Issuu

Issue 45 2026

Everything for Temperature Measurement

UK Manufactured. Trusted Worldwide. Sensors • Connectors • Cable • Instrumentation ISO 9001 Certified

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L60+ Thermocouple Welder, manufactured by Labfacility for thermocouple and fine wire welding

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CONTENTS INSIDE.. 04

Danfoss’ Dextreme Max

System reduces electric excavator power consumption.

What happend when AI

joins the Berkvens Doorsystems maintenance team.

The overlooked role of

EX-i SFC3000 Flow

optics in automated inspection.

Computer brings advanced flow measurement to water and energy applications.

More efficiency, more

Why you need to update

precision, no bend marks.

your machinery CE marking paperwork.

Factors to consider when

Rethinking deburring for

The missing link in mixed

How AI is becoming

selecting a thermocouple.

modern manufacturing.

powertrain manufacturing.

embedded in robotics engineering.

Editor in Chief Antony Holter antony@mhmagazine.co.uk 01304 806039 Sales Director Harriet Bennett director@mhmagazine.co.uk 0203 907 9161 Sales Manager Jamie Bullock jamie@mhmagazine.co.uk 01227 936971

Business Manager Josh Holmes josh@mhmagazine.co.uk Studio Designer Leila Schmitz leila@mhmagazine.co.uk Accounts Manager Lauren Holmes Lauren@mhmagazine.co.uk 01304 806039 Publishing Director Martin Holmes martin@mhmagazine.co.uk

Published by: MH Media Global Ltd 18/20 Newington Road Ramsgate Kent CT12 6EE Tel: 01304 806039 © MH Media Global

Every effort is made to ensure the accuracy and reliability of material published in Design Buy Build however, the publishers accept no responsibility for the claims or opinions made by advertisers, manufacturers 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.

MACHINERY, AUTOMATION, CONTROL & ENGINEERING

DANFOSS’ DEXTREME MAX SYSTEM REDUCES ELECTRIC EXCAVATOR POWER CONSUMPTION BY 35%, EXTENDING RUNTIME BY 53% PROJECT FUNDED WITH A GRANT FROM UK GOVERNMENT’S RED DIESEL REPLACEMENT PHASE 2 COMPETITION Danfoss Scotland, part of global hydraulics and electric powertrain systems supplier Danfoss Power Solutions, today announced the results of its Dextreme Max system validation in a 30-tonne battery-electric excavator. Undertaken with a £4.29 million grant from the UK Government, Danfoss demonstrated that its Dextreme digital hydraulic architecture reduced excavator power consumption by 35% across a representative duty cycle mix, corresponding to 53% longer runtime on a single charge. The results confirm the potential of the Dextreme Max system to significantly increase energy efficiency and accelerate the electrification of large excavators. Danfoss’ Dextreme Max system aims to cut excavator energy consumption by up to 50% by reducing energy losses and recovering energy that would otherwise be wasted. The system’s integral component is the DDP1X0D, a Digital Displacement® hydraulic pump/ motor with multiple independently controlled outlets. The Dextreme Max system provides independent actuator supply, eliminates flow-sharing losses, and 4

MACHINERY, AUTOMATION, CONTROL & ENGINEERING

enables energy recovery from excavator motions such as boom lowering. In 2023, Danfoss received a grant from the Red Diesel Replacement Phase 2 Competition, a program funded through the Department for Energy Security & Net Zero’s £1 billion Net Zero Innovation Portfolio, to develop and validate the Dextreme Max system. The program provided funding for projects developing low-carbon alternatives to red diesel for the construction, mining, and quarrying sectors. Danfoss used the funding to procure a battery-electric excavator and integrate its Dextreme Max system into the machine. The grant represented approximately 65% of the eligible project costs, with Danfoss funding the remaining portion. Danfoss selected a Develon DX300LC‑7 crawler excavator for the project. Originally diesel powered, the excavator was supplied in an electric configuration by Staad B.V., which replaced the engine with an electric drivetrain consisting of a Danfoss Editron

