Manufacturing & Engineering Production Magazine - January 2024

MANUFACTURING PRODUCTION

HEALTH & SAFETY

MANAGING CONTAMINATION RISKS IN PHARMA SETTINGS

MANUFACTURING

JANUARY 2024

INTERVIEW

RAF ENGINEER TURNED FE TEACHER, DOMINIC WHELAN

PRODUCTION

ENGINEERING

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PART OF THE

CONTENTS 24

06 Editor

Paul Attwood editor@mpemagazine.co.uk

Senior Editorial Assistant

Anna Startin editorial@mpemagazine.co.uk

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Injection Moulding & Plastics: Manufacturing bespoke filters in the UK with BEC Group Health & Safety: Managing contamination risks in pharma settings Interview: MPE Magazine speaks with RAF engineer turned FE teacher, Dominic Whelan Show Preview: Register online for Southern Manufacturing 2024 Technology: Motion technology integral to cardiovascular disease treatment devices

Features Editor

Harry Peters editorial@mpemagazine.co.uk

Production/Design

Laura Whitehead laura@lapthornmedia.co.uk

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Editors Note Welcome to the latest issue of Manufacturing, Production and Engineering Magazine.

This edition has an exclusive interview with Dominic Whelan, an RAF engineer turned Further Education teacher. Dominic discusses his journey into the Further Education and how Further Education can benefit students within the manufacturing sector.

Paul Attwood Editor

The issue includes the pre-registration details of the Southern Manufacturing Show, which will be held at the Farnborough International Exhibition & Conference Centre from 6th to 8th February, accompanied with show previews from exhibitors.

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

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

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Company News

Turnbull & Scott Researching Transportable Thermal Energy Stores Turnbull & Scott have been developing an idea which would allow for the storage and transfer of waste heat energy. The opportunity for such a solution emerged from recognition by the T&S team that there was an increasing number of enquiries from industrial customers that had excess waste heat but no immediate or near time use for any, or all, that they had available.

The project seeks to determine the feasibility of recovering surplus waste heat from industrial sites to a heat store, then transporting the heat store to a secondary site, or heat network where the heat can be discharged and reused. It will combine the company’s expertise in the design of heat exchangers with the

Zeroing in on a sustainable tomorrow Sulzer’s new licensing technologies help eliminate plastic waste and industrial emissions

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Sulzer Chemtech is launching a portfolio of licensing technologies to enable carbon-neutral polymer recycling. The solutions address rising demand for a more ecoconscious, circular economy of plastic and for the decarbonization of industries as a whole.

The latest addition to the licensing offering from Sulzer Chemtech leverages the company’s extensive experience in efficient separation and mixing technologies to meet growing carbon

net zero and zero waste needs. The portfolio includes technologies for the chemical processing of hard-to-recycle mixed plastic waste as well as capture and utilization (CCUS) of the carbon-rich emissions generated by the recycling stages.

The different processes are fully scalable and can be implemented as a fully integrated system that uses mixed plastic waste as feedstock to produce high-quality products such as petrochemicals, hydrogen and captured

Company News use of phase change materials (PCMs).

The company’s research and design team are building models to predict and optimise the sometimes conflicting goals of Thermal Efficiency, Transportability, Charge/Discharge times and of course costs.

T&S will construct a test unit this year, allowing for the testing of heat loss during transportation, discharge times, combinations of mediums and PCMs. They hope to find and install a demonstration site in 2024.

To develop the idea further, Turnbull & Scott have been selected as one of 16 companies to share a Scottish Enterprise fund that aims to strengthen Scotland’s ‘green heat’ supply chain. The support is set to bolster the development of novel products and processes that support the transition to low carbon heat or improve the thermal performance of buildings.

Other recipients include Aberdeenshire-based engineers Geothermal Energy Ltd and industrial heat pump developer and manufacturer Star Renewable Energy, located in Glasgow.

carbon dioxide for downstream activities.

Alternatively, the technologies can be adopted as stand-alone solutions within existing facilities.

Each single technology within the portfolio is designed to minimize energy requirements while maximizing performance and service life, reducing their operational costs and environmental footprint.

Furthermore, Sulzer Chemtech is able to deliver customized setups to accommodate feedstock variability and specific processing needs, thanks to its large-scale testing facilities that can mimic commercial plants.

The latest technology licensing offering complements Sulzer Chemtech’s existing plastic recycling and CCUS portfolio.

Backed by its expertise in the processing industry, Sulzer develops partnerships such as with Blue Planet, a leading carbon capture company in the USA, to support a wide range of applications in a variety of sectors, including decarbonization of the concrete industry.

20 year milestone for South Wales’ Philtronics October marks the 20th anniversary for the Aberdare based electronic manufacturer which has seen two decades of continuous growth.

Philtronics has been pivotal to manufacturing growth and investment in Wales, providing early design concepts, rapid prototyping and supply chain optimisation to aid the rising growth in semiconductor production in South Wales. The company has also been intrinsic to the development of products within the medical, automotive, sports and wellbeing sectors, one of which is a responsive protective mouth guard used by sports professionals internationally in rugby, boxing, UFC and MMA. Closer to home, providing employment opportunities has been a core focus for the company with a continued investment in homegrown talent. A notable example is their ongoing partnership with Swansea University, where summer internships are offered to students with the view to future employment.

Philtronics’ dedication to the people and communities of Wales is further solidified in their corporate social responsibility commitments. From a partnership with the Ospreys where they played a central role in transforming the Ospreys’ work in the community and their five-year programme with Action for Children in which £100,000 was raised over the period.

Philtronics CEO, Simon Pritchard, who was recently appointed to the board of Manufacturing Wales, says: “I am incredibly proud of the company we’ve built and what we’ve gone through to get to this celebratory occasion. Twenty years in this industry, with everything that has happened over the last few years, is an incredible achievement and it has been such a team effort.”

The firm are also investing in the future. Recently built is the 175m2 Class 7 cleanroom, making them one of the only contract electronic manufacturers in Wales able to supply clients with a full turnkey solution on one site.

Each single technology within the portfolio is designed to minimize energy requirements while maximizing performance and service life, reducing their operational costs and environmental footprint.

Manufacturing & Production Engineering Magazine

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Injection Moulding & Plastics

Manufacturing bespoke filters in the UK with BEC Group Plastic injection moulders BEC Group take us through what manufacturing hundreds of thousands of bespoke plastic filters each year looks like at their Hampshire based facility.

Producing filters for any industry can be a difficult business; particularly the smallest or most intricate. At BEC Group everything from complex AdBlue filters for the automotive industry to tiny biomedical filters are made. The end-to-end process of design, tooling, and moulding is all carried out at one specialised site.

Whilst blow moulding or compression moulding can also be used to produce similar filters, they lack the precision that injection moulding brings to manufacturing. This is key to producing complicated geometries and details to function effectively and meet stringent filtration requirements.

Injection moulding by nature is a costeffective way of manufacturing filters at high volumes, producing identical mouldings quickly and at a low cost per part. Despite a high initial outlay in producing steel tooling, payback times can be incredibly short when filters are mass produced.

The process of producing a mesh filter in plastic begins at BEC by loading a filter mesh onto a metal core. A steel mould tool closes around the mesh,

molten plastic is injected into the tool and around the mesh, encapsulating it in a plastic moulding to create a support frame for the filter.

The support frames are commonly made from nylon, polypropylene, or polyester due to their durability and chemical stability when filtering water, oil, or air. Typically, the mesh of the filter is made from nylon, but stainless steel and bespoke mesh media is also made. Dependent upon the application and particulate size requiring filteringmesh hole sizes can range from 10 micron to 2000 micron. These plastic encapsulated filtration devices are shipped around the globe, from Europe to the USA. Close working relationships between the BEC design team and their customers allow for a culture of innovation and communication. “We work with our customers to give them exactly what they want. A collaborative design process means we can produce a bespoke solution for unique problems.

We’re here to help.” Paul Holland, Design & Innovations Manager at BEC Group. The research and development team are frequently challenged to produce effective filters, at affordable prices, in tough environments.

ISO 9001:2015 certification demonstrates BEC’s dedication to outstanding customer service and

We work with our customers to give them exactly what they want. A collaborative design process means we can produce a bespoke solution for unique problems. We’re here to help.

- Paul Holland

providing consistently high-quality filters to customers. Extensive work in the automotive industry reflects their ability to keep to tight deadlines and strict quality requirements.

“BEC Group have been manufacturing two bespoke plastic filters for us for over 15 years. Initially producing tens of thousands of filters a year. BEC has been flexible and adaptable as the product became after-market, ensuring we could get parts in massively reduced quantities. A good example of a supplier who listens and is customer-focussed.

BEC are a reliable and trusted supplier I would highly recommend.” Ian Holloway, IMI Precision Engineering.

To find out more about filter manufacturing with BEC Group email hello@becgroup.com, call 01425 613 131 or visit becgroup.com.

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Manufacturing & Production Engineering Magazine

SCHMERSAL | Enigma Business Park Malvern, Worcestershire, WR14 1GL

www.schmersal.co.uk uksupport@schmersal.com

Product News

Oxford Flow expands its product range and grows market potential with new high- and low-pressure pilots Oxford Flow, the flow control equipment specialist, is launching two new pilots – designed for use in high- and low-pressure environments – following customer feedback while adapting to market demand in gas distribution networks (GDNs).

In a gas distribution network, gas regulators play a crucial role in managing and maintaining appropriate pressure levels throughout the system, with the pilot serving as the control mechanism that helps to ensure consistent output. Designed for use with Oxford Flow’s hydrogen-ready IM series gas regulators, the new high- and lowpressure pilots will expand Oxford Flow’s market potential and offer the

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GDN operator a solution that can be used throughout its system, with differing pilots in each pressure area.

Faris Churcher, Oxford Flow’s Business Lead for Gas & Energy Transition, said: “Our IM series gas regulators are already suitable for use in high and intermediate pressure environments, which makes up a large proportion of the gas network and by developing new pilots we can significantly expand the options available to our clients.

GDNs often need to operate with the energy transition at front of mind. So providing products that they know they can trust and have been designed with applications like hydrogen at the fore, means GDNs can feel confident that when they work with Oxford Flow, they are future proofing their systems for the long term. Like our ES and IM series regulators, our pilots have a minimum service interval of five years.”

Developed by Oxford Flow’s highly experienced engineering and innovation team, housed in its facilities in Oxford, UK, the PRX2H high-pressure pilot is now ready to be deployed to customers with the PRX2L low-pressure pilot due to be released to the market in early 2024.

The new range of pilots includes: PRX2L low pressure reducing pilot (13mbar – 1.2 bar); PRX2 pressure reducing pilot (0.5-25 bar); PRX2H high pressure reducing pilot (17-70 bar); and PSX1 pressure sustaining/ creep relief pilot (0.5-22 bar).

Altus Helps Sellectronics Advance Component Management with Scienscope Technology Altus Group, a leading distributor of electronics assembly equipment in the UK and Ireland, has helped Sellectronics, an innovative contract electronics manufacturer to significantly improve its component inventory management through the implementation of the Scienscope AXC-800 III automated X-ray component counter.

Product News

Alfa Laval Addresses Entry-level Needs with Expansion of Leading Valve Range In an effort to make double-seat technology more accessible to UK manufacturers, Alfa Laval has launched two entry-level additions to its Unique Mixproof range of valves, the Unique Mixproof Process, and Unique Mixproof CIP. Built upon the foundation of double-seat technology, the valves enhance product safety by ensuring media is separated at all times, while also enabling risk-free handling at high pressures thanks to fully balanced design.

The new additions will also allow process lines to reap the same sustainability and efficiency benefits as existing products in the range, but at a more cost-effective entry point, making the solutions ideal for startups and SMEs. When combined with the Alfa Laval ThinkTop valve control unit, consumption of water and CIP media can be reduced by as much as 90%, facilitating lower total cost of ownership and reduced environmental impact.

Leonardo Morabito, Business Unit Manager HFH for UK & Ireland at Alfa Laval, said: “Double-seat technology is something that we believe that every manufacturer should be able to benefit from. Integrating these valves into your process line not only guarantees the safety of your product but can also provide a boost to on-site efficiency through reduced usage of water and

Facing challenges related to inaccurate manual component counting, stock variances and possible production delays, Sellectronics approached Altus for guidance on achieving faster, more precise and efficient inventory management. On Altus’ recommendation, Sellectronics selected the Scienscope AXC-800 III automated X-ray component counter to help meet these challenges. Equipped with advanced X-ray imaging and AI technology, the AXC-800 III delivers rapid, highly accurate component counting and full traceability.

Since installing the system, Sellectronics has reduced the time it takes to count reels from 5 minutes to 20 seconds or less. The company has also eliminated miscounts on the production floor, driving greater efficiency and less downtime.

Jon Hurrell, Managing Director at Sellectronics, said: “The AXC-800 III’s ability to quickly and precisely count even the smallest components, along with its seamless data transfer between systems, has significantly improved

Double-seat technology is something that we believe that every manufacturer should be able to benefit from. cleaning media. This is a win-win for both manufacturers and the environment.”

The Unique Mixproof Process is a compact version of previous models but is still available in a variety of sizes and remains configurable to suit the needs of different process lines. Its counterpart, the Unique Mixproof CIP, is specially designed for cleaning-in-place (CIP) applications.

Both products have also been designed with simplicity of service in mind, in order to maximise uptime and minimise the burden of routine maintenance upon the business, featuring a maintenance-free actuator and proven seal technology to extend service intervals. Once a replacement is necessary, seals can be changed in a matter of minutes using standard Alfa Laval servicing tools.

For more information: www.alfalaval. co.uk/products/fluid-handling/valves/ double-seat-valves/unique-mixproof/

our inventory management and helped future-proof our operations.”

“We are pleased to see the transformative results the AXC-800 III has delivered for Sellectronics,” said Joe Booth, CEO of Altus Group.

“This solution underscores our commitment to providing customers with cutting-edge technologies that can optimise processes and advance their manufacturing capabilities.”

The Scienscope AXC-800 III has been instrumental in transforming Sellectronics’ component counting and inventory management. This third-generation X-ray counter features advanced AI technology that captures precise images of components and counts them with 99.99% accuracy in under 20 seconds per reel.

An integrated barcode scanner automates reel identification while simultaneous 4-reel counting maximises throughput. The userfriendly interface seamlessly communicates count data to ERP systems, eliminating manual errors.

With its high precision, speed and small

footprint, the Scienscope AXC-800 III marks a significant advancement for electronics manufacturers looking to enhance component inventory management through process optimisation and automation.

Website: www.altusgroup.co.uk

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People On The Move

Altus Strengthens its Inspection Team to Better Support Customers Altus Group, a leading distributor of capital equipment in the UK and Ireland, is pleased to announce a significant addition to their team with the appointment of a new Applications Engineer. This strategic move underscores Altus’s commitment to providing exceptional customer support in the UK.

