Manufacturing & Engineering Production Magazine - November 2023

MANUFACTURING PRODUCTION

TECHNOLOGY

WHAT’S THE FUTURE FOR PIECE-PICKING ROBOTS?

MANUFACTURING

NOVEMBER 2023

MANUFACTURING

TOP TRENDS IN THE SECTOR AS INDUSTRY 5.0 DAWNS

PRODUCTION

ENGINEERING

Lagun CM, Fixed Bed Milling

Kafo Double Column Machining Centres

You Ji VTL vertical lathes.

CONTENTS 15

04 Editor

Paul Attwood editor@mpemagazine.co.uk

Senior Editorial Assistant

Anna Startin editorial@mpemagazine.co.uk

44

34 04 15 34 44 49

49

Company News: ACO completes £13m manufacturing site expansion Automation: Are Manufacturers tackling contingency planning?

Manufacturing: Top trends in the manufacturing sector as Industry 5.0 dawns Technology: The Power of Digitalisation in Manufacturing Technology: Humanoid robots in warehouses: short-lived gimmick or vision of the future?

Features Editor

Harry Peters editorial@mpemagazine.co.uk

Production/Design

Laura Whitehead laura@lapthornmedia.co.uk

Sales Manager

Charlotte Chapman charlotte@mpemagazine.co.uk

Sales Executive

Alex Costa alex@lapthornmedia.co.uk

Accounts

Richard Lapthorn accounts@mpemagazine.co.uk

Circulation Manager

Leo Phillips subs@mpemagazine.co.uk

Editors Note Welcome to the latest edition of Manufacturing & Production Engineering Magazine.

In this edition we hear from Greg Wainhouse, Industry Account Manager for Water Applications at Bürkert. Greg explains the importance of reviewing input data for control valve specification.

We also feature Simon Jones from Exotec, he discusses whether humanoid robots in warehouses are a short-lived gimmick or vision of the future. An insightful and thought-provoking piece.

Paul Attwood Editor

We hope you enjoy this issue and as always, if you have any news that you would like to feature, please email details to editorial@mpemagazine.co.uk.

Publishing Director

Maria Lapthorn maria@lapthornmedia.co.uk

Lapthorn Media Ltd

5-7 Ozengell Place, Eurokent Business Park, Ramsgate, Kent, CT12 6PB Tel: 01843 808 117

Every effort is made to ensure the accuracy and reliability of material published in Manufacturing & Production Engineering Magazine however, the publishers accept no responsibility for the claims or opinions made by advertisers, manufactures or contributors. No part of this publication may be reproduced or transmitted in any form or by any means, mechanical, electronic (including photocopying) or stored in any information retrieval system without the prior consent of the publisher.

mpemagazine.co.uk @mpemaguk

Manufacturing & Production Engineering Magazine

03

Company News

ACO completes £13m manufacturing site expansion ACO Technologies plc has completed the first phase of the ambitious redevelopment of its UK manufacturing facilities. The £13m site expansion was officially opened

by Susan Lousada, His Majesty’s Lord-Lieutenant of Bedfordshire, Lord Deben, Chairman of the UK’s Independent Committee on Climate Change, and renowned architect Michael Pawlyn, in a ceremony on 28 September.

The completion of the first phase will see ACO significantly increase the number of products it can hold on-site, allowing it to respond to customer needs more efficiently. This is thanks to a new 141,000 sq ft warehouse and yard. The expansion also means ACO is reducing its need for third-party storage and transportation of its products, helping it to reduce carbon emissions and become more sustainable.

Pivotal to the entire site development was the protection of habitats and enhancement of biodiversity. In addition to caring for the surrounding water by diverting the nearby stream, ACO has transformed the former farmland into an area where biodiversity can flourish.

This has been achieved through planting over 10,000 trees and shrubs, which will

introduce new wildlife to the area, as well as pollinator-friendly plants. ACO Bat Boxes and Nest Boxes have also been installed throughout the development, providing shelter for bats and small birds, including blue tits.

In addition to Susan Lousada and Lord Deben, renowned architect Michael Pawlyn, who specialises in naturebased solutions and regeneration also supported the launch of the site, where he delivered a keynote address.

Michael’s experience aligns with ACO’s commitment to help create a built environment that can harmonise with nature by providing sustainable solutions for effective surface water management.

A fifth production line to its existing manufacturing facility has also been introduced, which will significantly increase ACO’s capacity to meet rising demand for its leading drainage and water management products. Crucially, the new line will also aid the company’s continued commitment to innovate new products in line with the needs of planning authorities, and allows ACO to respond to the effects of climate change in relation to water management.

For more information about ACO Technologies plc, please visit www.aco.co.uk.

Oracle’s award-winning early adopter MESTEC scores hat-trick of contracts A UK technology specialist has built on a record year by securing a trio of high-profile contracts and a prestigious global award.

MESTEC, which has seen sales grow by over 50% since its acquisition

by Eyelit Inc, will use its pioneering cloud-based Manufacturing Execution Systems (MES) solution to create smarter factories for clients involved in supercar customisation, advanced

04

Manufacturing & Production Engineering Magazine

engineering, and a golf equipment manufacturer.

The Bracknell-based business will work with the global brands to rapidly deploy its technology that promises to improve performance across 80+ key manufacturing KPIs in a bid to improve labour productivity, overall equipment effectiveness, quality, and compliance.

It comes at an exciting time for the firm after it was named as Oracle

Global Leaders ISV of the Year Award at a prestigious ceremony as part of Oracle CloudWorld in Las Vegas recently.

This is a major achievement for MESTEC and saw it recognised globally as a technology leader competing against 20 of the world’s leading software providers.

For further information, please visit www.mestec.net.

Company News Altus Group Ireland Partners with SMT Thermal Discoveries to Enhance Electronics Manufacturing in Ireland

Henry Brothers awarded £30m contract for Advanced Manufacturing Innovation Centre A contractor has been appointed for the Queen’s University Belfast-led Advanced Manufacturing Innovation Centre (AMIC), a £100m Belfast Region City Deal project, with almost £80m coming from the UK Government.

Henry Brothers has won the £30m contract to construct the 10,500m² Factory of the Future building at Global Point Business Park in Newtownabbey.

AMIC will reinvigorate Northern Ireland’s industrial potential and address the future technology and skills challenges faced by the region’s manufacturing sector.

It is being delivered by Queen’s in partnership with Ulster University, industry, and Antrim and Newtownabbey Borough Council and supported by the UK Government and NI Executive.

By 2050, it’s estimated that AMIC will have contributed more than £1bn to the local economy, directly and indirectly created over 1,500 permanent jobs and supported the training of 300 apprentices.

Henry Brothers, which is headquartered in Magherafelt, with more than 200 employees based across Northern Ireland, England, and Scotland, has been awarded the construction contract after a competitive tendering process.

Work includes the early contractor involvement process, construction of an engineering hall, a clean room, laboratory spaces, an auditorium and office accommodation as well as external landscaping and mechanical and electrical services.

Planning permission for the building was given in May, and it’s hoped that construction work at the site can start next spring.

AMIC plans to be operating from the Factory of the Future by 2026, with capacity for 150 staff, as it delivers for Northern Ireland’s manufacturing sector.

Mayor of Antrim and Newtownabbey Councillor Mark Cooper BEM, said: “The appointment of a AMIC is building on 50 years of sustained innovation and industry support through the Northern Ireland Technology Centre (NITC), the Polymers Processing Research Centre (PPRC) and the more recent university-industry partnership, the NI Advanced Composites and Engineering (NIACE). It will provide a specialised environment for advanced manufacturing, materials, and engineering sectors to access the latest digital, automation and robotics technology supported by experienced engineers.

Altus Group, a leading supplier of capital equipment and services to the electronics manufacturing industry, has signed an agreement with SMT Thermal Discoveries to distribute its advanced reflow soldering and thermal technology solutions in Ireland.

With over 30 years of expertise in thermal engineering for electronics manufacturing, SMT Thermal Discoveries offers cuttingedge convection reflow, curing, and thermal testing equipment. Their innovative product portfolio will significantly expand and strengthen Altus’ solutions for Irish customers across various electronics sectors.

Altus has recently celebrated significant milestones and growth of its Irish division, including welcoming three new pivotal team members, inaugurating a state-of-the-art demonstration facility, and enhancing its portfolio by adding leading brands, including Essemtec and PVA. The partnership with SMT Thermal Discoveries demonstrates Altus’ continued commitment to expanding its offerings and service capabilities for customers in the region.

This partnership is set to provide Irish electronics manufacturers with advanced yet accessible production solutions to help streamline processes, improve quality control, enhance efficiency, and increase productivity. By distributing SMT Thermal Discoveries’ innovative portfolio Altus is providing their customers with stateof-the-art, automated tools to optimise manufacturing output while controlling costs effectively.

To find out more about Altus Group’s advanced equipment visit www.altusgroup.co.uk.

Manufacturing & Production Engineering Magazine

05

Product News

Wanner secures order for 75 pumps to pharmaceutical giant Wanner International today (4 October 2023) announced their first contract for an order for a range of 75 Hydra-Cell chemical process pumps to one of the largest pharmaceutical manufacturers in the world.

After intensive testing, the company chose the Hydra-Cell Flow Chemistry and High Pressure Liquid Chromatography (HPLC) pumps over the incumbent traditional metering pumps because of

Interroll launches Autonomous Mobile Robot Top Module To keep up with the ever-growing demand for autonomous material handling, Interroll has developed an autonomous mobile robot (AMR) Top Module as an expansion to its Light Conveyor Platform (LCP).

This roving conveyor solution has been successfully tested with MiR and OMRON, two leading mobile robotics companies who have identified it as a preferred choice.

The current robotic market is evaluated with an annual growth rate (CAGR) of more than 20 percent by 2027, indicating a flourishing

06

Manufacturing & Production Engineering Magazine

the advanced mechanical and hydraulic design, with little ancillary equipment required, the high accuracy over the wide flow range and the technical support.

The pump technology and application knowledge capabilities deliver real value for the pharmaceutical company.

The pumps will be installed in a new production line for transfer, blending and injection of saline solutions, alcohols and other salts, within an ATEX Zone 2

demand for collaborative robots and the integration of robotics in diverse fields such as logistics. With the LCP AMR Top Module technology, Interroll is demonstrating its commitment to pushing boundaries and developing new robotics products to further revolutionise the market.

The LCP AMR Top Module conveyor module enables the handling of lightweight goods and offers a seamless interface which guarantees a smooth material flow when an AMR is integrated. The end user can trust in a complete solution, the highest level of customer comfort, and an easy integration process.

Setting new standards AMRs are used in a variety of applications in fields such as material handling, production, manufacturing and goods transportation. The robots themselves are used for repetitive, rough or dangerous setups and can operate in a variety of environments.

The new solutions can be integrated very quickly and easily installed at any user site.

environment; delivering flow rates from 1-14,000 l/hr at a discharge pressure of 30 Bar (435 PSI).

Wanner’s commitment to research and development, and its strong protection of this IP, has enabled it to evolve its capability and make it ideal for this application. This has wider implications for the whole pharmaceutical industry.

Critical for Flow Chemistry and HPLC applications, the Hydra-Cell pumps deliver an extremely low pulse flow, without the need for pulsation dampeners, and with a predictable and controllable flow rate for a consistent process.

Paul Davis, Wanner International’s Managing Director commented: “When you are manufacturing lifesaving and life enhancing drugs, you can’t let anything get in the way.

“These pumps are a perfect fit for this application. They will maximise the production line’s efficiency and productivity, safely and reliably - and reduce costs.”

Wanner designs and manufactures Hydra-Cell seal-less and packing-free, transfer, injection and metering & dosing pumps, helping customers around the world improve their processes by running safe, reliable and efficient pumping processes whilst lowering energy consumption, servicing and maintenance costs – lowering the total cost of ownership for a more sustainable future.

For more information, please visit www.hydra-cell.co.uk.

Moving forward, Interroll welcomes opportunities to continue advancing customers’ success by collaborating with all robotics manufacturers and system integrators who are working with such AMR solutions.

The Interroll Lifetime Service team will support system integrators and end users with the initial LCP AMR Top Module installation and throughout the solution’s complete lifetime of service.

When it comes to service, Interroll’s expert service technicians are valuable source of strength, closely supporting customers worldwide. Production of the LCP AMR Top Module will start this year in Europe, with other Interroll regions to follow.

Looking for a new compressor ?

Talk to us today about how the Almig Series F-Drive compressors can save you SPACE and ENERGY

Saving energy and space at the same time, that doesn’t have to be a contradiction. Quite the opposite. At ALMiG, we have been proving for many years that the concept of a vertical arrangement of motor and compressor unit is the key to success - to efficiency. Energysaving speed control through an oil-cooled permanent magnet motor, a highly efficient compressor stage combined with the most intelligent control technology and the lowest noise level are our answer to the increasingly demanding requirements of the future. o Extremely energy-efficient due to direct drive and speed control o Smallest footprint due to vertical arrangement of the motor-compressor unit o Easy accessibility and maintenance o Motor efficiency corresponds to IE4 or better o Heat recovery optionally available incl. utilisation of waste heat from the motor! o Air Control P as standard compressor control

SPECIALISTS IN COMPRESSED AIR

COMPRESSOR INSTALLATION

COMPRESSOR SERVICING

PIPEWORK INSTALLATION PART OF THE

Call us today on:

01909 519 519 WE CAN SERVICE AND REPAIR THE FOLLOWING

Air Power Products Ltd

Unit 1,2,and 8 Abbey Way │ North Anston Trading Estate │ Dinnington Sheffield │ S25 4JL UK │ 01909 519 519 │ airpowerproducts.co.uk

Product News

New Zealand’s PM gets to see the benefits of LiBiao Robotics parcel sorting robots up close Currently on the campaign trail in the run-up to the forthcoming general election in New Zealand, the country’s Prime Minister, Chris Hipkins, got a closeup view of LiBiao Robotics’ automated parcel sorting technology when he was guest of honour at a recent event held to mark the opening of leading homeware retailer Kmart’s new distribution hub.

The 40,0000 square metre site will service the long-term needs of Kmart’s stores and online customers across the North Island of New Zealand. The new distribution centre will supply 26 Kmart stores and fulfil website orders for affordable homeware, furniture, electronics, toys and children’s clothing direct to internet shoppers.

This is not the first installation that LiBiao Robotics has undertaken on behalf of Kmart in New Zealand. In May 2021 a high throughput LiBiao Robotics automated mobile robot solution went live at another Kmart distribution and fulfilment centre facility in Christchurch.

Sustainability is built into the new site - not only in the construction materials used but also the site’s operational processes - and the environmental

08

Manufacturing & Production Engineering Magazine

benefits offered by the LiBiao Robotics sortation robots was a big influence on the company’s decision to opt for a robotic solution.

With a typical LiBiao Robotics robot using just 30 watts of power an hour – approximately the same as a small indoor table lamp – the system is notably more energy efficient than a conveyor-based sortation solution.

Robotic sortation systems also deliver human resourcesrelated benefits – particularly in developed countries with a low population density. For example, with approximately 20 people per square kilometre, labour costs can be high in New Zealand. But thanks to the fact that robotic sortation solutions require very little human interaction, the wage bill is kept to a minimum.

In addition, with a robotic system it is not necessary to recruit extra personnel when the time comes to expand a site’s sorting capacity – it is simply a matter of introducing additional robots as required. With the price of a LiBiao Robotics robot being equivalent to a single warehouse worker’s monthly pay in some countries, the potential for cost savings is obvious.