EM-PMI375 permanent magnet synchronous motor, EC-C1200 inverter, and MC050 motor controller, plus three 140-kWh batteries. Danfoss engineers replaced the excavator’s conventional swashplate hydraulic pump with the DDP180D pump/motor. The excavator’s four primary services — boom, arm, bucket, and swing — are supplied through ten individually controllable outlets on the pump. These outlets are dynamically grouped through a ganging block, a digital distributor that reallocates capacity to the service requiring it. A dedicated valve operating as a hydraulic H-bridge was developed and applied to the boom function to allow independent metering, providing anti-cavitation, pressure amplification, and energy recovery during overrunning motions. Finally, the control system architecture was developed to provide real-time control of the hydraulic system, electric powertrain, and auxiliary subsystems. To compare system performance before and after conversion, multiple tests were carried out, including JCMAS air grading and JCMAS air dig and dump (equivalent to ISO/AWI TS 11152-2). Compared to the baseline electric excavator, the Dextreme Max system reduced battery energy use by 49.2% in air grading and 31% in air dig and dump, with negligible impact on cycle time. Assuming a duty cycle of 30% grading and 70% digging, Dextreme Max would reduce battery power consumption by 35% without significantly impacting work rate. This would result in 53% longer operating hours with the same battery capacity as the

baseline machine, or similar runtime as the baseline with two battery packs instead of three. “The results of this testing highlight the potential of digital hydraulic architectures to overcome the obstacles in heavy-duty machinery electrification. Electric excavators offer excellent responsiveness, smooth control, a quiet cab environment, and zeroemission operation. With Dextreme Max, they can also deliver the runtime, productivity, and total cost of ownership advantages required for wider adoption, thereby accelerating the decarbonization of heavy-duty machinery,” said Alasdair Robertson, Senior Director, Digital Displacement, Danfoss Power Solutions. “We are extremely encouraged by these results, but there is more work to do. Further gains are possible, and we will continue optimizing the system to maximize the energy savings and value for our customers.” Danfoss Dextreme systems offer an incremental approach to implementation through three levels: Swap, Flex, and Max. Dextreme Swap involves a simple pump replacement, offering improved system control and more efficient operation. Dextreme Flex introduces flexible allocation of the Digital Displacement pump outlets, reducing flow distribution losses and further improving efficiency. The Dextreme Swap and Flex systems are commercially available, and this project has advanced the path to commercialization for Dextreme Max. To learn more, visit the Dextreme systems webpage.

For more information, visit www.danfoss.com

MACHINERY, AUTOMATION, CONTROL & ENGINEERING

WHAT HAPPENS WHEN AI JOINS THE BERKVENS DOORSYSTEMS MAINTENANCE TEAM BY STEFAN VAN BUSSEL, TEAMLEAD TECHNICAL SERVICES, AND JEROEN WIJNEN, MAINTENANCE & INSTALLATIONS LEADER, BERKVENS DOORSYSTEMS. complete multi-step analysis, no new platform required. The morning review transformed almost immediately, with the system assembling and summarizing what once took up to an hour. Its output matches our own manual analysis more than 95 percent of the time recovering 125–250 hours per team lead annually, worth roughly €12,500–€25,000 per person. It wasn’t instant magic, though. The system is only as good as what feeds it - messy or inconsistent logging early on meant messier insights out. Poor data hygiene doesn’t get fixed by AI; it gets amplified. Years of disciplined EAM usage were the real prerequisite, not the software itself.

Every morning at Berkvens Doorsystems, before a single machine starts up, a maintenance team lead is already at work - reviewing overnight breakdowns, shift logs, and notifications to build a picture of the machine park. That process used to take 30 minutes to an hour, every day, per team lead. The stakes behind that hour are bigger than they look. Ultimo’s Maintenance Trend Report found 63 percent of manufacturing organizations are struggling with an aging workforce - a challenge that’s as much about vanishing knowledge as vanishing headcount. When experienced technicians retire, they take with them an understanding of how specific equipment behaves that exists nowhere in any system. That’s the problem we set out to solve.

Once the data was clean, the payoff went beyond time saved: the system revealed that certain equipment issues were recurring structurally, not randomly reshaping how we plan maintenance altogether. Next up is AI-assisted troubleshooting, suggesting fixes based on past failures. The goal is that any technician, regardless of experience, gets the instinct of a decadeslong veteran on tap. Which means that same team lead’s morning now starts not with an hour of digging through logs, but with the answer already on screen.