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Nick Hurrell has joined the Inspection Team and brings a wealth of experience and an understanding of electronics production and the industry landscape. His professional journey is marked by an impressive track record in the production environment, encompassing all aspects of electronics production, including Surface Mount Technology, Through-Hole Technology, and testing procedures. He has previously held roles that entailed machine selection, implementation, and process improvement, showcasing his proficiency in optimising production processes for maximum efficiency.

Nick has already built a strong relationship with Altus, working with the company on past projects. He is also well-versed in the diverse range of brands within the Altus portfolio, such as Koh Young, Kolb, YJ Link, and Heller. This knowledge positions him as an ideal addition to the team due to his comprehensive understanding of customer pain points, industry dynamics, and the unique pressures of those operating in the field.

As Application Engineer, Nick will work closely with Anthony Oh, Operations Manager - Inspection Products at Altus Group. His appointment significantly bolsters Altus’s Inspection Team, which is paramount in ensuring comprehensive support for customers across the southern region of the UK. Website: altusgroup.co.uk.

People On The Move BELOW: Laura Graham, Pictured Center Front, Retires after 11 Years with AIDAAmerica

Laura Graham Retires after 11 Years with AIDA-America AIDA-America, metal stamping press manufacturer in Dayton, OH, USA, wishes to thank long-term employee Laura Graham, who retired after 11 years of service. She held multiple positions within the Sales Administration Department and most recently served as Senior Sales Administrator. Please join us in wishing Laura all the best in retirement. Thank you, Laura, for your dedication over the past 11 years!

AIDA is a global leader in the design, manufacture, sale, service and support, refurbishment, and modernization of metal stamping presses and metalforming automation equipment.

AIDA servo and mechanical stamping presses range in capacity from 30 to 4,000 tons, from 1 to 1,500 strokes per minute, from gap frame to straightside, high speed to cold forging, transfer and progressive die, material handling and coil feeding equipment; AIDA provides one of the broadest selections of complete metalforming systems from a single manufacturer.

With a worldwide network of sales and service locations in nearly 40 cities across 20 countries, press installations exceeding 80,000 units in over 60 countries worldwide, producing a range of products for industries such as automotive, appliance, electronics and electrical, AIDA is truly a global metalforming solutions provider.

Learn more about AIDA at www.aida-global.com.

Fire engineering consultancy appoints four new board directors and new colleagues to fuel growth Award winning fire engineering practice OFR Consultants has announced the appointment of four colleagues to its board, news which comes amidst a spate of colleague announcements.

Stewart Dabin, Dr Danny Hopkin, Jack Wilshaw and Richard Rankin each join the board as directors, joining existing directors Andy Passingham and Ryan McCreadie. All four new appointees are long serving colleagues at OFR, helping the business in its quest to protect people, property and planet through fire engineering strategies.

London-based Stewart Dabin joined the business in 2018 serving as design director and leads the London Residential sector for the business; fellow Londoner Jack Wilshaw joined in 2019 as design director promoting best practice and managing some large accounts from the capital.

Richard Rankin has spent five years at OFR leading the Manchester office – predominantly leading on projects in the residential, healthcare and education sectors, while Dr Danny Hopkin joined the business in 2017, serving as technical director, where he has overseen the development

of OFR’s specialist technical skills areas, alongside being a driver behind research studies and outputs.

The news comes following a bumper month of appointments at OFR. Sarah Black joins as principal engineer, while Andrew Price, António Seara Cardoso, Christian Whilde, Finlay Collins and Budmika Karuna Pathirajage all joined as graduate fire engineers.

The appointments take the OFR team to more than 120 colleagues, with a continued year-on-year growth reflecting OFR’s success in delivering high quality, technically led, tailored fire safety solutions on projects across the UK and around the world. Since its inception in Manchester in 2016, it has extended its reach across the country, opening offices in Edinburgh, Glasgow, Leeds, Oxford, Bath and London.

Other colleague announcements this month came as Sam Bryant received a research award from the Society of Fire Protection Engineers, with judges acknowledging Sam’s work as “an important piece of research to assist engineers in dayto-day project work”.

To find out more about OFR visit: https://ofrconsultants.com

Manufacturing & Production Engineering Magazine

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Compressed Air, Pumps & Valves

KNF Expands Smooth Flow Series with FP 7 and FP 25 Liquid Pumps The latest members of the KNF Smooth Flow family are designed to meet the most demanding applications.

KNF has expanded its Smooth Flow series with the introduction of the new FP 7 and FP 25 low pulsation pumps. Combining the gentle flow characteristics of gear and centrifugal pumps with the advantages of diaphragm pumps, these innovative additions to the Smooth Flow family are designed to meet the needs of the most demanding applications.

KNF FP 7 and FP 25 Advance Liquid Pump Technology With the FP 7 and FP 25, KNF has added two new customizable pumps to its FP series. Designed with a built-in dampener to provide smooth, lowpulsation flow that minimizes friction in tubing and prevents bubble formation, these pumps reliably transfer fluids without the need for additional equipment like external dampeners. Other features include 4-point valves for reliable self-priming, even at reduced motor speeds, and a digitally adjustable BLDC motor for precise pump control and pinpoint matching to individual electronics.

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Compressed Air, Pumps & Valves The KNF FP 7 and FP 25 Smooth Flow pumps feature a built-in dampener for exceptionally low pulsation.

For a Variety of Applications: FP 7 and FP 25 The FP 7 has a nominal flow rate of 70 ml/min, a minimum suction height of 2.0 mH2O, and a maximum pressure of 10 mH2O. The FP 25 shares many of the same features as the FP 7, including the integrated dampener, innovative 4-point valves, and digitally customizable BLDC motor. However, it offers a higher nominal flow of 250 ml/min and a higher minimum suction height of 3 mH2O. Also available in high-pressure versions, both FP 1.7 and FP 1.25 achieve nominal pressures up to 60 mH2O.

Maximizing Efficiency Through Customization Like most KNF pumps, the new FP 7 and FP 25 are fully customizable to meet the specific needs of various applications. Pump head, valve and diaphragm materials can be matched to specific operating requirements, and a variety of DC motors are available, from simple brushed versions to advanced BLDC versions for digital customization and superior controllability, making these pumps an excellent choice for demanding applications such as inkjet printing, medical equipment, 3D printing and fuel cells. The ability to handle solvents and other demanding liquids further expands the range of applications.

Website: knf.com/en/uk

Manufacturing & Production Engineering Magazine

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Compressed Air, Pumps & Valves

Retrofitting pumps for a new role Cutting cost, time and carbon footprint of FPSO relocations

Floating production storage and offloading (FPSO) vessels are used for processing oil and transferring it to tankers or pipelines. Positioned close to an oilfield, they remain there until the field is exhausted. Originally designed with a service life of over 20 years, FPSOs represent a huge investment for international oil companies (IOCs) and to maximize their potential, they are refitted and relocated once a project is completed.

With sustainability paramount for modern industry, refurbishment projects support corporate goals by enabling the reuse of components, rather than installing all-new equipment, which requires more resources and investment.

Comparing costs Research carried out by a major IOC compared the investment value for new equipment with the final value of the project, and found that for offshore locations, project costs were five to seven times the investment. Therefore, the final cost of installing a new USD 5 million pump on an FPSO could be between USD 25 and 35 million.

BELOW: Floating production storage and offloading (FPSO) vessels are used around the world for processing oil and transferring this resource to tankers or pipelines that transport it to refineries.

In contrast, retrofitting existing equipment would equate to approximately 60% of the new pump price. Considering that it will be reinstalled without further modifications, there are no additional costs.

Comparing total project costs makes the retrofit investment just 10% of the whole project to install a new pump in an offshore situation.

Extending equipment life while realizing carbon reductions Relocation projects begin with establishing a scope of works for vessel upgrades. Improvements can be achieved via new equipment or modifying existing assets. However, every solution must be capable of delivering a service life dictated by the contract - typically 20-25 years.

Central to an FPSO are the water injection pumps which pressurize the well and maximize its productivity. It’s imperative that all pumps and auxiliary equipment are refurbished to the highest standard.

Sulzer research has shown that within the upstream business, production platforms account for 82% of CO2 emissions and of these, water injection pumps are responsible for 50% of the power requirement. Therefore, optimizing equipment for the new application

and upgrading pump efficiency can significantly impact carbon footprint and operational costs.

Mini case study: Lead by example In one project, an FPSO is being prepared for relocation to the North Sea. When the vessel was built, Sulzer supplied three water injection pump packages: 8-stage pumps designed to deliver 3’500 m head with a flow rate of 350 m3/hr using a 4.5 MW motor.

Before relocation, the vessel must undergo a refit. For example, an additional 20 m of height will be added to the bow to handle waves in the North Sea. All work will be carried out in a dry dock and as the original equipment manufacturer (OEM) of the pumps, and a leading retrofit expert, Sulzer is contracted to deliver the modifications.

Retrofits offer significant benefits over pump replacement. Financial savings equate to approximately 10% of the cost of a new pump. However, money isn’t everything, time is often the priority. With its global engineering facilities, Sulzer delivers a pump retrofit in around six weeks.

Double duty Equally important are pump efficiency and reliability. To attain optimum application performance, pumps need fine-tuning. In this case, two duty points were required – flows between 330 m3/ hr and 387 m3/hr with a differential head of 1750 m as well as a low flow, high pressure point of 104 m3/hr at 1960 m head.

To achieve the best solution, Sulzer proposed a pump de-staging, removing four of the eight stages. Super Duplex stainless steel de-staging tubes will guide the flow between the remaining impellers, preventing turbulence and maintaining efficiency.

The reduction in output also equates to lower power input. Here, the original fixed-speed, 11 kV, 5.5 MW motor could be replaced with a 3 kV, 3.5 MW unit controlled via a variable speed drive.

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Compressed Air, Pumps & Valves

Bespoke Engineered Pump Packages YOU DEFINE. WE DESIGN. At Cat Pumps we can provide engineered pump packages that are bespoke to customer requirements. We have over 50 years’ experience of providing Cat Pumps pump packages to a variety of industries and can provide skid systems with the following options: Electric Motors There are number of options available.

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Pump Package Accessories To compliment the Cat Pumps pump package, we can supply a multitude of pump accessories.

Contact us today to learn more about custom pumping systems!

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Power will be reduced from 4.5 MW to 1.8 – 2.0 MW, depending on operating conditions, while motor efficiency will increase from 96.4% to 96.9%, providing considerable energy savings. This reduces carbon footprint, important when governments are imposing environmental taxes based on carbon emissions.

Measure twice, fit once The reduction in motor power and discharge head enabled many original components to be retained, but a new lateral analysis of the de-staged unit was conducted, confirming the pump rotor stability throughout the operating speed range.

Due to the reduced speed of the new electric motor, the lube oil system output had to increase. A modification of the lube oil pump increased output by 30%, satisfying the demand of the pump, gearbox and motor.

Pipework also needs to be approached carefully to avoid costly reworks on site.

This can be achieved cost-effectively by using pipework with ‘green ends’ allowing it to be cut and welded in position on site, achieving a perfect

fit. An alternative is to deliver the pipe and fittings to all the pipework to be fabricated on site.

Taking advantage of retrofit Using updated equipment that fits back into the original footprint and performs at the best efficiency point has clear benefits.

In many cases, time is of the essence and with refits being completed in dry docks, it’s important to minimize the project time. A well-planned retrofit project can be completed within six weeks and minimizes changes to surrounding pipework and infrastructure.

Moreover, retrofits require much less energy and materials, maximizing sustainability and contributing to environmental, social and corporate governance (ESG) goals.

Sulzer is an expert provider of retrofit projects for pumps from any manufacturer. The retrofit team comprises around 60 personnel with access to all of Sulzer’s design engineering and manufacturing facilities.

Combined with its extensive network of service centers, retrofit projects can be delivered worldwide. Working as an engineering partner, Sulzer helps IOCs to optimize performance and reduce CO2 emissions with targeted pump upgrades.

There are also environmental advantages. Retaining most of the components means the original asset isn’t disposed of, producing less waste.

In the previous case study, the electrical motor was the only major item that wasn’t reused and instead recycled.

RIGHT: Retrofits offer significant benefits compared to procuring replacement pumps. The most obvious is the financial saving – approximately 10% of the cost of a new pump.

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Advice

Why winter maintenance is snow joke How to maximise heat transfer system uptime in winter

Just like the cold weather can affect our homes, it can also have an impact on the components of a heat transfer system and the fluid itself. So, what can manufacturers using heat transfer fluids do to maximise uptime in the winter months?

As we get closer to winter, taking the time to check and maintain our homes means we can be confident that, once we turn the heating back on, everything will work well.

Keep oil under cover

- Dave Dyer

Preparing for winter involves more than turning the heating on and digging out your winter coat. For example, blocking drafts, covering outside taps and bleeding radiators can all make your home more efficient while reducing energy costs.

Similarly, when working with heat transfer systems, manufacturers can follow some simple steps to optimise their facilities for colder weather. Here Dave Dyer, technical sales engineer at thermal fluid management specialist Global Heat Transfer shares his advice for maximising heat transfer system productivity during the winter.

To maintain uptime, businesses will often store barrels of new thermal fluid onsite to quickly top up or refill the system.

Facilities managers with limited storage space may store new fluid outside, but this can shorten fluid lifespan, reducing its efficiency once it enters the system.

Manufacturers must store thermal fluid indoors all year round, but this

is particularly important in winter and colder conditions.

When kept outside, water or condensation can enter the barrels, even if they are sealed. During temperature changes, thermal fluid drums, barrels

and intermediate bulk containers (IBCs) kept outside for longer periods will expand and contract, causing a vacuum. This process syphons any water or condensation sitting on top of the container into the oil, making it unusable. The greater the temperature change, the larger the expansion and retraction, so extreme weather or freezing temperatures could be more damaging. Moving barrels under cover, ideally indoors before the winter weather comes is therefore integral to keeping operations running.

Keep pumps circulating If thermal fluid is left in a system that is not operating, it can become viscous and waxed. Heat transfer fluid in this state is difficult to bring to temperature, and could damage the pump and other integral equipment.

The best way to avoid downtime caused by waxed viscous fluid is to keep pumps running when temperatures drop below -8°C. The friction and heat from the pump will keep the oil at a temperature that ensures it stays warm and less viscous — warm pipes also raise the ambient temperature, reducing the risk of surrounding water pipes freezing.

Taking these steps, particularly if plant managers shut down operations over winter, helps reduce unnecessary wear on critical parts of the system and avoid issues with lack of flow during start-up.