Website: libiaorobot.com

Ultra-flat inductive sensor delivers far-sighted detection Sensor specialist BAUMER continues to expand its range of miniature sensors helping system designers and engineers to exploit the benefits of reliable object detection using the smallest possible components. Their new ultra-flat and far-sighted IF250 Inductive Sensor is a perfect example, measuring just 6mm in height, yet will detect objects of up to 12mm. This sensor is the flattest of its type and Baumer claim that such performance is unrivalled in this class and opens up new application opportunities where standard cylindrical sensors will not fit due to limited installation space.

The new IF250 complements the existing Baumer portfolio of highperformance inductive sensors in an ultra-compact design, from cylindrical sub-miniature sensors (3mm diameter) up to M30 designs with maximum 24mm switching distance. The combination of metal sleeves and a mounting kit ensure easy pipe attachment along with a secure and robust sensor mounting.

An important benefit of the flat design is maximised safety reserves because it allows for long-distant safety installation towards the object and is therefore optimally protected - even in critical sensing applications.

Whilst ideally suited to new space restricted applications it can also be retrofitted into existing systems where initially sensors had not been possible.

The IF250 is available as a proximity switch with industry standard PNP or NPN output, or as a measuring variant with IO-Link interface. Digital transmission eliminates the need for shielded cables and a high-resolution A/D converter card - without affecting the sensors ability to provide precise distance measurements.

Furthermore, the IO-Link interface ensures the benefits of easy parameterisation, comprehensive diagnostic data, such as histograms, temperature or switching cycles, which are additional benefits.

DELIVER THE TOUGHEST CLEANLINESS SPECS.

RELIABLE PERFORMANCE WITH MECWASH.

Machined castings. Turned parts. Complex pressings and extrusions.

Customers expect parts to be pristine.

PRECISION AQUEOUS CLEANING demands MecWash.

Cleanliness specs are getting tougher and your customers are enforcing them ever more rigorously. Get a MecWash and relax.

• IMMERSION & ROTATION • ULTRASONIC AGITATION

• TARGETED JETTING • VACUUM DRYING

TRUSTED BY NAMES LIKE… • Renishaw • Rolls Royce • Delphi • SKF

• Goodrich • Parker Hannifin

• Perkins • Meggitt

• JCB • Husco

Cost-effective. Sustainable. Reliable. For the best wash machine solution for your production line, talk to MecWash.

Contact us today on 01684 271600 or visit www.mecwash.co.uk Designed and manufactured in Britain

YOUR EXPERTS IN COMPONENT CLEANING

125 YEARS OF MAKING CHAIN

...THERE MUST BE SOMETHING SPECIAL ABOUT OUR CHAIN +44 (0)161 491 9840 info@kobo.co.uk www.kobo.co.uk

Manufacturing & Production Engineering Magazine

09

Events & Awards News

Nim’s Fruit Crisps shortlisted for national manufacturing accolade One of Kent’s leading food manufacturers has been shortlisted in the prestigious Manufacturer MX Awards 2023.

Nim’s Fruit Crisps, which employs 22 people at its purpose-built factory in Sittingbourne, will now go head-tohead with six outstanding companies for the ‘Manufacturing in Action’ category, including Leonardo, LUSH Cosmetics and Ox Delivers.

Established by entrepreneur Nimisha Raja, the company impressed journalists from The Manufacturer magazine during a visit to its site earlier this year for the way it has continued to introduce new products and its commitment to zero food waste by making use of every bit of the ingredients it uses.

The business has also grown its volumes significantly and is now processing over 1000 tonnes of fruit and vegetables every year.

Nim’s Fruit Crisps now goes through to the second round of the competition, where the independent judging teams will travel the length and breadth of the UK to visit factories and gather first-hand evidence of the entries in action.

“We’ve won a lot of awards in our short lifetime, but to make it on to a shortlist that features some of the biggest and best names in the UK is a massive honour,” explained Nimisha Raja, who set the business up in 2016.

“It was especially pleasing that it came because of a site visit that took place with Joe Bush, the Editor of The Manufacturer. He loved the innovation we were deploying, he loved the passion of our people and he loved the fact that we were making products in England that help children and adults snack healthier.”

Nimisha sold her coffee shop in 2016 to start the UK’s first air-dried fruit crisp manufacturer and has seen it become a huge success, supplying its growing range of products to high street retailers, pubs and bars, Eurotunnel, British Airways and, more recently, to ‘Pret A Manger’, Zizzi and Wagamama restaurants.

In addition to the core air-dried range of fruit and vegetable crisps, the company also manufactures edible teas, garnishes for drinks, infusions and botanicals.

Any competition that celebrates the best in UK manufacturing is something we want to be involved in.

Nimisha concluded: “Any competition that celebrates the best in UK manufacturing is something we want to be involved in and we’ll give it everything we’ve got to take the ‘Manufacturing in Action’ title.”

The Manufacturer MX Awards gala dinner and ceremony, the culminating event of The Manufacturer Live 2023, will be held at the Exhibition Centre in Liverpool on 15 November and is always a true celebration of the best of British manufacturing.

For further information, please visit www.nimsfruitcrisps.com

AIDA Award Recipients AIDA-America, metal stamping press manufacturer in Dayton, OH, USA, congratulates this year’s award recipients, who have been recognized by its parent company, AIDA Engineering Ltd. in Japan, for their excellent work and outstanding contributions to the organization!

• Kozo Abiru, Project Manager • Kazuki Honjo, Engineer – Servo Technology • Hasekazu Ikeda, Engineer – Automation • Tetsuhito Kuroi, Mechanical Engineer • Jeff Martin, Customer Service Engineer • Brenden O’Brien, Project Manager • David Tierney, Senior International Project Manager

10

Manufacturing & Production Engineering Magazine

Events & Awards News

Feats of engineering prove popular as ‘The Third Angle’ wins British Podcast Award Going behind the scenes to learn about some of the world’s most fascinating engineering breakthroughs is proving very popular, with PTC’s immersive customer brand podcast securing a major title and breaking a significant milestone this month.

Hosted by PTC’s Paul Haimes, ‘The Third Angle’, aired bi-weekly, has raced to nearly 165,000 downloads in its first year, been recommended

by Apple as a top listen three times, enjoyed a number two ranking in the US Apple business podcast chart, and, last night, received the ‘Gold’ medal in the Business Category at the British Podcast Awards.

It is a remarkable success for the

programme that gives a voice to the engineers behind some mind-blowing projects as it transports the listener on the journey from conception to completion of their unique inventions.

To date, ‘The Third Angle’ has featured 24 different businesses, beginning with Arc founder Mark Truman, the man behind the world’s most advanced, fully electric motorcycle.

From there, the podcast has travelled the world, putting the spotlight on engineering geniuses that have produced flying cars, hightech football helmets, lightsabers for everyday jedis and homes of the future.

The ‘Third Angle’ podcast

averages just over 6,500 downloads per episode, with the most popular shows being electric vehicle charging company Casio, EVBox and Atronika, inventors of Skinetic, the haptics vest that allows you to experience the Metaverse.

The podcast has also featured exciting start-ups, like UK company Dynisma. Starting out in a small shed, they’ve quickly grown to become one of the world’s leading creators of dynamic simulators for F1 and motorsport.

Future guests include worldleading brands BAE, Marks & Spencer, Jabra and Vestas.

Are you a listener? Learn about all 24 episodes here: www.ptc. com/en/resources/corporate/ podcast/third-angle

• Control panel design and build • EIC / Mechanical design and build • ATEX design and installation • Electrical installations • Mechanical installations • PLC / SCADA software development • Process control and automation

Sibor Ltd Tel: +44 (0)844 504 7124 Email: enquiries@sibor.co.uk Web: www.sibor.co.uk Manufacturing & Production Engineering Magazine

11

Company News Sumitomo (SHI) Demag UK receives gold certification badge from Carbon Neutral Britain Sumitomo (SHI) Demag UK has earned what’s considered by over 1000 British businesses and FTSE 100 companies to be the emissionsreversal gold-certification badge.

Believed to be the first UK polymer machinery supplier exhibiting at Interplas 2023 to be measured against Carbon Neutral Britain’s credible and globallyvalidated offsetting standard, Sumitomo (SHI) Demag UK – the British subsidiary of Sumitomo (SHI) Demag Plastics Machinery GmbH - has offset 153.81 tonnes of CO2e emissions through the Woodland Fund™ portfolio of certified nature-based carbon reduction projects.

To achieve this certification, every day-to-day activities, from car journeys, flights, trains, taxi, hotel stays, recycling, waste, building electricity and gas consumption figures were measured and reported. Quantifying these carbon compounds caused by Sumitomo (SHI) Demag UK has provided the subsidiary with a benchmark to support ongoing emission-reduction improvements.

Compared against businesses of a similar size and headcount, 153.81 tonnes of CO2e falls within the lowest

quartile, assures Senior Environmental Consultant at Carbon Neutral Britain, Caspar Eccles-Williams. “It provides a good baseline and is testament to the efforts already taken by the Sumitomo (SHI) Demag UK team to reduce emissions. We liken it to a sprint within a marathon. This 2023 audit has helped to identify hotspots where further incremental improvements can be made,” explains Casper.

The company intentionally selected Carbon Neutral Britain as it follows the ISO 14064 and GHG Emissions Protocol Accounting Standards. “The Woodland Fund™ backs legitimate projects where carbon credits are measured, regulated, verified and audited,” reports operations manager Andy Hannan.

All of the carbon offsetting projects are authenticated to the highest standards by the Verified Carbon Standard (VCS), Gold Standard Voluntary Emission Reductions (VER), and the United Nations Certified Emission Reductions (CER) programmes. To counterbalance the global inequalities in CO2e emissions, Sumitomo (SHI Demag UK’s offsets are

funding four international Woodland Fund™ projects closely aligned to their business principles. They include energy reduction, socio-economic and environmental education, reforestation and biodiversity.

The next five years are essentially the most critical to shift the climate course, states the latest report by the UN Intergovernmental Panel on Climate Change (IPCC). It requires cooperation, scale and a faster pace. Studies by the UN panel suggest that the worst impacts of climate change could be irreversible by 2030. By partnering with Carbon Neutral Britain, Sumitomo (SHI) Demag UK hopes it can encourage more businesses in the supply chain to offset any emissions that cannot be removed completely.

In-Comm Training enjoys record 199 engineering apprentice recruitment drive as vocational learning on the rise Interest in engineering apprentices is booming in the West Midlands after In-Comm Training announced a 35% increase in the number of starts this September.

One of the UK’s leading training providers has recruited 199 individuals across its Aldridge and Telford technical academies, with learners starting their careers in machining, robotics, welding, electrical, mechatronics and toolmaking.

Companies, including Ansaldo Nuclear, Altrad Babcock, HS Marston

12

Manufacturing & Production Engineering Magazine

Aerospace, Magna Cosma Castings, Makita, RBSL and Veolia, are taking the long-term approach to beating the current labour and skills shortage by opting to grow their own.

In addition to the budding engineers of the future, In-Comm Training also successfully inducted 25 learners onto its Level 4 HNC programme - highlighting a strong move towards upskilling workers.

The first cohort of learners have already started at both sites, with the second one set to begin shortly.

Apprentices will go through a 1-week induction to their specific programme before progressing into workshops that blend theory with practical training on manual and CNC machines, and over £10m of metrology, CAD, fluid power, robotics and wire EDM capabilities.

Depending on their pathway, they will be either full-time at In-Comm or part time and spending the rest of the

Companies, including Ansaldo Nuclear, Altrad Babcock, HS Marston Aerospace, Magna Cosma Castings, Makita, RBSL and Veolia, are taking the long-term approach to beating the current labour and skills shortage by opting to grow their own.

course at their employers, gaining experience and knowledge from workbased mentors.

For information and to register your interest please visit www.in-comm.co.uk.

Company News ASG King & Fowler Announces £1.35 Million Investment in Revolutionary TSA Line Mouser Signs Global Agreement with MediaTek to Distribute Embedded Processors and SoC Solutions Mouser Electronics, Inc., the authorised global distributor with the newest electronic components and industrial automation products, announces a global distribution agreement with MediaTek, a world leader in developing innovative systems-on-chip (SoC) for mobile devices, home entertainment, connectivity and IoT products.

“This global agreement with MediaTek continues our commitment to providing the latest in highly-integrated semiconductors,” said Andy Kerr, Vice President of Supplier Management at Mouser. “Design engineers will have easy access to MediaTek’s world-class SoCs, backed by Mouser’s unsurpassed customer service and best-in-class logistics.”

“With Mouser Electronics as a

global channel partner, MediaTek can better support our customers and enhance our worldwide distribution network,” said CK Wang, MediaTek Vice President & General Manager, Internet of Things. “By capitalizing on Mouser’s excellent supply-chain services and support, we can expand our global presence and get our products into the hands of design engineers even quicker.”

Mouser now offers MediaTek’s Genio portfolio of power-efficient, high-performing IoT SoC and smart modules. MediaTek Genio is a complete platform stack for the IoT with powerful and ultraefficient chipsets, open platform software development kits (SDKs) and a developer portal with comprehensive resources and tools. This all-in-one platform makes it easy to develop innovative consumer, enterprise and industrial smart applications at the premium, mid-range and entry levels, bringing these devices to market faster.

The Genio platform includes the Genio 1200 (MT8395), a flagship-grade SoC developed for demanding AI and performancecentric IoT applications such as advanced smart home appliances, industrial IoT applications and demanding AI-embedded devices. The Genio 700 (MT8390) is designed for smart home, interactive retail, industrial and commercial applications. It provides highly responsive edge processing, advanced multimedia capabilities, a wide range of sensors and connectivity options, and support for multitasking OS. The Genio 500 (MT8385) is a highly capable and efficient IoT platform designed for mobile, home or commercial IoT applications that require responsive edge processing, advanced multimedia capabilities, connected touchscreen displays and a multitasking OS. To learn more about all the MediaTek products available from Mouser Electronics, visit https://eu.mouser.com/ manufacturer/mediatek/.

ASG King & Fowler, a historic manufacturing business with roots tracing back to its establishment in 1887, is excited to announce a significant £1.35 million investment in a state-of-the-art Tartaric Sulphuric Anodising (TSA) line. This strategic investment comes in anticipation of regulatory reforms driven by the REACH initiative, which aims to ban the use of hexavalent chrome in aerospace applications. The investment showcases ASG King & Fowler’s commitment to innovation, sustainability, and staying at the forefront of industry standards and ahead of regulatory reform.

The new TSA line, which is currently being manufactured and commissioned

by Jacquet Weston Engineering, is set to revolutionise ASG King & Fowler’s production processes. This fully automated line promises increased productivity and throughput advantages, all while adhering to stringent environmental standards.

The new TSA line is expected to be installed in approximately 14 weeks, significantly enhancing ASG King & Fowler’s manufacturing capabilities. With this addition, the company will have greater capacity, improved efficiency, and the ability to allocate skilled labour to other critical tasks, further solidifying its competitive edge, both securing existing roles and likely to create new jobs in the future.

ASG King & Fowler was acquired by ASG Group in 2020 and has also invested £140,000 in a new passivation line, driven by customer requirements at Airbus.

This investment showcases ASG Group’s proactive approach to staying ahead of regulatory changes and customer demands.

The new trivalent passivation process will enhance the company’s offerings and its ability to meet the evolving needs of the aerospace industry.