Berkvens Doorsystems is a family-run manufacturer in Someren, Netherlands, part of Xidoor, producing interior doors, frames, and sliding door systems across Western Europe. We’d already invested in an EAM platform to structure maintenance planning, but as data volumes grew, manually reviewing it all became the real bottleneck. Our answer is digital workers - AI systems embedded in our existing enterprise asset management (EAM) workflow that independently monitor data and

www.berkvens.nl

MACHINERY, AUTOMATION, CONTROL & ENGINEERING

NULOGY TO SHOWCASE SMART FACTORY AND QUALITY & COMPLIANCE SOLUTIONS AT PPMA 2026

Returning to PPMA for 2026, Nulogy will demonstrate how real-time visibility across production, quality and compliance can help food manufacturers make faster, more informed decisions, reducing the unexpected issues that can keep operations leaders awake at night. Exhibiting on Stand A92, the brand will showcase the latest in-built capabilities of Nulogy Smart Factory, as well as introducing Nulogy Quality & Compliance to attendees. Originally launched at PPMA 2025, Nulogy Smart Factory enables food and beverage manufacturers to monitor equipment performance, workforce allocation, throughput, downtime and OEE in real time. The platform provides a single view of minuteby-minute factory floor operations, as well as valuable insight to explain anomalies or issues as they appear. Smart Factory gives manufacturers a clearer picture of factory floor performance and the information needed to act on it. New for PPMA 2026 are the latest additions to Nulogy Smart Factory: a maintenance solution and AI assistant, Nora. Nulogy Maintenance is a built-in solution that connects maintenance activity directly to live production information, enabling teams to prioritise work according to machine condition, usage and production impact. Also integrated within Nulogy Smart Factory, Nora enables users to ask questions in plain English and

receive answers based on live production and maintenance data. Whether reviewing downtime trends, assessing production performance or identifying outstanding maintenance activity, Nora helps users access relevant information faster and reduce the time between recognising an issue and taking action. Alongside Smart Factory, Nulogy will showcase Nulogy Quality and Compliance. Designed to simplify quality management processes and documentation, the solution provides real-time traceability, evidence capture, and audit preparation tools that help food manufacturers maintain control of quality processes. The platform also centralises supplier documentation and certification records, providing easier access to critical compliance information. By giving teams greater visibility and access to quality-related information, manufacturers can identify issues earlier and maintain greater consistency across operations. Nulogy Quality & Compliance helps reduce the administrative burden associated with compliance activities while supporting a more proactive approach to quality management, enabling teams to spend less time preparing for audits and more time focused on driving operational improvement. Visitors to Stand A92 will be able to explore the latest developments across Nulogy Smart Factory and Quality & Compliance through live software demonstrations.

www.nulogy.com

MACHINERY, AUTOMATION, CONTROL & ENGINEERING

THE OVERLOOKED ROLE OF OPTICS IN AUTOMATED INSPECTION Knight Optical Interference Bandpass Filters

Machine vision has become a core part of modern manufacturing inspection, with Gartner predicting that by 2027, half of warehouse operations will rely on AI-enabled vision systems rather than conventional scanning-based cycle counting. The quality of the data generated by these systems begins with their optical components. Regardless of how sophisticated the software is, poor image data will ultimately limit performance. Managing unwanted optical noise Automated Optical Inspection (AOI) systems rarely operate in perfectly controlled environments. Natural lighting varies throughout the day, overhead factory lighting can be uneven and highly directional, and many manufactured parts contain reflective surfaces. As a result, unwanted light often reaches the sensor alongside the information the system is intended to capture. These variations can reduce repeatability, introduce intensity fluctuations, and create colour inconsistencies. Reflective materials can also generate stray light that obscures critical features. In sectors such as food processing and pharmaceutical manufacturing, the consequences include missed defects, undetected contamination, and false rejects, where perfectly acceptable products are unnecessarily removed from the production line, increasing waste and reducing yield. Addressing this challenge starts with spectral control. Interference bandpass filters allow only a specific wavelength range to reach the sensor while blocking unwanted ambient illumination. When matched to a system’s LED light source, they help maintain consistent exposure under changing conditions and improve contrast between the target object and its 8