Have contingency fluid Thermal fluid will contract when temperatures change significantly, reducing the amount of fluid in the system. A reduction in fluid quantity will impact system efficiency and could accelerate wear on critical system components. To maintain productivity, operations engineers should regularly check fluid levels, top up when needed and have reserve fluid available to ensure they can intervene.

Order a spill kit To maintain safe operations, it’s always good practice to keep a spill kit on site, placed close by the system so it’s easily accessible. The kit includes personal protective equipment (PPE) and absorbent materials to quickly address

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Manufacturing & Production Engineering Magazine

Advice any spills or leaks. This is particularly important in winter so that any spilled fluid doesn’t freeze, which could lead to slips and trips.

Check your CDX tank Many heat transfer systems are susceptible to moisture and debris contamination over time. If left unattended, moisture can negatively impact the system’s performance and efficiency. Expansion tanks, such as CDX tanks, have a drain on the condensate (dump) side to help manage this.

Manufacturers that have a CDX tank can open this valve during winter months. As the thermal fluid expands and contracts during production, air will move around the tank, which can release moisture content. Opening the valve to release one or two litres of fluid will let out any moisture and debris — it’s good practice to do this on a monthly basis all year round to prolong fluid life and maximise uptime.

As we get closer to winter, taking the time to check and maintain our homes means we can be confident that, once

we turn the heating back on, everything will work well. Similarly, when working with thermal fluids, adding a few extra steps to your preventative maintenance plan, can help manufacturers keep operations running over the colder months and during winter shutdowns.

For more advice on thermal fluid management in winter months, contact Global Heat Transfer.

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Measurement, SensorS & Monitoring

Making the most of your machine tool set-up “The pace of change has never been this fast, yet it will never be this slow again.” This popular quote is often bought up when speaking about today’s fast-paced technological development. Industry 4.0 is paving the way for manufacturing in transformation with ground-breaking innovations, which in turn bring opportunities to develop workshops and aim for higher revenues. However, investing in new technology is not the only way to optimize a machine tool set-up. In the first of a new article series from Sandvik Coromant, Blasius Reschreiter (pictured right), global manager of machine tool solutions at the metal cutting organization, explains how tool shop owners can make the most out of their machines through improved equipment utilization, quick change tooling and modular solutions.

In light of recent technological advances, investing in forefront technologies can at first hand appear like a given strategy to conduct a successful business.

However, markets are fluctuating.

To continually strive for the latest, most high-tech solutions might not be the natural way to go forward in uncertain times. The ability to adapt production to current and future demands in a flexible way is crucial for surviving in today’s economy.

Here, we take a closer look at flexible approaches to workshop machinery.

Make the most out of your machine tool set-up Machine tool and cutting tool development is rapidly progressing.

However, this can involve considerable investments, requiring time, capital and somewhat secure predictions for future demands. If the market situation and business forecasts are unsure, major investments might not be an option.

When your primary goal is to stay in cost reduction mode and to handle a temporary market downturn, a key consideration should be to investigate

your current workshop, to make use of existing machines and existing capacity and, preferably, without dramatically increasing overhead costs.

Another consideration is productivity.

Often, we put our focus on achieving maximum metal cutting efficiency. Metal removal rate is one way of measuring efficiency when producing parts.

However, what can be an even more important aspect to consider is machine utilization. In an average machine shop, only 50% of a machine’s in-use time is used for machining. Breakdowns, changeovers and maintenance consume the remaining 50%.

Machine utilization in focus Increasing machine utilization is a cost-effective way to boost productivity and make use of the capacity already available. This should be measured as a percentage of the time that the machine is actually producing components.

Pushing up active machining time by only a few percentage points makes a big difference.

Increased machine utilization can be attained by working actively with typical time killers often appearing in a common workshop related to these areas: batch set-up, measuring the component in the machine, tool setting, coolant pipe setting, changing worn tools, chip removal around tools and workpieces or blocked conveyors and component change-over.

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Manufacturing & Production Engineering Magazine

Measurement, SensorS & Monitoring production rate increases. Over the course of a year, the use of quick change will result in significantly higher component production and reduced scrap.

Besides from a significant increase in machine utilization, quick change also brings many benefits for the operator, such as user-friendliness and a more ergonomic working environment. For example, changing tools outside the machine reduces accidents, errors and searching for dropped parts.

Turn flexible, go modular

Two key approaches to overcome this type of challenge are to work with quick change tooling and modular systems.

By applying quick change and modular solutions, machine utilization can be greatly increased.

Quick change tooling solutions A quick-change solution can reduce time spent on measuring, set-up and tool change, allowing for drastically improved machine utilization. Through coolant delivery helps to further maximize productivity. There are several benefits with quick change that support keeping the green light on, including reducing batch change-over time.

Changing time from one style of tool to another is dramatically reduced using quick change. Up to ten minutes can be saved in one typical turning operation.

Increase the number of tool positions with double tool holders can also help. Turning centres with driven tool holders often have limited space. Using double clamping units allows either sister tooling or an increased variety of tools, thereby reducing the tool change requirement for a wider range of components. Double clamping units can be used when the machine has Y-axis, half turret or sub-spindle.

There’s also potential to reduce downtime when changing worn-out tools. Every time a solid carbide tool with a driven tool holder is changed the tool offset needs to be re-calibrated.

With indexable mills and drills, multiple inserts need to be changed. Using sister tool and changing the cutter

The benefits that modular tooling systems bring are flexibility, reduced tool inventory and multiple tooling combinations, all contributing to increased machine utilization.

- Blasius Reschreiter

outside the machine is much quicker.

For static tool holders, being able to remove the tool ensures improved maintenance of the tool, correct mounting and no unexpected stops due to needs for spare part purchases.

Eliminating coolant pipe setting can also prove to be a time-saving exercise.

When operators are setting the coolant pipe direction, it normally takes two to three attempts to get it right. Poor chip control often then knocks the pipe which means that setting is quite a regular occurrence.

Lastly is improving the speed of production start-up. By eliminating the “first-test component” or “measuring cuts”, scrap is reduced and the

Another strategy for keeping your machines running is modular solutions.

A modular system offers a large variety of tool assemblies with different characteristics, decreasing the need for costly, customized tools with long delivery times. Modular tooling helps to avoid spending on separate tools for each machine, component and feature.

The benefits that modular tooling systems bring are flexibility, reduced tool inventory and multiple tooling combinations, all contributing to increased machine utilization. The ability to maintain continuous production for a long period provides the flexibility needed to make your workshop better equipped to handle changing market conditions.

Four applications where modularity has proven to be extra valuable include reaching difficult to access features, stability in vibration prone operations, small or varying production and extra clearance when machining large components.

While it is certainly true that the “pace of change has never been this fast”, various strategic approaches emerge to ensure adaptability and bolster financial gains in a continuously evolving market landscape. Enhancing machine utilization, reducing changeover time and investigation into modular systems all contribute significantly to increasing the flexibility of machine shops. In our upcoming article, we will thoroughly explore the effects of investing in new technologies. This will help shed light on how these investments can improve efficiency and open up new opportunities for workshops. Stay tuned!

Website: www.sandvik.coromant.com

Manufacturing & Production Engineering Magazine

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Measurement, SensorS & Monitoring

Electronic / Semiconductor Testing Solution - E-LIT Non-destructive Testing and Modular Automated Test Bench

E-LIT – Lock-In Thermography for electronics, from InfraTec (available in the UK and Ireland through Quantum Design UK and Ireland), is an automated testing solution system (as part of NDT techniques) which allows non-contact (electrical) failure analysis of semiconductor material during the manufacturing process. Inhomogeneous temperature distribution, local power loss, leakage currents, resistive vias, cold joints, latch-up effects and soldering issues can be measured with Lock-in Thermography. This is achieved by using the shortest measurement times combined with a high-performance thermographic camera and a specialised lock-in procedure.

• Thermal analysis of electronic and semiconductor devices • Modular test bench for online lock-in measurement • Reliable detection of thermal anomalies in the mK and μK range • Spatial location of defects in multilayer PCBs and multi-chip modules • Use of thermographic systems with cooled and uncooled detectors • Operational software IRBIS® 3 active with comprehensive analysis options in laboratory conditions

The powerful Lock-in Thermography software uses the latest algorithms and routines from most recent scientific publications.

The power supply for this process is clocked with a synchronization module and failures that produce mK or even μK temperature differences are reliably detected by the Lock-in Thermography system.

Smallest defects at electronic components like point and line shunts, issues from overheating, internal (ohmic) shorts, oxide defects, transistor and diode failures on a PCB surface, in integrated circuits (IC´s), LED modules and battery cells can be detected and displayed in x and y positions.

Additionally, it is possible to analyse stacked-die packages or multi-chip modules in z-direction with merely changing the lock-in frequency.

The powerful Lock-in Thermography software uses the latest algorithms and routines from most recent scientific publications.

E-LIT is extremely powerful also in resolving smallest geometrical structures as it can be equipped with strong microscopic lenses and additional SIL lenses. Identifying smallest structures with InfraTec´s E-LIT does not mean that the resulting field of view will also be smallest – implementing thermal cameras with detector sizes of up to (1,920 x 1,536) pixels provide large scale microscopic imaging. For even larger imaging stitching options are available.

InfraTec is available in the UK and Ireland through Quantum Design UK and Ireland. More information can be found at qd-uki.co.uk or call (01372) 378822.

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Manufacturing & Production Engineering Magazine

­

The modular test bench offers the following benefits:

UK/Ireland Distributors for Tel: +44 (0)1372 378822 | Email: info@qd-uki.co.uk

www.qd-uki.co.uk

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Manufacturing & Production Engineering Magazine

Health & Safety

Lightning Protection – Compliance and Safety The potential for damage as a consequence of lightning is a genuine and real concern for building and facility owners throughout the world. In the UK alone, there are typically around 2-300,000 lightning strikes per year, all of which have the potential to strike anywhere and cause harm. Most companies are completely unaware of the threat lightning activity poses to their infrastructure, assets and most importantly personnel. Here, Ian Holmes - Senior Consultant from EA Technology, explores lightning protection and how to gain compliance with British Standards.

Lightning “prevention” or “protection” is a formidable task, however a reduction of its consequences, together with incremental safety improvements, can be obtained by the use of an holistic or systematic hazard mitigation approach.

EA Technology aims to assist our clients in delivering this service, achieving compliance with the current British Standards BS EN 62305 series,

and helping to mitigate against the often-catastrophic effects of lightning.

Lightning protection systems are utilised to prevent or reduce the consequences of a lightning strike.

Hazard mitigations in the first instance can be achieved by a Strike Risk Assessment, in which a site survey on behalf of the client is undertaken to ascertain each individual structure’s susceptibility to the effects of a lightning strike.

Impartial surveys are conducted to review structures for their construction, the existing lightning protection afforded to any buildings and to establish whether the present arrangements for lightning protection are satisfactory in relation to the lightning protection standard BS EN 62305 (Step 1).

BS EN 62305 indicates the mathematical analysis needed to assess the overall risk factor and decide whether a building or structure needs specific lightning protection.

It proposes that acceptable lightning strike risk factors, when considering the loss of human life, is 1x 10-5 per year. Where the analysis is applied to a range of parameters, a numerical solution to the risk factor is obtained.

If the assessed risk factor is less than 1 x 10-5, and in the absence of other considerations, lightning protection is deemed unnecessary.

If the risk factor is greater than 1 x 10-5, then lightning protection is normally the recommendation of EA Technology.

Note that a risk factor greater than 1 x 10-5 (less than 1 in 100,000)

means that there is a greater risk that a structure will be hit by lightning and/ or consequences may be deemed unacceptable.

It is accepted that some considerations cannot reasonably be assessed in this manner and are given paramount importance, and of course, safety and risk to life will always bias a decision in favour of installing lightning protection.

The BS EN 62305 series standards are essential for engineers, architects, and professionals involved in the design and installation of lightning protection systems. They provide a systematic approach to assess the risk of lightning damage and specify measures to reduce this risk.

Compliance with these standards helps ensure the safety of structures, their occupants, and the electrical and electronic systems within them.

The lightning protection survey will review the sites susceptibility to lightning, the outcome of which will be presented in a formal digital report, identifying the outcome of each numerical risk calculation with regards to all studied structures along with detailed and impartial recommendations which outline how compliance can be achieved.

Upon completion of the lightning protection survey, any structures deemed to require the installation of lightning protection and surge protection devices will be afforded a full and impartial detailed formal design (Step 2).

This formal design will facilitate tender document requirements for the installation of any necessary lightning protection to be installed, and this formal design will also act to facilitate for system commissioning and all future periodic inspection and testing requirements.

The importance of enlisting the help of professionals to accurately determine the risk and provide practical and impartial solutions, cannot be overstated in order to gain or remain compliant and to protect your business and its assets.

EA Technology offers this service and a wealth of experience, and we also undertake HV earthing compliance studies, providing everything from audits to substation design services.

For independent, expert advice on predicting lightning strikes and the most cost-effective ways to protect assets during electrical storms, visit: https:// eatechnology.com/services/ condition-assessment/earthinglightning-services/

Manufacturing & Production Engineering Magazine

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Health & Safety

Managing contamination risks in pharma settings The importance of correct lubrication in pharmaceutical manufacturing

There’s more pressure than ever on pharmaceutical companies to meet production demand. Consequently, the global pharmaceutical market size is expected to reach USD 2,067.36 million by 2028, growing at a compound annual growth rate (CAGR) of 5.7 per cent during the period from 2022 to 2028. Here Chris Johnson, managing director at bearing lubrication specialist SMB Bearings, explains the importance of careful lubricant selection to manage contamination risks and boost drug output.

Drug shortages pose a significant threat to public health. As the global population ages and access to drugs increases, pharmaceutical companies face growing pressure to meet the production demands needed to provide critical care to patients. While it may seem like the obvious solution is to simply ramp up production, the manufacturing realities are more complex.

According to an FDA report, product or facility concerns are the leading cause of pharmaceutical manufacturing disruption, being responsible for 66 per cent of all production disruptions.

Due to these disruptions, producing more drugs would be challenging for facilities and could be an inefficient and wasteful approach to increasing output. The alternative lies with increasing the quality of each batch.

To address this growing challenge, manufacturers are turning toward more flexible factory operations to support the manufacture of a wide variety of specialised drugs. To achieve this, drug manufacturers should accelerate the adoption of digitalization and address infrastructure upgrades to bring transformation to the entire manufacturing process. This will

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Manufacturing & Production Engineering Magazine

As the global population ages and access to drugs increases, pharmaceutical companies face growing pressure to meet the production demands needed to provide critical care to patients.

- Chris Johnson

increase the overall quality in any given batch, thus minimising shortages.

Here are three key considerations for pharmaceutical plant managers to minimise contamination risks and increase output while maintaining compliance.

simply a compliance issue, but can lead to additional financial and environmental costs, ultimately impairing productivity.