With these strategic investments, ASG King & Fowler is poised to not only maintain its historical legacy but also to compete effectively with larger organisations in the aerospace manufacturing sector. The company’s proactive approach to staying ahead of regulatory changes and customer requirements demonstrates its commitment to excellence, sustainability, and long-term success.

BELOW: The new TSA Line being manufactured for ASG King & Fowler, an environmental leap in aerospace finishing.

Manufacturing & Production Engineering Magazine

13

Company News

Offshore Electronics Commits to Sustainable PCB Production With Major Solar PV Installation Offshore Electronics is set to add a large solar PV array to its 20,000 sq. ft manufacturing headquarters in St. Peter Port, Guernsey. Due to be fitted in early 2024, 96 highefficiency panels will be added to the site’s roof, generating around 44,460kWh per year. This equates to roughly 11% of the business’s annual energy consumption and will save 8,600 kg of CO2.

The green energy will be used to power Offshore’s key production equipment, such as select soldering and state-of-the-art pick and place machinery, the latter capable of placing 95,000 parts per hour. It will also be used to power the site’s critical building services, such as lighting and IT infrastructure.

Little Green Energy Co, a local Guernsey business, will provide and install the panels. Offshore has chosen not to add a storage solution. This allows any excess energy generated to be redirected back into the local grid when not used during production hours. The array’s modular design also

14

Manufacturing & Production Engineering Magazine

allows more panels to be added at a later date.

The installation of solar panels demonstrates the business’s ongoing commitment to low-impact PCB assembly. Offshore’s carbon footprint is significantly lower than a typical manufacturing site. This is afforded by Guernsey’s community power that is mostly derived from imported sources, of which 92% is generated from hydro, wind and solar.

By relying on this source, Offshore is capable of producing PCBAs with a much lower level of embodied carbon, especially when compared with competitors in other regions using grid power derived from coal or natural gas.

The move comes at a crucial time for the business, having experienced a record financial year over 2022-2023.

With this growth, the board saw fit to reinvest some of the proceeds back into production, with green power deemed a top priority.

The addition of solar not only makes the site more resilient, but

also complements Offshore’s other sustainability initiatives, such as the adoption of circular economy principles to minimise the impact of electronics waste on the island community.

Paul van der Tang, Purchasing Director at Offshore Electronics, said: “This solar array is a serious investment in our future as a business, making us more resilient to outside disruption in the energy market.

“But it’s also an investment in the environment, allowing us to minimise the impact of electronics manufacturing as a whole. We’re proud of our record success over the past year, though we also recognise the importance of investing in the future. Guernsey is in a fortunate position with low-carbon community power, but that shouldn’t be considered a free pass.

“We want to be good to our word when committing as a sustainable outsourced partner for clients. This installation is just one of the many ways we’ll continue to do that.”

Automation

Are Manufacturers tackling contingency planning?

Contingency planning is of the utmost importance for any manufacturer, and it can be imperative to get the right support as fast as possible, being able to stock a massive range of parts on site means you can cater for almost any eventuality - and fast!

In the world of manufacturing, business continuity reigns supreme.

The ability to keep operations running smoothly, even in the face of unexpected challenges, is crucial for any successful manufacturer.

In this quest for uninterrupted production, obtaining prompt and effective support is of utmost importance. Equally significant is the ability to maintain a diverse and vast inventory of parts on site. This allows manufacturers to swiftly tackle any unforeseen circumstances, ensuring minimal disruption to their business operations.

The essence of business continuity is planning. It lies in a manufacturer’s preparedness to face unexpected events. From equipment breakdowns to supply chain disruptions, there are numerous potential obstacles that can hinder production. However, with the right support system in place, manufacturers can overcome these hurdles efficiently. Time is of the essence in such situations, and a timely response can make all the difference between

a minor setback and a significant interruption.

In addition to robust support, stocking a wide range of parts on site is a vital component of contingency planning.

With an extensive inventory readily available, manufacturers can respond promptly to any eventuality that may arise. Whether it’s a critical component failure or a sudden increase in demand,

having the necessary parts on hand eliminates delays caused by sourcing, ordering, and shipping. This quick response capability is an invaluable asset that allows manufacturers to meet customer demands and maintain production schedules, regardless of the circumstances.

The ability to cater to almost any eventuality is a major advantage for manufacturers. It not only ensures customer satisfaction but also contributes to their reputation and brand image. By providing prompt and reliable deliveries, manufacturers enhance their credibility, instilling trust, and loyalty among their clients. This, in turn, leads to improved customer retention and increased business opportunities.

In conclusion, having a good contingency plan is a key priority for manufacturers aiming to remain active in a competitive industry. Fast, reliable support, coupled with the ability to stock an extensive range of parts on site, offers significant advantage in handling unforeseen challenges. By prioritising these aspects, manufacturers can safeguard their operations, minimise disruptions, and ultimately achieve longterm success.

Kardex has been delivering solutions for stocking spare parts and stocking production equipment in the UK for more than 40 years. With nationwide full services technicians and engineers, plus remote support, Kardex enables business continuity for its 20,000 UK installations across the country.

To learn more visit our website: www.kardex.com or go to Mechanical Engineering | Automated Storage & Retrieval | Kardex

Manufacturing & Production Engineering Magazine

15

Automation

Movu Robotics: Bringing easier automation to the world’s warehouses stow Group, a globally recognized leader in the design, manufacturing, and implementation of advanced storage solutions and automated warehouse systems, announces the launch of the new “Movu Robotics” brand, developed to strengthen its “Robotics” business unit and to meet increasing customer demand for Automation and Robotics solutions.

The new brand replaces the name “stow Robotics” as of Sep 19th 2023.

Movu Robotics is a new and dynamic warehouse automation brand that stands out by bringing easier Logistics automation solutions to the world’s warehouses and ensuring that, when it comes to opportunities for automation, no warehouse is left behind. Movuis based in new headquarters located in Lokeren, near Antwerp in Belgium that, under a single roof, includes engineering, R&D, production, and a state-of-the-art Experience Centre

where the latest technologies can be demonstrated live in operation to customers and partners.

Background stow Group is a highly successful company with 40 years’ experience as a supplier of logistics and materials handling solutions, and a product DNA based on racking. As customer and market demand for automated solutions increases–driven by labour shortages, the need to increase profitability, efficiency, flexibility, accuracy as well as shortening lead times –stow has been delivering innovative solutions to meet these challenges. stow Robotics was established in 2021 as part of the stow Group and has developed a comprehensive and competitive portfolio of automation and robotics solutions for pallets, bins and items that provides a more energy efficient and practical alternative to stacker crane based solutions. This comprises Movu atlas,one of the leading pallet shuttle systems in the market; Movu escala, an innovative ramp shuttle solution for bins; Movu ifollow, a collaborative Autonomous Mobile Robot (AMR)system for pallets and additional load carriers and the new picking robot Movu eligo.

Despite all their advantages, automated technologies and robotics are perceived by many customers as being complex, expensive, resource intensive with long lead time for installation. Movu Robotics addresses this issue by bringing easier automation to the world’s warehouses.

LEFT: Jos de Vuyst (pictured top), CEO of stow Group & Stefan Pieters (pictured bottom), CEO of Movu Robotics

16

Manufacturing & Production Engineering Magazine

stow Group now has two independent brands under its roof: stow Racking and Movu Robotics.

Movu –No warehouse left behind For projects in the main vertical markets, especially in e-commerce, FMCG and cold storage in Europe and North America, Movu Robotics will deliver simple, standardised plug and play solutions that require less engineering and grant short lead times for execution, allowing customers to keep their operations running.

Jos de Vuyst, CEO of stow Group commented: “Faced with challenges of labour shortages, cost increases, storage density, growing volumes and improving accuracy, companies are turning to robotics and automation for solutions. Movu Robotics offers an integrated ecosystem of standardised and scalable automation technology that speeds roll out and reduces risk for all kinds of customers. We want to democratise materials handling through bringing the opportunities of easier automation and robotics to warehouses that would otherwise find them hard to attain. Expecting the global material handling equipment market to reach USD 350 billion and understanding the key driver AS/RSsystems and Robotics for this, we are optimistic that Movu Robotics will become an essential player.”

Automation This makes upgrading warehouses easier, not only for existing users of logistics automation who want to upgrade their systems with plug and play robotics and automation, but also those yet to adopt automation but who urgently want to take the first step.

Stefan Pieters, CEO of Movu Robotics, commented: “Smart enough to make any operation feel simple and easy, Movu robots help to take a load off the customers’ minds as well as their shelves. Our solutions are designed to make warehouse automation and robotics not only more accessible, but also more scalable. They will enable any warehouse around the world –big or small, regular or awkwardly shaped– to be upgraded and become more productive, more efficient and more successful. This is the philosophy behind our brand claim: ‘Movu –No warehouse left behind’.”

Group structure stow Group now has two independent brands under its roof: stow Racking and Movu Robotics. While both of these brands retain their independence, they strongly impact each other in terms of expertise, know how, technology, and global resources.

All products, business activities and operations of stow Group in the field of Robotics and Automation, including R&D, production, sales and finance, will be grouped as an independent and stand-alone business unit under the Movu Robotics brand in the new headquarters in Lokeren. This includes the operations of the ifollow business, which is now the brand name of the Autonomous Mobile Robots (AMRs) offered by Movu.

The management team will be led by Jos de Vuyst, CEO of stow Group and Stefan Pieters, CEO of Movu Robotics.

Both stow Group and Movu Robotics are driven bya strong team of board members, comprising experience from the Logistics Industry and from other sectors.

Movu Robotics technologies

solutions –for example, the Movu atlas shuttle system working with Movu ifollow mobile robots, or Movu eligo acting as a workstation for Movu escala. A key benefit is that a customer talks to a single face representing a single partner, providing efficient project management and reliable lead times. They will also receive efficient project commissioning for a safe and resilient supply chain that assists in delivering high service levels to their customers.

Autonomous sub-systems for minimal TCO Technologies in the Movu Robotics product portfolio can be integrated into a single autonomous sub-system as a solution, with components including racking, shuttles or AMRs, software, wi-fi and commissioning. This enables easy installation, adaptability to new business needs through simple integration of new applications and a minimal Total Cost of Ownership (TCO) approach.

Standardisation and simplification, which is an essential part of Movu Robotics, results in shorter lead times and lower engineering costs, producing higher profitability. To maximise flexibility, Movu Robotics systems are modular in design, acting as a set of building blocks to minimise complexity and cost of upgrading. This makes the systems highly scalable –installations can start small and then expandor, if needed they can downsize just as easily. Modularity also enables a fast roll out for projects.

For not leaving any warehouse behind, Movu Robotics will target the market with a dual strategy: providing end users with a direct channel, for which Movu relies on a network of sales offices in main territories. Its portfolio of simple, standardised, scalable, and flexible systems provide opportunities for SMEs with as few as 5000 pallet locations to automate, to address challenges such as labour shortages and cost efficiency –a huge growth area. The other part of this strategy is the indirect channel where Movu can supply a fully functional storage sub-system from its portfolio to a systems integrator for integration into a complete project.

All of this is supported by a global network in customer service and stow’s 40 years’ industry experience.

Movu Robotics is consistently working to improve existing technology for the customer, with innovation, R&D and entrepreneurial thinking being an integral part of the dynamic business unit. The next product launch is planned for 2024, to further expand the portfolio.

Unlike many automation companies that have a single product, the new Movu Robotics brand includes a range of key technologies: Movu atlas pallet shuttles, Movu escala bin shuttles and Movu ifollow Autonomous Mobile Robots (AMRs) for pallets and roll cages that work either stand-alone or as collaborative robots. Joining these is the new Movu eligo picking robot, which is offered as a picking workstation for escala.

Movu Robotics provides solutions for easier automation that can make better use of every corner of the warehouse –irrespective of the customers’ storage space or what they are storing, conveying, picking or handling.

Customers gain the key advantage of seamless integrated racking and robotics Manufacturing & Production Engineering Magazine

17

FARNBOROUGH | Hants | GU14 6TQ 6th - 8th February 9.30am - 4.30pm

(3.30pm close Thurs)

Where Industry and Innovation converge

FREE SEMINARS FREE PARKING

Incorporating The Subcontract Engineering Exhibition

Over 600 national and international AUTOMATION suppliers come together to exhibit at DEFENCE Farnborough International Exhibition and Conference FOOD & DRINK Centre this February for Southern Manufacturing AUTOMOTIVE / AUTOSPORT and Electronics (inc AutoAero) 2024. Meet the ELECTRONICS power behind UK manufacturing industry and see AEROSPACE live demonstrations and new product launches of TRANSPORTATION machine tools & tooling, electronics, factory & PACKAGING process automation, packaging & handling, ELECTRICAL & MECHANICAL ENGINEERING labelling & marking, 3D print technology, test & measurement, materials, composites & adhesives, ADDITIVE MANUFACTURING LOGISTICS rapid prototyping, ICT, drives & controls, plastics & MARINE polymers and laboratory equipment.

ENERGY

Free industry seminar programme online @ www.industrysouth.co.uk

SPACE ENGINEERING R&D MEDICAL

The exhibition is free to attend, free to park and easy to get to. Doors open at 9.30am on Tuesday 6th February.

PRE-REGISTER TODAY for your Fast Track Entry Badge, Preview Magazine and Event Catalogue at:

www.industrysouth.co.uk

MATERIALS / COMPOSITES CONSTRUCTION PLASTICS & POLYMERS

SOUTHERN MANUFACTURING & ELECTRONICS is an ETES event organised by European Trade & Exhibition Services Ltd

01784 880890 | philv@etes.co.uk

Education / Recruitment Feeling stuck in your current role? Become a lecturer and train the next generation of engineers!

Are you tired of working on your feet all day and feeling stuck in your job? Are you fed up working split shifts and need more time off to rest or spend it with your family? If you have a passion for engineering and want to pass your knowledge and experience on to the next generation of workers, maybe it’s time to consider becoming an engineering instructor or lecturer?

Do I have what it takes to become a lecturer?

If you like working with young people, have great people and communication skills as well as industry experience, time management and organisational skills, you have what it takes to become an instructor! Any additional experience working with apprentices or training junior staff would be an advantage. Our team will help you move into education and support you throughout the process every step of the way.

What does the job look like?

A day in the life of an engineering educator involves teaching 16 to 19-year-old students in a classroom or workshop, sharing your theoretical and practical knowledge of working in the engineering industry, assessing the standard of their work, providing constructive feedback, and preparing them for a career in engineering.

Depending on your experience and preferences, you can become a lecturer and spend more time in the classroom, or a lecturer and provide more practical knowledge in the workshop.

What are the benefits?

What jobs are available?

Here are just few out of many benefits of becoming an educator:

We work closely with a variety of further education providers across the UK, who are always on a lookout for instructors, assessors and lecturers in the following sectors:

• More paid holidays – lecturers and instructors get up to 52 days annual leave with bank holidays as well as Christmas.

• No shift work – all lecturers and instructors work Mon-Fri, maximum five times a week.

• Pension scheme up to 23.6% – further education providers will pay the employer’s contribution to your pension.

• Funded training and progression – provider will train you on the job, invest in you and offer ongoing professional development to support you through your career.

• Job satisfaction - you’ll gain satisfaction from sharing your industry knowledge and experience with your students and have a direct impact on shaping the next generation of engineers.

Why work with jjFOX? We have a dedicated team of experienced recruiters specialising in the engineering sector who are ready to help you with the transition from trade to education. Our specialists have the insight knowledge of the market and organisations and will be happy to share them with you to help you secure your first exciting role. They also know the recruitment process insight out and will assist you in the interview preparation if needed.