MACHINERY, AUTOMATION, CONTROL & ENGINEERING

background, making defects, colour variations, and dimensional irregularities easier to detect. Different applications require different filter specifications. Broadband filters are suited to environments where maximising light throughput is the priority. Narrowband filters are often preferred where ambient interference is significant. Standard filter configurations are designed to match commonly used LED wavelengths, while UV filters are used to reveal fluorescence and coating layers that cannot be observed with the naked eye, making them valuable in pharmaceutical and security inspection systems. When inspection reliability suffers Selecting the wrong bandpass filter can undermine inspection accuracy. Uncertain image data may cause systems to slow down, increase false rejection rates, or allow defective products to pass through the process. In automotive production, a missed weld defect could lead to costly recalls. Within pharmaceutical manufacturing, contaminated blister packs present both regulatory and patient safety risks. In food and beverage processing, overlooked foreign matter can result in product withdrawals and reputational damage. In each case, inspection quality depends on optical performance. Most engineers involved in specification recognise this connection, but it is sometimes overlooked when optical components are treated as purchasing decisions instead of engineering decisions. A filter that is nearly suitable but not optimised for the real lighting conditions within a facility, can gradually reduce inspection performance. The impact may be difficult to detect during initial validation yet become significant over extended production runs.

Spectral imaging and high-speed sorting

Durability in continuous operation

The optical demands become even greater when

AOI systems are expected to operate continuously while being exposed to vibration, thermal cycling, UV radiation, and aggressive cleaning processes. Any deterioration in optical performance directly affects the quality of the inspection data being produced.

systems move beyond simple pass/fail inspection and must identify materials at production-line speeds. In recycling facilities, hyperspectral imaging (HSI) systems monitor conveyor belts moving at speeds of up to 3 m/s, distinguishing polymers such as PET, HDPE, PVC, polypropylene, polystyrene, and ABS through their unique spectral signatures. These signatures are measured within the near-infrared (NIR) and shortwave infrared (SWIR) regions, requiring optics that can deliver clean, consistent spectral data in difficult industrial environments. Research published by UCL in 2025 demonstrated that HSI could identify contaminated plastic packaging with accuracy rates of up to 99%, highlighting both the capability of the technology and the importance of optical quality in achieving those results. At such operating speeds, optical components must provide high transmission to ensure sufficient light reaches the detector during short integration periods. Mixed-material surfaces and glossy finishes can introduce flare and unwanted reflections. Bandpass filters designed to isolate the required NIR and SWIR wavebands suppress this interference and improve measurement reliability. The same principles used to stabilise AOI systems are therefore equally important in advanced sorting applications, albeit under more demanding operating conditions.

Diamond-like carbon (DLC) coatings improve resistance to abrasion in applications requiring regular cleaning or physical contact. Dielectric coatings provide stability when temperatures fluctuate, while protective windows, commonly manufactured from sapphire because of its hardness and optical transmission characteristics, help shield internal optics from dust, debris, and impact damage while preserving optical alignment. Optical specification as an operational advantage A properly specified optical system delivers higherquality image data, more dependable inspection outcomes, reduced false reject rates, and reliable performance throughout the working life of the equipment. Knight Optical supplies precision optical components for machine vision and automated inspection systems used across manufacturing, food and beverage, pharmaceutical, and recycling applications. Its range includes interference bandpass filters, protective windows, and custom optical solutions designed for demanding environments, supported by technical guidance to help ensure components are matched to real-world operating conditions.

Knight Optical Windows & Diffusers

www.knightoptical.com

MACHINERY, AUTOMATION, CONTROL & ENGINEERING

Electrical, Instrumentation, Control and Cyber Security in Industrial Engineering • 'By Industry, For Industry’, practical guidance for everyday and irregular situations and tasks • Readily accessible for all in the industry – wherever they are, whatever time they have • E-learning for continuing professional development • Webinars and seminars for knowledge sharing and professional networking Selection of specialist publications and more resources including FREE task and procedure checklists

Code of practice for calibration and validation of process analysers

Publication 175 Edition 3

e iti w on

Guide to the application of IEC 61511 to safety instrumented systems in the process industries Publication 222 Edition 2 N

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Alarm systems: Guide to design, management, and procurement