Managing contamination Despite evolving manufacturing techniques, safety and the control of contaminants remains of the utmost importance. One such area that introduces potential contamination risk if not managed effectively, is the use of bearing lubrication in equipment.

Effective bearing lubricant selection in pharmaceutical settings starts by considering the application of the machine. Equipment used in the production of pharmaceuticals, such as tablet packaging machines or peeler centrifuges, generally use very little lubrication or no lubrication at all. This is because contact between active pharmaceutical ingredients and products such as lubricants cannot take place.

Pharmaceutical quality assurance is one of the most fundamental aspects of the whole drug manufacturing process. This regulation is designed to ensure medicines conform to industry standards and there are no contaminants present at any stage of development.

Food grade lubricants are used for the lubrication of machinery in the pharmaceutical industry and are purpose-designed to help minimise risks. Lubricants are classified by NSF into several food-grade categories H1 and H2. H1 lubricants are food-grade lubricants used in food-processing environments where there is the possibility of incidental food contact.

However, for equipment that is not situated in the production zone and does not have any direct contact with production machinery, the product or packaging — H2 lubricants will suffice.

If environmental conditions are poorly managed, this can lead to poor quality standards, regulatory violations and delayed drug approvals. This can also result in deteriorating equipment, which creates more variable product quality. In such instances, it’s not

Cleanroom applications may demand the sterilisation of tools and machine components. If lubrication is needed in these environments, extreme low volatility (low outgassing) cleanroom lubricants must be used to avoid contamination of the environment.

Pharmaceutical quality assurance

Health & Safety Typically, these lubricants will not contain lithium, molybdenum, calcium, aluminium, barium, zinc or sodium.

Another consideration is whether a bearing can be used without lubricant at all. Ceramic is non-porous and as a result, it is practically frictionless.

Unlike stainless steel bearings, full ceramic bearings do not suffer heat build-up within the bearing and therefore do not need lubrication to help dissipate the heat. Therefore, unlubricated full ceramic bearings do not run the risk of contaminating the product due to lubricant leakage.

Other contamination risks such as using the correct personal protective equipment, storage conditions and handling procedures should also be considered. A dedicated system to control and monitor environmental conditions, real-time energy monitoring and production correlation can be installed.

Real-time data Human error is one of the biggest risk factors in quality control. By effectively digitalising their operations, plant managers can better adhere to regulatory requirements, promote

Effective bearing lubricant selection in pharmaceutical settings starts by considering the application of the machine.

- Chris Johnson

data integrity and ensure traceability throughout the product lifecycle.

Introducing a digital dashboard showing real-time data from across the manufacturing plant makes data easily accessible to operators.

Through simulation, data modelling and analytics software, plant managers can make data-backed decisions relating to individual machinery or entire production lines.

For example, by installing sensors on bearings used in pharmaceutical

manufacturing, operators would be able to clearly see if a bearing needed to be regreased and could prevent equipment failure in the long run.

Data is also used to fact check and make informed decisions.

Missing or inaccurate data can lead to non-conformance, which will ultimately result in delays and could even cease production. As plants consider revamping their physical infrastructures, simulation can allow businesses to conduct real time testing to gain insight without production disruption.

It’s clear that the pharmaceutical facilities of the future will need to be agile and flexible to face the risks that can impact production capabilities. By choosing the correct bearing lubricant for the desired pharmaceutical operating environment, plant managers can dramatically reduce contamination risks in this area.

For more information about SMB Bearings product range or relubrication services visit the website.

Manufacturing & Production Engineering Magazine

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Training & Education News Cast Iron success for foundry workers on new training programme An innovative new training programme, which improves the competitiveness of the foundry sector, has been completed and is looking to recruit its next cohort.

The Certificate in Cast Iron Production, Metallurgy and Quality Control - delivered as a joint venture by ICME and The Cast Metals Federation (CMF) - has helped increase the knowledge and progression of nine staff at four different companies.

Delivered over an 18-month period, the course has combined focused learning through a mix of classroom delivery, practical sessions, and workplace projects.

The results have been fantastic with many of the shopfloor improvement exercises delivering cost savings and efficiency gains, whilst several new processes have been introduced to rectify material failures and reduce defects.

A special celebration event was held to mark the culmination of the learning, with ICME Junior Vice President Antony Evans (CEng FICME) presenting students with their certificates.He praised the quality of presentations from all candidates and reinforced the importance of staff receiving a sound understanding of metallurgical best practices and how it is fundamental to the success of cast metal companies going forward.

Dorset-based Eurac Poole, which specialises in high volume iron castings and grey cast iron brake discs, enrolled 3 students

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Manufacturing & Production Engineering Magazine

on the programme. They gave a presentation showcasing how the learning from the course had allowed them to complete a project on ‘investigating a suitable replacement for wire inoculation’, helping to reduce casting defects and identifying processes that will cut scrap and has already led to cost savings.

The company was joined by Thomas Dudley, who used it as a key progression tool for two of its employees involved in technical and quality positions.

Results from the project have been implemented by the Dudleybased company, with additional staff trained in best practice leading to productivity gains and a host of financial savings secured.

WM Lee is an iron foundry based in Dronfield, specialising in parts for truck manufacturing.

The students undertook a project based on ‘identifying issues causing sub-standard ductile iron conversion treatments and redefining the operating parameters for the HWS plant sandwich process for ductile iron treatment’. The completion of this project has resulted in substantial financial savings that have more than paid for the training.

The Cast Iron Production, Metallurgy and Quality Control course is ICME approved and comes complete with ICMEaccredited CPD hours.

A new cohort is currently being recruited for a start date of March 2024, with more information available by emailing training@icme.org.uk.

(L-R) Adam Rochelle (Castings PLC), Kai Robertson, Luke Powell (both Eurac), Declan Morris (Thomas Dudley), Michael Birch (Castings PLC), Amy Worrallo (ICME), Joshua Malbon-Williams (Thomas Dudley), Eddie Lindsay (Tutor), David Parson (WM Lee), Richard Keyes (WM Lee) and Chris Allott (Tutor)

Multidisciplinary Engineering Firm adi Group Doubles Manufacturing Capacity with New Production Facility adi Group is announcing the opening of a new facility adjacent to its Birmingham headquarters, allowing the firm’s Automation division to double its manufacturing capacity.

Due to an increase in demand for the company’s services, with a variety of new clients coming onboard, the new building was a much-needed addition to allow it to boost its production capability.

As a UL certified control panel manufacturing facility, the new building will enable the division to build UL certified control panels, significantly enhancing its product offering.

Commenting on the launch of the new facility, managing director of adi Automation Kevin Parsons said: “We are thrilled to be able to boost our manufacturing capacity to such a considerable extent.

Housing around 30 people, the new facility will also serve as a training facility for both staff training and external training, offering relevant resources to help its clients to better understand the systems adi Automation utilises and also the services

Training & Education News

the rest of the Group provides, further enhancing the adi/client relationship.

The building will allow for staff training at all levels and for a variety of purposes, creating new exciting ways for adi apprentices and employees to work towards their professional goals.

“Our outstanding new facility has been designed for the training and

upskilling of all adi employees in mind, from apprentices, to engineers, to managers and directors,” said Kevin.

A crucial aspect of adi Group’s mission is to drive growth and create more employment opportunities within the engineering industry as a whole, which the business facilitates by offering best-in-class pre-apprenticeships and

New programme to help engineers return to work after a career break

apprenticeships, as well as striving to build a highly diverse workforce.

By doubling its manufacturing capacity, the company has created new job opportunities at different levels for both established professionals and young talent looking to enter the engineering sector, working towards closing the STEM skills gap.

Safran Seats has launched a second programme to help engineers return to work after a career break following the success of a pilot scheme last year.

Safran Seats is a leading designer of products for pilots and commercial air crews, as well as the needs of helicopters, with pilot and passenger seating. The programme is run in partnership with return-to-work specialists STEM Returners, who work with engineering’s biggest firms to improve recruitment practices within the industry.

Roles will include In-Service Solution Design Engineer, Project Engineers and Programme Quality Engineer, and be based at the Safran Seats offices near Newport and Cardiff.

Annual research from STEM Returners (The STEM Returners Index) has revealed the challenges people face when trying to return to work. Recruitment bias is shown to be the main barrier to entry. The STEM Returners programme acts as a ‘returnship’, transferring experienced engineers back into industry following a career break, allowing them to be re-integrated into an inclusive environment.

STEM Returners will source the candidates and offer them mentoring throughout the recruitment process.

Since STEM Returners first launched in 2017, more than 400 STEM Returners candidates have joined programmes across the UK. To view STEM Returners opportunities, visit https://www. stemreturners.com/placements/.

Manufacturing & Production Engineering Magazine

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Training & Education News

Aggreko continues bridging energy skills gap through growing apprenticeship scheme Dumbarton-based global leader in temporary power, temperature control and energy solutions, Aggreko, is reaffirming its commitment to development, skills and training as its successful apprentice programme celebrates its latest class of graduates.

Andrew MacNaughton (below), Calum Michie, Lewis Chisholm, Derek Collie and Rafal Fijalkowski will all be graduating from Aggreko’s apprentice programme in Scotland, with all being offered permanent roles within the company.

Aggreko is continuing its focus on developing talent by taking on their latest cohort of new recruits, with a group of eight joining their

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Manufacturing & Production Engineering Magazine

apprenticeship schemes. Following the success of previous years, the business has increased the class of 2023-24, with three more apprentices joining compared to last year.

The three- to four-year programmes give participants on the job training throughout the business and see them attend university or college one day a week. Equipping learners with practical experience of all aspects of the business, this includes building new products, maintaining existing products and supporting Aggreko’s ambition to provide new efficient technologies and greener upgrades to all sectors.

It also gives apprentices the opportunity to travel and support Aggreko’s event business, where in 2023 apprentices have supported the FIFA Women’s World Cup, Goodwood Festival, Rugby World Cup and the Ryder Cup to name a few.

The apprenticeship programme forms part of Aggreko’s wider commitment to addressing the skills gaps in engineering through training and development and instilling passion for the industry in its global teams. One such example is current second year apprentice Harley

Higgins (above), who won Scottish Apprentice of the year in March, and was commended for having a huge passion for engineering.

Aggreko has apprentices throughout Europe, including in France, Italy, Germany and the Netherlands and in the Americas and Australia. For 2024, the company is launching an additional one-year programme in the Middle East for recent apprentice graduates – either with Aggreko or with other organisations – or recent university graduates with a technical or engineering degree.

To learn more about Aggreko’s apprenticeship and graduate schemes and to apply, click here.

Significant new Babcock Wanson Group factory to lead the field in decarbonised process heating The Babcock Wanson Group, of which industrial process heating equipment and solutions specialist Babcock Wanson UK is a founding company, has announced the building of a substantial new plant in Nérac, France. Covering 80,000m², the new plant will enable the Group to increase overall production capacity to meet increased demand, specifically its decarbonisation solutions in which the Group is a leading player.

There are five key production plants, including the existing factory at Nérac. Rather than alter this existing building, the decision was made to design and build a new state of the art plant in the same location, with the capacity to meet existing and predicted growth in equipment sales that has resulted from the Group’s expansion.

The new plant will also be able to readily accommodate the manufacture of larger product.

For more information, please contact Babcock Wanson on 020 8953 7111 or info@babcock-wanson.com or go www.babcock-wanson.com

Manufacturing & Production Engineering Magazine

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Robotics & Automation

What are the risks of stock profile changes to warehouse automation?

Do possible changes to stock profiles present a serious barrier to warehouse automation? Just how much should you care? By Dan Migliozzi, Head of Sales at Invar Group.

A concern voiced by many businesses looking to adopt warehouse automation is: what happens if stock profiles change?

Commercial survival in a competitive market requires a company to respond and adapt quickly, often with upgrades to existing products or the introduction of entirely new ones. These items may have different profiles – perhaps larger or smaller dimensions /weight, or new packaging characteristics.

So, can automation cope with problems of this nature – is there the necessary flexibility?

This question often comes up. But is it really such a big issue? What are the risks? Most businesses, whether they be in fashion retail, electronics or engineering tend to stay within the parameters of their existing product focus, and in most instances this means that only a relatively small degree of flexibility may be needed when designing an automated system. The risk of changes to stock profiles being disruptive is low and should be considered in the light of the huge advantages that automation can offer in terms of capacity, speed and customer service.

Of course, that’s not to say that radical changes to stock profiles never happen. Therefore, there are important ways of mitigating the risks, if you do your homework.

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Manufacturing & Production Engineering Magazine

Before any investment in automation is made it’s critical that due diligence is paid to understanding the future objectives and direction of the business.

Beyond short-term objectives, such as sales targets and planned promotional peaks, it’s essential to gain insights into the future strategic ambitions of the business. Gaining a full understanding of C-suite plans and objectives to a five-year horizon is invaluable in determining the scope and scale of solution that may be required – and any likely radical changes to product profile should be flagged up at this stage.

Careful analysis of data, aligned to future business expectations, is critical when setting the design parameters of the solution and the degree of flexibility and scalability required. Product profile is just one consideration, order profiles, volumes, capacity and peaks are equally important – if not more so.

However, even if some stock profiles do change over time, there are ways forward. Using the example of a tote-based system, the limitation in this instance is the size of the tote. For products that get smaller, totes can be easily subdivided and a simple software update made. Oversized items may need to be accommodated through a different solution, which could be automated or manual. One of the key advantages of working with an

independent systems integrator, with in-house software capabilities, is that alternative technologies can be more easily introduced and integrated to create a cohesive, holistic and flexible solution.

Product profile may be an important consideration when setting out to design an automated system, but the risks associated with changes to profiles are relatively low. However, order profiles and volume growth forecasts are far more susceptible to change and can hold much greater influence over the flexibility and scalability required of a system.

Traditional rigid, fixed to the floor automation is unlikely to offer the agility needed these days. But, thankfully, new technologies, such as autonomous mobile robots (AMRs), are transforming fulfilment operations by offering far more flexible and scalable solutions for goods-toperson order picking operations.

AMR systems combined with pickto-light technology can boost order picking performance from under 100 units per hour using traditional methods, to up to 400 picks per hour, with an ROI that can be as little as 12 months.

As AMRs are used to transport individual mobile shelf units between storage and picking stations, any significant changes to product profile can be accommodated by simply making adjustments to the required number of mobile shelf units. Provided there is adequate space within the warehouse, it’s a highly effective means of providing flexibility.

And autonomous mobile robot systems have a huge advantage over fixed systems in that you can simply scale up the operation by adding more robots – increasing the capacity of the system as required. Having 80 robots working independently in a warehouse is not a problem, as each performs its duties by plotting their own path, following QR codes placed on the warehouse floor. Installation is straightforward and fast, and provides a future-proofed solution suited to a fast expanding business.

