator for smaller revolving doors. One of the plus points of the interlock is the rotating actuator head which can be locked simply by putting the lid on rather than a screw fitting. The rotating actuator head has two feeder slots to enable a range of installation positions and approach options. This makes the interlock really flexible to use. The AZM150 is an electromechanical design which can be combined with high safety standards. The interlock comes with a low coding level as standard but is also available with an optional high coding level. The benefit for users: In accordance with ISO 14119, a higher coding requires fewer measures to prevent the bypassing of locking mechanisms, such as fitting out of range or in a concealed position. Schmersal is the only manufacturer which can offer electromechanical safety switches and solenoid interlocks with high coding levels. Scan the QR code to see the AZM150 in action or visit our website for more information.
SCHMERSAL | Enigma Business Park Malvern, Worcestershire, WR14 1GL
Modern-Day Supply Chain Resilience Never before has modern-day manufacturing needed to be as resilient as it is today, as supply chain issues continue to evolve at pace. While risks within global supply chains are omnipresent (shipping, port delays, customs, and general logistical hold-ups), recent events have propelled this to the forefront of many businesses operating considerations - in every corner of industry.
aw material availability, compounded by labour shortages and freight challenges have found manufacturers learning hard lessons, forcing them to rapidly adapt to volatile market conditions as increased demand outstrips production volumes. Long gone are the days of viewing supply chain as a singular element, replaced by an acute awareness of the whole spectrum of constantly moving parts that make up this critical service. With the tumultuous state of supply chains, now is the ideal time to reassess sourcing and procurement
issues, futureproofing in the long-term against external factors and removing needless complexity. Where disruptions and reliance on an uncertain vendor-base have highlighted the cost and reliability risks inherent in modern world supply chains, these challenges have made way for greater forecasting, greater control of costs and ultimately, a renewed approach to externally sourcing parts and goods. Manufacturers are actively shifting focus - decreasing reliance on overseas supplies and an emphasis placed on supply visibility, communication and a need for realtime data and predictive analysis to
allow companies to be proactive in production forecasts, costs reduction and increased efficiencies. For Optimas Solutions, a leading global distributor and manufacturer of industrial fasteners, C-Class components, and data-driven inventory management systems, this is where the company excels. Already renowned for providing customers with supply chain solutions that elevate efficiencies, the company has, in more recent times, invested huge sums of money into powerful industry-standard software for increased demand planning and inventory optimisation and an advanced ERP system that allows for greater control of internal data and a maximised synergy throughout its entire global footprint. While there’s no escaping the fact fasteners are a low value commodity, overlooking or not placing importance on this critical part can bring production lines to a stop. Fasteners are in essence holding production lines together, both figuratively and
literally and perhaps are the least of manufacturers worries until something does go wrong, be that supply, or a quality issue. Optimas’ manufacturing facilities, on both sides of the Atlantic, are clearly positioned to help alleviate impacted production schedules through its expertise in fasteners, bolstered by some of the most advanced cold form technology available. As supply chains continue to buckle under pressure, localising
supply has never made more sense – allowing manufacturers to access high-quality product, in a much smaller timeframe and negating the need for unnecessary inventory surplus. So as industry battles with a once-in-a-lifetime seismic shift, manufacturers can learn to use data and forecasting to decrease risk and increase efficiency by partnering with onshore suppliers capable of keeping production lines moving.
For further details on Optimas visit: https://international.optimas.com
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RMIG is the world’s largest manufacturer and supplier of perforated metal and its related products. We know our customers’ requirements for price and quality and meet their demands with uncompromising service. Not only do we offer standard and bespoke perforated metal sheets, we are able to offer you a range of secondary operations as detailed below. Complete solutions With a continued investment in the latest equipment and a network of professional partners we are able to produce prime quality products and solutions – from a simple perforated sheet to the fully formed and coated custom made part.
Cutting We can cut and shape perforated sheet to meet the needs of your final application. Levelling For some applications a high degree of flatness is required, we have processes in place to ensure our perforated coils and sheets meet with your most demanding requirements. Rolling and forming We can roll, bend and form perforated sheets to match your design. Aesthetic finishes and protective coating We can offer powder coating and hot dip galvanizing solutions to meet your specifications.
For more information please contact us tel: 01925 839610 | email: email@example.com | www.rmig.com
Ahead of the Curve:
Titan Enterprises Celebrates Over 40 Years of Innovation In a constantly fluid economy, continuous innovation is a primary focus for the manufacturing industry in order to maintain its footing.
itan Enterprises has been manufacturing optimised liquid flow metering solutions for more than 40 years. Supplying a diverse range of industries, Titan’s design and engineering expertise is fundamental to the company’s success. Trevor Forster, Managing Director of Titan Enterprises, founded the company in 1981 with the aim of producing modestly priced, highquality, low flow measuring devices for OEM customers. Trevor recognised from the outset that improvisation and creativity were the key to securing their footing in the market, delivering affordable and lasting solutions that resolved issues for their customers. Titan’s R&D is primarily driven by customers looking for solutions that
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will support their specific applications and deliver more efficient, reliable and accurate results. “More than once we’ve been told ‘You can’t do that’, but we’ve just done it anyway!” Trevor recalls. “The way we work with customers from research, development, through to production has enabled us to solve a lot of OEM application issues,” Trevor adds. “Through that process, we’ve helped customers decrease their assembly times, improve efficiency, and provide extra functionality.” R&D projects could be anything from testing new materials for longer life, chemical inertness, robustness, testing under high pressure or temperature or software development. Design improvements and technological
advancements are focused around finding innovative solutions for our OEM customers, pushing the boundaries of both the physical properties and performance of the products.
Work on developing a viable, accurate ultrasonic meter began in 2001 with a collaboration between Titan’s R&D team and The Cranfield Institute of Technology. The resulting patented ultrasonic technology led to an expanding line of Atrato® ultrasonic flowmeters.
Some of Titan’s most popular flow meters have been born out of collaborations. “We have a proud history of working with some of industry’s key players, such as Coca Cola Enterprises Ltd, RS Components and Vianet, to industry specialists like Formula 1, the Virgin Atlantic Challenger II team, Paxman Coolers, Stored Crop Conservation and Green Fuels,” Trevor says. “Our USP is our flexibility, adaptability and ability to work with customers to understand their applications and find workable solutions.”
“We do not shy away from spending on Research and Development. Industry doesn’t stand still and investing in R&D is paramount to us staying ahead of the game and taking advantage of the latest technologies. Our R&D spend is 20% of our turnover where the norm is 8-10%,” Trevor says. The focus technology for Titan at present is our ultrasonic liquid flow measurement devices. Taking our Atrato® ultrasonic flowmeter product design understanding, we have pushed both electronics and physical design to improve the overall performance window. From our extensive pioneering work with a USA medical company to produce a disposable ultrasonic flowmeter that measures the volume of liquid manually injected into a patient, to recently launching our new software interface for the Atrato. Trevor concludes, “When you are confident in your own capabilities, willing to take a few risks, invest resources into R&D and know what your customers and market want, taking on challenges can be very fruitful.” To discuss an optimised flow measurement device for your OEM application please contact Titan Enterprises on +44 (0)1935 812790 or email firstname.lastname@example.org.
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On track: Rail supply sector to meet at Railtex / Infrarail 2022, setting out roadmap for progress
Following last year’s successful return from the pandemic, it’s now full steam ahead for the spring edition of Railtex / Infrarail, the number one showcase for railway technology and infrastructure in the UK. Taking place from 10–12 May 2022 at Olympia London, the popular exhibition will once again bring the entire rail supply sector together, presenting the latest developments in sustainable and smart rail operations. Plenty of products and services, impressive on-track displays and a high-profile conference programme will help attendees to find, assess, and source the best suppliers and technical solutions for their specific railway needs.
More than just an exhibition •
On–Track display: Placed in the hall, one length of track will be used by exhibitors to display and demonstrate tools and equipment in an authentic rail setting. Strong conference programme with 40+ speakers: A comprehensive supporting programme, including insights from leading industry figures, keynote addresses and industry seminars centred on the latest developments in the industry, organised by the main show partner Railway Industry Association (RIA).
CPD accredited programme: The sessions are all free to attend, and CPD certified.
Matchmaking: Numerous networking opportunities, allowing exhibitors and attendees to foster new relationships and strengthen existing ones.
Plant and Machinery exhibits: Exhibitors can bring and display larger plant and machinery products for railway works.
RBD Eagle Lab, RIA SME Hub and Recruitment Wall.
Railtex / Infrarail will take place from 10-12 May 2022 at Olympia London. Opening times are from 10 am to 5 pm on 10th & 11th May, and 10 am-4 pm on 12th May. Visitors can now register in advance via the show website and benefit from FREE entry tickets and fast-track admission to the event. Entry tickets are valid on all three days of the exhibition and include free access to all conferences and associated events.
Find out more: www.railtex.co.uk
International Exhibition of Railway Equipment, Systems & Services International Railway Infrastructure Exhibition
ON TRACK FOR THE FUTURE
10 – 12 May 2022 | Olympia London For the first time, Railtex / Infrarail takes place at Olympia London, covering all aspects of railway technology, including:
• • •
Infrastructure Rolling Stock Rail+
• • •
Passenger Experience Net Zero And many more
MORE THAN JUST AN EXHIBITION! Extensive conference programme CPD ACCREDITED On-Track display
Recruitment wall Plant and machinery exhibits
hotocentric are leading the way in helping businesses evolve through additive manufacturing. They have been extremely successful in bridging the gap between prototyping and injection moulding for clients from all industries, using LCD screen technology for 3D printing. Whether trialling new products, looking to begin rapid production whilst waiting on tooling, producing on a lower volume, looking for a speedy go to market response or delivering bespoke products, Photocentric has been able to help clients adopt additive manufacturing. The newly launched Photocentric LC Opus delivers fast, highly accurate prints, suitable for a huge variety of industries and applications. It’s intuitive, simple operation and UV open source freedom of material choice, makes the LC Opus perfect for beginners and experienced users.