Control rooms: Guide to specification, design, commissioning and operation

Publication 191 Edition 4

Publication 201 Edition 3

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Also... Cyber Security e-learning – with CPD / PDH – on-demand To make EEMUA’s guidance, training, events and other practical resources work best for you and your team please ask@eemua.org or visit www.eemua.org

Programmable LED Screens & Signs Outdoor & Indoor LED Screens & Information Signs Production Line Displays Health & Safety Signage Target & Actual Boards Site Entrance

For Selig Group, sustainability is increasingly shaping how packaging components are designed and developed. As regulatory pressures and demand for recyclable packaging grow, the company is focusing on solutions that support these ambitions without compromising performance. Regulations such as the EU’s Packaging and Packaging Waste Regulation (PPWR), alongside restrictions on substances including PFAS, are driving the move towards lighter, simpler and more recyclable packaging formats. Components such as liners have an important role to play, supporting recyclability and weight reduction while maintaining seal integrity and product protection. Reflecting its commitment to innovation, Selig recently completed the world’s first successful pilot of a foil-free induction liner, designed to deliver the performance of conventional induction heat seal liners.

UK Designed Software

wwww.LEDsynergy.co.uk Tel: 01264 303030 sales@LEDsynergy.co.uk

Showroom in Hampshire

SUSTAINABILITY: RE-THINKING EVERY PACKAGING COMPONENT

MACHINERY, AUTOMATION, CONTROL & ENGINEERING

Through its expanding range of liner solutions, Selig Group is helping customers rethink packaging design and make progress towards their sustainability goals without compromising performance.

For more information, visit www.seliggroup.com www.tbafirefly.com

To be the first choice for complex, innovative and expert solutions in industrial electronics.

www.fortec.uk

EX-I SFC3000 FLOW COMPUTER BRINGS ADVANCED FLOW MEASUREMENT TO WATER AND ENERGY APPLICATIONS ACCURATE FLOW MEASUREMENT SUPPORTS MORE EFFICIENT MANAGEMENT OF WATER, HEAT AND PROCESS ENERGY. or redirected for other applications. Accurate measurement of these flows is essential when assessing energy balances and determining where efficiency improvements can be made. Cooling towers provide another important application. While essential to many industrial processes, cooling systems can represent a significant source of energy and water consumption. Monitoring make-up water, circulation and discharge flows can help operators understand system performance, identify losses and assess opportunities to reduce water and energy consumption. The EX-i Flow Measurement Ltd SFC3000 Flow Computer has many applications across the water, utilities and process industries, where accurate measurement of liquid and steam flows is increasingly important for managing both resources and energy. Water is a critical resource in many parts of the world, and in industrial applications it can also be considered an effective means of transporting energy in the form of heat. From power generation and industrial processes to cooling systems and district heating, monitoring the movement of water and steam can provide valuable information for improving efficiency, reducing waste and identifying opportunities for energy recovery.

The same principles apply to water treatment and distribution networks. Accurate flow measurement enables operators to monitor consumption, manage distribution and identify potential inefficiencies. In regions where water is a particularly precious resource, reliable measurement can play an important role in supporting responsible management. The SFC3000 can also support applications involving steam and other process fluids, providing a common measurement platform for facilities where water, steam and energy flows are closely interconnected. By providing reliable flow calculation and monitoring, the SFC3000 enables engineers and operators to turn flow data into actionable information – helping

The SFC3000 provides a flexible platform for flow

them understand where water and energy are being

measurement and calculation, making it suitable for

consumed, where losses may occur and where

applications where flow data needs to be accurately

opportunities exist for recovery and improved

monitored, recorded and integrated into wider process-

efficiency.

control systems.

EX-i Flow Measurement Ltd specialises in flow

In power generation and industrial processing, for

measurement solutions for demanding industrial

example, water and steam flows can represent

applications. The SFC3000 Flow Computer provides a

significant quantities of energy. Hot water may be used

flexible solution for monitoring and calculating flow in

to transfer excess process heat, while steam generated

applications ranging from water and process industries

as a by-product can potentially be recovered

to energy and steam measurement.