With AMRs being so easily scalable, flexible and affordable, automation is nearly always the right answer. The risk of stock profile changes should not be seen as a serious barrier to adopting automation. Building capacity and resilience for the future should be the key objective.

More on smart warehouse automation at invargroup.com

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Images: © Jude Edington

Interview

Interview: Dominic Whelan Manufacturing & Production Engineering Magazine speaks with an RAF engineer turned FE teacher, Dominic Whelan.

Firstly, could you please tell us more about the start of your engineering career?

I started my engineering career as an apprentice car mechanic in the 1990s.

Those were the days when every new car that rolled into the garage brought a thrill of excitement – I vividly remember the buzz when a Porsche made its grand entrance. It was during this apprenticeship that I gained my engineering qualification from City and Guilds.

While I started my career working with cars, my real passion for engineering developed from my lifelong fascination with planes, which later led me to the RAF Careers Office in Liverpool. Enrolling as a mechanic with the RAF opened up a world of opportunities. It began with tough basic training and early starts, but the training was invaluable to my future career. I have some of the best memories of camaraderie and unforgettable experiences of working on Hercules planes, including exhilarating low-level flights over the Bristol Channel and Cheddar Gorge.

It was during my time working with the RAF that I became a mentor for new recruits and I first discovered the joy of sharing my skills with the next generation. Ultimately it was this passion for guiding and instructing learners which led me to the world

It was during my time working with the RAF that I became a mentor for new recruits and I first discovered the joy of sharing my skills with the next generation.

from planes to trains and everything in between.

- Dominic Whelan

During my time with Harriers, I underwent upskilling to become a multi-skilled technician, specialising in aircraft electrical and propulsion systems. This diverse skill set prepared me for a rewarding position at the Defence College of Aeronautical Engineering Cosford. There, I played a vital role in training future mechanics and ground crew, an experience that I loved every minute of.

of further education teaching. This made me want to keep teaching, so I started exploring how I could share my skills and experience from industry with people interested in joining the engineering sector. I now teach in the automotive department at Sandwell College, helping to inspire a new wave of engineers to explore the vast world

Can you talk more about your time and role in the RAF? I had the privilege of serving in the Royal Air Force (RAF) as an aircraft airframes mechanic. My journey began with hands-on experience working on Hercules aircraft at RAF Lyneham. After completing my training at RAF Cosford, I transitioned into the role of an engineering technician. My responsibilities extended to working on VC10 aircraft at RAF St. Athan before taking on the challenge of Harrier aircraft.

Continued >>>

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Interview

What inspired you to transition into the Further Education sector?

Transitioning into further education was a natural progression sparked by my passion for teaching. While at the RAF’s Defence School of Aeronautical Engineering, the joy of sharing knowledge and skills with students convinced me that teaching

Engaging with students in further education involves blending realworld experiences with interactive methods. I connect by sharing insights from my career journey and utilising engaging activities, for example further education teaching can be really hands on with classes often taking place in workshops.

- Dominic Whelan

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Manufacturing & Production Engineering Magazine

was for me. Whether in a traditional classroom setting or a practical workshop, guiding and inspiring the next generation of engineers became the most fulfilling aspect of my career transition. For the past eight years at Sandwell College, I’ve really enjoyed teaching my students about cars. But more than that, I like showing how the things we learn about cars can be used in different jobs and drawing on examples or stories from my own career. Whether it’s applying engineering principles to aviation, railway systems or various other sectors, I emphasise to my students the adaptability of the knowledge they’re gaining. In essence, it’s the fulfilment of guiding the next generation that inspired my move into further education. I’d strongly encourage other industry professionals who are interested in taking on a new challenge to consider sharing their skills through FE teaching too. It’s a great way to stay connected to your current industry and change lives without changing your career.

How did you find the transition from the RAF to Further Education Teaching?

Industry skills and experience are highly valued in FE; whether you’re an engineer, a mechanic or a manufacturer you already have the skills colleges look for in a great FE teacher. My existing skills really helped me transition into further education teaching, plus I already had good experience from my RAF mentoring role that also helped. For example, I earned my Certificate

for Education from the University of Wolverhampton during a fixed-term RAF teaching role. However, you don’t always need a teaching qualification to start teaching in FE - you can complete teacher training on the job so you can begin earning straight away.

Many professionals don’t realise they already possess many of the skills and knowledge they need to teach in FE. For example, my industry experience meant that I was able to connect with students, developed from my own journey from apprentice car mechanic to RAF engineer. Moving from rigid routines within the RAF to the dynamic world of FE teaching brought a new level of fulfilment to my career.

How do you effectively engage with students in Further Education teaching?

Engaging with students in further education involves blending realworld experiences with interactive methods. I connect by sharing insights from my career journey and utilising engaging activities, for example further education teaching can be really hands on with classes often taking place in workshops. By bridging theory and application, I can show my students the transferability of their automotive skills across industries, helping them envision a broader world within engineering.

Tell us about the Pearson National Teaching Awards where you received a silver in the FE Lecturer of the Year category in 2022?

Receiving Silver Award in the FE Lecturer of the Year category at the 2022 Pearson National Teaching Awards was a tremendous honour.

The award ceremony celebrated educators who go above and beyond,

Interview and it was a humbling experience to be acknowledged among such dedicated professionals. I was recognised for my work in merging industry experience into FE teaching and this is something all industry professionals have it within their power to do. The award win solidified my dedication to delivering a vibrant and impactful education for students at Sandwell College.

In your opinion how does Further Education engineering opportunities benefit students?

In my view, engineering FE courses offer a valuable pathway for students wanting to join the sector, providing them with practical skills and a broad perspective on the industry. The hands-on nature of FE courses allows students to directly apply theoretical knowledge, bridging the gap between the classroom and real-world scenarios.

FE courses not only prepare students for the demands of their chosen field but also cultivate a mind-set of adaptability and problem-solving.

Exposure to diverse engineering challenges within FE fosters a wellrounded skill set, ensuring students

In the automotive department, I connect with students by ensuring that lessons are not only practical but directly relevant to their future careers.

I emphasise the real-world application of the automotive skills they are learning to help foster that connection between theory and practice.

- Dominic Whelan

are versatile and ready to navigate the dynamic landscape of the engineering sector. Overall, further education engineering courses play a pivotal role in shaping well-equipped and adaptable professionals for the evolving demands of the industry.

How do you engage students, particularly in the automotive department?

In the automotive department, I connect with students by ensuring that lessons are not only practical but directly relevant to their future careers. I emphasise the real-world application of the automotive skills they are learning to help foster that

connection between theory and practice. Hands-on projects and collaborative learning create an immersive and engaging environment.

By showcasing the broad applications of automotive knowledge, from traditional cars to aerospace, I can help all students find their calling within the wider industry.

If you’re interested in finding out more about how you can share your industry skills by teaching in FE, visit: gov.uk/teach-in-furthereducation.

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Technology & Software

Servitization and digital transformation: The two must go hand-in-hand With more and more manufacturers looking towards servitization as a way to drive growth and improve customer satisfaction, Keith Tilley – CEO of workflow automation specialist Intoware, explores the important role digital transformation has to play in the transition.

Servitization - it’s the buzzword of the moment, describing the shift towards a more customer-centric way of working, focusing on an all-round service package rather than just a product.

For manufacturers, the servitization model holds many benefits. For example, building services into product sales that include planned or predictive maintenance allows firms to upsell and increase revenue, as well as improve customer satisfaction by minimising product faults or future downtime.

However, having the right systems in place to successfully achieve servitization is key.

Digital thinking Frontline workers and field service engineers play a pivotal role in any service-focused business model and must be able to respond quickly to customer needs, as well as equipped with the right tools and information to identify potential maintenance issues and find a solution.

For this reason, digital transformation and workflow automation has a vital part to play in the success of any manufacturers’ servitization strategy, moving away from the outdated paper-based systems that allow room for error when it comes to following workflows and managing regulatory and compliance requirements.

But where should companies start when it comes to embarking on this journey towards both servitization and digitalisation?

The key is to put the workforce at the heart of the process, as they’re the ones who understand not only how their day-to-day jobs can be

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made more efficient through the transformation of existing systems, but what customers want to see in terms of service provision, too.

This insight – all too often missed by companies looking to change how they operate – is vital to the success of both servitization and digitalisation within a business.

Servitization catalyst Once the right digital processes are in place, the shift towards servitization is made much simpler.

The wealth of data that digitalisation can provide a business with is enormous, allowing manufacturers to identify trends, customer preferences and areas for improvement, to create a robust servitization strategy.

Once in place, digital automation is what drives the strategy’s ongoing success, with the ability to streamline workflows to ensure tasks are carried

Keith Tilley

out correctly and service calls are followed up consistently.

Engineers can also use digital tools such as our own WorkfloPlus to access information such as equipment manuals, service history and customer data in real-time on a mobile or wearable device, meaning they can make informed decisions on the spot and provide better service to customers.

And, predictive maintenance is made possible by integrating with IoT sensors and predictive analytics tools, meaning engineers can monitor and proactively identify and address issues before they become major problems.

Detailed reporting tools and compliance checklists then ensure the job’s been done properly and the customer is happy with the service from beginning to end – critical to servitization success.

Show Preview: Southern Manufacturing

Register online for Southern Manufacturing 2024 The best of what the mechanical engineering and electronics sectors have to offer manufacturing industry will be on display at Southern Manufacturing & Electronics 2024, which will be held at the Farnborough International Exhibition & Conference Centre from 6th to 8th February. Pre-registration is open and tickets are free at www.industrysouth.co.uk.

The venue is easy to access by road and rail and both parking and the regular bus service between the railways stations and the show are also free.

Expect to see all the latest in machine tools, tooling, workholding, automation and robotics, test, measurement, inspection and metrology, and supply of materials including composites.

There will be mechanical, electrical, electronic, electromechanical, hydraulic and pneumatic components and assemblies, surface mount technology, PCBs, box build, connectors, cables, mechatronics assembly, plastic injection and rubber

mouldings, sensors, drives, encoders, fasteners, pressings, wireforms, springs, gaskets, and more.

Other diverse products and services on offer will encompass business and manufacturing software, production and planning aids, oil and coolant supply, workshop equipment, dust and fume extraction, humidity control, workplace storage systems, bespoke case and foam manufacture, plastic packaging, injection moulding, hand tools, adhesives, industrial The event this time will be more flooring, waste removal and recycling, international than ever, following a training, freight services and financial large number of stand bookings by consultancy. The usual AutoAero overseas companies. It is a musttheme will run throughout the attend event for anyone involved in show, as will a comprehensive and design, production, procurement or management in manufacturing.

SM&E24_AD_MPEM_2023-24_180Wx132H_ADVERT.qxp_14122023 14/12/2023 11:01 Page 1informative seminar programme.

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

(3.30pm close Thurs)

Where Industry and Innovation converge

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Incorporating The Subcontract Engineering Exhibition

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

Free industry seminar programme online @ www.industrysouth.co.uk The exhibition is free to attend, free to park and easy to get to. Doors open at 9.30am on Tuesday 6th February. your Fast Track Entry PRE-REGISTER TODAY for Badge, Preview Magazine

www.industrysouth.co.uk and Event Catalogue

SOUTHERN MANUFACTURING & ELECTRONICS is an ETES event organised

by European Trade & Exhibition Services Ltd

01784 880890 | philv@etes.co.uk

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Show Preview: Southern Manufacturing

The winning formula With the uncertainty of the economy and the vast number of electronics manufacturing companies within each sector, companies are looking at ways to stay ahead of the game, streamline, save time and money and remove unnecessary links in your supply chain.

We believe the winning formula is Advanced Rework Technology for all of your training, product and process consultancy, audit preparation and inspection report requirements.

Why use multiple companies when just one company can provide the necessary resources to increase quality and productivity and help to bring down your rework numbers?

Advanced Rework Technology have been established for over 30 years and progressed within the industry to becoming a world leader as an IPC and bespoke training provider.

Whether you require certified or bespoke training courses, ART have the knowledge and trainers to support your needs. Many companies often do not have the need for certified training

but would like to provide evidence that their personal have received industry based training to support the needs of the product or process. ART specialise in preparing and presenting bespoke syllabuses working closely with each customer to ensure the content, duration and theory versus practical proportions meet their exact needs.

ART can offer bespoke courses based around many industry lead subjects that can include but not limited to:• Introduction to hand soldering • Rework of surface mount devices • Rework and repair of printed circuit assemblies • Wire and terminal assembly and soldering • Cable and wire harness assemblies Should you customer or internal quality plan require official IPC certification, ART, as an IPC Approved Training Provider, offer IPC certified courses to all three levels of instruction, Certified IPC Trainer-CIT, Certified IPC Specialist-CIS and Certified Standards Expert-CSE. LEFT: Managing Director, Debbie Wade

See us at Stand B30

Choosing the right level of certification for you is important. Becoming certified allows individuals to provide keen insight to your company on IPC standards and how they are applied within manufacturing.

Standardisation is a dynamic function of the electronics industry and is constantly evolving. ART Ltd work with IPC to continually move forward with improvements and best practices to support manufacturing.

Managing Director, Debbie Wade, who chairs many IPC committees including vice chair of IPC Technical Activities Executive Council and Chair of European Standards Development and European Training committees, to name a few, explained why Advanced Rework Technology should be your training provider.

“ART training staff are highly experienced with every part of the industry from design, fabrication, through to assembly and quality and inspection so this will assist the trainer with every step of their teaching which makes our courses second to none.

The staff here at ART also dedicate their time to sitting on numerous IPC Standards Development and Training Committees. This gives us the added advantage and skills required to not just teach the latest requirements but fully understand the changes to the technical standards and associated training courses. For our knowledge, skills and dedication, we are proud to be the recipients of many industry and IPC awards. In particular, recipients of the prestigious IPC Presidents Awards.”

For more information visit: www.rework.co.uk

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Manufacturing & Production Engineering Magazine

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Technology & Software

Miniature motors act as the heart of medical devices used to treat cardiovascular disease

Motion technology integral to cardiovascular disease treatment devices

By Nicole Monaco, Global Marketing Manager, Portescap

Motion technology integral to cardiovascular disease treatment devices From the treatment of narrowing arteries through to circulatory support, miniature motors act as the heart of medical devices used to treat cardiovascular disease. When selecting motor solutions for such applications, compact size and precision control are crucial factors. Optimised motion technology choices for atherectomy, thrombectomy, and circulatory support procedures will greatly impact the effectiveness of treatment devices and have a significant outcome on patients.

Earlier this year, the World Heart Federation, the global organisation that focuses on cardiovascular disease prevention, reported that deaths caused by this condition had increased globally from 12.1 million in 1990 to 20.5 million in 2021, making cardiovascular disease the highest cause of deaths worldwide.