Our consultants will act on your behalf and help you negotiate the salary. This means no awkward conversations between you and your future employer. And, most importantly, our service is free of charge for candidates. You won’t have to pay for our help.

• Automation • Automotive Engineering • Electrical Engineering • Electronics • Fabrication/Welding • Maintenance Engineering • Manufacturing Engineering • Mechanical Engineering

Do I need a DBS check?

Working with students under 18 requires a DBS check. You need to be enhanced DBS checked, which can be done through us; we have a specialist in-house vetting team that can help you with it.

How do I become a lecturer/ instructor?

Whether you are considering a parttime, contracted position or want to transition into a full-time teaching career, we have a variety of roles available for you. Your first step will be to get in touch, discuss your options and send us your CV. If you don’t hold any teaching qualifications, don’t worry. Due to staff shortages, a lot of organisations will be happy to train you on the job and provide funding to your courses.

Interested and curious to find out more? Get in touch with our team today!

Email us on contact@jjfox.com or, alternatively, call our office on 0345 0655 370.

Your new, exciting career awaits! www.jjfox.com/candidates2

Manufacturing & Production Engineering Magazine

19

Asset Finance

Views of the small business owner…

Manufacturing and Engineering Close Brothers Asset Finance surveys around 1,000 small and medium-sized business owners three times a year across our key sectors, asking them a variety of questions.

1. Energy costs 2. Inflation 3. Interest rates 4. Materials supply 5. Cash flow

In this article we take a close look at the views of those firms in the Manufacturing and Engineering sector.

Where appropriate, the UK average will be included to provide high-level context.

• Manufacturing and Engineering

FINANCE • On average, 80% (UK: 73%) of

Manufacturing and Engineering SMEs plan to seek funding for business investment in the next 12 months.

• 47% (UK: 43%) of Manufacturing and Engineering SMEs are confident the economy will grow in the coming 12 months, against 45% (UK: 46%) who expect a further slowdown of economic activity. The rest anticipate no change.

• 35% (UK: 36%) of Manufacturing and Engineering firms expect to grow in the coming year; 54% (UK: 54%) will tread water while 9% (UK: 9%) will contract.

• The top five concerns for Manufacturing and Engineering businesses, currently, are:

firms’ main business priorities at the moment are:

1. Achieving growth: 36% 2. Developing our products/services: 17% 3. Business consolidation: 15% 4. Survival: 11% 5. Investing in staff: 11% 6. Paying down debts: 8%

• Late payments are an issue for 56% (UK: 51%) of M&E firms.

INFLATION • 53% (UK: 48%) of M&E SMEs think

inflation has peaked; 35% say ‘no’ with the rest unsure.

• The four biggest impacts of inflation are: 1. Raising of prices and passing them onto customers 2. Increased wages to support employees 3. A negative impact on cashflow

4. Some businesses have chosen to absorb cost increases rather than pass them onto customers

• 42% (UK: 40%) of M&E SMEs think

the Bank of England’s aim to get inflation below 5% by the end of the year is realistic; 45% don’t agree, and the rest are unsure.

• 48% (UK: 46%) of M&E firms have experienced lower demand for their products & services because of higher inflation against 36% (UK: 32%) who have seen an uplift; the rest have felt no impact.

COST OF BORROWING • 54% (UK: 53%) have seen an increase in their cost of borrowing; 37% (UK: 38%) haven’t, and the rest are unsure.

• 45% (UK: 36%) of M&E SMEs have switched funders because of increased interest rates.

• 57% (UK: 51%) have considered alternative forms of finance because of increased interest rates.

• 42% (UK: 39%) think interest rate rises have peaked while 42% (UK: 45%) do not.

• 62% (UK: 59%) have had to increase their prices to cover the increased cost of borrowing.

INSOLVENCIES • 63% (UK: 55%) of M&E SMEs are

concerned about rising company insolvencies in their supply chain.

• The 5 most popular measures firms are taking to ensure their firm remains solvent are: 1. Cutting costs 2. Improving efficiency 3. Seeking new funding 4. Taking out insurance 5. Considering refinancing their assets

• 45% (UK: 43%) of M&E firms have

seen a rise in mergers & acquisitions in their sector over the past 12 months.

For more information, please visit: closeassetfinance.co.uk/ manufacturing

20

Manufacturing & Production Engineering Magazine

SUPPORTING THE UK MANUFACTURING INDUSTRY WITH ASSET FINANCE With specialist industry knowledge and tailor-made support, we offer a range of finance options which can: • Unlock the value of your existing assets • Let you invest in new equipment • Create positive cash flow for your business

Contact us today, we’re here to help closeassetfinance.co.uk/mpe

Products and services are subject to eligibility, status, terms and conditions and availability. All lending is subject to status and our lending criteria. The right to decline any application is reserved.

Close Brothers Asset Finance is a trading style of Close Brothers Limited. Close Brothers Limited is registered in England and Wales (Company Number 00195626) and its registered office is 10 Crown Place, London, EC2A 4FT.

Latest News

First machine arrives as Alloy Wire International kickstarts £500,000 investment drive The first specialist machine in a £500,000 investment drive has been installed at a leading manufacturer of round, flat and profile wire.

Alloy Wire International (AWI), which supports more than 6000 customers across 65 countries, has purchased a new wet drawing machine that will allow it to significantly increase capacity as it looks to take advantage of a rapidly growing order book.

The AWI team has worked with the manufacturer to ensure this new machine will fit seamlessly into the production set up at its state-of-the-art factory, with its specific features helping to reduce lead times even further.

Capabilities on the new £145,000 machine include pre-programming to allow for set spool weights or wire lengths and flexibility to work with a wider range of both inlet and finish sizes – this in turn increases the range of mechanical properties that can be offered across all its 62 grades.

Alloy Wire International, which has two sites in the West Midlands and Yorkshire, was purchased by Directors Tom Mander, Andrew Du Plessis and Adam Shaw in January.

The new-look management team has overseen a significant growth in sales, with orders up nearly 40%, placing the company on course for nearly £18m turnover by the closer of 2023 – the best 12 months in its 77-year history.

Investment in its people and increasing stockholding of its 62-strong High Performance Alloys to over 400 tonnes has been crucial in attracting spring makers, fastener manufacturers and critical suppliers to the automotive, aerospace, oil and gas, nuclear and MedTech sectors.

For further information, please visit www.alloywire.com

22

Manufacturing & Production Engineering Magazine

New study into new renewable and affordable microgrid using biogas from agriculture farming Bear Instruments, leading edge power electronics systems and instrumentation design and manufacturer, announced on the 25th September it is part of a consortium to deliver an affordable, reliable and clean energy microgrid for Vietnamese agriculture farms.

Bear Instruments are delivering the prototype microgrid to include the gas turbine, solar array, 2nd life EV battery for storage and a grid tied connection. This includes modelling of batteries, evaluating state of health and state of charge along with development of the micro grid hardware itself.

The company is developing power electronic energy conversion (DC/DC converters, AC/DC rectifiers, and DC/AC inverters) for optimum microgrid performance.

Many existing AC-networked microgrids, in this application space, with solar PV and battery storage are high cost with low efficiency. The payback period in the Vietnam PV power plant industry is 10 to 14 years. And secondary life batteries for energy storage are quite new in Vietnam and are still not mature in more developed countries.

Combining these factors with very expensive biogas treatment in Vietnam means development of a clean, affordable microgrid is of great importance to rural families, who are generally low income and lack the resources to pay the upfront costs.

The other key technical challenge is to develop a cost effective treatment process for the raw biogas, based on bentonite, a waste material which is readily available from local mines. This is expected to reduce this cost by 20%.

The innovations work for both islanded mode and on-grid application, particularly for communities with off-grid/ unreliable power-systems. They also work for second life batteries as energy storage solutions.

This project is sustainable in producing low carbon energy but also using pollutants from other industries. Methane from farming is also a much more reliable energy source than other solutions and has potential for wider application in other developing countries.

The consortium is led by Dr Khoa Dang Hoang at the University of Huddersfield. Along with Bear Instruments, the consortium includes Allgreen Energy, who have strong expertise in project management and building business models within the renewable energy sector; and Hochiminh City University, with its chemical process engineering lab focusing on bio-gas treatment.

The project is funded by Innovate UK and expects to deliver power efficiency of up to 5% and cost local communities 30% less to develop.

For more information, please visit bearinstruments.co.uk/, www.hud.ac.uk/ or www.allgreenergy.org/.

Latest News

Northern Ireland’s largest 5G testbed in Derry-Londonderry set to supercharge smart manufacturing Local technology consortium Smart Nano NI, formed to further the development of smart manufacturing in Northern Ireland, has launched the largest 5G testbed in Northern Ireland in Derry-Londonderry, marking a significant step in a five-year plan to accelerate smart manufacturing in the country.

Led by consortium partner Digital Catapult, the UK authority on advanced digital technology, the 5G testbed is the organisation’s latest innovation activity to bolster economic growth and investment opportunity in Northern Ireland. The investment by the Smart Nano NI consortium will

create a valuable, open access facility and provide expert technical support to local start-ups and businesses through the Digital Catapult Smart Nano Accelerator Programme.

The ground-breaking testbed facilities will be delivered by the global IT and business consulting services firm CGI, in partnership with Digital Catapult Northern Ireland. The cuttingedge 5G and 4G private network is a first-of-its-kind smart manufacturing and education setting in Northern Ireland, providing access to the latest network technologies including 5G and NarrowBand-Internet of Things (NB-IoT), and will be instrumental in upskilling the next generation of

innovators and experts across the country.

The smart education site at the Industry 4.0 Centre in the Northwest Regional College’s Springtown Campus, will give both students and industry access to test and explore new use cases of the 5G private network, while the manufacturing site, hosted at Seagate’s manufacturing facility, will give businesses the opportunity to test the technology in a live manufacturing setting.

The Manufacturing Innovation Challenge will take place from Jan 2024 to March 2024, with applications closing on 15th November 2023.

Businesses who are interested in participating can apply online here.

Totalkare’s ergonomic positioners are single or double column devices that enable the lifting and rotation of a product during welding and assembly operations.

With overall capacity from 2,000 - 90,000kg to suit, they are both compact and flexible.

GET A QUOTE: T:0121 585 2724 / WWW.TOTALKARE.CO.UK

Manufacturing & Production Engineering Magazine

23

Compressed Air, Pumps & Valves

Optimising control valve specification by challenging the input data Greg Wainhouse, Industry Account Manager for Water Applications at Bürkert, explains the importance of reviewing input data for control valve specification.

When specifying control valves, ensuring the right input data is provided offers the best chance the resulting performance of the application will be optimised. To show the effects, a recent example based on deionised water production highlights how accurate specification is essential whenever control valves are used. Full consideration of the application’s key criteria, as well as accurate calculation of input application data, are vital to optimise control valve specification.

Recently, a system integrator approached Bürkert to supply a valve for a water conductivity blending application, with the objective of achieving water quality with a conductivity level of 10µS (microsiemens). Their process design schematic included a ball valve that would isolate the flow of softened water, while a control valve would modulate the flow of deionized water. By controlling this media combination, once blended, the customer’s expected outcome was water production at the desired conductivity level. With this plan, the system integrator requested a control valve that would regulate the deionized water flow.

To calculate the size of control valve required, it is important to understand

the required flow rate and pressure. The integrator suggested that upstream pressure was 4 bar, with 3 bar pressure downstream. Moreover, they suggested a total flow rate of 1.5 m3//h. Even at this stage, Bürkert suggested a review of this input data because the suggested flow rate appeared to be inaccurate.

Furthermore, using the pressure and flow data, the calculation generated a requirement for a 1” diameter valve, which would likely be too large for this application. However, the integrator was satisfied with the validity of their initial input data, and they confirmed the resulting valve specification, supported by the fact that they had used this size of valve on a similar project with the same input data.

Oversized valve specification The Bürkert team remained unconvinced and they sought wider input data to help confirm the specification. The integrator reported that when installed, the previous valve project would operate at 10 to 20% of its total capacity. However, the reverse situation should ideally apply, sizing a valve to operate at 70%-90% of its capacity would enable the use of a smaller, more cost-effective valve, that could also achieve more efficient operation.

Burkert decided to recalculate the valve size, based on optimising 80% capacity. This time, to ensure a comprehensive approach, the input data was reconfirmed.

With a reading from the system’s pump, the upstream pressure was confirmed.

LEFT: Achieving the optimum valve selection depends on accurate process data and expert valve knowledge.

24

Manufacturing & Production Engineering Magazine

Thanks to an installed flow meter, the flow reading was also verified. Using these input data, it was possible to work backwards and determine the actual downstream pressure.

This highlighted that the downstream pressure was significantly less than the figure initially provided. Instead of the suggested 3 bar, the new calculation was just 0.1 bar. Based on this new data, it was realised that the customer’s desired, repeatable, and controllable flow range could not be achieved.

Optimising control accuracy On further investigation, the customer revealed that an open tank was positioned downstream of this system, which both explained and confirmed the almost 0 bar downstream pressure reading. As a result, the customer agreed to resize the valve, sufficient to handle a difference from 4 bar upstream pressure down to 0 bar downstream.

By this stage, the system integrator was working more closely with Burkert, and as a result, were also able to challenge a fundamental assumption about the system’s design. Although the conductivity value of the deionized water was very low, at 0.5 µS, the value of the softened water was very high, around 600 µS. Without modulating the softened water flow, the resulting conductivity level after blending the media would be far higher than the objective of 10 µS. Bürkert advised that instead of regulating the flow of deionised water, by controlling the softened water, the desired conductivity level could be reached.

Get it right first time Switching the position of the control valve and resizing it accordingly enabled the integrator’s system to achieve the low, 10 µS water conductivity rating for their customer. Without assistance in making the correct calculation, the customer would have integrated a much larger – and much more expensive – control valve. Most significantly, the

Compressed Air, Pumps & Valves brati

ce

40

ng

Dependable Under Pressure

le

UK Official Years Distributor Since 1983

Your trusted partner since 1975

Pumps & Pumping Equipment - Cleaning Equipment - Hose & Hose Reels - Fluid Handling Components Fittings, Connectors & Filters - Spraying & Watering - Engines, Motors & Generators

www.dualpumps.co.uk Call 01664 567226 for more information

Dual Pumps 180x132 July.indd 1

system would have been far less likely to have produced the desired quality of water. Had the system designer engaged with valve sizing and application expertise at the outset, they would also have avoided rework in design, instead achieving a faster time to market.

Although this example demonstrates specific implications of incorrect specification, the same principles apply for any application that requires control valve modulation. The fundamental calculations to ensure correct control valve sizing are essential whatever the purpose and sector, from food & beverage, to pharmaceutical and life sciences.

A crucial aspect for optimum sizing of control valves is achieving valid application input data. If the input application data is incorrect, or incomplete, then the type, position, and size of the control valve will be sub-optimal. While specifiers can make mistakes in calculations, valve specification errors can also have historic origins. If the original system wasn’t designed according to the right data, like-for-like replacement will also

Follow / Like / Subscribe 19/06/2023 11:04:24

be sub-optimal. As technology has advanced, valves today are frequently more accurate, impacting open and close rates, and this means that smaller, less expensive valves can potentially be used instead. So, even when upgrading an existing system, the best practice is to recalculate control valve sizing each time.