For more information on the SFC3000 and its suitability for water, steam and energy-management applications, contact EX-i Flow Measurement Ltd, +44 (0)1243 554920, email sales@exiflowmeasurement.co.uk or visit www.exiflowmeasurement.com

MACHINERY, AUTOMATION, CONTROL & ENGINEERING

MORE EFFICIENCY, MORE PRECISION, NO BEND MARKS FIMAB MANUFACTURES ELECTRICAL ENCLOSURE CABINETS WITH THE RAS UPDOWNCENTER 2 AT A NEW LEVEL OF QUALITY.

The foundation for deep electrical enclosure cabinets is formed from a large-format sheet blank in a single operation.

With the RAS UpDownCenter 2, FiMAB has taken the production of electrical enclosure cabinets to a new level. A 66% reduction in bending time, 22% faster welding processes, and bend mark-free visible surfaces clearly demonstrate the benefits. Manufacturing enclosure cabinets from a single blank with automatic setup and precise step bending enables economical batch size 1 production while maintaining exceptional quality. Today, the second-generation family business employs around 30 people and remains committed to training skilled young professionals. “Preserving what works while embracing new ideas perfectly reflects who we are,” says Markus Fiedler, Managing Director of FiMAB. Investing in the RAS UpDownCenter 2 was the logical next step in bringing this philosophy to the shop floor. Electrical enclosure cabinets Around one quarter of FiMAB’s annual turnover 14

MACHINERY, AUTOMATION, CONTROL & ENGINEERING

is generated in the electrical enclosure business. The company manufactures high-quality steel and stainless steel enclosure cabinets for customers in the special-purpose machinery and mechanical engineering industries, where dimensional accuracy and repeatability are critical. “Our customers require enclosure cabinets in a wide variety of sizes and configurations. Producing this level of product variety economically is one of the biggest challenges in manufacturing,” explains Markus Fiedler. Orders from an online configurator are transferred directly to production. CNC programs for laser cutting and metal folding are created automatically and transferred directly to production, enabling economical batch size 1 manufacturing. Previously, enclosure cabinets were produced on a press brake, requiring multiple parts, extensive setup work, manual turning of the sheet metal between bending operations, and numerous weld seams.

Press brake bending also left visible bend marks on the surface. For high-quality enclosure cabinets with visible surfaces, this was a significant quality disadvantage. Side panels had to be welded separately and precisely aligned, resulting in additional production time and increasing the risk of assembly errors. The UpDownCenter 2 as a powerful bending center

Automatic setup keeps production flowing. While the operator loads the next part, the machine changes tooling automatically, eliminating manual tool changes and ensuring continuous production. Especially for individually configured enclosure cabinets, this automation ensures a seamless workflow and economical batch size 1 production. Measurable efficiency gains throughout the entire process chain For the past three years, the UpDownCenter 2 has delivered measurable productivity gains at FiMAB. Manufacturing enclosures from a single blank has reduced material cutting requirements by 17%, while bending time has been cut by 66% through automatic setup, reduced manual gauging, and fewer adjustments. Welding processes are also 22% faster, as separately attaching and aligning side panels is no longer required. The result is greater dimensional accuracy, highly repeatable production, and virtually error-free assembly.

With bending lengths up to 4,060 mm, box heights up to 600 mm and a capacity of 4 mm mild steel, the machine is ideally suited to FiMAB’s production.

Software that simply works Ease of use was another key factor in FiMAB’s decision. Programs can be created directly at the

The machine is operated from the gauging side, while long or high flanges can be removed from the folding beam side when required, ensuring ergonomic handling and reliable material flow. Made from a single piece rather than from multiple parts FiMAB selected the RAS UpDownCenter 2 because it enables the production of deep electrical enclosure cabinets from a single sheet blank. “Our key requirement was the ability to manufacture deep cabinets from a single blank. This reduces weld seams and eliminates potential sources of error,” explains Thomas Ohngemach, Production Manager at FiMAB.

machine or in the office, while the intuitive RAS Bendex software enables quick adaptation to different enclosure sizes. Compared with alternative solutions, Bendex proved considerably easier to use. Another advantage was the ability to manufacture box heights of up to 500 mm, a feature rarely found in comparable systems. Close proximity to RAS, personal support, and the opportunity to test sample parts further reinforced FiMAB’s investment decision. A future-proof investment The RAS UpDownCenter 2 has fundamentally transformed FiMAB’s electrical enclosure production.