The LC Magna delivers significant speed, volume and cost savings. The evolution of the LC Magna continues with a host of new features added, LCD printing and the LC Magna 3D Printer continues to represent the pinnacle of Photocentric’s product development. The versatility of the LC Magna supercharges product design enabling you to move from prototyping to production, in hours. With end use parts comparable to injection moulding, whether it's a small batch, on demand or full production the LC Magna consistently delivers accurate end use parts at scale and is the essential choice for those seeking an agile and flexible solution for product manufacture.
Micron Sprayers A few months ago 3DGBIRE headed to Micron sprayers to see how they were adopting the Photocentric LC Magna, they impressed our
technical trainer Steve Taylor with their seamless transition from FDM to Resin printing. Micron Sprayers Ltd has been established since 1954 and is a leading manufacturer of specialist sprayers and weed control equipment for a wide range of applications worldwide. Micron decided that the next step was to move into custom mass manufacturing with the Photocentric Magna, as a lot of their products were designed by injection moulding. By 3D printing, Micron Sprayers have been able to get prototypes out there quickly, change them and test how certain parameters affect results. Book a free consultation with one of our experts to learn how you can adopt additive manufacturing into your business: https://bit.ly/consultation3DGBIRE
Erwin Hymer Centre Travelworld is one of the UK’s leading motorhome dealerships. With the largest array of premium German brand motorhomes, they are perfectly suited to meet the current unprecedented demand facing the UK market.
Efficiency of Space at Erwin Hymer
fficiency of space was a key consideration when designing their new 20-bay service area and showroom. By investing in a new automated storage and retrieval system, they were able to deliver greater customer engagement.
The Erwin Hymer Centre has established itself as the company’s premier spare parts division. Their Service Centre and MOT testing facility delivers innovative solutions to their customers. Delivering new parts and accessories in real-time was a priority when designing the Service Centre, to ensure customers received their parts as soon as they were stocked in automated systems. Kardex enabled Erwin Hymer to store all parts in a single Vertical Lift Module (VLM) unit, close to the bespoke manufacturing department, as 80% of vans require bespoke parts (often one offs), Kardex helped establish speedy customer service. A customised solution based on a standard Vertical Lift Module (VLM) utilised the overhead space, which operates like an elevator. It’s comprised of a shaft in the middle
with two columns of trays and shelving, which contains hundreds of motorhome parts and accessories for fast retraction. Alongside the economy of space, the warehouse management software Kardex Power Pick System provides valuable data insight using algorithms. Data is produced on various topics, including the most popular parts ordered, as well as the ideal amount of stock to have of a certain product. Using this knowledge, they can store three quarters of their inventory within the system. Moreover, the Kardex solution allowed them to increase order throughput as well as reduce the number of personnel by more than half. Next to this, the faster and smarter processes brought on by the custom solution, allowed Erwin Hymer to deliver innovation and excellence to customers visiting their service centre. For more information contact Kardex direct: firstname.lastname@example.org or visit our website at www.kardex.com
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Evaluate. Adopt. Optimise. Analyse the opportunity Discover your application Learn from user success stories Understand capabilities and limitations Choose the right solution Optimise existing technology Consider enterprise adoption Ensure return on investment
With more than 80 speakers and 150 exhibitors, discover your additive strategy at TCT 3Sixty.
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Introducing Famatel Eventline Catalogue 2022V1 Famatel UK LTD a r e manufacture and distributor in the South west of England, We are also member of “Made in Britain” they bring together the British manufacturing community and upholds the made in Britain high standards. With this in mind we have launch our new catalogues for down load and announcing our partnership with GIFAS Electric (Germany), who has a close working relationship like us with our customers and staff to produce high quality Power distribution system servicing many market sectors across the UK and Ireland. We bring together UK manufacturing with German Engineering in perfect harmony, and the new range we are developing brings a quality build power distribution assembly to the UK.
Please visit www.famatel.co.uk and click the download section to view our range .
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Selected radiation resistant fixed focus and zoom lens designs (courtesy : Resolve Optics Ltd)
rawing upon over 25-year experience of the nuclear industry – Resolve Optics can quickly adapt existing designs to produce optimised non-browning fixed focus and zoom lenses for Nuclear Systems Integrators supplying monitoring systems to operate in medium and high radiation environments. Suppliers of tube or shielded CMOS cameras, for use in the nuclear industry, require lenses and optical systems that can withstand exposure to high levels of radiation and sometimes endure extreme temperatures. Resolve Optics has built a strong international reputation for design and manufacture of smaller production quantities of radiation resistant lenses and optical products on time to strict quality and target price guidelines. All optical elements used in Resolve Optics radiation resistant lens designs are made using cerium oxide doped glass or synthetic silica enabling them to withstand radiation doses of up to 100,000,000 rad and temperatures up to 55°C without discoloration or degradation of performance. These radiation
resistant lenses provide high image resolution and minimum geometric distortion from 400 to 750nm. Today Resolve Optics non-browning lens expertise is helping nuclear systems integrators operating in a growing number of different and interesting applications subject to radiation including suppling the lenses for use in a high-radiation-resistant pan-tiltzoom tube camera deployed in Chernobyl, Ukraine. For further information on the Model 357 non-browning zoom lens please visit www.resolveoptics.com/nuclear/ or contact Resolve Optics on +44-1494-777100 or email firstname.lastname@example.org. Resolve Optics offers an extensive range of nonbrowning (radiation resistant) fixed format and zoom lenses for use in environments subject to radiation. All these lenses are manufactured to the highest standards of quality and performance. In keeping with Resolve Optics tradition of designing unique lenses the company is also able to provide custom nonbrowning lenses to meet your exact specification.
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MR Swing handles help put the squeeze on litter Swing handles and hinges from Telfordbased access hardware manufacturer Industrilas have been specified as part of a new, automated smart wastebin that is delivering significant cost savings to municipal authorities - as well as helping to keep towns and cities tidier
Fill is a unique waste bin which harnesses solar power to drive a compactor that compresses the litter which people feed into it. By reducing down the volume of the rubbish in this way, a typical MR Fill bin can hold up to five times as much as an ordinary standard bin of the same size – which results in far fewer visits being needed to empty it. Some of the numbers involved in the collection of this type of waste are surprising – in Amsterdam the council empties normal bins up to seven times a day, a number that is now massively reduced thanks to the MR Fill solar powered compactor bins. So the advantages seen from this clever design include reduced vehicle emissions by cutting down council truck journeys, less congestion on the roads, and a tidier environment. Cost savings to authorities of up to 75% are claimed by the manufacturers of MR Fill bins. Launched with a 120 litre capacity, the product portfolio has since grown to include 240 litre versions: and the bins themselves are said to be 98% recyclable. All bins can be connected to MR Fill’s bespoke digital platform called Smart City Manager which communicates with the bins 24 times a day via an app, allowing precise condition monitoring and obviating unnecessary visits to check bins which don’t actually need looking at. Industrilas provides swing handles and hinges for the MR Fill smart bins, with the products featuring on every version as the uptake spreads across Europe.
Industrilas GB half pp generic.pdf ENGINEERING PDATE
04/03/2022 May 2022
The complete range of quality access hardware from Swedish manufacturer Industrilås is now available direct from its Telford ofﬁce and warehouse. Most items are ex-stock. Key advantages to designers and users include: Ease of assembly Secure Choice of key locking options Ex-stock or bespoke designs to customer speciﬁcations ✔ Massive range of options
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Details available from Barry George • email@example.com Industrilås GB • Halesﬁeld 17 • Telford TF7 4PF Ofﬁce: 01952 580 845 • firstname.lastname@example.org • www.industrilas.com
Accreditations: ISO 9001 • ISO 140O01 • DIN EN 61373
The swing handles, available in various sizes and in a variety of materials and finishes, are used to lock and open each MR Fill smart bin. Industrilas also supplies the hinges featured on the lids of each model in the MR Fill range too. These are just part of a large hinge range that encompasses many different types including lift off, concealed, friction, internal and external in a number of metal and plastic finishes. The contract is a significant one for Swedish manufacturer Industrilas, with smart waste bins now being used in 30 countries and growing. “High quality is still the main focus for us” says MR Fill’s Theo Kik. “Our products should always be top quality and with a solid partner like Industrilas providing great solutions, we never have problems with the handles and hinges” he concludes.
Prima Tooling Ltd are established as PCD and Carbide CNC Tooling Manufacturers and distributers of standard and bespoke cutting tools. Providing quality precision rotary cutting tools for Wood and Composites. Formed in 1979 we are built on over 40 years of experience in manufacturing PCD, Carbide CNC Tooling and HSS Tooling. From our Essex base in the UK we supply tooling to companies such as aerospace, automotive, defense and woodworking industries. Our woodworking tools are available through a network of distributers across the UK, Ireland, Europe, Canada and USA. What may not be so familiar is that prima Tooling are also a distributer of Engineering tooling for machining applications such as Endmills, Drills, Taps and reamers manufactured by Sutton Tools. With four manufacturing operations Sutton Tools are Australia’s only production manufacturer specialist and supplier of globally competitive quality cutting tools. Stocked in Europe, with a fuss free delivery, we are able to provide customers
with cost effective solutions for the reliable machining of a variety of materials used in various sectors including Aerospace, Automotive and general engineering industries. The HARMONY range of endmills offer the very best in cutting tool technology and are used predominantly in High Temp alloy applications and also when performance machining is required. Sutton Tools compliment his range with the TECLINE brand which offers a reduced cost alternative. Both Prima Tooling and Sutton Tools also offer a one-stop shop for 'specials' giving our customers the ability to be efficient and productive. Our Services Offering tool design and manufacture we are able to advise on the best cutting material for the job. Above all our experienced staff can advise on the right tool for the application. With this in mind we heavily invest
in the latest technology to keep up with the current tooling needs, in both our standard and bespoke tooling. With our sharpening and repair servicing of all tooling
from any manufacturer; we are able to offer a complete solution to Precision Cutting requirements. Most importantly, if you have a problem we will help you to find a solution.