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Manufacturing & Production Engineering Magazine

While improvements in diet, regular exercising and advances in medication can help prevent and manage the disease, medical procedures are often required to treat more advanced symptoms.

Procedures as such can have various purposes like removing defective or harmful biological matter in arteries, supporting the administration of medication to better the condition, and assisting with the overall blood circulation. The commonality between these procedures is their requirement for medical devices that rely on the controlled rotation of an electric motor.

The size requirements, as well as the relatively low power needs, mean that miniature DC motor technology is commonly used.

Atherectomy Atherosclerosis is the accumulation of fatty substances, cholesterol and calcium within the arteries. Significant narrowing can cause conditions such as peripheral and coronary artery

Another key advantage of a BLDC motor’s external commutation is enhanced control precision. disease, and the deposits, known as plaque, need to be removed from the artery walls to restore blood flow.

This atherectomy process is achieved by cutting, shaving and sanding the inhibiting material with a motor-driven medical device.

Considering the small space envelope of operation and the potential for damage to a healthy artery, the main motion requirement is precise control of the end effector. This must be combined with high speed, sufficient to effectively cut or grind the plaque, whilst minimising procedure time to improve the patient outcome.

Technology & Software Brushless DC motors (BLDC) are the preferred technology. With a design that uses electronic commutation via an external controller, this precise modulation enables rapid switching of the motor’s windings that achieves high speed. Improving synchronisation between the rotor’s position and the current applied to the coils allows smoother motor operation, necessary to reach the required speed. Portescap’s Ultra ECTM BLDC motors, for example, can deliver speeds up to 73,000 rpm. In combination with speed, providing high torque to weight and footprint, a motor as small as just 16 mm diameter can be used.

Another key advantage of a BLDC motor’s external commutation is enhanced control precision. This allows close modulation of speed and torque, ensuring effective plaque removal while minimising the risk of damage to the arterial wall. Improved control also enables more targeted treatment, resulting in reduced procedural complications and better outcomes for patients. Precise control is enhanced with low vibration, a feature of a BLDC motor like the Ultra EC™, while low noise enhances the experience, both for the patient as well as surgical staff.

Thrombectomy While a stroke is categorised as a neurological condition, an acute ischemic stroke involves the blockage of an artery, preventing blood flow to part of the brain. This blockage could be caused by a plaque build-up, or a blood clot. Procedures can be used to dissolve the blood clot, and this treatment may also be required for cases of DVT (deep vein thrombosis) and pulmonary embolism. A thrombolysis procedure involves drug administration to remove the clot, while alternatively, thrombectomy uses specialised catheters and devices to capture, dismantle, and remove the clot.

Within these devices, coreless brushed DC motors are preferable, primarily for their characteristics of light weight combined with high power to weight ratio. The design of the motor removes the traditional iron core, replacing it with a specially designed winding. This makes coreless brushed DC motors, like the Portescap AthlonixTM, compact and lightweight, ensuring ease of manoeuvrability within the catheter, enabling rotation of the end effector to break up the clot.

Coreless brushed DC motors also give smooth and precise speed regulation, particularly at lower speeds, while

RIGHT: Portescap’s Athlonix™ motors are compact and lightweight, making them ideal for thrombectomy applications.

operating with minimal vibration.

These factors are essential to maintain control precision, and they also ensure smooth and reliable functioning of the thrombolysis treatment devices. As coreless brushed DC motors generate low noise levels and are low in vibration, the patient experience is also optimised.

Circulatory support Even when under close medical monitoring, patients with weakened hearts, such as those awaiting a heart transplant or wider cardiovascular treatment, are at risk of a temporary pause in heart function. Though heart pumping can restart, this can impact the heart’s ability to resume normal flow thereafter. To help prevent this, ventricular assist devices, also known as cardiac assist devices, support the heart in pumping blood through weakened chambers.

These devices can be intracorporeal (inside the body) or extracorporeal (outside the body). In both cases, the pumps are driven by miniature motors, essential for the form factor, particularly for intracorporeal use, and the main motion requirements are high precision with maximum responsiveness to follow

Within these devices, coreless brushed DC motors are preferable, primarily for their characteristics of light weight combined with high power to weight ratio.

the natural rhythm of the heart. As a result, BLDC motors are the typical choice.

As BLDC motors use electronic commutation, this optimises precise control over speed and torque, which in turn means accuracy in pump speed and flow. Consequently, the pump can closely mimic the natural functioning of the heart and is able to dynamically adapt to a patient’s changing requirements. Portescap’s Ultra EC BLDC motor enhances this level of control with smoother torque flow thanks to the lower inductance and cogging torque generated by the slotless design.

To ensure reliable operation, as well as patient safety, minimising motor temperature rise during operation is also crucial. BLDC motors ensure high efficiency with minimal losses, thanks to the reduction in friction that they provide, keeping temperature at a controlled level. This efficiency, combined with reduced mechanical wear, also enhances reliability.

Customisation To specify the optimal miniature motion solution, it is crucial to fully understand the requirements of the procedure and host device. Getting this right from the start will ensure a more efficient development and integration programme, achieving a faster time to market.

This is particularly important as customisation of the motion solution is often required. Customisation can impact form factor and weight, overall design integration, as well as performance. As a result, working with motor designers like Portescap from outset of the project will ensure the best outcome for the patient experience, the surgical staff, as well as the OEM device designer.

LEFT: Artery disease treatment devices rely on the controlled rotation of an electric motor of a compact size.

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Technology & Software

While your product technology is jetting full throttle into the Space Age, your planning tools tend to crawl around in the Stone Age. Here’s why AI will change that.

By Jan Brittner, Business Development Manufacturing, INFORM, a global pioneer in AI-driven optimization software Manufacturers face many challenges today including supply chain disruptions, rising material costs, skilled labor shortages, and rising interest rates. It’s understandable why, according to a National Association of Manufacturers (NAM) survey, manufacturers’ optimism caused the Manufacturing Outlook Index to drop to 55, a reduction of 4.2 points since the first quarter of 2022. It also explains why manufacturers are adopting new strategies.

In Their Words In its 2023 Manufacturing Trends, Alithya found that 43% of manufacturers plan to continue increasing their technology investments, driven by their focus on improving efficiency and productivity. Survey respondents

reported efficiency and productivity as their top priorities in an environment of rising input costs and tightening margins.

So how is it that well over 50 percent of all one-off and small-batch manufacturers are only too familiar with one or more of these problems?

1. They are planning unrealistically against unlimited capacities and based on dates from the past.

2. Their delivery dates are brewed from a mixture of standard delivery times, intuition, and “Excel-Magic”.

3. They suffer high manual planning efforts and dissatisfied customers despite all the trouble.

4. They are never sure whether they are really getting the most out of their production environments.

Well understandable, manufacturers seek solutions to better address these challenges and support their greater agility and resilience. Deloitte reported that 86% of manufacturers believe that digital solutions and transformation will be the main drivers of their future competitiveness. The 2023 Deloitte Manufacturing Outlook Survey indicated that 61% of respondents are partnering with specialized technology companies to deploy intelligent technologies such as advancing planning and scheduling systems (APS) that support their planning needs, while also enabling reliable delivery dates, needs-oriented procurement, optimized material flow, and the ability to detect, prevent and respond to unexpected developments.

APS systems incorporating leadingedge technologies such as Artificial

Images: (SOURCE: INFORM)

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Manufacturing & Production Engineering Magazine

Technology & Software Intelligence (AI), machine learning, operations research, fuzzy logic, and proprietary algorithms. INFORM, a global leader in AI-powered optimization software, has developed FELIOS, an APS system that synchronizes all production processes and evaluates the resulting data to facilitate agile short- and long-term production planning. FELIOS is used by over 300 manufacturers optimizing over 23.5 million production work sequences daily.

FELIOS – For Intelligent Production Planning An add-on to any conventional Enterprise Resource Planning (ERP) system, FELIOS compensates for an ERP’s planning weaknesses and enables interdepartmental planning transparency in production, purchasing, construction and sales. It ensures that all processes are implemented as planned and to meet delivery deadlines.

Manufacturers with multi-variant products, and those with single-item and small-batch production, need to focus on several factors in planning and managing their production. FELIOS tackles these complex production requirements. It helps ensure that all orders are executed on time, efficiently with short production cycles, minimal work-in-progress, and high quality. An intelligent production planning solution, INFORM’s FELIOS provides manufacturers with essential capabilities, including the ability to:

• Keep customers informed at any time with reliable delivery dates, • Establish the optimal sequence of all production process, • Ensure a backlog-free production process, • Create the production plan without time-consuming team meetings, • Integrate high-priority orders on short notice, • Dissolve capital-binding stock buffers while preventing missing parts that would cause assembly standstills, • Relieve foremen and machine operators from planning tasks, and • Proactively plan the production as a whole system while considering all limiting conditions, FELIOS delivers these critical capabilities, providing extensive transparency by linking all involved departments and merging all relevant data in one central planning system.

Through its automated real-time planning support, FELIOS schedules all production orders simultaneously.

It plans realistically within the context of potential constraints (e.g., limited personnel, machines, and materials).

When faced with unexpected changes, FELIOS automatically recalculates the production plan during the next optimization run.

Deloitte reported that 86% of manufacturers believe that digital solutions and transformation will be the main drivers of their future competitiveness.

Focusing on providing manufacturers with agility and resilience for longterm success, FELIOS takes a holistic approach to order processing by not only optimizing the scheduling of a single resource but the complete order network, arming manufacturers with agile planning capabilities and related intelligence that supports their simultaneous production based on market demands. Complete planning transparency is achieved along with high adherence to production schedules, low stocks, and short lead times.

- Jan Brittner

Three Steps to Optimizing Planning FELIOS operates in three key steps: 1. FELIOS is connected to a manufacturers’ existing ERP system via an interface. It extracts all relevant planning process data (e.g., purchase orders, materials availability, machine capacities).

2. Based on the ERP data, FELIOS plans the production process for the next and subsequent days and weeks. Applying intelligent optimization processes, it calculates worklists, considers realistic machine capacities, and creates delivery deadlines for materials, machine parts and components.

It distributes the capacities to meet predicted delivery deadlines for all customer orders.

3. FELIOS gives production foremen and workers a work plan for what must be completed on a given day.

Time horizons can be selected individually so foremen can organize optimal setup times. When unexpected changes in relevant production parameters occur, or a worklist cannot be completed, FELIOS addresses them in its calculations for the next day.

FELIOS can be configured to a customer’s specific requirements with additional modules available to support other functions such as project and assembly planning, shift and personnel planning, and production and machine data acquisition.

For more information, visit: www.felios.com

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Latest News

One small step for two girls, one giant kick for mankind

England Lioness and Women’s Euros 2022 winner Beth England joins two inspirational schoolgirls for a football kit reveal in anticipation of the first-ever football match on the Moon, as children across the UK competed to design the first official Moon United kit.

The Institution of Engineering and Technology (IET) with the help of Beth England has today unveiled the world’s first football home and away kits for the lunar footballers of the future following a campaign in which engineers predicted humans could be playing a competitive game of football on the moon as early as 2035.

The big reveal follows a nationwide competition by the IET for school children aged 4 to 13 to design the first-ever ‘Moon United’ home and away kit – with the aim of challenging outdated perceptions of (L-R): Lioness Bethany England, winner Erim Ali, winner Ishaani Nair and aerospace engineer Sophie Harker

Hiring new talent cited as one of the biggest challenges for a third of UK manufacturers Over a third of UK manufacturers (34%) say that hiring new talent is one of their biggest challenges, according to new research by Visual Components, the developer of 3D simulation software. This is also reflected by 42% of US

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manufacturers as technology skills shortages persist around the world.

These skills shortages look set to worsen as businesses expect 25% of their workforce to leave over the next five years, and over half (53%)

don’t have a solution to deal with lost knowledge when skilled professionals leave or retire. Many are also failing to bring in new talented hires to replace the ones who leave, with half (53%) having not yet built relationships with educational institutions to build a pipeline of new talent into the business.

In the midst of too few skilled employees in the sector, 81% believe that their current solutions allow their workers to be at the centre of the production process, but only 46% are training them in the use of new technologies. Prospective talent is also likely to be deterred by the fact that almost a third (31%) of factory machinery is legacy equipment, with the younger generation more accustomed to digital solutions.

Current employees are largely enthusiastic to adopt new solutions, with 78% of respondents stating there’s no hesitancy among their workers to make use of new platforms.

Upskilling is also the highest priority for (46%) UK manufacturers, with 60% of French respondents stating the same.

Latest News The judges ‘loved the colourful design and the smart idea to turn the planet Saturn into a football with rings as the central focus point.’ engineering and showing children how they could combine a passion for football and space with a Science, Technology, Engineering and Maths (STEM) related career.

With bold and eye-catching futuristic designs that would rival any Premier League club’s shirt, the kits were designed by two talented winners Erim Ali, 13, and Ishaani Nair, 7.

Winner of the 8–13-year-old category, sports enthusiast, aspiring engineer, and keen Tottenham Hotspur fan, Middlesex-born Erim counts astronaut Mae Jemison, and education activist Malala Yousafzai as two of her idols.

Based in Coventry and winner of the 4–7-year-old category, Ishaani created a bold space-themed shirt, with striking colours and playful solar system illustrations. According to Ishaani the Earth and Sun featured are meant to give positivity to the game, and the shooting stars represent the speed and spirit of football. The judges ‘loved the colourful design and the smart idea to turn the planet Saturn into a football with rings as the central focus point.’

First launched in July, the Moon United campaign saw the IET assemble a panel of engineering and technology experts to predict the possibilities of Lunar Football, and, with just one-sixth of the gravity of Earth and no wind or air resistance, just how the game would need to be adapted for the harsh conditions of the Moon. These changes, including the ball travelling roughly six times further than that on Earth, the need for a football nearly twice the size, a bigger goal and the game becoming a strictly no-contact sport released in the first-ever Lunar Football Rule Book.

The campaign and competition were designed by IET to inspire the next generation of engineers and encourage more children to be excited and inspired by a potential future in Science, Technology, Engineering and Maths.

To find out more about the campaign, the Lunar Football Rule Book or information about STEM visit: https://eabw.theiet.org/

More than two-thirds of UK businesses failing to gain a competitive edge when it comes to servitisation Businesses see investing in supply chain and R&D as an optimum way to get ahead in competitive landscape Only 28% of senior leaders in UK organisations think their area of business is ahead of the servitisation curve when compared to the same area within competitors. This is according to findings of research commissioned by IFS, the global cloud enterprise software company, polling senior leadership across multiple industries about servitisation maturity.