Valve sizing Bürkert’s process valve sizing tool, comprising control valve selection, helps designers and specifiers configure the right specification through a sequential set of application criteria. This tool helps to make control valve selection fast and simple, however, it’s imperative to remember that valve specification depends on valid input data.

Moreover, when used in an application like conductivity blending, Bürkert has additional internal tools to determine whether a complete system could achieve the desired outcome.

The surest way to achieve optimised valve specification, first time, is to involve a flow control specialist as early

As technology has advanced, valves today are frequently more accurate, impacting open and close rates, and this means that smaller, less expensive valves can potentially be used instead. as possible in the process. Sharing access to details on the wider application enables an experienced valve provider to make an accurate specification based on all of the relevant criteria. This process might involve challenging the input data, but in so doing, a more effective outcome can be achieved.

Manufacturing & Production Engineering Magazine

25

Compressed Air, Pumps & Valves

Elta Fans Launches New ‘Prefabricated Solutions’ Service as Offsite Manufacturing & Modern Methods of Construction Spikes With offsite construction and the prefabricated building systems market booming, a new ‘Prefabricated Solutions’ service from Elta Fans is now available for a wide range of its fans. The solution is set to help cut installation costs and speed up building projects with greater efficiency and compliance while enhancing site safety.

Modern Methods of Construction and offsite initiatives are growing exponentially across the UK. To highlight this, earlier this year, the Crown Commercial Services selected 29 firms to be part of the £10bn Offsite Construction Solutions framework, with public sector buildings across healthcare, education, justice and defence all expected to swing toward modular construction.

Elta Fans’ Prefabricated Solutions service is ideal for specifiers and contractors working on commercial building projects of any scale. Fans and ancillaries, such as acoustic equipment, mounts, panels, flexible connections, fan controls and more, can all be assembled offsite and delivered as a compliant assembly.

These are then ready for crane lifting, resulting in quick, efficient installation.

A key benefit of the new service from Elta Fans is the provision of both acoustic and air flow performance data when engineering a solution.

This means an engineered acoustic solution can be developed from the start, and there is no need to re-select or re-calculate separately were they sourcing these components from elsewhere.

The ventilation and air movement manufacturer is one of the first in its sector to offer this kind of solution across multiple fan types and ranges.

Luke Hammond, Applications Specialist of Elta Fans explains that prefabricated assembly of fans also unlocks a host of other benefits. These include a more streamlined design process, offering simpler compliance with both ‘The Golden Thread’ and environmental requirements while reducing disruption to the local community, and other related site activities.

Colin Moss from Elta Fans has pioneered the service and elaborates on the multiple benefits specifiers and contractors can gain by going down the prefabricated assembly route. He said: “Installing individual components on-site can be a cumbersome and time sensitive task. It requires ample storage and working space, leading to congestion on busy sites and increasing the potential for site safety issues. The collection and assembly of various parts can also be timeconsuming, causing delays to projects.

“Not only this, but site time is costly, and labour costs can quickly add up when dealing with unnecessarily complex, site installations. With Prefabricated Solutions by Elta Fans, these challenges are a thing of the past, and you can manage these expenses and have better quality control of the finished product.”

A key benefit of the new service from Elta Fans is the provision of both acoustic and air flow performance data when engineering a solution. Using Elta Fans selection software, the Acoustic performance data can be supplied at the initial stages to help simplify the process for specifiers and contractors.

26

Manufacturing & Production Engineering Magazine

Elta Fans’ Prefabricated Solutions service means units are built to the highest standards within a controlled factory environment. The company, which has UK-manufacturing sites in Kingswinford, Fareham, and Colchester, holds ISO 9001 accreditation for quality management, guaranteeing that finished products are reliable, durable, and ready on time.

“Gone are the days of waiting for single components to be delivered to the site, which can get lost or damaged while other elements of the project are in transit. With our Prefabricated Solutions service, all necessary components are packaged together, ensuring a hassle-free delivery,” said Luke.

“Preassembled units also mean other costly, disruptive activities on-site, such as crane lifting and road closures, can be minimised. Shipping materials like pallets, packaging and strapping is all reduced as well, and with better overall coordination, Prefabricated Solutions allows workforces to focus on boosting productivity in other areas.”

For more about Elta Fans and its Prefabricated Solutions service, visit www.eltafans.com/ prefabricated-solutions

One order. One frame. One delivery.

Prefabricated Solutions from Elta Fans.

Discover how our Prefabricated Solutions can help you to boost on-site productivity, along with enhancing efficiencies and streamlining your processes. Off-site assembly not only reduces waiting times but saves on cost and eliminates installation problems. The all in one solution.

eltafans.com

Scan the QR Code to find out more.

Drives & Controls ABB is helping to ensure that we continue to have the highest levels of availability in our processes.

Top aluminum producer and recycler Novelis to increase uptime with ABB modernization Novelis Inc., a leading sustainable aluminum solutions provider and the world leader in aluminum rolling and recycling, is working with ABB to upgrade its third-party drives and controls system as part of a brownfield modernization project at its hot rolling mill in Oswego, New York, USA. To futureproof the mill, ABB is replacing obsolete and outdated equipment with new switchgears, transformers, medium voltage drives, medium voltage synchronous motors, motor control centers and auxiliary controls, all integrated with the facility’s existing non-ABB control system. This will support Novelis’ ambitions for increased power capacity and reliability. Commissioning of the upgrade is expected by the end of 2023.

The Oswego mill was the company’s first US operation and is today the company’s largest, wholly owned fabrication facility in North America. It produces high-quality aluminum sheet for the automotive, beverage can, and building and construction markets. Novelis is also the world’s largest recycler of aluminum and seeks sustainability

28

Manufacturing & Production Engineering Magazine

commitments from its supply chain as its customers look for environmentally friendly and circular aluminum products.

“In order to continue to provide our customers with the highest quality, sustainable aluminum sheet, and do so reliably, we are focused on increasingly optimizing our production output,” said Ganesh Panneer, Vice President of Operations, Novelis North America. “ABB is helping to ensure that we continue to have the highest levels of availability in our processes.

The expertise of the ABB metals team, together with their commitments on providing the latest, most energy efficient products, will secure Oswego’s future as we maintain our leading position.”

“We’re proud to support Novelis in meeting their production targets, which promote efficient use of energy and other resources,” said Siraj Boudighar, Sales Manager North America for Metals, Process Industries, ABB. “By leveraging our long-term experience and in-depth knowledge of metals industry processes, including more than 400 references for modernization projects since the year 2000, we are able to tailor technology packages that meet the specific needs of each customer.”

ABB’s Process Automation business automates, electrifies and digitalizes industrial operations that address a wide range of essential needs – from supplying energy, water and materials, to producing goods and transporting them to market.

With its ~20,000 employees, leading technology and service expertise, ABB Process Automation helps customers in process, hybrid and maritime industries improve performance and safety of operations, enabling a more sustainable and resource-efficient future. go.abb/processautomation ABB is a technology leader in electrification and automation, enabling a more sustainable and resource-efficient future. The company’s solutions connect engineering know-how and software to optimize how things are manufactured, moved, powered and operated. Building on more than 130 years of excellence, ABB’s ~105,000 employees are committed to driving innovations that accelerate industrial transformation.

Latest Product Launches

Rugged power and signal interface featuring quick locking The new Power Bayonet Connector PBC15 from binder is suitable for power supply and signal linking of devices via just one cable. Important features of the compact connector with quick locking include its high power density and easy-to-use design, which is tailored for fast wiring and installation. binder, a leading supplier of industrial circular connectors, presents the Power Bayonet Connector PBC15.

Its size corresponds to an M15 thread.

Thus, in the field of power supply connectors, the PBC15 bridges the gap between the widely used M12 and M23 designs. The compact, yet robust

connector is suitable for power supply particularly to three-phase motors or frequency converters. It features 3 power pins, for example to supply the 3 live phases of a 3-phase motor, 2 additional pins for signal transmission, as well as a Protective Earth (PE) contact.

The PBC15 design is specified within the DIN EN IEC 61076-2-116 standard.

The quick-lock ensures simple, fast, and reliable locking by means of a quarter turn. Termination is provided by screw clamps. The PBC15 is initially available from binder as wireable female or male cable connectors, in each case as an unshielded or shieldable variant.

Fields of application Thanks to the rated values of 630 V and 16 A for the power interface, the circular connector is suitable for the power supply of small to mediumsized drives. With rated values of 63 V and 10 A, the signal pins can be used, for example, to control brakes or to query operating parameters such as temperatures. The shieldable variants of the Power Bayonet Connector are prepared for use in environments exposed to electromagnetic interference. Typical applications are in the fields of intralogistics, factory and process automation, as well as machine engineering.

New at TTI: Amphenol DuraEV E-Mobility Battery Charging/Discharging Connectors TTI, Inc. – Europe, a leading specialty distributor of electronic components, is now stocking the new DuraEV battery charging and discharging connectors from Amphenol FCi (ACS), suitable for both portable and fixed e-mobility battery applications in twowheelers and three-wheelers.

These hybrid connectors, which support 2-power and 4/6 signal pins, employ a patented contact system capable of carrying a continuous current of up to 70A. The charging and discharging connectors are IP67-sealed in both mated and unmated conditions

30

Manufacturing & Production Engineering Magazine

to prevent the ingress of dust and moisture – the DuraEV connectors come with an IP cap for the socket side and an optional IP cap for the plug side. In addition, the connectors are rated for 10,000 mating cycles and at temperatures from -20°C to +90°C. The Poka-Yoke mechanism employed by the DuraEV connectors helps eliminate mis-mating errors, and the first mate last break (FMLB) power sequencing supports safe plugging.

Finger protection helps ensure safe, manual handling during everyday use. In addition, the positive latch and connector position assurance (CPA) feature ensures easy mating and un-

mating and provides secure locking.

“In recent years, the e-bike battery connection problem during charging and discharging has been well-documented with common issues including connector oxidation, water ingress, mis-mating and contact wear,” explains Dermot Byrne, Industry Marketing Director - Transportation at TTI Europe.

“Amphenol’s DuraEV connectors enable e-mobility manufacturers to provide a robust, safe and reliable solution for both the e-bike and its owner.”

For more information about Amphenol’s DuraEV e-mobility battery charging/discharging connectors, which are now available from TTI, please visit: https://www.ttieurope.com/ content/ttieurope/en/apps/partsearch.html?q=duraEV

Latest Product Launches Thermo Fisher Scientific Launches Next Generation Optical Emission Spectrometers

Design features The compact design of the PBC15 is a unique feature: on the one hand, it offers very little space for an isolation appropriate to the voltage levels. On the other hand, the high currents require wire gauges of up to 2.5 mm2 and sufficiently large contacts in order to be able to ideally connect the wires.

Nevertheless, the engineers at binder succeeded in designing the PBC15 in such a way that convenient assembly by means of the screw clamp terminals is possible.

Another challenge arose with the coupling of the PE pin, which is designed here as the center contact, to the connector housing. The connection was established by means of a spring plate which was pressed together with the PE contact inside the contact body, thus forming a secure connection to the housing.

Standardization Until now, electrical connectivity for small and mediumsized 3-phase drives has often been characterized by products from different manufacturers that have featured different designs for connecting the same motor. Those products are not interchangeable. A committee of various companies, also including binder, developed a standardization proposal to create a uniform interface for this application field. This proposal was published in April 2022 as the official draft standard DIN EN IEC 61076-2-116. The Power Bayonet Connector from binder complies with this design standard, which allows customers to achieve a substantial level of independence from individual suppliers when developing their applications.

The shieldable variants of the Power Bayonet Connector are prepared for use in environments exposed to electromagnetic interference. Typical applications are in the fields of intralogistics, factory and process automation, as well as machine engineering.

Thermo Fisher has announced the release of its new Thermo Scientific™ ARL iSpark™ Plus Optical Emission Spectrometer range, designed to streamline elemental analysis in the metal production, processing and recycling industries, as well as in contract and research labs.

The new line of ARL iSpark Plus Optical Emission Spectrometers offers metal producers, processors and recyclers – as well as contract and research labs – the rapid and reliable spectral analysis needed to achieve key productivity, quality and environmental objectives.

The new instruments build on the legacy of Thermo Fisher’s flagship ARL iSpark range, combining stateof-the-art technologies, user-friendly features and advanced automation algorithms to enable the widerange spectral analysis of metal samples and ultra-fast detection of non-metallic inclusions. The ARL iSpark Plus line adds a new and improved spark stand to extend maintenance intervals by 30 %, minimize signal drift for most elements and ensure virtually no memory effect from preceding samples. With seamless software and firmware interaction also cutting down on processing time by 15 %, these are Thermo Fisher’s most advanced optical emission spectrometers yet.

Ryan Lydon, Senior Director and General Manager of Metals and Minerals at Thermo Fisher, commented: “As an industry-leading instrument supplier, we are always conscious of the industrial challenges faced by our customers, which is why we are continuously improving and updating our product portfolio to provide the best tools possible. The increased analytical speed and stability of the new ARL iSpark Plus spectrometers illustrate this ethos perfectly, allowing steel plants and foundries to minimize tap to tap times, save energy, reduce carbon footprints and realize a faster return on investment.”

Key applications: Streamlined elemental analysis for the metal production, processing and recycling industries.

Features/benefits: • • • • • • • • • • •

Unique high sensitivity photomultiplier tube optics Digital spark generation Single spark acquisition Smart argon management Advanced data collection technologies Intelligent processing algorithms Ultra-fast analysis of non-metallic inclusions 15 % faster processing times 30 % longer maintenance intervals Minimal signal drift Virtually no memory effect

Manufacturing & Production Engineering Magazine

31

Machines & Machinery

Breathing New Life into Used Machines: A Guide to Smart Ownership and Maintenance Affordable, immediately operational, and eco-friendly.

Used machines provide an ideal addition for industrial operations.

How can they be optimally utilized, maintained, and traded? And why it’s important to rely on professionals from the get-go.

The used machinery market is booming. Companies are increasingly recognizing the value in buying and selling pre-owned equipment. Instead of sending machines to the scrapyard once they’ve served their purpose, these assets can be revitalized and redeployed in another operation.

Used Machinery: Advantages for Buyers and Sellers Used machinery is currently very much in vogue and for good reasons.

It offers significant advantages for both buyers and sellers. Sellers benefit from freeing up budget through the sale of used machines, which can be used for new investments. Buyers, on the other hand, appreciate that used machines are more affordable than new purchases, are immediately available, and are sustainable since they don’t have to be scrapped.

Quality doesn’t have to be compromised either. If used machines are properly maintained, they promise a long lifespan and prove to be both

32

Manufacturing & Production Engineering Magazine

Used machines can be an ideal addition to an operation and elevate production to a new level. They perform just as well as newer models and integrate seamlessly into the workflow. an economical and eco-friendly option compared to purchasing new machines.

Maximizing Performance Through Proper Maintenance Used machines can be an ideal addition to an operation and elevate production to a new level.

They perform just as well as newer models and integrate seamlessly into

the workflow. However, to maintain their efficiency and reliability, careful maintenance and upkeep are required.

Here’s how you break it down: Inspection: Regular checks and assessments of the current condition of the machines, including necessary measurements.

Maintenance: Preserving the ideal state and delaying wear and tear through actions such as cleaning, lubricating, refilling, adjusting, and preserving.

Repair: Prompt repairs must be conducted in case of defects to restore operational condition.

Improvement: Supplementary optimizations and adjustments can make machines operate even more efficiently and extend maintenance intervals.