THE LARGEST UK EVENT DEDICATED TO DESIGN ENGINEERING
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27-28 APRIL 2022
BACK FOR 2022! THE VIRTUAL EVENT FOR THE ENGINEERING DESIGN SECTOR
Stay up-to-date with all the opportunities and challenges facing the sector through inspirational keynotes, case study led presentations and interactive panel sessions. Browse the latest cutting-edge technology, projects and innovations spanning the length and breadth of UK engineering. The best part... you can join us wherever you are and it’s all free to attend.
Interested in exhibiting? Head to the website to find out more about our virtual booths and sponsorship opportunities.
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Experience Rittal live! There are only weeks to go until the 2022 Drives & Controls exhibition which is held at the NEC Birmingham from the 5th-7th April. With a wide and diverse range of over 400 companies exhibiting , the show provides a unique opportunity for engineers to experience latest technologies in Automation, Power Transmission, Motion Control Equipment and Systems.
s a global leader in mechanical and electrical infrastructure, you would naturally expect Rittal to have a strong presence at the show, this year we are on stand E100. For our total presence, also exhibiting is our sister company, EPLAN a leader in electrical design software on the same stand. Rittal and EPLAN provide a partnership that delivers a unique approach to the industrial automation process from design to deployment and all points in between. Discover at this year’s Drives & Controls how Rittal and EPLAN bring together a modular engineering philosophy, precise and automated Rittal Automation Systems machines, and powerful, database-driven electrical engineering.
Rittal – The System” on show at Drives and Controls 2022 Visitors to Rittal’s Stand E100 will be able to see Rittal’s renowned infrastructure solution - widely specified as the No.1 choice for protecting critical equipment.
With a range of innovative enclosures for internal and external applications, climate control heating and cooling systems, power distribution switchboard and motor control products on display – plus some exciting new product innovations. We’re taking the opportunity to take not only our VX25 baying system but also our AX and KX range of small enclosures. These innovative ranges demonstrate how Rittal can offer time saving cost effective solutions for a wide range of industries. In addition, we’ll be show casing our new VX 25 Ri4power system, the modular based switchgear system ideally suited for both Power Distribution Systems and Motor Control Centre’s. Cooling solutions are key to effective and efficient enclosure solutions, at this year’s Drives and controls be sure to check out the new IIoT Interface. This allows Blue e+ cooling units to be networked with customer-specific monitoring and energy management systems. This in turn makes it possible to add new applications such as
The Blue e+ range has become the industries leading enclosure cooling solution, with energy savings of up to 75% its difficult to see how Rittal could improve the range. Be sure to check out our stand for a sneak peek at our latest ground-breaking development to the Blue e+ range The Rittal team will be on-hand to discuss key issues: Our experts will be available at the show to answer some of the key issues facing the industry in today’s challenging and ever-changing environment. • How can systems and people be reliably protected against danger? • How can power consumption be made transparent and significantly reduced? • How can maintenance scenarios for cooling devices be planned in advance?
UNIQUE SYMMETRY. INFINITE POSSIBILITIES. 88|
• How can enclosures in the food industry be hygienically climate controlled? • How can controller and switchgear manufacturers implement Industry 4.0 solutions, automate production processes and set up data centres quickly and easily? • How can Smart Production facilities face the change of creating IT infrastructure in harsh environments So let our teams guide and assist you with any current applications or requirements you have for protecting critical equipment and delivering game-changing industrial automation. The digitalisation of Smart Production - Shielding your IT equipment in harsh environments The development of Smart production facilities creates challenges when creating the IT infrastructure to support the latest technologies such as IOT devices, robotics and the collation of industrial analytics. Frequently these new technologies require IT to get closer to Smart production equipment to improve the speed and reliability of data communication. This means that increasingly IT has to move out of its secure computer room and be located on the factory or shop floor. Rittal will be using the event to exhibit quick and easy IT solutions for all
applications. IT product highlights on display at the show will include the NEW VXIT Rack and IT cooling units.
Smart Engineering at Eplan Thanks to the synergies between EPLAN systems and Rittal products, almost all aspects of control panel manufacture can be automated, which shortens processing times, minimises the risk of errors, optimises the use of materials and increases productivity. At this year’s Drives and Controls 2022 EPLAN will be showcasing innovative solutions for enhanced engineering
efficiency and the use of the digital twin. So, If you’re attending the show be sure to visit Rittal & EPLAN on E100 to Discover how Rittal & EPLAN can deliver major productivity enhancements in your business and see how both companies provide the winning combination that will help improve efficiencies for your business. For further information on the entire Rittal range visit www.rittal.co.uk or check out our linkedin page @rittal-ltd-uk
VX25. SYSTEM PERFECTION. More options, more efficiency, less effort: This is thanks in particular to a frame profile with a 25 mm pitch pattern that is symmetrical across all levels. The VX25 is also infinitely extendable and accessible from all sides – even from the outside.
SOFTWARE & SERVICES
T&D Corporation Mr Minoru Ito, European Sales Office, Gronauer Straße 1, 61194 Niddatal, Germany 0049 (0)6034 930970 firstname.lastname@example.org www.tandd.com
Unit 3A, Whitworth Court, Manor Park, Runcorn WA7 1WA. Tel.: (0044)-330 002 0640, email@example.com www.odu-uk.co.uk
Curtiss-Wright Surface Technologies
TR Fastenings LTD
European Corporate Office, Hambridge Lane, Newbury, Berkshire, RG14 5TU 01635 279621 www.cwst.co.uk firstname.lastname@example.org
Trifast House, Bellbrook Park, Uckfield, East Sussex, TN22 1QW Free phone: 08454 811 800 E-mail: email@example.com www.trfastenings.com
Phoenix Mecano Ltd
Blackfast Chemicals Ltd
26 Faraday Road, Aylesbury, Buckinghamshire, HP19 8RY +44 (0)1296 611660 www.phoenix-mecano.co.uk
Unit 5 Russell House , Molesey Road, Walton-onThames, Surrey, KT12 3PE 0207 339 7370, firstname.lastname@example.org www.blackfast.com
Ecopac (UK) Power Ltd
Monitran Ltd, Monitor House, 33 Hazlemere Road, Penn, HP10 8AD, UK T: +44 (0)1494 816569 E: email@example.com www.monitran.com
Unit 4, Ridgeway, Crendon Industrial Area, Long Crendon, Bucks, HP18 9BF Tel: +44 1844204420 www.ecopacpower.co.uk
Foremost Electronics Ltd
Seepex UK Ltd.
14 Bluegate Business Park Great Bardfield, Essex CM7 4PZ TEL: +44 (0) 1371 811171 FAX: +44 (0) 1371 810933 WEB: www.4most.co.uk
3 Armtech Row Houndstone Business Park Yeovil, Somerset, BA22 8RW
HRS Heat Exchangers 0-12 Caxton Way, Watford Business Park, Watford, Hertfordshire, WD18 8JY www.hrs-heatexchangers.com Email: firstname.lastname@example.org Tel: +44 (0)1923 232 335
T +44 1935 472376 email@example.com www.seepex.com
Mecmesin Ltd Newton House, Spring Copse Business Park, Slinfold, West Sussex, RH13 0SZ w: www.mecmesin.com t: +44 (0) 1403 799979 e: firstname.lastname@example.org
1 Brownfields Court Welwyn Garden City Hertfordshire, AL7 1AJ www.rotechmachines.com
BÜLTE GmbH Kunststofferzeugnisse Carl-Sonnenschein-Straße 22 D-59348 Lüdinghausen – Germany Phone: (+49) 02591 / 91 94 – 0 email@example.com www.bulte.com
Wood Automated Systems UK (ATG – Systems) Tenter Road, Moulton Park Industrial Estate Northampton, NN3 6AX +44 (0)7827 327231 Tim.Bednall@woodplc.com www.the-atg.com
Lascar Electronics Ltd UK Module House Whiteparish, Wiltshire SP5 2SJ +44 (0)1794 884 567 firstname.lastname@example.org www.lascarelectronics.com
Rotech Machines Limited
Pets versus cattle:
Cloud Computing in Manufacturing The benefits of cloud-native applications in manufacturing
he cloud-native approach is often conceptualised using the “Pets vs. Cattle” DevOps concept, which compares traditional server systems, which are unique and cared for, to pets and cloud systems to cattle. Cattle are identical, assigned, scalable systems where if one of the systems were to be unavailable or fail, the whole network would not be affected. In this piece, Neil Bellinger, head of EMEA at global automation parts supplier EU Automation, delves into the native cloud and why it is the future of manufacturing. Given the value of the cloud, one wonders why the manufacturing industry is resisting the move to cloud-native systems, especially
with companies already using various cloud-based applications.
training more than 200 specialists for its cloud-innovation centre.
Until recently, manufacturing industries have been up to date with the latest innovations, from production tracking systems to artificial intelligence. Although financial and retail sectors have followed business giants like Netflix and Spotify, many still resist the switch to cloud-native. While 83 per cent have a strategy for cloud implementation established, many still struggle to visualise the business value and cost savings of the cloud-native approach. However, forwardlooking businesses are making the first steps in this direction. For example, one company currently implementing cloudnative applications is Volkswagen,
Cloud-native is the term used to describe software and services that run on the internet instead of a local computer system, allowing businesses to be faster and more agile. Cloud-based applications, however, are not created in the cloud but instead transferred from an in-house web application to a cloud server. This cloud-based system allows for the availability and scalability of cloud-native applications without redesigning current applications. Cloudenabled is similar to cloud-based, with the migration of the traditional application to the cloud. However, it does not have easy availability and scalability of cloud-based or cloud-native. continues on page 40....
Protecting Your Plant Before
Rotech Motion Sensor’s can be used whenever information or monitoring of shaft rotation, position, direction, speed, slip etc is required! Rotech Motion Sensor’s can be used for indication, control, interlocking, protection, sequencing, alarm initiations and many more functions! Rotech Motion Sensor’s can be used wherever materials are transported or processed By conveyors, elevators, screws, mixers, etc!