With servitisation becoming an increasingly popular approach for organisations looking to inject value into their business processes, many are already identifying where it can provide greatest value for them. From the survey, 88% of leaders highlighted supply chain and 80% pointed to R&D as areas that can evolve to deliver servitisation benefits, but the process is ongoing.

More than four out-of-ten leaders (43%) also point to the supply chain, and 32% to R&D, as areas that need to evolve fastest, integrating disparate data and systems to develop a customer-centred, as-as-

service approach to enable these benefits.

To help them evolve, respondents also highlighted key technologies organisations will need to invest in to achieve their servitisation goals.

Nearly half of respondents (48%) recognised they need to implement AI in order to evolve, with 47% saying they must implement machine learning, and 41% considering automation.

However, the technology is only one part of a wider business shift, as senior leaders also need to turn their attention inwards, looking at their own current skills and capabilities. They identified limited analytics for effective delivery, insufficient technology, and difficulty in integrating service offerings as the top barriers to servitisation.

When combined, improvement in these areas will enable organisations to strengthen internal efficiencies, deliver a better customer experience, and allow for new innovations to come to the fore which will in turn, help set them apart from competitors and encourage business growth.

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Specialist Equipment

Redefining industrial connectivity with TSN John Browett, General Manager at the CLPA Europe, looks at how CC-Link IE TSN solutions are being implemented to advance manufacturing facilities around the world.

In the dynamic landscape of Industry 4.0, a significant and transformative interconnectivity wave is sweeping the globe – TimeSensitive Networking (TSN). The technology, supported by a large portfolio of industrial automation devices that leverage CC-Link IE TSN open industrial gigabit Ethernet with TSN functions, is being rapidly adopted and enabling remarkable productivity gains in manufacturing.

to set up ultra-high speed industrial automation applications, such as complex motion systems, and improve productivity. In addition, by providing a platform for convergence, TSN can help create simpler, leaner and more cost-effective networks that streamline troubleshooting. Also, it supports data-driven decision making, thanks its ability to facilitate the merger of information technology (IT) and operational technology (OT).

TSN is a network technology designed to advance industrial Ethernet communications through determinism and convergence. Thanks to these capabilities, it enhances the way companies’ processes operate as well as how their machines and components communicate, bringing with it a host of benefits that can drive competitiveness throughout the industrial landscape.

Driven by the competitive advantages that TSN can bring to companies in various manufacturing sectors, for example, the demand for the technology is rapidly growing. To address this, automation vendors at the forefront of the industry are beginning to offer devices that can leverage TSN, with CC-Link IE TSN open industrial Ethernet a popular choice. This network technology, which combines TSN functions and gigabit bandwidth, already boasts over a hundred compatible products that are readily

The solution can guarantee determinism across a network, enabling machine builders and users

The European market is now following in the footsteps of companies in the East.

- John Browett

available and can support advanced Industry 4.0 setups. As a result, the number of CC-Link IE TSN applications is rapidly growing.

The land of CC-Link IE TSN’s rising sun The CC-Link IE TSN adoption curve found its origin point in Asia, where forward-thinking companies across the continent quickly realised the potential of the network technology as well as its many benefits. For example, Shashin Kagaku, a Japanese producer of additive manufacturing systems, also known as 3D printers, turned to CC-Link IE TSN for its new SZ-6000 machine. The resulting solution provided the company with a significant lead over other businesses in what is already a highly competitive marketplace. More importantly, its customers can also benefit from a LEFT: Keller, a leading OEM of machines that perform screen and pad printing as well as hot stamping, has developed an innovative new system that leverages CCLink IE TSN network technology to boost productivity. (© Keller poligrafia dla przemysłu)

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Specialist Equipment LEFT: Orisol saw its OFA240 series upper to sole flash activator machine as an ideal candidate to benefit from the principles of TSN technology. (© Orisol)

is not merely an Asian phenomenon but a growing global trend. As more companies recognise the transformative potential of this technology, we can anticipate further breakthroughs and improvements in industrial processes in Europe as well as on a global level.

A global shift towards CC-Link IE TSN is underway

significant increase in productivity through a highly cost-effective unit.

In China, CC-Link IE TSN has been adopted by a leading producer of automated lithium-ion battery manufacturing lines. The company was looking for a new technology that would improve the productivity of its systems, while simplifying their designs and reducing time to market. Also, the Instrumentation Technology & Economy Institute (ITEI) of the People’s Republic of China selected CC-Link IE TSN as an enabling technology within the Smart Manufacturing Comprehensive Test Platform. This is a full-scale, fully automated demonstration of a manufacturing system that leverages key technologies to showcase best practices for future manufacturing facilities.

Another leading example of the advantages of this cutting-edge network technology was developed by Orisol, a leading provider of automated systems for footwear production. The company saw its OFA240 series upper to sole flash activator machine as an ideal candidate to benefit from TSN technology. By using CC-Link IE TSN, this updated setup could increase the speed of internal communications by a factor of 220, with execution time shortened by 7 times and application speed increased by 12 times overall.

CC-Link IE TSN also enabled machines to be synchronised to an accuracy of 1 millisecond for almost instant data sharing, delivering precise communications within the machine itself, and to other devices and IT systems.

Go west The adoption of CC-Link IE TSN in Asia, highlighted by the aforementioned examples, marked the first steps in a global shift towards a more interconnected and efficient industrial landscape. The European market is now following in the footsteps of companies in the East. Applications built on CC-Link IE TSN are helping companies enhance their connectivity, productivity and efficiency.

The latest project completed by Keller poligrafia dla przemysłu, for example, stands as a testament to the technology’s fast-growing adoption in Europe. The Polish company, a leading OEM of machines that perform screen and pad printing as well as hot stamping, developed an innovative bottle printing system that leverages CC-Link IE TSN network technology to boost productivity. By incorporating TSN, the solution delivers next level productivity via deterministic motion control over a multitude of servos.

This has resulted in significant improvements in terms of speed, accuracy and precision that can greatly benefit end users.

Today, more and more companies spanning various sectors have embraced CC-Link IE TSN. These include industry players in automotive, food and beverage, logistics, consumer electronics, semiconductor, lithiumion batteries as well as consumer packaged goods. This broad spectrum of industries leveraging the technology underscores its ability to address Industry 4.0 challenges across the board and signals a turning point in the industrial connectivity landscape.

The continuous increase in applications that use CC-Link IE TSN for effective communications is a compelling indicator of the technology’s role as enabler for the creation of the Connected Industries of tomorrow.

The total number of installed devices that are compatible with the CLPA’s range of open technologies, from CC-Link fieldbus to CC-Link IE open gigabit Ethernet and CC-Link IE TSN, surpasses 40 million globally and continues to climb. This therefore provides an unmistakable sign that the trend of adopting CC-Link IE TSN is not merely a passing phase but a fundamental shift that is here to stay.

The success of Keller’s implementation demonstrates that CC-Link IE TSN RIGHT: Shashin Kagaku is a Japanese manufacturer of AM systems that form high precision parts using a ceramicsbased process turned to CC-Link IE TSN to add value to additive manufacturing operations. (© Shashin Kagaku) Manufacturing & Production Engineering Magazine

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Events & Awards News

The UK Manufacturing Awards Celebrates the Titans of the Industry in 2023 The UK Manufacturing Awards 2023 honours the trailblazers of the industry, from companies that have stood the test of time with decades of heritage to young enterprises pushing the boundaries of sustainability and innovation. With an unwavering commitment to quality, adaptability in an everevolving market, and a deep understanding of consumer needs, these industry leaders embody the spirit of British manufacturing excellence.

Business Awards UK Manufacturing Awards 2023 Winner • Opus Ventures - Best Online Marketplace Manufacturer • BIL Group - Best Company to work for • The Somerset Toiletry Company Best Newcomer Manufacturer • Trust Electric Heating - Best Use Of Recyclable Materials • Smith Tool Traders - Fastest Growing Business • ParkAcre - Best Manufacturer UK • DarkFrame Ltd - Best Lone Wolf Manufacturer • DoorCo Ltd - Fastest Growing Team

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• Miniml (The Friendly Chemical Co) - Most Positive Community Impact • Hygienic Pigging Systems Ltd Most Innovative Business • Ontic - Best Youth Development • TAD Electronics - Best Use of Technology • SMC Ltd - Best International Manufacturer • Blends - Business Transformation Award Navigating an industry landscape marked by rapid technological advances and shifting consumer demands, these winners and finalists have consistently demonstrated adaptability and foresight. Blends, which began as a modest family venture, now operates expansive facilities in Liverpool. Similarly, TAD Electronics showcases the speed and efficiency of modern manufacturing, swiftly transitioning from concept to prototype. Each story underscores the vibrancy, resilience, and innovation of UK manufacturing. We extend our hearty congratulations to all winners and finalists for their remarkable achievements and anticipate their future contributions to the sector.

Plexus Corp. awarded Silver SC21 status Plexus Corp., the UK’s largest Electronics Manufacturing Services (EMS) company, is pleased to announce that it has been awarded Silver status in the global SCS Competitiveness SC21 (Supply Chains Solutions Competitiveness – Supply Chains for the 21st Century) improvement programme.

Launched in 2006, the SCS Competitiveness programme is designed to accelerate the competitiveness of the Aerospace and Defence industry by raising the performance of its supply chains. It is the largest supply chain improvement programme in the UK Aerospace and Defence sector and endorsed by all major UK Aerospace and Defence companies.

To achieve silver status, Plexus aligned its internal guidelines and its own Plexus System of Operational Excellence (PSOE), an integrated manufacturing execution system that forms the foundation of operational excellence and drives continuous improvement at Plexus, with the requirements of the SC21 accreditation.

Plexus’ overarching aim is to enable all of its manufacturing sites to deploy PSOE based on their individual needs, priorities and absorption capacity.

Since implementing the programme, Plexus has been able to accelerate its efforts to reduce set-up time, improve workforce skills and the efficiency of its production processes, and reduce waste.

This supports Plexus’ experience in delivering optimal supply chain solutions in increasingly connected and competitive economies, helping customers deliver complex products in demanding regulatory environments.

For more information on the SC21 continuous improvement programme, please visit the website here.

Events & Awards News Gold Membership to The 5% Club demonstrates IMH’s commitment to its workforce Industrial and Marine Hydraulics, based in Middlesbrough, has been awarded gold accredited membership via The 5% Club’s 2023-24 Employer Audit Scheme.

From a notable list of 180 members, IMH was one of 120 UK employers who met the gold standard.

The award recognises significant contributions made to the development of employees through ‘earn and learn’ schemes as well as auditing companies on a number of other requirements. This includes having 5% of their UK workforce on formal training programmes and auditing employee retention rates.

The award enables IMH to further highlight and demonstrate its proven commitment to investing in its workforce through its apprenticeships, placements and training schemes.

IMH has recently appointed its 28th apprentice and has developed a partnership with Hartlepool College of Further Education to elevate practical learning in hydraulic engineering.

The partnership has seen the launch of the IMH Hydraulic/ Pneumatic Lab to which IMH has donated hydraulic equipment to enable students to have practical experiences.

Launched in 2013, The 5% Club works with UK employers and key influencers to inspire positive action for increased and accessible workplace learning, focused primarily on the number of apprentices, sponsored students and graduates employed. The goal of The 5% Club is to increase the employment and career prospects of today’s youth and equip the UK with the skilled workforce it needs to safeguard Britain’s economy.

DESIGN DEVELOPMENT MOULDING TOOLING BEYOND THE MOULD Pentagon delivers a full turnkey solution for plastic injection moulding from one site of UK Manufacture.

With over 50 years’ experience you can be confident that your Bespoke Moulding project is in the hands of the experts for both mould tooling and repeat production.

Meet us at this years’ Interplas UK – 26- 28 September at the NEC, Birmingham.

www.pentagonplastics.co.uk | websales@pentagonplastics.co.uk Tel: +44 (0) 1403 264 397 |

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Latest Product Launches

ABB conveyor drive technology will enable LKAB underground mine to significantly increase energy efficiency LKAB has awarded ABB a contract to install two ABB Gearless Conveyor Drives (GCDs) on the existing conveyor belt system at its Malmberget mine near Gällivare, Norrbotten County, Lapland, the most northern province in Sweden.

The existing setup already carries up to 15 million tons of iron ore every year, using a 2,800kW wound rotor induction motor (WRIM) with gearbox to drive the conveyor. It will be replaced with ABB’s latest GCD technology, two 1,600kW models with permanent magnet motors (PMM), to enable an increase in annual production while reducing energy consumption per ton.

ABB’s installation engineers and project management team face the challenge of working in a tight space at around 1,250 meters underground to

Microchip Expands Development Ecosystem With MPLAB® XC-DSC Compiler With Flexible Licensing Options With the rapid growth of the industrial and autonomous vehicles markets, there is an everincreasing demand for software tools that enable faster and more efficient coding and debugging in real-time control applications. To better serve developers utilizing

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dsPIC® Digital Signal Controllers (DSCs), which are often employed in real-time control systems, Microchip has launched the MPLAB® XC-DSC Compiler.

The latest addition to Microchip’s compiler line, the MPLAB XC-DSC is optimized to allow developers

to write and debug efficient, highperformance code for dsPIC DSCs with greater ease and efficiency. dsPIC DSCs combine the high performance of a Digital Signal Processor (DSP) with the simplicity of a standard microcontroller (MCU) to meet the requirements of time-critical embedded applications.

The MPLAB XC-DSC compiler PRO license unlocks access to optimizations that allow designers to minimize code size, generate faster code and reduce memory and power requirements and access the full potential of DSC designs. Unlike traditional licensing options, Microchip offers access to the software on a perproject or as-needed basis, reducing cost and increasing flexibility.

MPLAB XC compilers provide support for Linux®, macOS® and Windows® operating systems, enabling designers to use their platform of choice for embedded development.

Latest Product Launches ABB was awarded the project contract in the third quarter of 2023 and the installation will take place during scheduled maintenance stops with the final commissioning due in August 2025. remove the large equipment and replace it with the new units. Once the upgrade is complete in 2025, LKAB will be able to achieve overall energy savings of between 6 and 10 percent, which will translate to considerable OPEX savings per year.

ABB GCDs have a motor power of between 0.2MW and 8MW, removing the need for a gearbox and thereby lowering maintenance costs while improving overall reliability and leading to greater uptime. A unique ABB innovation, they are known to be the most energyefficient conveyor drive solution.

The GCD’s PMM are directly coupled to the existing conveyor’s drive pulley and can also adapted to meet the particular demands of this underground installation. The main advantages are energy savings, health and safety improvements, reduced maintenance costs and steady, solid production due to higher reliability.

ABB was awarded the project contract in the third quarter of 2023 and the installation will take place during scheduled maintenance stops with the final commissioning due in August 2025.