This structured approach ensures that used machines operate effectively and for an extended period, thus contributing to sustainable and economically viable production.

The Right Strategy Makes All the Difference The way an operation keeps its fleet of machines running can vary greatly, and different approaches offer different pros and cons.

Some operations rely on a reactive procedure, repairing machines only when they break down. This approach saves planning and manpower but may result in higher costs and longer downtimes. In contrast, some operations take a proactive approach, creating detailed maintenance plans and using modern technologies to constantly monitor the condition of the machines. This allows for timely intervention and minimizes unexpected failures.

The choice of maintenance strategy depends on many factors, including the production model, industry, and company size.

Regardless of the approach, careful selection and professional support— such as from experts at Surplex.com — are crucial to maximize the efficiency and longevity of the machine fleet.

YOUR PARTNER IN ALL MARKET SEGMENTS MAPAL are a global tooling manufacturer represented in 43 counties.

Our two UK manufacturing facilities service and support our customers throughout UK and Ireland. Local expertise and support is on hand for new, regrinding and modifications for solid carbide tooling to support various sectors including Die & Mould, Medical, Automotive and Aerospace.

Our Capabilities and Services: • • • • • • •

PCD special tool producer Full manufacturing of solid carbide tooling Inhouse design and turnkey project engineering Full domestic regrinding services Vending solutions Tool management (cost per piece) Know how for strategic parts in all market segments

View our 2024 product innovations and solutions.

MAPAL.COM

MAPAL.COM | Your technology partner for machining.

sales.uk@mapal.com

+44 (0) 1788 574700

Manufacturing

Top trends in the manufacturing sector as Industry 5.0 dawns

By Haider Al Kaleedy, Manager, Visual Components

The manufacturing sector is undergoing transformative change. The rise of Industry 5.0 has reflected the trend towards a working environment that places humans at the forefront, as well as circular production models to help ensure a sustainable future. But there’s a significant amount of work to be done before many businesses get to where they need to be. Almost one-in-three (30%) manufacturers are concerned by a lack of in-house skills for using automation and robotics, and a staggering 70% believe that the current economic climate is a detriment to their sustainability strategies. To ease fears, it’s up to technology to drive innovation and efficiency in 2023 and beyond.

Continued challenges Manufacturing organisations have faced a blend of macro and micro challenges this year. Driven by supply chain constraints, increased costs due to rising inflation and sustainability concerns, reshoring is on the agenda.

34

Manufacturing & Production Engineering Magazine

Manufacturing Additionally, the once low-cost strategy of shifting manufacturing to countries in Asia has now become more expensive, and the extended lead times that materialised during the pandemic have encouraged decisionmakers to explore alternatives to avoid the same situation in the future.

With more businesses bringing operations back to the country of origin, are their premises fully prepared to deal with an influx in production capacity, and is inhouse talent ready to manage these operations? The skills shortage is another trend that shows little sign of abating, both this year and the next. A study by Deloitte and The Manufacturing Institute discovered that 2.1 million manufacturing jobs could go unfilled in the US by 2030.

On top of that, there’s the issue of sustainability targets and ensuring green practices that contribute to reduced energy use and lower carbon emissions.

Uptake of new technologies It’s perhaps unsurprising that these developments have led to more businesses exploring the value of automation and robotics to increase efficiencies, upskill in-house talent and drive throughput. This is no doubt a trend which will ramp up over the coming years. Industrial robots provide value via tasks such as welding, cutting, polishing and painting of items on the production line, all in an automated and rapid fashion.

Cobots, or collaborative robots, can then provide their own value by working with humans to complete lightweight applications such as material handling. Their ability to be moved around means they have the flexibility to be applied to other tasks such as picking and placing, and they are usually more cost-effective.

Cobots, or collaborative robots, can then provide their own value by working with humans to complete lightweight applications such as material handling.

- Haider Al Kaleedy

of time, helping to justify outlay in a time of stretched budgets and hesitancy among the C-suite to invest in new solutions.

Digital twins and virtual commissioning Two major features of simulation software are digital twins and virtual commissioning, which are key solutions in the growth of the industrial metaverse and will become part of the toolkit for more organisations in the future.

With digital twinning, two way communication between the real manufacturing environment and a virtual recreation means that manufacturers can test new deployments and their impact on operations, such as robots or cobot integrations. This way, all testing is completed in a risk-free sandbox environment that avoids the need for any downtime to physical systems.

As an extension of digital twinning, virtual commissioning can allow

commissioned hardware to be tested for its impact within the software before deployment. Organisations can ensure optimum uptime of their reshored operations.

Simulation tools, combined with offline robot programming (OLP) to avoid time-consuming manual programming of robots, can help upskill humans in digital applications and plug the skills shortage. An intuitive library of pre-defined components can encourage employees to build their capabilities and put themselves at the forefront of Industry 5.0 innovation.

Effective programming of robots with these tools can also prevent the need for products to be reworked on the production line, helping to reduce energy use. The collaborative nature of the technology can also enable more remote meetings and avoid the need for emissions-heavy car or plane travel.

A bright future Manufacturers face a myriad of modern challenges in 2023 and beyond, such as increased costs, skills shortages and blockers to sustainability, but each can be overcome with the right technology deployments. While negative trends have placed pressure on operations, those who prioritise investment in digital twins, virtual commissioning and OLP technologies are in prime position to make the most of efficiency-enhancing robots and cobots on the factory floor. Humans can also become more of a central focus in manufacturing innovation as the industry moves into the Industry 5.0 era.

Cobots and robots can work together to enhance efficiencies on the factory floor, but programming deployments can be a time-intensive manual process and investment in these technologies can be hard to justify to the board. To confidently bring in such equipment, organisations hoping to make progress in their Industry 5.0 roadmaps can make use of simulation software to prove their value. This technology can for example calculate how many assembled products a cobot can complete over a set period Manufacturing & Production Engineering Magazine

35

People On The Move ETG Grows Team With Prismatic Expertise The industry is continually demanding increasingly complex components that require equally innovative solutions. The Engineering Technology Group (ETG) has long been at the forefront of innovation with its high-end multi-axis machining solutions, to complement this offering, the Wellesbourne company has employed Ian Deacon as its new Prismatic Product Manager.

Packaging and Machinery specialists NPP appoint John James as Account Manager Leading packaging and machinery specialists NPP are pleased to announce the appointment of John James as Account Manager, as part of their UK expansion.

John’s day-to-day responsibilities will involve furthering existing client relationships while also activating new leads and onboarding new clients.

With over 10 years of experience in the packaging industry, John will help to contribute by using his strategic skills and sharing industry knowledge as part of a team effort to grow the client portfolio of NPP across the UK. Speaking upon his appointment, John said: “I am thrilled about the prospect of working for a company with the reputation of

36

Manufacturing & Production Engineering Magazine

NPP in delivering for its clients. I look forward to working with the wider team to retain existing clients while also expanding our market share across the UK. This will enable us to grow the company while also providing our clients with successful outcomes.”

NPP combines best in class packaging, high performance machinery and systems along with a partnership approach to offer a complete packaging solution. The packaging specialists have over 40 years of experience in the industry with team members located in the UK, NI and ROI, and is a trusted partner for businesses across a wide range of sectors, including food and beverage, agriculture, industrial and pharmaceuticals.

For more information on NPP: www.nppgroup.co.uk

ETG has created this new role as it recognises the importance of supporting manufacturers that encounter the challenges of everything from 3 to complex 5-axis machining that often requires innovative machining solutions, creative programming and machining strategies, strategic workholding technologies and even automation solutions for increasing productivity and reducing costs.

ETG has long been an industry leader in prismatic machining with its portfolio that includes Quaser, OPS Ingersoll, Chiron Group, bavius and the recently introduced AXILE brand. The brands cater for everything from simple to complex multi-axis machining and high-speed machining with automation that covers everything from the smallest to the largest of components.

To support manufacturers in identifying the right solution for their business, Ian Deacon has been employed to share his expertise with ETG customers to streamline their journey to the most productive and profitable solutions.

Over the last 30 years, Ian has worked as a senior application engineer, product manager, key account project manager and sales manager for some of the most prestigious machine tool brands in the industry.

During this prestigious career, Ian has supported the complete spectrum of the machine tool industry - from small subcontract manufacturers with simple requirements to multinational OEMs with complex turnkey projects for some of the most challenging projects in the industry.

It is this expertise and understanding of customer requirements that will ensure ETG customers have the support they need to successfully navigate any machining challenges that arise.

THE REX-SYSTEM Your all-in-one solution

YOUR BENEFITS: Benefit from the comprehensive DC 24 V circuit protection solution for mechanical and plant engineering. The REX system combines power supply, communication, circuit protection and power distribution in one system.

• Increased machines availability: Clear error detection, high transparency and remote diagnosis • Flexibility: Easy assembly, modularity and convenient adjustment • Time saving: Innovative and flexible connection technology • Cost efficiency: No further accessories necessary

E-T-A Circuit Breakers Ltd. +44 (0) 1296 420336 info@e-t-a.co.uk

www.e-t-a.co.uk

ENGINEERING TECHNOLOGY

EcoCooling Evaporative Cooling – Cool a 250m² area for the same cost as boiling a kettle Refrigerant free cooling and ventilation The ideal solution for cooling production and warehouse facilities, energy efficient evaporative cooling can be used to blanket cool large spaces or spot cool problem areas or mezzanine floors. Air supply temperatures off the coolers do not exceed 25C, without the need to utilise any refrigerant technology.

UK based with established installation network Utilised in 100s of facilities across the UK, EcoCooling are the go-to provider for evaporative cooling for industrial applications. Our installation network provides free site visits and quotes for supply and install of equipment. All spares and coolers are held in our Suffolk warehouse, ensuring rapid delivery and maintenance options.

Website: www.ecocooling.co.uk Email: sales@ecocooling.co.uk Phone +44 (0)1284 810586

Manufacturing & Production Engineering Magazine

37

Women In Engineering

IET YWE: Young women engineers make national final and get set to inspire more girls to join the industry Georgina Andrew is a Civil Engineering Graduate Apprentice at Amey Consulting.

Georgina works within the structures team as a designer for projects covering structural maintenance to major road bridges. She is responsible for providing sustainable engineering solutions that promote safety, journey time reliability and connectivity between areas, improving some of Scotland’s busiest roads.

As a STEM ambassador, Georgina has been involved in numerous STEM outreach and early careers initiatives, promoting engineering careers to the younger generation. She is also an Arkwright Engineering Scholarship mentor on behalf of the Smallpeice Trust.

Jade Kimpton is an Apprentice Substation Engineer at National Grid. Jade’s role involves carrying out maintenances on substation assets and getting involved in the commissioning of new renewable generation connections. She repairs and replaces assets to ensure the electricity supply around the UK remains reliable. Safety is critical on a substation, so Jade’s role focuses heavily on establishing and maintaining safety procedures not only for herself, but also for other colleagues, contractors and the public.

Jade is also a volunteer and Vice Chair on the Women’s Engineering Society (WES) Apprentice Board, working on projects to promote women in engineering.

38

Manufacturing & Production Engineering Magazine

To celebrate Ada Lovelace Day, six young women engineers have been announced as finalists for the Institution of Engineering and Technology’s (IET) Young Woman Engineer of the Year Awards 2023.

These prestigious engineering industry awards celebrate women working in modern engineering – and aim to help change the perception that engineering is predominantly a career for men by banishing outdated engineering stereotypes of hard hats and dirty overalls.

Georgina Andrew (21), Jade Kimpton (22), Krystina PearsonRampeearee (35), Laura Hoang (33) Titi Oliyide (32) and Zainab Adigun (31) have all been shortlisted for awards.

As well as highlighting engineering talent, the IET Young Woman Engineer of the Year Awards seek to find role models who can help address the UK science and engineering skills crisis by promoting engineering careers to more girls and women. Just 16.5 per cent of those working in engineering occupations are women (source: Engineering UK).

2022 Young Woman Engineer of the Year, Ama Frimpong, said: “The IET’s YWE awards are all about celebrating the achievements of women engineers and shining a light on the work they’re doing to make a difference in the world, so to be named the IET’s Young Woman Engineer of the Year was such an honour, and it means so much to me.

“We don’t talk enough about the phenomenal women in STEM, past or present, who have improved the lives of so many.

These awards recognise and champion women in STEM to

Women In Engineering Engineers make an ongoing difference to the world around us, and we want to celebrate those engineering a better world for us all.

Krystina Pearson-Rampeearee is an Engineering Team Lead for BAE Systems Submarines.

As a committed STEM ambassador, Krystina volunteers for events all over the country, talking to the younger generation about working in engineering.

As a result of her outreach work, Krystina was highly commended for a STEM Inspiration Award for her outstanding contribution to widening participation and diversity and inclusion in STEM.

- Dr Laura Norton

inspire the next generation, where girls and women that pursue STEM subjects and careers are supported and encouraged to stay, make their mark and change the world.”

Head of Equality, Diversity and Inclusion at the IET, Dr Laura Norton said: “Engineering and technology have been improving our world and shaping our future for centuries.

Engineers make an ongoing difference to the world around us, and we want to celebrate those engineering a better world for us all.

“However, due a lack of understanding around what engineering is, perceived gender norms and not enough visible role models for the next generation, the UK has a shortage of women engineers.

“Our awards tell the stories of incredible women engineers who are changing our world for the better and shines a spotlight on them as roles models to get more girls excited and inspired about a career in engineering.

“I’d like to congratulate Georgina, Jade, Krystina, Laura, Titi and Zainab for making the final six and demonstrating the tremendous talent of women working in our industry today.”

The winner will be announced at the IET’s Young Woman Engineer of the Year Awards ceremony on Thursday 7 December 2023. Registration is now open for the awards - for more information and to register to attend, please visit youngwomenengineer. theiet.org This year’s YWE Awards are being sponsored by Airbus, Collins Aerospace, Frazer-Nash Consultancy, Leonardo, London Stansted Airport, MBDA, National Grid, Northrop Grumman, Ofcom, Royal Air Force, RS Components Grass Roots and Thales.

Laura Hoang is a Consultant at ERM. As a Technical Subject Matter Expert in Human Factors Engineering, Laura designs and delivers solutions to help clients with their safe and sustainable operations, primarily focussing on contractor performance management, with an emphasis on safety.

Laura also mentors several engineers, supporting them through their professional development and professional engineering registration. She has also been recognised for her contribution to the Aerospace industry and was awarded the HerbertLe Sueur Award in 2019 by the Royal Aeronautical Society.

Titi Oliyide is a Senior Process Safety Engineer at Supercritical Solutions.

Titi provides technical process safety expertise for innovative hydrogen production technology to facilitate the energy transition, whilst contributing to the energy security strategy and the UK’s net zero plan for 2030.

Titi is part of the Association for Black and Minority Ethnic Engineers (AFBEUK), managing two organisational partner accounts, facilitating their Diversity and Inclusion improvement programmes

Zainab Adigun is a Senior Structural Engineer at Pell Frischmann. Zainab manages a small engineering team that develops and delivers engineering solutions for clients. She is responsible for undertaking structural design and analysis, as well as coordinating, managing, delegating and implementing structural designs with a range of building requirements.

Zainab is a board member for the Association for Black and Minority Ethnic Engineers (AFBE-UK) and team lead for the school’s programme, which works with young people from black and ethnic minority groups and lower socio-economics backgrounds to expose them to careers in engineering.