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RELIABILITY Tel : +44 (0)151 356 2322 Website: www.rotechsystems.co.uk Fax: +44 (0)151 356 2437 Email: email@example.com
Monitoring the world
...continued from page 38
Some examples of cloud computing in the manufacturing industry are cloud-based marketing, product development, production and stock tracking, and productivity management. The responsiveness, innovative features and zero downtime deployment of the cloud-native model provide businesses with a database needed to succeed in modern times. Successful examples of this implementation are Netflix and Uber. Netflix currently operates using over 600 services, with an update rate of around 100 times per day. The structural design of the cloud-native enables the rapid response, scalability, and selective deployment observed in companies such as Uber, Netflix and Spotify.
The cloud-native revolution cloud-native model can also Cloud-native is the clear future of all businesses, including manufacturing. As seen in the last two years, implementing changes to aid when mass disruption like the pandemic occurs is extremely important for business survival. With accessibility possible from across the globe via the internet, the cloud-native approach is the best change companies could make. The restriction of large on-premise systems has held back the manufacturing industry for years, but cloud-native applications enable companies to use small, reusable and independently deployable microservices. It can also allow the automation infrastructure, application delivery, recovery and scaling to increase, providing a more resilient and high performing system. The
aid in lessening the strain of managing back-end software and infrastructure. Cloud-native apps also enable the sharing and analysing of data across the organisation by being the central repository for data flowing from sensors, machines, programmable logic controllers (PLCs), and more. At EU Automation, we value the importance of keeping with the times and understanding the cost of downtime. Cloud-native is the next step in lessening the impact of failures in company systems. If you wish to stay informed about the developments of the cloudnative approach and how to unlock success in an industry 4.0, visit EU Automation’s Knowledge Hub.
Outdoor solutions: Not all enclosures are created equally Author: Emma Ryde
he need for outdoor systems is increasing, due to the ever-expanding requirement for all things to be connected. This need will only increase but it is paramount that when a system is to be placed outside serious consideration, is given to the design of the housing that the critical infrastructure equipment, will sit in. Whether it be telecommunication, rail, airports or highways the overriding factors are the same. Outdoor enclosures usually contains, critical infrastructure equipment and as such we need to ensure that we are protecting that equipment. The key question from within industry is, why would you put equipment in an enclosure that isn’t specifically designed to work in that environment? Rittal’s product manager for industrial and IT enclosures Emma Ryde, often asks, why do people continuously put important pieces of equipment into an enclosure that will most likely leak, allow the equipment inside to overheat, or cause condensation during the winter months, as well as offering no form of security protection, against individuals who wish to gain access, to damage or remove the equipment. In larger or more critical applications, the equipment placed internally will cost in excess of tens of thousands of pounds, In industry today more than ever before we are seeing businesses, choosing enclosures based on cost, rather than its ability to protect critical equipment. The enclosure itself, is just as important as the equipment it is protecting. It is key to bare in mind that if the enclosure fails, then so will the infrastructure it protecting. When deciding on the most suitable outdoor solution for your project or network, Rittal’s experts advise you decide what factors are most critical to you and your application and do your research before you select an enclosure, simply
because its labelled ‘Outdoor’ does not mean it has the right characteristics, to face the elements and securely protect your critical equipment.
Protection from the elements included When an enclosure spends its lifetime outdoors, it will most likely face many years the hottest summers and the harshest winters, the most vulnerable part of the enclosure, is usually the door seals. Protecting the door seals means prevention from water leakage into the enclosure, this in turn increases the enclosures lifespan. Water that is contaminated can cause degradation and over time the seal will fail, in many cases the seals can’t be replaced. This then becomes a costly fix with the requirement for a new door or a new enclosure. Adding an after market seal often means a compromise and the IP rating no longer be valid. Water sitting on the seal during the colder months can freeze, as the water expands it will push the door away from the body of the housing and again, allows water inside. The best way to avoid these types of issues, is to choose an enclosure that has an overhanging roof, or a design that protects the doors seals. Standard enclosures that have no
Enclosure Climate Control Whatever the scale...... ......we have the solution ENCLOSURES
such design features, meaning often they are unsuitable to be placed outdoors.
Security and vandalism Security and vandalism is one of the most concerning issues, when placing equipment outside and in public spaces. Selecting an enclosure, where careful consideration has been given to the design, to prevent vandalism or a member of the public gaining access to the enclosure and its contents is key. Although eradicating this possibility completely is slim. However you can select an enclosure that has features that act as a deterrent. If someone wants to gain access then they will attack the weak points, of the enclosures first, these being the handle and lock then they may also look at the hinges of the door, if these are visible. Choosing an enclosure where different handle and lock options are available, having a lock inserted that requires a specific key and cannot be opened with a tool. Hidden hinges on the doors also prevent unauthorized access, when trying to prevent someone gaining access. In most cases, this only needs long enough before they are disturbed, or they get bored of trying. Hidden hinges mean they cannot easily remove the doors, trying to gain access in other ways, will then mean bigger tools or more noise. Both of which again are usually a deterrent enough.
Double walled protection as standard Double walled enclosures offer huge benefits for outdoor applications. Not only by helping to regulate UV solar gain, but a double walled enclosure means it is twice as hard to gain access to the equipment inside, if you don’t have the authority. Double walled enclosures offer a chimney style effect, to eradicate some of the heat created by UV Solar gain. Whilst it does not stop all of the heat transfer, the outer layer assists with reflecting some of the light and what is transferred through the outer wall, some of this is then taken away between the two layers up and out of the roof area which is ventilated. Any heat gain left along with heat generated by the equipment inside, should then be able to be dealt with
using a range of climate control options. This maybe simple fans and filters, louvre arrangements or by using forced air cooling. Considering if the enclosure you have selected can offer these options, as a retrofit at a later stage is key during the decision making process.
Climate control solutions More often than not climate control is hugely overlooked in outdoor applications, the assumptions is that any heat loss generated by the internal equipment, will be lost through the transfer of the walls especially when placing an enclosures in a cooler country such as the UK. Sadly experience tells us that this isn’t the case, sitting equipment in an enclosure works much like a flask, some heat transfer will be lost, but how much heat is being generated in the first place? Has a thermal calculation been carried out? If the enclosure is subjected to higher ambient temperatures, or more equipment is installed at a later date, can cooling be added as an option later on? These are important points that if considered early can save huge amounts of time and cost further down the line. Double walled enclosures also offer the benefit of refurbishment, in the event of damage. Rather than removing the whole enclosure, which would mean a shut down of the infrastructure network it is part of, then the outer walls can simply be replaced.
Durable enclosure materials Lastly are you using the right materials? Stainless steel outside may sound suitable, however its costly and again not always the right option. Painted aluminum means lightweight but durable and has the ability to be handled more efficiently, dependent upon the application GRP may offer more benefits and would be significantly cheaper than stainless steel. The next time you need an outdoor enclosure, I urge you to really consider the enclosure as a critical piece of equipment, within the project or build. Selecting the right solution initially will ultimately save and you time and money overall. For futher information please click here.
SOFTWARE & SERVICES
TF Automation support Parker Filtration with update to production line TF Automation were approached by Parker Filtration to replace and update part of a production line for the manufacture of oil filters. This is TF’s first of several automation projects for Parker Filtration, although we have supplied them with pneumatic components for a number of years. The machine was required to improve the production efficiency of what was a very high maintenance line to create a seam between an oil filter cylinder and cap, whilst also presenting the finished item correctly to its next stage of production. The design team at TF re-engineered the complete system using the existing conveyor loop provided by the customer. The filters are placed on the conveyor manually and the conveyor then moves the item to one of two seamer lift stations. Using pneumatics, the seamer lift station pushes the cylinder firmly into the lid to create the seam. The filter moves along the conveyor to the final station which lifts and turns the cylinder 180 degrees, using a servo lift axis which caters for different cylinder lengths. The cylinder is then correctly oriented for the next stage of production which is to screen print for identification purposes. The whole process is managed by a new control system designed by the TF project team. Tony Hubbert, MD at TF Automation comments, “We are delighted to be supporting Parker Filtration with updates to their production line and process efficiencies. We have supplied them for many years with pneumatics and industrial components, but this is the first of a number of automation projects we are designing and manufacturing for them in the coming months.” For more information please visit www.tfautomation.co.uk
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Creaform at Hannover Messe: Hall 6, Booth G30 Creaform announces its participation at Hannover Messe. The latest 3D measurement technologies will be presented there which, in the field of Industry 4.0 and digital manufacturing, help manufacturers to design and manufacture better quality products, while reducing lead times and costs.
he future of quality control in smart factories begins with the use of new approaches to quality control, including the use of portable or automated dimensional inspection systems directly on the production line. Advantages of portable 3D scanners With a 3D optical measurement solution, manufacturers have a fast, portable, accurate and versatile instrument for measuring, testing and validating parts and components during iterative product development processes, as well as during quality control and maintenance. Additionally, a color palette can be used to quickly identify discrepancies between a part and its CAD file. The software displays the results in a clear and intuitive way, which facilitates the analysis. Unlike probing measurement, 3D scanning displays an overview of the inspected part and measures surface profiles, not just individual points. With the portable 3D scanners Go!SCAN 3D, HandySCAN 3D and MetraSCAN 3D and the 3D measurement software VXelements, Creaform provides the tools that the industry needs to perform precise measurements directly in the production environment. Online and offline metrology solutions Many manufacturers are turning to online and offline metrology solutions, including 3D scanners, to automate their inspections and quality control. Solutions such as Creaform's MetraSCAN 3D-R robot-mounted optical 3D scanner and CUBE-R, a fully customizable, turnkey, automated 3D scanning CMM, are game changers and enable manufacturers to perform quality control fully automated. Automated 3D measurement solutions are used for a wide variety of different applications, including in-process inspections of parts and tools, online and offline ISPs, inspections of supplier parts before they go into production
and the digitization of quality control records for archiving, traceability and updating old plans. “Hannover Messe is for us an important platform for presenting our technologies to the manufacturing industry and winning new customers", comments Pierre Tanguy, Sales Country Manager DACH. Creaform at Hannover Messe: Hall 6, Booth G30
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6 Ways the Manufacturing Sector Can Reduce Carbon Emissions The UK has a net-zero carbon emissions to hit by 2050. To help them hit that target, all businesses across every sector must reduce their CO2 output. According to the March 2021 Industrial Decarbonisation Strategy, the manufacturing sector accounts for a sixth of all greenhouse gas emissions within the UK, indicating that there is a lot of work needed in the sector to reduce emissions.
here’s no suprise why the manufacturing sector is one of the biggest carbon emissions contributors in the UK, due to its energyintensive processes. So with that it’s not possible for the sector to completely eliminate those emissions however, there are ways in which it can reduce them and balance them out to reach a level of carbon neutrality. In this article, we’ll look at how at how the sector, if it uses the right machinery and components can accelerate the route for not only reducing its greenhouse gas emissions but also save money in the long run.