Another key advantage of metal folding technology is the absence of bend marks. Smooth surfaces reduce rework while improving the appearance of finished enclosure cabinets.

Fewer weld seams, bend mark-free surfaces, precise

Processing sheet thicknesses from 0.5 to 3.0 mm, UpDown bending keeps the blank on one side throughout the process, simplifying handling of largeformat parts while improving repeatability.

“Choosing the UpDownCenter 2 was the right decision

Automatic setup for seamless production

Visit us at Euroblech in Hanover hall 11 booth B154

step bending, shorter setup times, and measurable productivity gains have made the machine a key element of FiMAB’s manufacturing strategy.

for us. We work more efficiently, achieve greater precision, and consistently deliver higher quality to our customers,” concludes Markus Fiedler.

www.ras-online.de www.ras-online.de/en/products/bending/updowncenter-2 www.fimab.eu

MACHINERY, AUTOMATION, CONTROL & ENGINEERING

FLEXIBILITY AND SHARED FAMILY VALUES DRIVE GROWING PARTNERSHIP BETWEEN GAZEBO FINE FOODS AND JS DAVIDSON A shared family ethos and a flexible approach to logistics are laying the foundations for a growing partnership between premium food manufacturer Gazebo Fine Foods and temperature-controlled storage and distribution specialist JS Davidson. Having begun working together around a year ago, the relationship has already expanded beyond storage to include value-added services such as container unloading, tempering, sleeving and date coding, with further opportunities now being explored as Gazebo continues to grow. Established in 1987, Gazebo Fine Foods is one of the UK’s leading manufacturers of handcrafted frozen and chilled ethnic snacks and ready meals. Employing more than 160 people, the business manufactures products in the UK while also working with carefully selected production partners in India and China to meet growing demand ensuring all products are manufactured to Gazebo’s stringent requirements. And as those international supply chains have expanded, so too has the need for a temperaturecontrolled solutions partner capable of providing an end to end product offering. Gazebo initially approached JS Davidson following a recommendation from industry contacts and quickly found a business whose culture closely reflected its own. Tanoj Shah of Gazebo Fine Foods said: “We are both family businesses and that was important to us from the outset. We operate with a small, proactive team and needed a logistics partner that would be flexible, responsive and easy to work with. “As our imports have increased, having access to container unloading, storage and value-added services such as tempering and date coding has become

increasingly important. JS Davidson has given us that flexibility while providing a service that’s both reliable and approachable.” Before appointing JS Davidson, Gazebo managed these operations from its own Wembley facility. Outsourcing selected elements of the operation has enabled the company to increase capacity while maintaining the agility needed to respond to changing customer requirements. The partnership is continuing to evolve, with Gazebo now exploring opportunities to extend the range of services provided to include additional sleeving, date coding and repacking activities across a wider range of products. Tanoj Shah added: “One of the biggest strengths of JS Davidson is that nothing ever seems too much trouble. John and his team are always approachable and if an issue arises, it is dealt with quickly. That gives us confidence as we continue to grow.” For JS Davidson, the partnership reflects its ability to provide a complete outsourced service for food manufacturers, combining temperature-controlled storage with a wide range of value-added services including container devanning, tempering, repacking, sleeving, date coding, labelling and product rework. John Davidson, Managing Director of JS Davidson, said: “Many food manufacturers are looking for more than somewhere to store products. They need a logistics partner that can adapt as their business evolves and provide the additional services that keep products moving efficiently through the supply chain. “We’re delighted to be supporting Gazebo Fine Foods as the business grows. Like us, it’s a family-run company that values long-term relationships, flexibility and good customer service. Those shared values have helped create a partnership that continues to develop, and we look forward to supporting the business for many years to come.”

www.jsdavidson.co.uk

MACHINERY, AUTOMATION, CONTROL & ENGINEERING

Selling machinery to the EU from outside. Hold Tech Files can act as Authorised Representative.

Get compliant: holdtechfiles.eu

WHY YOU NEED TO UPDATE YOUR MACHINERY CE MARKING PAPERWORK BY DEREK COULSON In less than a year, the new EU Machinery Regulation 2023/1230 (MR) supersedes the Machinery Directive 2006/42/EC (MD) on 20th January 2027. Machine builders must be prepared, including manufacturers of series machines already in production. There is no transition period – the change will, in effect, be overnight. While some machine builders will only need to revise their paperwork, others may have to go much further.

autonomous operation, will probably need assessing by competent IT professionals.