Manufacturing & Production Engineering Magazine

39

Measurement, Sensors & Monitoring

Application - Aircraft Screwdriver Fastener Torque Control Interface Force was recently approached by an Aircraft manufacturer who wanted to ensure the correct torque and clamping force were being applied to fasteners during assembly.

The Customer’s Challenge An aeroplane manufacturer needs a solution where they can control the torque when fastening screws on their aeroplane models. They do not want to create any damage to materials or apply too much torque when plane components are being fastened together.

Interface’s Solution Interface’s Model T15 Hex Drive Rotary Torque Transducer can be attached to the fastening workbench, measuring and recording torque, rotational speed and angle of the screwdriver. The LWCF Clamping Force Load Cell is installed, measuring the forces applied on the screw being fastened.

Interface’s Model T15 Hex Drive Rotary Torque Transducer can be attached to the fastening workbench, measuring and recording torque, rotational speed and angle of the screwdriver.

Results are sent to the SI-USB4 4-channel USB Interface Module, which is connected to the customer’s PC or laptop where data is logged, graphed and displayed.

How It Works 1. The T15 Hex Drive Rotary Torque Transducer is attached to the screwdriver fastening bench.

The Results

2. The LWCF Clamping Force Load Cell is placed beneath the bolt head.

The aeroplane manufacturer was able to calibrate their screwdriver by measuring its torque, rotational speed, and angle when attaching components to their aeroplane. They were also able to measure the forces being applied to the screw, to ensure it was not applying too much torque to the components.

3. The T15 Hex Drive Rotary Torque Transducer measures the screwdriver’s torque, rotational speed and angle, for the customer to determine the right amount of torque needed to be applied to the screw to prevent any damage to the materials being fastened together.

Items Used to Complete the Test • T15 Hex Drive Rotary Torque Transducer • LWCF Clamping Force Load Cell • SI-USB4 4-channel USB Interface Module • Customer PC or Laptop

4. The LWCF Clamping Force Load Cell measures the forces applied to the screw, so the customer can determine the maximum torque it can take.

5. The measurements and results are sent to the SI-USB4 4-Channel USB Interface Module, where the customer can record the results when connected to their PC or laptop.

For more information about the force and torque sensors mentioned in this application note or how Interface Force Measurements could help with your force, torque or pressure measurement challenges please email us at info@interface.uk.com or visit our website www.interfaceforce.co.uk

40

Manufacturing & Production Engineering Magazine

Tinytag Data Loggers:

Tinytag Plus 2

Energy Logger

Rugged outdoor/industrial temperature/RH logger From £110 +VAT

Non-invasive single & three phase power monitoring Full kit £995 +VAT

Radio and LAN loggers

Tinytag Ultra 2

Robust Environmental Monitoring Solutions Data loggers for indoor, outdoor and industrial/process applications • Rugged and compact • Easy to use • Dust, splash or waterproof

Manufactured in the UK

• Data downloaded to PC • Cost-effective Accompanying probes are available for monitoring extremes of temperature, and for awkward to reach areas such as pipework.

Automatic data collection Bundles – 3 loggers/receiver/ software from £1,100 +VAT

For sites requiring remote data access, Tinytag Radio and LAN loggers gather data automatically for viewing on a PC, across a LAN, or remotely across the internet. temperature

»

humidity

Gemini Data Loggers (UK) Ltd Scientific House, Terminus Road, Chichester, West Sussex, PO19 8UJ, England

»

power usage

»

co2

»

count

Indoor temperature & RH From £80 +VAT

»

voltage

»

current

Telephone: +44 (0)1243 813000 email: info@tinytag.info www.geminidataloggers.com www.tinytag.info

Manufacturing & Production Engineering Magazine

41

Measurement, Sensors & Monitoring

Measurement and control of the lowest liquid flow quantities Troy Stehr, Industry Account Manager – Lab & Medtech at Bürkert, explores the technology behind Coriolis mass flow meters and controllers.

To optimise measurement and control accuracy for low liquid volumes, Coriolis sensors are often the prime technology choice. Providing a true mass flow reading with accuracy down to ±0.2%, these devices are also highly repeatable. Coriolis technology is suited to applications that must ensure precise flow control, whether to meet quality requirements in food & beverage products or maximise efficacy of a medicine. However, high accuracy over low liquid volumes can also save costs long term when expensive media is involved.

When you next enjoy a packet of potato crisps, you almost certainly won’t notice a difference in flavour from one crisp to the next. This is thanks to the highly accurate dosing of relatively low volumes of strong yet concentrated flavouring, and the consistency in taste is an essential aspect of ensuring consumer quality.

Accurate control of low volume liquid dosing is also vital to ensure the safety and potency of food additives, such as thiamine (vitamin B1) and vitamin D

in fortified breakfast cereals. This also applies to pharmaceutical products, and to ensure optimal drug effectiveness while preventing overdosing, in medicines ranging from liquid capsules to vaccine injections, here too, exacting accuracy is imperative.

Before such products reach their end users, they will typically undergo controls. If inaccurate dosing is identified, down to the smallest possible volume, this could impact an entire production batch. When expensive media is involved, the investment in technology to prevent this situation becomes essential.

Coriolis effect To achieve high accuracy fluid control and metering for applications like these, the original theory came from the nineteenth century Parisien mathematician and scientist, GaspardGustave de Coriolis. He discovered an effect that relates to an inertial force acting on objects in motion within a rotating system. In the field of liquid and gas flow, Coriolis control and metering devices involve a suspended, S-shaped measuring tube, set in high-frequency magnetic vibration by an exciter coil.

When a liquid flows through the tube, the liquid’s inertia acts on the tube’s vibration, causing what’s known as a phase shift. This vibrational change is directly proportional to the mass flow of the liquid, and is measured by two sensors, positioned at each end of the tube. The higher the flow rate, the greater the oscillation deflections of the measuring tube.

LEFT: Bürkert’s Type 8756 mass flow meter/controller, based on the Coriolis effect, has a flow rate accuracy reading as low as ±0.2%.

This is achieved with a repeat accuracy deviation of just ±0.1% for a flow rate up to 25 kg/h, or ±0.05% repeatability for a flow rate up to 120 kg/h.

42

Manufacturing & Production Engineering Magazine

This process can also provide a density reading of the flowing liquid by measuring the vibration frequency, instead of the oscillation deflections.

The higher the density, the lower the frequency. In fact, with a Coriolis-based device, it’s possible to simultaneously measure mass flow, volumetric flow, density and temperature.

High accuracy In recent years, technology has allowed the Coriolis principle to be used for increasingly lower flow rates, enabling dosing of the smallest volume of liquids, precisely, quickly, and repeatably.

Bürkert’s Type 8756 mass flow meter/ controller, based on the Coriolis effect, has a flow rate accuracy reading as low as ±0.2%. This is achieved with a repeat accuracy deviation of just ±0.1% for a flow rate up to 25 kg/h, or ±0.05% repeatability for a flow rate up to 120 kg/h.

Crucially, this reading is based on true mass flow, independent from the impact of the media, pressure, or temperature.

Compared to other mass flow meter technologies, this means much higher accuracy. A thermal mass flow meter, for example, is accurate to around ±1%, and also requires recalibration for every new fluid type introduced. However, this type of mass flow meter takes a volumetric reading that is then corrected to mass, a device based on the Coriolis effect measures mass flow directly in milligrams, grams, and kilograms.

Maximising productivity The Type 8756 can also be supplied with an integrated batch controller, providing extremely fast measurement and control for fast dosing, which increases productivity. With a dosing range as low as 0.05g…100g, a dosing time of 0.05s…7s can be achieved.

Productivity is also enhanced through a digital connection, meaning that dosing processes are reproducible. This digital approach means that all ingredients

Measurement, Sensors & Monitoring

Leaders in temperature measurement

Industrial Automation Pt100 RTD Sensor with M12 connectors InHeading Stock3For Immediate Worldwide Despatch

An industrial automation temperature sensor with a Pt100 class A 4 wire Resistance thermometer detector (RTD) with a measuring range of -75 to +250°C. • Pt100 RTD class A 4 wire resistance thermometer as per IEC 751 • Sensor temperature rating -75 to +250°C

XE-7201-001

XE-7214-001

• 4 pin M12 A coded instrument connection • 3 & 6mm 316 stainless steel sheath • 100, 150, 200 & 250mm standard lengths • Plain barrel or screw in options 1/4 BSPP, 1/2 BSPP & 1/4 & 1/2 NPT process threads • For use with M12 female connectors & extension cables

www.labfacility.com Bognor Regis tel: +44 (0)1243 871280

and quantities can be recorded and documented, which is advantageous to save time in set up, as well as for conformance purposes.

To develop a highly accurate and productive system, where there is an external pressure source, Bürkert combines the Type 8756 Coriolis flow sensor with a matched control valve suited to the process specification. This could range from a proportional valve for continuous pulsation free flow delivery, through to a Lorentz actuator valve for extremely fast dosing applications.

When an external pressure source isn’t available, Bürkert combines the Coriolis flow sensor with a gear pump. Pump speed is controlled by the Coriolis device itself to generate the precise pressure required for the desired flow rate. The fine teeth of the gear pump give continuous and extremely smooth flow delivery. To achieve modular mass flow control, it’s also possible to combine the Coriolis mass flow meter/controller with wider pump technologies, like peristaltic pumps, syringe pumps, or motor speed controllers.

XE-7232-001

XE-7242-001

sales@labfacility.com Sheffield tel: +44 (0)1909 569446

When a liquid flows through the tube, the liquid’s inertia acts on the tube’s vibration, causing what’s known as a phase shift.

Low total cost of ownership While Coriolis technology is often the first choice for applications that demand optimum accuracy, even for applications where the stakes for the process outcome aren’t as high, investing in Coriolis technology can be advantageous to reduce costs long term.

For example, municipal water companies often insert a small quantity of orthophosphoric acid into sections of

the water supply network that involve lead piping, in order to prevent water contamination. Control accuracy down to 0.2% is not required for this process itself, but because of the high cost of orthophosphoric acid, minimising the quantity used can save significant costs over time. Coriolis technology can also be used in measurement for cost-saving purposes to ensure suppliers deliver agreed volumes and concentrations of liquid media.

Even if accuracy still isn’t a concern for a low volume liquid control and metering application, Bürkert can provide a broad choice of other technologies.

Alternatively, for applications that require even greater accuracy for smaller doses than Coriolis devices can provide, the new µLDC technology is the next step.

Watch our latest video with a demonstration of our new Mass flow controller Type 8756 and its highly precise control and measurement of liquids here.

Manufacturing & Production Engineering Magazine

43

Technology David Malan

The Power of Digitalisation in Manufacturing

By David Malan, Sales Director – UK & Ireland, DocuWare In the evolving landscape of the manufacturing industry, large global manufacturers have seen the advantages of technology and the successful ones have consistently driven the adoption of digital document management solutions. In the present climate, where manufacturers contend with growing competition, supply chain vulnerabilities, and shifting regulations, a pivotal transformation beckons and manufacturers must elevate their technological prowess.

Now, more than ever, the convergence of unprecedented challenges and

remarkable opportunities necessitates this shift. In order to stay profitable, manufacturers need to accelerate product journeys, conquer global markets, and streamline costs without compromising on quality and customer satisfaction. The good news is that they have a lot of tech tools to choose from and this article can help identify priorities and pick the best ECM for your business needs.

The path to sustainability, efficiency, and elevated outcomes necessitates the automation of both manufacturing and administrative processes.

Manufacturers are tasked with

operating smarter, managing costs astutely, and delivering unparalleled results - these are all achievable through the power of digitalisation.

Instant results from digital investments Time-to-value matters and digital tools have the potential to impact various facets of manufacturing positively and quickly, beginning with automation and flexibility in production. It extends further to encompass digitisation and automation in the back office and administrative functions, such as material procurement, financial operations, quality control processes, and human resource management.

Manufacturers of all sizes can see almost instant ROI’s from digitalisation investments in these four areas: 1. Productivity, profitability and worker happiness By digitising paper records, data flows securely and seamlessly across various departments, overcoming constraints of time and location. Automated workflows are activated following document reviews and approvals. Ultimately, when data can be retrieved, searched, and archived electronically, bottlenecks are eradicated, and processes are expedited. This results in a more efficient and content workforce, thereby enhancing the overall work setting and boosting employee satisfaction.

44

Manufacturing & Production Engineering Magazine

Technology 2. Security and compliance Manufacturing companies can control unauthorised access to sensitive documents and establish protocols safeguarding proprietary information.

A good ECM solution supports adherence to regulatory mandates and effectively protects data from cyber threats through the use of encryption.

A secure and compliant document archiving process stands as another significant benefit, especially in the medical, aerospace, and photonics sectors, where government regulations necessitate that manufacturers retain documentation about the parts they supply for the entire lifespan of the respective product or instrument.

Overall, the adoption of a paperless, digitised document storage system translates to substantial reductions in time, cost, and stress.

3. Time to market To maintain a competitive edge, it is imperative to streamline time to market, even while an organisation upholds rigorous reporting, compliance, and security benchmarks. Achieving this demands the implementation of an effective document management solution.

Through this approach, all documents pertaining to production, logistics, or accounting procedures are digitised and centrally stored. Be it design blueprints, material requisitions, production records, sales orders, or invoices, staff can conveniently access these documents around the clock, whether situated in the office or working remotely from home.

This instantaneous, secure access ensures relevant information is always immediately available, production risks are mitigated, and costs are managed.

4. Environmental sustainability Many modern organisations are now prioritising reducing their carbon footprint and embracing paperless operations as essential sustainability goals. By digitising operations and streamlining workflows, companies can make substantial reductions in paper consumption. Embracing a paperless strategy not only conserves precious resources, leading to long-term cost savings for businesses but also plays a role in the preservation of forests.

This aligns with the larger mission for many organisations of safeguarding the planet’s essential and fragile ecosystems.

Case study Swagelok Manchester, a leader in fluid systems solutions, embraced digitisation to boost productivity. The switch from paper-based processes to an electronic document management system streamlined workflows. A fourstep plan phased in department-centric implementation, improving order processing and inventory tracking. With top data security and time-saving benefits, 70% of daily invoices are now emailed.

Where to begin?

1. Prioritise simple and frequently used business processes – Automated processes effectively decrease the time and effort required from employees, resulting in higher productivity. So, it’s essential to prioritise business-critical processes that align with objectives.

2. Improve paper-based processes instead of emulating them – Seize the chance to remove unnecessary steps during the process of digitisation. Reflect on the rationale behind previous procedures and assess whether those actions remain essential within this new context.

Embrace enterprise content management (ECM) systems and encourage employees to digitise files, memos, and reports instead of relying on hard copies.

3. Take advantage of the cloud - By choosing the cloud, the responsibility for system upgrades and security patches shifts to the ECM provider, simplifying scalability without the need for additional inhouse IT resources. Cloud systems also cater to mobile device users, ensuring secure remote work settings and enhanced flexibility for teams.

4. Electronic signatures offer tighter security and easier compliance – choosing a provider who offers this can further protect your business.

E-signatures hold legal validity, fulfil security prerequisites, and mitigate the potential for document alterations, unauthorised signatures, or missing signatures.

In the dynamic landscape of manufacturing, embracing digital transformation is pivotal to sustainable success.

- David Malan

5. Streamline with automation Workflow choices can substantially diminish the duration required for manual tasks. Automated workflows mean individuals can effortlessly transmit documents with a simple click, ensuring that everyone has instant visibility into their designated tasks.