Invest in quality machine components A lot of manufacturers tend to invest in cheaper machinery and parts that help them minimise the hefty upfront cost, but this can lead to more expensive route in the long run. In many cases, cheaper machinery and parts are made with cheaper materials. This means that they’ll have a shorter shelf-life than higher-quality items, so you’ll be required to replace these parts more frequently. This also creates more waste, which has a serious impact on the environment.
Switch to renewable energy sourcing equipment There are some machinery and components that run on fossil fuels, which are one of the biggest contributors to climate change. Switching to equipment that runs on renewable energy will save you money in the long run and allow you to dramatically reduce your carbon emissions.
The production of certain materials can also require a lot of energy being sourced such liquid silicone rubber, which requires temperatures of 179–198oC. Other materials, like most plastics, are well-known for their reliance on fossil fuels. By reviewing the raw materials you work with and the products you create, you can further cut down your energy requirements and move to renewable sources.
Opting to multitasking equipment One key way that manufacturers can cut down on their energy costs and therefore their carbon emissions is to make use of multitasking equipment. These machines combine several processes – for example, cutting processes – which would have traditionally been carried out by multiple machines in one solution. This would help companies reduce setup and manufacturing time dramatically by getting more processes done in one go.
Having fewer machines on the go for one project will reduce the amount of energy required to produce materials or items, which has the double benefit of reducing business’ energy costs and carbon emissions. It also means that manufacturers will require fewer component parts for multiple machines. Fewer machines will free up factory space and increase business’ output efficiency.
Effectively maintain your equipment There are significant ways to extend the life of manufacturing equipment it maintain it effectively. Equipment maintenance will vary based on the machinery itself, but generally speaking, maintenance is straightforward. Setting up processes for qualified technicians to regularly review your machinery is essential, but there are steps you can take yourself. Cleaning your equipment and its component and keeping them free from debris is an essential step,
because this can heavily impact their efficiency. In the shipping industry, energy-efficiency regulations have come into place that include keeping the propellors and other underwater parts of the ships clean, reducing waste heat production and the need for frequent new replacement parts.
Stop energywasting leaks Leakages are one of the most common energy-wasting problems with manufacturing equipment. While checking your equipment is essential for general maintenance, including leak checks is recommended. This will allow you to spot and fix any leaks before they become a bigger problem. Using the right type of seal on your cylinder parts will help prevent leakages in the long run.
Seek sustainability into your supply chain Its not just business practices that need to be switched for a more sustainable outlook, which would ultimately reduce your carbon emissions. The same can be said about your suppliers? If the businesses you’re sourcing your machinery and raw materials from aren’t sustainable, you may still be indirectly contributing to greenhouse gas emissions. Sustainability is a key requirement in tender process, for many businesses, with others reviewing their suppliers based on their green credentials. A brand’s sustainability credentials are more important than ever, with research showing customers are seeking companies that are
environmentally friendly. But large businesses including Nike and Adidas have come under scrutiny for poor practices in their supply chains. The fashion giants were found to use suppliers that discarded toxic waste in rivers in China, but the backlash was primarily aimed at those brands. For the UK to meet its net-zero target, sustainability and reducing carbon emissions is essential for all business. As one of the biggest contributors to greenhouse gases in the UK, the manufacturing sector has a large role to play. By addressing the machinery and component parts your business uses, including how and where you source them, how you use them, and how you maintain them, you can reduce your emissions to support important environmental causes.
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Be inspired by innovation at Advanced Engineering Find out what’s in store for this year’s attendees On November 2 and 3, Advanced Engineering will return to the NEC, Birmingham for its 13th edition. With 80 per cent of exhibitor space already sold, engineering and manufacturing businesses should act fast if they want to secure a stand. Last year, over 7,000 people attended across the two days, including representatives from Airbus, Jaguar Land Rover, Alpine F1, Ford, BAE Systems, Rolls-Royce and the Ministry of Defence. This edition of Advanced Engineering will celebrate and display innovation, growth and development within the UK’s engineering industry. Across the show’s seven zones — aerospace, composites, automotive, advanced metals, connected manufacturing, space and satellite and, new for this year, product testing and quality control, businesses will showcase their latest, ground-breaking technologies and inspire cross-industry collaboration that pushes the UK’s engineering industry to new heights. Following the success of the 2021 edition, attendees also found the 60 hours of free learning, courtesy of the four forums scattered across the show floor, insightful and inspiring. Highlights included workshops and talks from automotive lifestyle blogger James William Walker, also known as Mr JWW, the Aerospace Technology Institute, Rolls-Royce, Airbus, ADS, the UK Space Agency, Jaguar Land Rover, Composites UK, BAE Systems Make UK and more. These four forums will return in 2022, sponsored and supported by companies including HP, University of Strathclyde, GRP Solutions, Euroresins, Cristex Composite Materials, Ripley Solutions and more. Advanced Engineering is the place to be for the UK’s engineering community. Exhibitor space is selling out fast. To book your stand, visit www.advancedengineeringuk.com and make an enquiry. Alternatively, you can contact our Head of Sales, Ali Farr on +44 (0)20 3196 4244.
2 & 3 November 2022 | NEC Birmingham
The UK’s LEADING annual gathering of OEMs and engineering and manufacturing supply chain professionals An absolutely outstanding event! We’ve met many great people who we will be looking to work with in the future, and overall it has been a very successful couple of days. Matt Travis, Engineering Manager, JCB
Scan the QR code to discover the event
Association partners Composites
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firstname.lastname@example.org | +44 (0)20 3196 4300 advancedengineeringuk.com
HARTING connectors deliver time and space saving benefits HARTING has been producing robust industrial connectors for over 75 years, with a focus on developing products which are easy to handle, durable and adaptable. Another important consideration is continuous innovation, an ethos which gives users reliable solutions even as their requirements evolve.
or example, using connectors in control panels has always involved a complex and time-consuming installation process. To enable companies to offer the flexibility of modular manufacturing, they now need the ability to change the configuration of their connections quickly and efficiently. As a result, HARTING have developed the Han-Eco® B, a new series of hoods and housings available in a range of designs including bulkhead, surface mount and cable-to-cable. They are manufactured from highperformance polyamide plastic, which offers IP65 protection and complies with standards IEC 61948 and EN 45545-2. In addition, the hoods and housings are suitable for both indoor
and outdoor applications, thanks to their resistance to environmental impacts. A big advantage of using Han-Eco® B in control panels is the time-savings that can be achieved, thanks mainly to the ability to rear mount inserts. As a result, engineers no longer need to install cables through the bulkhead mounted housing before assembling the contact inserts. Instead, pre-assembled inserts can be directly snapped into the housing from the rear, simplifying cabinet assembly and saving time. This development also gives you the flexibility to pre-assemble the switch cabinet units and cable harnesses separately, further improving efficiency and time-savings.
Both monobloc and modular inserts can be inserted into the Han-Eco® B housings, the latter in combination with the Han-Modular® hinged frame, giving you an unparalleled choice of data, signal and power options. Furthermore, the Han-Eco® B is entirely compatible with standard metal Han® B housings, meaning both variants can be integrated into your current production equipment. In addition to supplying standardised products, HARTING can also design and create custom solutions tailored to customer requirements. All customised products are built at their manufacturing facility in Northampton and are based on market-leading connectors from the extensive HARTING range, including M12, RJ45 and modular solutions. Using these standard products, they design and manufacture cable assemblies for a wide range of markets, including transportation, mechanical and plant engineering, automation technology, data centres and energy distribution. The HARTING manufacturing facility holds ISO 9001 certification for Quality Management, the ISO 14001 Environmental Standard and UL certification for Wiring Harnesses ZPFW2 / ZPFW8. To learn more about HARTING’s range of connector solutions, please visit www.harting.com or contact us via email@example.com with your query.
Smart ideas make work more efficient and faster. Han-Eco® B. Rear mounting option allows for the separate pre-assembly of cable harnesses.
The new connectors of the Han-Eco® B series provide valuable time advantages for equipment using the Han® B industry standard. Learn how! Han-Eco® B. Thought differently. Done better.
Ultimo empowers plant operators to protect uptime with autonomous maintenance Enterprise Asset Management (EAM) software provider Ultimo has added an autonomous maintenance feature to its platform to allow plant operators to carry out and track simple maintenance tasks using the same software as the maintenance team. Operators can manage recurring tasks, such as lubrication and inspection, independently and log them in Ultimo. This helps optimise uptime, as most issues can be avoided by ensuring that machines are clean and well lubricated. If minor problems occur, the operators don’t need to wait for the maintenance team to action them. It also bridges the communication gap between the departments, ensuring that every maintenance task is managed in the same software to increase asset availability, improve efficiency, and enhance safety. “Operators have a lot of knowledge about the equipment they work with, but organisations don’t leverage that resource,” says Chris van den Belt, Team Leader Product Management, Ultimo. “The operator standing next to the machine might be able to recognise a fault at an early stage and could often identify and fix many issues in a matter of minutes.
Having to wait for the maintenance team to arrive to solve minor faults is frustrating for them and inefficient for the business. Maintenance technicians, on the other hand, are frustrated by the fact that most failures are caused by improper operation, dirt and poorly lubricated parts.” By empowering the operators to look after first-line maintenance tasks, Ultimo helps organisations move away from the siloed approach where one team uses a machine, and another maintains and repairs it towards a culture of shared responsibility and ownership. The operators don’t need to waste time waiting for minor tasks to be actioned, and the maintenance team can spend time on more valueadding activities. Maintenance costs are also reduced when minor tasks are carried out by operators with lower hourly rates than maintenance technicians.