For more information visit: go.abb/processautomation and www.abb.com

New Danfoss H1F fixed displacement bent axis hydraulic motor delivers up to 95% overall efficiency Danfoss Power Solutions, a leading global supplier of mobile and industrial hydraulics as well as electric powertrain systems, has launched its H1F fixed displacement bent axis hydraulic motor. Designed for open- and closed-circuit applications, the H1F motor offers best-in-class efficiency, proven reliability, and a compact design.

The latest development in Danfoss’ high-power H1 series of pumps and motors, the H1F fixed bent axis motor offers overall efficiency of up to 95%. Highefficiency motors deliver fuel savings, improve productivity, and reduce heat generation. Together with its high pressure and speed ratings, the motor enables operators to maximize the performance of their machines.

The new H1F motor builds upon the capabilities of Danfoss’ fieldproven H1B variable displacement bent axis motor. The H1F motor uses the same high-quality nine-piston H1B rotating group and optimized single-piece flange, delivering longlasting reliability.

The lightweight H1F motor features a power-dense, compact envelope for ease of installation. With its short length and 32-degree angle, the package size is one of the most compact on the market, enabling machine manufacturers to reduce

the space claim of the hydraulic system.

“H1F represents the continued evolution of the H1 series, our popular, customer-trusted line of high-power pumps and motors.

While this is a new motor for Danfoss, it is leveraging a design that has been on the market for over 10 years with more than 1 million rotating kits in use,” said Kenneth Befus, portfolio manager, Hydrostatics, Danfoss Power Solutions. “In our H1F motor, OEMs and distributors will find high quality, proven technology, marketleading efficiency, and outstanding speed and pressure performance.”

The H1F fixed bent axis motor is designed for closed- and opencircuit applications in agriculture, construction, and forestry machinery.

It is ideal for fan drives, feeder drives, drill drives, track drives, winches, and vibration and shaking functions. The motors will be available in SAE, DIN, and cartridge flange styles, with twin, side, and axial port configurations.

Integrated loop flushing and speed sensing are options; future additions will include a bolt-on counterbalance valve and load-holding valve for open-circuit applications. The first frame size, 80cc, is now available.

Additional sizes will follow, ranging from 60cc to 250cc.

Visit the Danfoss H1F motor webpage to learn more.

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Robotics & Automation

Why the automotive industry needs unloading standardisation Challenger brands in the automotive market are introducing innovation at every stage of the manufacturing process. From electric vehicle design to mega production plants, these businesses are achieving new levels of efficiency and automation, prompting the rest of the market to invest fast to keep up.

Within the supply chain, automated loading and unloading of components is one example of how automotive companies are reducing cost and risk. Still, Tier 1 suppliers are asking why every Original Equipment Manufacturer (OEM) has a different set of demands for component storage and transport. Why add complexity to a market already struggling with supply chain disruption, inflation and unpredictable demand?

Wouter Satijn, Sales Director, Joloda Hydraroll, discusses the benefits of a standardised, end-to-end automated model.

Competitive market Inflation-driven cost pressures.

Ongoing supply chain disruption. A lack of consumer confidence leading to erratic demand. And, of course, a set of new competitors transforming the concept of automotive design and manufacture. How can traditional OEMs compete? How can challengers succeed? Efficiency and automation are vital, but for an industry renowned for Just-inTime (JiT) manufacturing and slick supply chain operations, where are the opportunities to drive additional cost savings and performance improvements?

One key area where brands can compete to differentiate themselves is within their production sites and manufacturing processes. Supply chains and factories are becoming more connected with technologies such as AI, 5G, and robotics to ensure efficiency and transparency at every stage. In the loading bay, replacing forklift trucks, winches and ropes with automated loading and unloading systems has proved faster and safer, while protecting valuable components from damage.

Drastically reducing the time taken to unload items has minimised driver waiting, improving delivery certainty and thereby supporting greater JiT efficiency throughout the supply chain.

For example, wheels are traditionally unloaded using a ‘one wheel at a time’ system – a process

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With a standardised model for component storage and transport, the industry could transform the adoption and expansion of automated unloading and loading solutions.

- Wouter Satijn

individual OEM contract. Inevitably, this financial burden is slowing down the adoption of automation to the detriment of the entire industry.

There is no value in this approach.

OEMs share suppliers; suppliers work with multiple OEMs. Every organisation requires the fastest, most efficient way to load, move and safely offload products to meet tight production deadlines.

Automation is transformative, yet by enforcing different requirements, OEMs are constraining progress.

Working together, with an automated loading partner, the industry could define a set of standard requirements to which all suppliers can comply, making automation quicker and cheaper to achieve.

Working together that takes up to two hours to unload one truck. By comparison, an automated wheel unloading system can complete the entire process in less than three minutes, delivering a step change in efficiency.

Standards imperative Now, while many automotive companies are exploring the power of automated unloading and loading systems, another major problem is adding unnecessary cost and complexity to the Tier 1 supply base.

Today, every OEM has a different set of demands for component storage and transport, which is placing a huge burden on suppliers to invest in an array of solutions to support each

It is time for the automotive industry to work together. With a standardised model for component storage and transport, the industry could transform the adoption and expansion of automated unloading and loading solutions. Furthermore, a standardised, end-to-end automated model can provide the foundation for continuous improvement. It will support the creation of efficient, lower-risk operating models required for automotive brands to manufacture innovative products and truly compete. Without standards, however, that competitive opportunity could be missed.

Website: www.joloda.com

Robotics & Automation

AMR solution automates production transport Digmesa, a Swiss manufacturer of precision flow sensors found in coffee machines worldwide, is reaping the benefits of investing in an automated mobile robot (AMR) solution from KNAPP. The Open Shuttle AMR system, which transports containers to and from the injection-moulding machines, is enabling Digmesa to handle ever-growing production volumes. With the navigation not relying on physical infrastructure, the system was installed in just a few weeks. RFID tags on the containers ensure continuous traceability and an integrated lifter enables totes to be picked up and delivered at heights of 550mm to 1500mm.

KNAPP’s intelligent Open Shuttles undertake path planning, as well as obstacle detection and avoidance.

Their tasks are evenly distributed 8544_KNAPP_AD_LM-190x130_Layout 1 05/12/2023 08:18 Page 1

and transport routes optimised via swarm intelligence. The technology provides a dynamic solution, with KNAPP’s KiSoft FCS (Fleet Control System) enabling reconfiguration of the layout and processes with just a few clicks of a mouse.

Open Shuttles can transport containers, cartons, trays and tray stacks. A version with a widthadjustable clamp is suitable for handling loads in the electronics sector, such as circuit board magazines and reels. There is also a model with forks for pallet transport. Open Shuttle AMRs are ideal for seasonal peaks, as you can simply add more robots – they can even be rented.

KNAPP UK Tel: 01865 965 000 sales.uk@knapp.com www.knapp.com

knapp.com

KNAPP UK Ltd Tel: 01865 965 000 sales.uk@knapp.com

Open Shuttle AMRs Flexible, intelligent transport #ValueChainTechPartner

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Heating

8 reasons to switch to thermal fluid process heating

By Etienne Fourie, Technical Sales Manager, Babcock Wanson

Sometimes, the simple things in life really are the best things. Take thermal fluid process heating systems. Their design and operation follows a similar principle to a simple hot water system in that it features a heater connected to carbon steel flow and return pipework which can simultaneously provide heat to one or more users or systems.

The big difference between the two systems is that water is replaced by a thermal fluid running through the pipework as the heat transfer medium. It’s a closed loop system, with the fluid passing back to the Thermal Fluid Heater for reheating.

Clearly, there has been a lot of R&D and technological advances made in thermal fluid heating over the years, but essentially the system is a simple one.

Thermal fluid systems have become increasingly popular across a very wide range of industries where heat rather than actual steam is required.

If you have yet to be swayed by thermal heating systems, here are eight good reasons you should reconsider:

A thermal fluid system should easily serve you 30 or more years without any reduction in productivity as it ages.

- Etienne Fourie

Energy efficiency Top of the list of benefits for many thermal fluid heating system users is their energy efficiency, especially when they come with an integral economiser which ensures very low fuel consumption even when operating at high fluid temperatures. With Babcock Wanson’s TPC1000B thermal fluid heating system, for example, between 20-50% energy

savings can be made when compared to the transfer of the same amount of heat using traditional steam boilers.

The system precisely matches fuel input to plant energy requirements for high efficiency. With lower energy input demand also comes lower total exhaust emissions, so there are also environmental benefits.

Cost effective One of the key factors in achieving very high levels of system energy efficiency is the ability of a thermal fluid system to work at high temperatures (up to 350°C in standard form) in a simple closed loop. When compared to a steam system this means no change of state of the fluid so no condensate and therefore no flash steam losses, no blow down losses or make up water required, no effluent discharge and completely corrosion free without the need for expensive chemical treatment. There’s also no requirement for specialist plant rooms and distribution pipe work. It all adds up to substantial savings.

Easy to use and maintain When you bear in mind the above, and the fact that it is a closed loop system, you can immediately see how much easier a thermal fluid system is to operate daily, and to maintain. It’s not quite a fit and forget system, but it’s probably as close as you’re going to get in process heating! Furthermore, these systems operate outside the Pressure Systems Safety Regulations as the fluid is not maintained in the liquid phase by pressure, so statutory inspections are eliminated.

Safety The move away from water also has implications for safety. In a water system, pressure rises as a function of temperature: the higher the temperature, the greater the potential for problems within the system and the higher the system’s materials cost. Not so in a thermal fluid system as there is little relationship between temperature and cost so the fluid doesn’t have to be kept

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Heating Different fluids – typically mineral and synthetic based fluids – can be used to meet specific process heating requirements.

- Etienne Fourie

under pressure (other than the very small pressure of the circulating pump). This also brings significant advantages in the sizing and cost of heat exchangers.

Space Thermal fluid heating systems are compact when compared to fire tube steam boilers, but the biggest gain here is that they don’t require space for all the additional equipment that is required for a steam boiler to operate. A thermal fluid heater needs no specialist site work meaning it can usually be sited in the most convenient location, often close to the user.

Equipment durability and longevity A thermal fluid system should easily serve you 30 or more years without any reduction in productivity as it ages. A Babcock Wanson thermal fluid heater will usually run for more than 100,000 hours, although we are still servicing heaters that are more than 40 years old. This exceptional longevity is a direct result of their passive nature (there are very few moving parts) and the swapping out of water for a thermal fluid as the heat transfer medium. Unlike water and steam based systems, thermal fluid heaters are unaffected by corrosion caused by water over time, or by ambient temperature where water freezing within pipes leads to costly failures. In fact, most thermal fluids are mineral oil based so are effectively lubricants that help keep the system components protected in use.

Temperature control For many industrial processes, maintaining a constant temperature is vital to the quality of the product being produced. Whilst a steam generator can be operated to maintain a constant temperature, it’s much harder to do so – with temperature ramp up and

cool down difficult to control – and is far more labour intensive; skilled operators are imperative, and they are in short supply. Maintaining a constant temperature is much easier to achieve in a thermal fluid system, especially if it has been fitted with temperature control software. Composites manufacturer Gurit has a Babcock Wanson TPC450LN thermal fluid system in its multi mould production facility which features a unique menu driven software to allow up to 50 programmes to be created for

the simultaneous heating and cooling system of multiple users. It provides absolute control over the process as well as flexibility in the temperature rise and cooling stages.

Versatility Different fluids – typically mineral and synthetic based fluids – can be used to meet specific process heating requirements. Thermal fluids typically operate at up to 350°C at atmospheric pressure and can remain pumpable down to minus 20°C and lower with special fluids, which makes thermal fluid systems incredibly versatile. They are used in numerous different industries and applications, with the most common being pressing, curing and moulding; tanks, vessels and cookers; printing, coating, laminating and drying; and heating and cooling systems.

Babcock Wanson offers a complete range of products and services for boiler houses and other process heating needs, including Thermal Fluid Heaters with integrated gas, oil or dual fuel burners.

020 89537111 info@babcock-wanson.com www.babcock-wanson.com

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Training & Education

LEFT: Managing Director Reg Larkin with the firm 33 years is leading this cultural handover ABOVE: Metal-Craft Industries UK are fortunate to have a balanced work force to transfer experience

UK Manufacturers Urged to Tap into Vital Skills of Retiring Workforce As the sun sets on the careers of many skilled manufacturing professionals in the United Kingdom, Metal Craft Industries, a leading name in stainless steel fabrication of catering equipment, trolleys, sinks, and store equipment, is championing a nationwide call to action. The firm is urging manufacturers to harness the invaluable skills and experience of vital manufacturing workers who are on the verge of retirement before they exit the industry.

In a sector known for its intricacies and exacting standards, the expertise of veteran craftsmen and craftswomen is indispensable.

As the UK manufacturing landscape seeks to develop and inspire the next generation, there is a golden opportunity to tap into the knowledge that’s been honed over decades of service.

Reg Larkin, Managing Director of Metal Craft Industries, underscores the importance of this initiative. “The UK has always been at the forefront of manufacturing excellence, and a substantial part of that legacy is owed to the countless professionals who have dedicated their lives to perfecting their craft. These skilled artisans possess an immeasurable wealth of knowledge that we simply cannot afford to lose. By engaging them in mentorship and training

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At Metal Craft Industries, the emphasis on engaging retiring professionals has yielded positive results. programs, we can ensure that their expertise is passed on to the next generation, securing the future of our industry.”

The focus on specialism, such as stainless steel fabrication of catering equipment, trolleys, sinks, and store equipment, presents a unique set of challenges and opportunities. It is in these niche sectors where specialised skills are vital, and the transfer of these skills should be prioritised.

At Metal Craft Industries, the emphasis on engaging retiring professionals has yielded positive results. Their commitment to this cause has not only benefited their own operations but also contributed to the wider manufacturing community. The firm’s structured mentorship programs have enabled them to retain and leverage the knowledge of seasoned experts, while simultaneously facilitating the development of the younger workforce.

Larkin highlights how their approach has been particularly successful, “Our retiring professionals are not just leaving, they are transitioning into roles as trainers, passing on their skills to the next generation. This process of knowledge transfer ensures a smooth transition and enhances our productivity. The result is a win-win situation for both our experienced workers and the fresh talent.”

The UK manufacturing sector is at a crossroads, with opportunities for innovation and growth on the horizon.

However, without a concerted effort to harness the knowledge and skills of retiring workers, it could find itself at a disadvantage. The call to action is clear: UK manufacturers should make the most of this golden opportunity to engage, train, and mentor retiring professionals to ensure the sector’s long-term sustainability.

Metal Craft Industries and other forward-thinking companies are ensuring that a new generation is ready to rise and shine. Together, they are fortifying the foundation of the UK manufacturing industry, securing its future for generations to come.

LEFT: Blending experience; A seasoned engineer nurtures a young apprentice

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