In the dynamic landscape of manufacturing, embracing digital transformation is pivotal to sustainable success. As industry challenges intensify, manufacturers must invest in technology to streamline operations, conquer markets, and manage costs effectively. Manufacturers who successfully navigate this path of digitalisation will reshape their industry landscape, foster innovation and thrive for years to come.

DocuWare is built for the dynamic needs of manufacturers, in fact almost 20 per cent of our customers are from the manufacturing industry. Our ECM solution organises, archives, secures and processes critical business data: employee documents, client records, compliance and certification information, and much more.

Find out more and read how our Manchester-based customer used DocuWare to improve their business here.

Manufacturing & Production Engineering Magazine

45

Technology

What’s the future for piece-picking robots?

Piece-picking robotics is making big strides in the warehouse and with the aid of AI could soon be within the grasp of SMEs. Dan Migliozzi, Head of Sales at independent systems integrator, Invar Group, sets out where we are on the journey.

Presented with a mixed selection of items, the robot can now identify the correct piece, either by scanning a barcode or RFID signal, or purely by analysing the input from a vision system.

- Dan Migliozzi

What news can there possibly be around piece-picking robots? Arm finds item, picks it up, manipulates or orients it, puts it in the right place - end of. It’s the classic application of industrial robotics and has been so, at least on high volume production lines, for four decades.

But in a sense, that application is barely robotics at all – functionally, an old-fashioned juke box did much the same thing, and the machine typically can only work with one or a very limited set of items, presented to it in a very structured way.

As early investors in robotics discovered to their cost, these ‘general purpose robots’ were in practice highly task-specific and although they have become essential in high volume production, they have been of limited utility in the warehouse and similar situations where the need is to pick from a very wide range of items varying in shape, size, robustness and orientation.

Now, however, and seemingly overnight – although in reality these developments have been years in the making – advances in sensors, vision systems, handling devices and the means of controlling them, including the beginnings of Machine Learning (ML) and Artificial Intelligence (AI), are making general purpose picking robots a practical reality. For Invar, as a leading independent systems integrator, this is becoming a very exciting space.

46

Manufacturing & Production Engineering Magazine

Technology Presented with a mixed selection of items, the robot can now identify the correct piece, either by scanning a barcode or RFID signal, or purely by analysing the input from a vision system. Either way, algorithms can work out the current and required orientation. The robot can handle the piece according to parameters ‘attached’ to the identity of the piece, including what tool to use to pick the piece up, and how much force is appropriate – or in the case of increasingly popular manipulation by vacuum suckers, which elements from an array of suckers to use, and how much suction to apply. Using developing forms of ML/AI, the robot can be ‘trained’ to deal with novel items, and even optimise its own operations.

This is important for many industries and companies because up to now, piece part picking has tended to be highly labour-intensive and stubbornly resistant to automation. Many parts were awkwardly shaped, too fragile, too small or there was too large a range of sizes/weights. Also, they might require prior operations to present them in the right orientation for the robot or there may be quality issues which require pre-screening, and so on.

There are a number of options as to how picking robots are deployed. Picking arms may be in fixed locations with goods reaching them on conveyors, AMRs, mobile racking, carousels or the like – and completed picks similarly removed.

- Dan Migliozzi

In these circumstances any return on investment in automation has often seemed nebulous, and manual labour has often been preferred. But now, not only is human labour scarce and increasingly expensive, manual pick rates may be slow by comparison with more advanced forms of automation, with high numbers of errors – often exacerbated by illness or fatigue. A business operating in, for example, direct to consumer pharmaceuticals, a growing field, cannot tolerate less than 100% accuracy. Similarly, there is no ‘acceptable’ level of damage to electronic components and this can’t be guaranteed with manual systems.

However, the good news is, item picking technology is moving ahead at quite a pace and is fast becoming affordable to SMEs, with a reasonable ROI. So, as labour continues to be hard to find and costly, piece picking robots are likely to become more and more attractive, and when allied to the availability of highly scaleable Autonomous Mobile Robots (AMRs) can represent a significant de-risking of the business.

There are a number of options as to how picking robots are deployed.

Picking arms may be in fixed locations with goods reaching them on conveyors, AMRs, mobile racking, carousels or the like – and completed picks similarly removed. Or they may rove the warehouse floor mounted on AMRs. They may be designed as cobots, specifically to work safely alongside people, or they may be ‘fenced off’ – physically, or through software and safety features.

There is a further important point of consideration. As noted, previous piece-picking robots have often required goods to be presented in closely defined orientations. For example, so that the barcode can be scanned, or the shape recognised, or so that they don’t overlap. This can require either manual intervention or an array of handling devices that in sum may be as complex and expensive as the robot itself – they also take up a lot of space. It is increasingly likely that with advanced, AI-enabled vision and other systems, much or all of this preparation can be dispensed with.

Piece-picking robots are becoming far more dextrous, quick-learning and adaptive. But, of course, there is still a need to train the robots with the right images and algorithms. It’s fair to say

As labour continues to be hard to find and costly, piece picking robots are likely to become more and more attractive, and when allied to the availability of highly scaleable Autonomous Mobile Robots (AMRs) can represent a significant derisking of the business.

- Dan Migliozzi

that both suppliers and integrators are actively engaged in working out the most effective ways of organising this, but what is evident to us is that, at this stage in the development and adoption of the technology, there is a real need for open collaboration between all the travellers on this journey into robotic picking.

As independent integrators of advanced warehouse technology with a dedicated division of software developers, we are closely involved in the fast-evolving field of piecepicking robotics and in progressing the smooth interface between robots, controllers and warehouse management systems.

Further independent advice on transforming operational performance in the warehouse can be found at: www.Invargroup.com

Manufacturing & Production Engineering Magazine

47

Technology

Techn

Accelerating time-to-market using digital twin technology

Revolutionising manufacturing for competitive advantage In an era where time-to-market is a critical factor for success, manufacturers are turning to digital twin technology as a gamechanging solution. Here Stephen Hayes, managing director of automation specialist Beckhoff UK, explores the transformative power of digital twin technology and how it delivers instant return on investment (ROI) for manufacturers, revolutionising their ability to accelerate innovation and gain a competitive edge in today’s fast-paced market.

Digital twin technology empowers manufacturers to simulate and optimise their operations with unprecedented precision. By creating virtual replicas of physical assets, manufacturers can analyse and optimise manufacturing processes in a risk-free virtual environment.

This capability allows them to identify bottlenecks, test alternative strategies and optimise efficiency before implementing changes on the shop floor.

For example, manufacturers can leverage digital twins to predict the performance of production lines as well as identifying potential failures and optimising maintenance schedules, resulting in reduced downtime and improved productivity. Additionally, digital twins enable the exploration of different operational scenarios,

48

Manufacturing & Production Engineering Magazine

helping manufacturers uncover the most efficient and cost-effective approaches. By fine-tuning processes virtually, manufacturers can minimize wastage and reduce production errors — enhancing overall operational performance.

Digital twin technology can also revolutionise product design and development processes.

Manufacturers can create virtual replicas of their products, allowing them to simulate and test various design iterations before investing in physical prototypes. This iterative approach enables rapid prototyping, accelerating the product development lifecycle.

With digital twins, manufacturers can analyse product behaviour under different conditions to ensure optimal performance and reliability. Using this approach can identify potential design flaws and validate engineering assumptions, optimising product characteristics based on real-time data. This feedback loop enhances the quality of products while reducing costly design errors and rework.

Furthermore, digital twin technology facilitates collaboration between different teams involved in product development. Designers, engineers and stakeholders can access and interact with the virtual replica, fostering cross-functional collaboration and knowledge sharing.

This streamlined communication helps align efforts and ensure that the final product meets customer expectations.

Digital twin technology goes beyond just optimising manufacturing processes and product design — it also plays a crucial role in predictive maintenance and asset performance management. Beckhoff’s software tools, such as TwinCAT, provide a robust platform for designing, modelling and implementing digital twin models. By leveraging Beckhoff software, users can create virtual representations of physical assets, monitor and analyse data in real-time, and perform advanced simulations and optimisations. Integrating real-time data from sensors and IoT devices into the digital twin model means that manufacturers can monitor the health and performance of their physical assets.

This predictive maintenance approach allows manufacturers to detect potential failures or anomalies early on, minimising unplanned downtime. By leveraging the datadriven insights provided by digital twins, manufacturers can optimise maintenance schedules, improve asset performance, and extend the lifespan of their equipment. The ability to predict and prevent breakdowns not only enhances operational efficiency but also reduces maintenance costs, providing significant savings for manufacturers.

Embracing digital twin technology is no longer an option, but a necessity for manufacturers aiming to thrive in the competitive market. By leveraging its power, manufacturers can achieve reduced time-to-market, enhanced product performance, significant cost savings and a culture of continuous improvement and innovation. The transformative capabilities of digital twin technology are reshaping the manufacturing landscape, empowering manufacturers to stay ahead of the curve and meet the everevolving demands of customers and the market.

To find out more about how Beckhoff’s software can enable digital twin technology, visit the website.

nology

Technology

Humanoid robots in warehouses: shortlived gimmick or vision of the future?

By Simon Jones, UK Sales Executive at Exotec

In recent years, robotics systems able to fulfil increasingly complex tasks have become more commonplace, representing an important shift in the development of next-generation warehouses.

A next step now being proposed by some companies is the development of robots that can carry out a variety of roles and are deliberately designed to look and operate like people, with dextrous fingers and an ability to transport heavy boxes around the warehouse.

This prompts the question, are humanoid robots the future, or do their less anthropomorphic counterparts actually have greater potential to make the warehouse safer and more efficient?

Rise of the machines As a species, we’ve long been curious about the possibility of robots that can behave, talk, and experience human attributed emotions.

While we’re still a long way from producing sentient robots, the physical characteristics of some designs are already resembling our own. Startups such as Boston Dynamics, Apptronik and Figure have either developed, or are in the process of developing, humanoid robots that could be deployed in warehouse environments.

aesthetics and are produced without needing to invest additional time and money into human characteristics.

Apptronik’s Apollo robot, for example, is 172cm (5 feet 8 inches) tall, weighs 72.5kg and can lift objects up to 25kg in weight. Such technology is still in its infancy and has not yet been fully commercialised, but a report by Goldman Sachs has predicted the market could be worth $6 billion or more in the next 10 to 15 years.

Clearly there’s plenty of promise to this technology and it will have uses in a range of different industries, but I’m not fully convinced these robots will supersede non-humanoid designs, already highly adapted to warehouse work.

Warehouse robotics: An established art Robots are a common sight in many warehouses, with systems built for function and efficacy rather than

Automated storage and retrieval systems (ASRS), for example, are already able to do what humanoid robots are aiming to achieve, and they can do it faster and in much less space. Such a system can autonomously navigate a warehouse floor and can safely retrieve boxes or totes from shelves several metres above the ground. Crucially, these systems are underpinned by advanced software that plans, guides and analyses their every move, ensuring consistently high performance.

A robot that looks like a human, on the other hand, will likely possess many of the same limitations that we do as people when it comes to warehouse work, especially when the technology is in its infancy.

Robots the future, but a bit less human Robotics are already a feature of the warehouse, but it’s unlikely they’ll be the humanoid robot types, for the time being at least. However, humanoid robots surely have potential to make a difference in other industries – NASA’s Valkyrie project is a prime example.

As for now, non-humanoid robots and their accompanying software are more established as a technology, cheaper and more viable to implement, and are built to address very specific needs that are often beyond the reach of humans.

This leaves the more complex, intricate tasks to those who do them best – people.

Manufacturing & Production Engineering Magazine

49

People On The Move

Get It Made bolsters team with new appointment amid growth Manufacturing specialist Get It Made has appointed Mahin Ahmed as its new Customer Account Manager, to drive growth and expansion.

Mahin is a mechanical engineering graduate from Brunel University, and also brings with him experience from the recruitment industry, having worked as a consultant at TEKsystems, prior to joining Get It Made.

In Mahin’s new role at Get It Made, he will leverage both sets of specialist skills to drive the business forward by strengthening relationships with its expanding client base and identifying new business opportunities, as part of the company’s aim to accelerate its growth trajectory.

The strategic addition to the team comes amid a period of new contract wins for the London-based business which has ushered in significant growth.

The London-based firm provides bespoke, high-quality manufacturing services including CNC machining and 3D printing to companies all over the globe, across multiple sectors from aerospace and automotive to healthcare and consumer.

Mahin said: “It is an exciting time to be joining Get It Made. The role gives me the perfect opportunity

to leverage both my fundamental skills as an engineer and in business development. I am relishing working with the talented team here to deliver second to none customer service to align with the business’ transparent and communicative manufacturing approach, as well as to drive sales growth, and enhance Get It Made’s position as the go-to UK manufacturing partner of high-quality parts.”

Get It Made Founder and Director Luke Smoothy said: “We are lucky to have Mahin onboard and I’m delighted to welcome him to the team. To have someone with his academic background and engineering knowledge combined with his understanding of client relationship management means we can confidently build on our peoplefirst approach, something that sets us apart in the manufacturing sector. We have someone who could not be better placed to help steer our rapid growth while also tap into new markets. We’re experiencing high demand for our services and I look forward to seeing what the rest of the year holds for us.”

ECI Software Solutions Welcomes Riz Karim as New Chief Customer Officer ECI executive team fills leadership role to elevate global customer experience and help drive profitable growth of small- and medium-sized businesses.

ECI Software Solutions, a global provider of cloud-based business management software and services, today announced that Riz Karim has been appointed as chief customer officer to support customer growth and success globally. Joining ECI with more than 20 years of experience in the global software industry, Karim will lead customer-facing teams, collaborating across divisions—including building supply, office technology, wholesale/ retail distribution and manufacturing industries—to deliver exceptional customer support and professional services.

Previously, Karim served as senior vice president of global services and support at Everbridge, a global

50

Manufacturing & Production Engineering Magazine

leader in critical event management and national public warning software solutions, where he launched and managed the company’s customer success function. Karim also served on Everbridge’s senior leadership team as the company went through a successful IPO and growth phase, consistently achieving strong net promoter scores and gross revenue retention rates and establishing an award-winning customer support organisation.

“The chief customer officer position is incredibly important, as we’re wholly focused on helping small- and medium-sized businesses compete and grow. Riz not only brings a deep understanding of customer needs, but also has a proven track record of leading global support teams,” said Trevor Gruenewald, CEO of ECI Software Solutions. “At ECI Software Solutions, we’re dedicated

to empowering SMBs and lifting the entrepreneurial spirit through purpose-built solutions, and Riz’s customer journey expertise will drive greater value for our customers across the world.”

Website: www.ecisolutions.com/en-gb/

DALBY EVOLUTION+ SPRAY BOOTHS Proactive Energy Saving Technology

dalby.co.uk enquiries@dalby.co.uk | 0116 291 6000

 Gas Fired or Full Electric Option  Automatically modulating airflow with 100% in Performance mode & 50% in Economy mode.  “HighLight” high performance LED lighting system  Hi-visibility Mode indicator countdown timer  ‘ProActive’ Touchscreen control  Stop/Start energy saving technology  Energy consumption as low as 1KW*  Energy Savings Of Up To 65%*  AquaDry blowers  Invertor control  Rear Extract, Pit extraction or Raised Floor airflow options  Conveyorised line options  Space Saving Design  Energy cost per job recording  Robotised paint application options  Turnkey installation available *Terms & Conditions apply

Engineering the Highest finish

Harry Dalby Engineering Ltd. Gloucester Crescent, Wigston Leicester, LE18 4YQ