The autonomous maintenance feature - which is fully integrated in the Ultimo Shift Handover module – is designed as a simple, easyto-use checklist functionality. It allows operators to log their repairs quickly, include pictures, and escalate jobs to the maintenance team, improving collaboration between the departments. A recent survey of asset managers (EAM Trend Report 2021) identified poor communication between teams as the second most significant threat to uptime, only preceded by the risk posed by ageing assets. Autonomous maintenance helps address this issue, ensuring that vital information on asset health and safety is shared between the teams for the benefit of the entire business. To find out more, visit www.ultimo.com
5-6 OCTOBER P&J LIVE, ABERDEEN
17TH YEAR! LiftEx 2022, the leading lifting equipment networking event, provides the first major opportunity in 3 years to meet face-to-face with the industry. Taking part is your chance to reconnect, meet new vendors and get back to business!
Book your free visitor ticket now at liftex.org/liftex-aberdeen At LiftEx you’ll meet global and local vendors of lifting equipment and services supplying vertical markets including Oil & Gas, Ports & Maritime, Offshore, Construction, Manufacturing, Automotive, Utilities and Entertainment. If you are responsible for purchasing or decision making in this sector, you can’t afford to miss this exhibition. New this year - 10 hours of free content for visitors:
Day 1 - Knowledge Sharing and Industry Insights - Panel discussions, guest speaker interviews, case studies and interactive sessions delivered by industry experts. Day 2 - Education Zone - Learning and development, with free
training including Advanced Programme (Diploma) refresher courses (ideal for individual CPD or exam preparation), and the all new End User Guidance (EUG) and Introduction to Lifting Equipment (ILE) training courses.
Ask the Expert Surgeries - 15-minute sessions with the
LEEA CEO and SLT on key topics of importance.
Exhibitor Fast Pitch - A series of 5-minute pitches from our
exhibitors to engage the audience giving a succinct overview of the key brands, services and innovative products on the market.
Exhibition Space - To secure a stand on the exhibition show floor, or to become one of our sponsors, contact the team on +44 (0)20 3488 2865 or email enquiries@L2Events.com
LiftEx is the flagship show from LEEA, the global trade association for the lifting industry. @LiftEx2022 | #LiftEx2022
Heatsense see 30% growth after implementing 123insight MRP system during pandemic Heatsense Cables Ltd, based in Rochdale, Greater Manchester, manufacture high performance cables and wires used in extreme environments. The company had seen significant growth, doubling within a couple of years, but Commercial Manager Aaron Hulse knew that they needed to change internal procedures; “The growth brought other stresses. We needed a solid system in place that would give us rules. We knew where we wanted to be, and we knew that we were never going to get there pushing spreadsheets and paper around - it’s ‘old school’.”
he main issues centred around planning and stock management. Stock was held in an Excel spreadsheet, with stock-takes manually performed every six months. Stock outages affected delivery performance, as products couldn’t be manufactured due to missing stock. The company evaluated several MRP systems, but quickly narrowing down to two. The other vendor provided a demo of what the system could do, however this was quickly discounted. Said Aaron; “It got quashed before we
went very far, as it was clear that we would have to change our business to fit the system. It was also expensive, at around £50,000 for the software, plus implementation, training and annual maintenance.” Heatsense attended a 123insight Evaluation Workshop in January 2020, which Aaron identified as a stark contrast to the other vendor; “It was brilliant. There was no hard sell it was all about the system and what it could give us. That really made our minds up.”
The decision was made to move forward with 123insight, however shortly afterwards the country was in lockdown due to the COVID-19 pandemic. Despite this, the company started the implementation, hiring a consultant with previous experience of 123insight. Staff attended online training in the Summer of 2020. Although the training is offered under noobligation prior to registration, Heatsense were confident enough that 123insight would meet their needs and registered as a customer before attending the training. “We were able to ask any questions we needed, and after this we were fully confident that the system would work for us - we asked the right questions and got the right answers.”
A series of implementation sessions were held online, with key staff being allocated tasks such as structuring bills of materials and routings, or reshaping some of the existing Excel spreadsheets into the required format
for importing into 123insight. Aaron said; “We aimed for a go-live over Christmas, took account of where we were and transferred it to 123insight so that we knew we could go live on the first day of January 2021.” The company went live in the New Year, and immediately saw benefits. “For the first time ever, the sales team could see live stock. Previously it might take up to an hour for someone to check stock, and this might be 10-15 times a day. Invoicing and purchasing were quicker and now electronic, with PDFs being emailed. Procurement also saw massive benefits, as we could immediately see what needed to be purchase, how much and what supplier to use, with most purchase orders being emailed to suppliers with a couple of clicks.” Stock control improved, as minimum stock levels were set for all key materials. Stock locations allowed items to be found much quicker than before, so ex-stock items could be ordered, picked and despatched 50% quicker. As the stores department doesn’t have dedicated staff, a unified system delivered significant time savings; “All of our staff are multi-skilled, so we don’t have a dedicated person in stores or despatch. 123insight has given extra time to all the staff that perform these functions. I’d estimate this as at least a 25 % timesaving. It’s certainly freed up a lot of my time.” continues...
Aaron also noted that 123insight allowed them to consolidate across many areas, providing environmental benefits. Inbound deliveries from suppliers could be grouped, as could outbound deliveries to customers; “We can now ask the customer if they would prefer us to send multiple orders together.” Consolidation also continued onto the shop floor; “We’re
also now pairing jobs together. For example, if we have an extrusion job using red plastic, we might consider consolidating other jobs, reducing head waste and saving on material.”
Works orders now included much more information. Aaron explained; “Previously we would list a part number and rely on staff experience as they had made the parts many times before, but this can lead to errors. Works orders now list both the materials and routings, plus we’re using document linking to include data sheets and other technical information.” While works orders included more content, it was estimated that paper usage overall dropped by 20%. Lead times improved by 10% due to better stock availability and planning visibility. The company was hampered by industry supply chain issues, however the additional visibility that 123insight provided helped them to purchase more strategically, avoiding outages. Aaron expects lead times to improve further as supply chain issues ease.
Heatsense already had ISO9001 and ISO14001 quality accreditations but plans to expand its business within the aerospace sector and therefore sought AS9100 accreditation. Said Aaron; “During our AS9100 implementation and subsequent audit traceability was evident. Part of the audit was remote, and all the information was easily retrievable onscreen. In the old days we would have been looking through reams of files and scanning documents.” Every industry has issues that are unique to them. When Heatsense produce a batch of products for stock, items within the batch might often be different lengths, requiring more work to book items in. Heatsense discussed this with their 123insight Customer Care Manager, who identified that a modification to the software would not only elegantly solve the problem for Heatsense, but by applying the same logic elsewhere would benefit other customers. Said Aaron; “It just shows that 123 Insight listen and are there to help. I can’t think of many suppliers that would consider a change to their system for a customer.” A third of 123insight’s monthly subscription is re-invested into development, with many new features based on customer feedback.
Heatsense also uses Access Dimensions accounts software, and later in 2021 decided to link it to 123insight using Accounts Gateway. This allows invoices to be created automatically within Access Dimensions, and 123insight users to be able to see data such as credit limits or if a customer is on stop. With a system that is relied on company-wide, support is an important aspect, but Aaron could not be more pleased; “Support has been fantastic - I could not give them more credit. They are always at the end of the phone if I need them, and it’s always a positive experience. There’s
no comparison with other suppliers, where I might be waiting 2-3 weeks for a simple answer.” After already taking on larger premises, the company has significant growth plans, moving more into supplying the aerospace sector now that they have AS9100 under their belt. Aaron finalised; “We could easily double in size with 123insight. One of the key tools it has given us is staff being able to quickly retrieve any information, reducing the need for more staff. 123insight was also essential to us gaining AS9100 approval, which the auditors acknowledged.”
Implemented remotely during the pandemic
Paperwork reduced by 20%
Lead times reduced by 10%, with ex-stock items despatched 50% quicker
Stock inaccuracies reduced
Acquired AS9100 accreditation
New feature developed based on feedback from Heatsense
Consolidating inbound/ outbound deliveries
Have already seen 30% growth and could double without more admin staff
Integrated with Access Dimensions
Three days of innovation, partnerships and excellence: Subcon is back for 2022! Subcon returns on the 7- 9 June 2022 to the NEC, Birmingham. Now in its 45th year, it remains the UK’s premier event dedicated to subcontract manufacturing buyers, enabling them to source suppliers, benchmark capabilities, and form new manufacturing partnerships. At Subcon, find everything from product design, prototyping and development, contract and subcontract products and services through to machine tools, systems and equipment. This June, Subcon will once again be collocated with The Engineer Expo and Manufacturing Management Show, bringing together even more of the best suppliers, latest innovations and practical advice. World-class solution providers: The exhibition Across the three show days the exhibition will deliver the contacts, connections and content that engineering and manufacturing businesses in the UK need to succeed. Visitors will be able to harness new innovations from over 200 world class suppliers to help increase capacity, optimise productivity and improve flexibility, whilst also driving down costs to stay competitive in a global market. Subcon exhibitors span a massive range of manufacturing and engineering businesses, including assembly work, CNC machining, metal fabrication, 3D printing and many more. As this diversity of exhibitors shows, there will be huge opportunities to forge strategic partnerships and improve existing processes.
Exhibitors include: Lapping Services The UK’s largest bespoke lapping and polishing sub-contractor, Lapping Services specialise in double sided lapping, high volume to 1 off’s AS9100 Rev D and they are RR nuclear accredited. Mintdale Engineering Mintdale Engineering are a family run business that have been supplying precision engineered parts to clients throughout the UK and internationally in a variety of industries for over 40 years.
experts discussing the key issues and trends that are driving innovation and shaping the UK’s industrial landscape in 2022: from the latest developments in key technology areas such as hydrogen mobility, electrification, and nuclear fusion to keynote insights on automation, finance and engineering skills. Speakers confirmed this year include: •
Dave Short - Technology Director, BAE Systems: Innovation in the defence sector
Ian Whiting – Commercial Director, UK Battery Industrialisation Centre: Scaling up UK electric vehicle battery manufacture
Tony Langtry – Head of Mechanical Engineering, Tokamak Energy: The engineering challenges of nuclear of fusion
Hugo Spowers – Founder, Riversimple: Transforming mobility with hydrogen
Professor Ric Allot – Director of Business Development, STFC: Industrial applications of Big Science.
Professor Chris Tuck – University of Nottingham: Insight from the cutting edge of the UK additive manufacturing research community.
Nick Hawker, CEO and co-founder, First Light Fusion on the commercial application of nuclear fusion
Martin Little, commercial director, Rail Alliance on the overlooked opportunities within rail
Trust Precision Engineering Trust Precision Engineering is an AS9100 for Aerospace accredited subcontract service provider specialising in sliding head machining. The proven cost savings of 1 hit machining for both simple and complex components is fundamental to their philosophy. Trust Precision will competitively provide the highest quality for your machined component requirements. Shaping the future: Free conference sessions Visitors can also enjoy over 30 hours of free conference sessions lead by industry
Jason Dante, event director for Subcon, points out that this wide range of opportunity and the chance to see so many diverse companies is no accident: “With Brexit, Covid-19 and the ongoing conflict in Ukraine, we are even more aware than ever of the pressures on UK engineering and manufacturing businesses, so we have crammed as
much value into the event as we can. This year, alongside the Engineer Expo and Manufacturing Management Show theatre, we also have a brand new supply chain theatre that will bring together an expert line-up of speakers to talk about the biggest challenges and opportunities for the sector. We also once again have ensured there will be ample networking opportunities available at the show, including the VIP buyers lounge, sponsored by Qimtek. Plus, there will even be a couple of extra surprises in celebration of the Jubilee! We are incredibly excited to include so much new material and look forward to opening the doors at the NEC.”
Sponsored by: |63
Tank Storage Best and Brightest Confirmed for StocExpo 2022 Leading names in the tank storage industry will have the opportunity to network with each other at StocExpo 2022, the largest and longest-running international bulk liquid storage event, from 23-25 May at the Rotterdam Ahoy.
hroughout the three-day event, attendees can meet up with the industry’s brightest minds on the exhibition floor, including senior decision makers from Vopak, Shell, Honeywell and Emerson. 1-2-1 meetings will be available to book in the designated SE Connect lounge, and throughout the event, industry professionals will be able to book face-to-face time with each other through the event’s online meeting platform. Taking place on the exhibition floor on the event’s opening night, the official late-night networking party will be a chance for people to network in a relaxed environment over drinks and nibbles. On the second night of the event, the Global Tank Storage Awards, now in its fourth year, will showcase achievements and innovations in terminals, processes and equipment, as well as individual successes. The evening will include a drinks reception on arrival, followed by a three-course
dinner and a casino-based evening of entertainment. Allinclusive drinks will be available throughout the evening. Rikki Bhachu, Head of Marketing for StocExpo, says: “We know that networking is a key reason why so many tank storage professionals love StocExpo. The industry is going through an interesting period, and collaboration has never been more important. There is much to discuss and business to be done. We can’t wait to welcome everyone back in May!” For more information about StocExpo and to register to attend, exhibit or speak at the event, click here.
What’s on at StocExpo?
Women in Tanks
Find out why these inspiring women believe the tank storage sector is a great industry to be a part of
Meet old and new industry peers and create new business opportunities in a relaxed environment
Forty Under 40
Cutting-edge solutions and insights in important topics and trends within the bulk liquid industry
Recognising those with potential to become industry leaders in the future and those who have achieved greatness
Join the leading conference for terminal operators worldwide during StocExpo with industry experts
The prestigious awards highlight those that excel in a range of different categories
23 - 25 May 2022 | Ahoy, Rotterdam
Register using code > 1011 | www.stocexpo.com
REDUCING YOUR OFFGRID CARBON FOOTPRINT With more companies looking to hit the magic net zero target by 2030, Fulton’s Leigh Bryan asks what options there are for those businesses with processing facilities that are off grid and having to rely on sometimes ageing heat transfer solutions using high-carbon, oilbased fuels for firing.
ccording to official statistics for England and Wales, there are over 1.6 million nondomestic buildings, with nearly 300,000 of those located in areas not linked to the gas grid and many using fossil-based fuels for various heating purposes. Why? Because their location makes connection to the grid too expensive or, in some case, not even possible. So, with heat transfer solutions in mind, what are the options for those operating a business that is situated offgrid and facing the challenge of sourcing a reliable and efficient source of energy?
Liquid Petroleum Gas (LPG) When it comes to off grid, LPG is considered the cleanest, most efficient and effective fuel compared to traditional fuel types, including coal, oil and electricity. It emits almost no particulate matter, with oil emitting 10x the value and coal a massive 100x. Additionally, LPG emits 35% less carbon than coal and 12% less than oil; and, for those struggling to meet current MCPD regulations LPG can, utilising the correct burner equipment, also significantly reduces NOx emissions compared to traditional off-grid fuels, with oil seeing 50% more emissions. Aside from the environmental benefits of LPG there’s also cost benefits to consider, with the UK government scrapping fuel duty on Class D Red Diesel in April 2022, which could see fuel costs for those operating oil-fired heat transfer solutions rise by as much as 50%. For a recent installation at leading British condiments maker Tracklements, production capacity has been boosted and the company’s environmental credentials enhanced by replacing its existing oil-fired steam boilers with modern, efficient liquid gas-fired Fulton VSRT vertical steam boilers. With a relationship exceeding 40 years, Tracklements approached Fulton when specify a cutting-edge system
that would help minimise its environmental impact. With a requirement for an off-grid solution, Fulton initially suggested a packaged system comprising of its Europack electric steam boilers but, following a site audit, it was realised that the infrastructure wasn’t in place to support a solution. So the company instead specified its award-winning VSRT steam boilers with LPG burners and recommended Flogas as the liquid gas supplier. By modernising their steam raising equipment and changing their fuel type to liquid gas, Tracklements can expect an impressive 21% financial saving and a near 25% reduction in carbon emissions, with the cost savings being based on current oil prices before the planned withdrawal of tax relief on red diesel in April 2022 so, looking forward, they are actually far more favourable. These savings, along with improved carbon emissions, can be improved further by up to 30% when combined with the potential steam system efficiency savings by running the latest fully-modulating, high-turndown boilers – each genuinely capable of a 10:1 turndown – resulting in the production of high-quality steam at up to 99.75% dryness. What’s more, our liquid gas-fired VSRTs will help minimise other pollutants, with NOx levels at commissioning reduced by 75% compared to the previous oil-fired steam boilers.
Based on the current cost of 32 second oil combined with the planned increase in production and efficiency of the VSRT steam boilers, the customer expects a return on investment within 18 months. However, if the planned duty increases on fuel are factored in, that period will be significantly shorter. The installation at Tracklements is also supported by both service and water treatment contracts from Fulton, who have also provided certified boiler operator training for several employees at the facility.
Electricity Grid Some experts believe that electric steam boilers are superior to fuel-fired steam boilers in a few ways. They believe that using electric boilers may be less expensive than using a fuel-fired boiler in the long term, whilst also being more environmentally friendly. Using Fulton’s portfolio of electric steam boilers as an example, less ancillary equipment is required than a traditional steam boiler, therefore helping to reduce the installation costs that come with a fuel-fired boiler. Electric boilers also generally have a smaller footprint and can therefore fit into smaller areas thanks to the way they are constructed and the lack of ancillaries that a fuel-
fired boiler needs to operate. And thanks to their small footprints and the fact there are no flue requirements to consider, they can often be used for point-of-use steam requirements, making them a good choice for many smaller operations, including small-batch distillery, microbrewery and autoclave applications. Electric boilers are sometimes overlooked as a potential solution to steam generation due in part to the higher cost of electricity versus the cost of traditional fuels such as LPG, kerosene (gas oil), etc. However, with the UK government scrapping fuel duty in April 2022 and the cost of gas oil set to increase dramatically as a result, many companies are now turning to more sustainable methods of generating electricity, including solar or wind generation, with such schemes offsetting, or at least partially offsetting, the higher fuel costs. Traditional fuel-fired steam boilers generally require multiple elements to operate successfully. In contrast, electric boilers are relatively simple devices. Additionally, because electric steam boilers do not use complicated forms of heat exchange, they do not contain many of the potential hazards that are commonly present in a fuelfired boiler. Electric boilers are also generally easier to maintain because they don’t require tube replacements, burner maintenance or statutory non-destructive testing (NDT), all of which fuel-fired boilers often require.
Electric steam boilers are more efficient than fuel-fired boilers because they require less energy to be put into them for operation at capacity. This is because there is little energy lost when the transfer of heat from the heating element to the water occurs, unlike traditional fuel-fired boilers where there is a substantial amount of energy loss from the air flow required to supply oxygen to the flame. Additionally, because electric steam boilers can be fitted, in some cases, with as many as 12 electrical elements (dependent on model), they have a high turndown – up to 12:1 in the case of Fulton’s electric steam boiler range – so are able to modulate efficiently to varying steam loads. Electric boilers are, as already stated, more efficient and recognised as having smaller carbon footprints than their fuel-fired counterparts, but for large generating capacities are frequently impractical to install due to large supply cables and infrastructure requirements. However, with no burner service and no NDT inspection required every five years, the actual maintenance costs can be up to 50%* less than those of fuel-fired steam boilers. Generally, the only major parts that are periodically changed are the electric elements themselves, yet these are often replaced quickly and cost effectively. This balances lower life cycle costs against the high maintenance requirements of fuel-fired boilers, including refractory repair/replacement, 5-year NDT requirements, burner maintenance, flue maintenance, and the requirement for highly-skilled and often highly-paid plant operatives.
Blended Fuels With the UK government scrapping fuel duty on Class D red diesel in April 2022, many companies unable to invest
in upgrading existing or installing new plant are looking to equivalent blended fuels to fuel their steam boilers which, at present, are not subject to the implementation of the fuel duty scrappage. The use of blended fuels requires little change to an existing boiler setup, with only minimal re-commissioning of the burner required. However, blended fuels burn at the same calorific value as Class D oil, there will also be minimal benefit from the reduction in carbon emissions or NOx levels achieved from switching to electric or LPG. Compared to Class D oil, there is also a shortage of blended fuels in the marketplace. Additionally, like many other fuel types, there are winter and summer grades to be aware of. So, if you’re still running a summer-grade fuel in the winter, you need to be conscious of potential waxing of the fuel pipes, filters and other burner components. Many blended fuels also required agitation to ensure the fuel mix remains consistent. This can be achieved with a simple two-pipe system that runs back to the tank to achieve circulation, but without this type of system, the installation of an in-tank agitator is recommended to ensure there is no stratification of the fuel.
typically up to 11% loss in efficiency due to the insulating properties of the residue in the boiler causing an increase in flue gas temperatures of around 90ºC.
What does the future hold? We have of course only looked at three firing options for operating steam boilers off-grid in this article, but there are others. And what about the future? At Fulton, we are already developing hybrid steam boiler solutions that combine a LPG-fired boiler with electric, where the base load of the process is picked up by the electric boiler and seasonal swings and high loads by the traditional boiler; all of which helps to dramatically reduce carbon emissions. We are also working with partners, such as Weishaupt, and looking at the future of hydrogen, although a move to 100% hydrogen-fired steam boilers is unlikely for off grid solutions. firstname.lastname@example.org
Finally, there’s the residue found in boilers from blended fuels and their associated bio-components not burning as efficiently. Any residue will impact the overall efficiency of the boiler and we have seen cases where we estimate
Packaging Innovations and Empack returns to NEC Birmingham for 2022 Packaging Innovations and Empack 2022 will reunite
the entire packaging community when the UK’s flagship event returns to Birmingham’s NEC on 25 and 26 May. The event will feature a sold-out show floor with over 280 leading exhibitors presenting their newest innovations and technologies, allowing visitors to get up close to the industry’s most cutting-edge products. Elsewhere, the event’s curated seminar programme will provide visitors with the opportunity to hear from a raft of experts, plus the event will offer several networking opportunities which will allow professionals to make new industry connections. 70|
May 2022 with FFS machinery, or as pre-made bags and stand-up pouches. Both barrier and non-barrier films are available, and the material is suitable for food and non-food applications. The development in PE film reduces the need for unrecyclable structures made from several different polymers and offers improved optical clarity.
Event Features Packaging Innovations and Empack will also host a curated seminar programme across three stages, catering for every part of the packaging supply chain. The Empack Technology stage will feature topics aimed at the manufacturing, logistics, and processing sectors. Talks will cover a range of subjects, including robotics, e-fulfilment, and energy efficiency. On day one, the BCMPA will host a session covering the value of outsourcing manufacturing, packing, and fulfilment operations, with the session incorporating expertise from several industry-leading companies, including Prolog, Lemonpath, and Worldwide Logistics.
New Exhibitor Launches Excelerate will display its unique perforated stretch product - ‘Flow’ film. The aerated wrap is designed for light to medium pallets and allows its contents to ‘breathe’ during transport by reducing moisture and condensation levels. The wrap can be used to transport a range of items, including those in the horticultural industry. Consumables Manufacturing will display its CoPacking controlled dose sachets, which deliver a predetermined volume of liquid with one hand movement. The sachets can be used to house and dispense a range of consumer goods, including seasonings, condiments, drinks, spreads, and creams. The product does not disperse any residue, with up to 98 percent of contents used without spillage, and it is recyclable. Waddington Europe will display its Piranha™ tray, which uses a series of raised teeth that run around its seal, instead of applying a layer of polyethylene or adhesive which are typically used to seal the lid of modified atmosphere packaging (MAP). Piranha can also be made with up to 100 percent recycled PET (rPET) and is Plastic Tax compliant in the UK. As a mono-material package, the tray is capable of being fully recycled, and can be used for meat, fish, and poultry products. Global Trading UK will debut its newest innovation, EVO-PE Recyclable Flexible Packaging Films. The printed film can be supplied as roll stock for use
Meanwhile, the Innovation and Design stage and Ecopack stage will dissect the latest industry news affecting packaging designers, agencies, and technologists. The show’s headline feature, The Big Debate, will discuss how new government legislation will impact the industry, and whether the new laws will deliver the change promised. In association with OPRL, The Ecopack Challenge calls for industry professionals to prioritise sustainable design, by creating an all-new packaging product. Top innovations will be presented to a panel of judges, including Pret A Manger and Ocado. The Innovation Showcase will return to the event floor, as 12 exhibitors compete for the title of ‘Most Innovative Pack’. The interactive nature of the competition allows visitors to get up close to some of the industry’s most innovative solutions and vote for their favourite, with the winner announced live at the event. Renan Joel, Easyfairs’ Divisional Director, comments: “Our exhibition floor is already sold out and will feature the most forward-thinking packaging companies out there, offering a unique opportunity for professionals to discover the latest trends and capabilities for the entire supply chain, all under one roof. Nothing beats doing business face to face. We can’t wait to see you all there in May!” To register to attend Packaging Innovations and Empack NEC 2022, please visit the registration page. For any further information, please visit the Packaging Innovations and Empack NEC 2022 website or contact the show team on +44 (0)20 196 4300 or packagingUK@easyfairs.com.
Industry Stars Take to the Stage at Packaging Innovations and Empack 2022 Ocado, Nestlé, Pret A Manger, and Waitrose are just some of the major brands taking to the stage at Packaging Innovations and Empack 2022. They will form part of the event’s most comprehensive seminar programme to date when it makes its long-anticipated return to Birmingham’s NEC on 25 and 26 May. New for 2022, the seminar programme will be set across three stages; the Innovation and Design stage; the Ecopack Stage; and the Empack Technology Stage. These have been designed to provide visitors from every point of the supply chain with the chance to capitalise on the latest industry developments and solutions, as well as hear predictions for the future of packaging technology from a variety of leading experts.
Innovation and Design Stage The Innovation and Design stage will analyse the latest industry changes and the knock-on effect it is having on packaging designers, technologists, and agencies. Day one kicks off with a session by Neil Farmer, Founder of Neil Farmer Associates, to assess the current state of the global packaging market and what will influence the sector in the next 12 months, including developments in sustainability and material innovations.
Day two will host the Packaging Tax Forum, in partnership with The Pack Hub. The UK Plastics Packaging Tax has been in place less than two months, but it is already having a significant impact on the UK’s packaging industry. Speakers from Mondelez and Bantam Materials will explore the tax’s effects on the packaging operations of major brands, retailers, and packaging suppliers. The Inclusive Packaging Forum will see speakers from 1HQ, Waitrose and Nestlé discuss the industry’s responsibility to deliver easy-to-use, accessible packaging, alongside being sustainable. The Innovation and Design Stage will also host the HP Innovation Lab across both days of the event, as well as the E-commerce and Refills Forums.
Ecopack Stage The Ecopack stage will deliver the latest in green packaging trends and technologies, designed to help brands reach
OPRL, which will see innovators pitching their ‘green’ solutions to a panel of judges including Ocado, and Pret A Manger.
Empack Technology Stage The Empack Technology stage is aimed at arming visitors with advice on logistics, manufacturing, and processing. Talks and discussions will cover a range of integral topics, such as e-fulfilment, energy efficiency, and the use of robotics within the packaging supply chain. On day one, the BCMPA will host a session covering the value of outsourcing manufacturing, packing, and fulfilment operations. The organisation will incorporate expertise from several industry-leading companies, including Prolog, Lemonpath, and Worldwide Logistics. Also speaking on day one is Juan Cano, Business Development Director for SCREEN EUROPE, who will highlight sustainable water-based inkjet digital printing solutions for flexible packaging.
their sustainability goals. On day one, the stage will feature a session from the Cambridge Design Partnership who will discuss the future challenges for packaging sustainability, as well as the role innovation and technology will play in the development of future solutions. Also on the first day, Chair of IOM3 Packaging Society Jude Allan will lead a discussion on the future of packaging materials, where an expert panel will explore what the industry might look like in 30 years’ time. Day two will feature a session on the ‘heroic’ status of paper in packaging, delivered by Sarah Lesting, MD of LEIPA. Sarah will explore how paper has become the preferred material for companies seeking to reach net zero, due to its multiple uses and ease of recyclability. Supplementing this will be The Big Debate, which will delve into the pressing financial implications of packaging legislation, and the return of the Ecopack Challenge, in association with
Nulogy, GXO, and Nestlé will feature on day two to demonstrate how leading logistics providers and brands leverage purpose-built technology to level up its co-packing. Other noteworthy sessions include seminars covering ultrasonic sealing, automation in the packaging process, and digitising supply chains for efficiency wins. Renan Joel, Easyfairs’ Divisional Director, comments: “Our carefully curated seminar programme sets Packaging Innovations and Empack apart from any other packaging event. The sessions allow visitors to hear from an array of speakers that are leading the way in every part of the packaging industry to discover new ideas and gain tangible advice they can put into practice to further push the boundaries of their packaging projects. With just six weeks until the event, the excitement is building! We can’t wait to see you there.” To register to attend Packaging Innovations and Empack NEC 2022, please visit the registration page. For any further information, please visit the Packaging Innovations and Empack NEC 2022 website or contact the show team on +44 (0)20 196 4300 or PackagingUK@easyfairs.com.
Packaging Innovations & Empack 25 & 26 May 2022 | NEC, Birmingham
Discover the future of your brand’s packaging and production journey!
Do you want the chance to see what’s new in the world of packaging and discover the latest innovations and technology? Then it’s time to add Packaging Innovations and Empack to your diary – and find out why thousands of brands make it their must-attend event. Over two days, experience... • 280 innovative suppliers • Free-to-attend seminars • Live demonstrations • Brand NEW interactive features • Networking opportunities with decision-makers and buyers
“It allows us to do a lot of meetings in one location and see what is new on the market, you can’t beat seeing things in real life rather than just online.” Ian Stapleton European Technical Packaging Manager
Register to attend Scan this QR code or use code 1144
“The UK is leading the way on environmentally friendly packaging. It’s great to see it showcased at Packaging Innovations.” Rob Cooke Packaging Design