The new MR has additional essential health and safety requirements (EHSRs), such as those relating to cybersecurity. Any machine with a USB or network port will require an assessment. Machinery linked to networks or the internet, or that is capable of

Annex I machinery (formerly Annex IV) built to harmonised standards will need a Notified Body Type Approval until the standards are updated and harmonised to the MR. It could be months or years until these are all harmonised.

MACHINERY, AUTOMATION, CONTROL & ENGINEERING

It is imperative that machine builders study the new MR and understand the implications. A new risk assessment might be needed for the whole machine or just certain aspects. Depending on the outcome, changes to the design, software or hardware could be required.

Instructions Instructions for use no longer have to be in ‘hard copy’, as the MR allows them to be provided digitally. However, a hard copy must be supplied free of charge if requested when the machine is ordered. Machine builders can potentially save money by not including a printed set of instructions with every machine but they need procedures for providing printed copies on request. For partly completed machinery, the assembly instructions may be provided digitally, with customers able to request a free printed copy. Declaration of Conformity From 20th January 2027, the EU Declaration of Conformity (DoC) (previously an EC Declaration) must refer to the Machinery Regulation 2023/1230 instead of the Machinery Directive 2006/42/EC. A number of minor revisions must be made to the DoC; Annex V Part A of the MR states what the DoC must contain. Previously, a machine might have been accompanied by more than one DoC for different Directives or Regulations. Under the new MR, a single DoC can list all of the laws with which conformity is being claimed. For partly completed machinery, the changes to the DoI are similar to those for the DoC (Annex V Part B). Many existing standards are not yet harmonised to the MR, so these should not be listed on Declarations.

example, the MD requires the technical file to include a ‘general description’ of the machinery, while the MR requires a ‘complete description’ – and ‘complete’ is not defined. Generally, the technical documentation needs more detail than previously. Authorised representative mandate Today, under EU regulation 2019/1020 on market surveillance and compliance, machine builders are required to have an economic operator established in the EU. The new MR requires the same. Unless a UK machine builder has a related company based in the EU, it is likely that the only feasible way to name an economic operator is to appoint an EU Authorised Representative (EU AR). The machine builder must provide a mandate specifying tasks the EU AR is authorised to perform. If a mandate already exists for regulation 2019/1020, then it must be updated to refer to the MR as well. Conclusion Machine builders exporting to the EU must be ready for the new Machinery Regulation, even if the only changes are to paperwork. Non-compliant machines and paperwork could be held at the border. Hold Tech Files Ltd is established in the Republic of Ireland and can act as an EU AR. Furthermore, its consultants can provide advice to help machine builders prepare for the new Machinery Regulation.

Machine builders can now choose to provide an internet address or machine-readable code (eg QR code) from where the EU Declaration of Conformity can be accessed. Quality assurance paperwork The only revisions to quality assurance paperwork are likely to stem from changes necessary for complying with new EHSRs, such as those relating to cybersecurity. Technical documentation In the old MD, the term ‘technical file’ was used when referring to machinery, whereas ‘technical documentation’ was used for partly completed machinery. In the new MR, ‘technical documentation’ is used for both. Unfortunately, some areas of the MR Annex IV (Technical documentation) are a little vague. For

For more information, contact Hold Tech Files Ltd. www.holdtechfiles.eu

MACHINERY, AUTOMATION, CONTROL & ENGINEERING

DIGITAL QUALIFICATION IS BECOMING AEROSPACE’S COMPETITIVE ADVANTAGE, SAYS ADDQUAL As aerospace manufacturers accelerate production and MRO providers respond to unprecedented global demand, competitive advantage is increasingly being shaped by how quickly organisations can qualify, verify and release critical components—not simply how quickly they can manufacture them. Across the aerospace sector, attention continues to focus on digital transformation, artificial intelligence and connected manufacturing.

knowledge become connected into a single decisionmaking environment. Rather than inspection existing as a standalone quality function, manufacturers are increasingly integrating qualification data throughout the lifecycle of a component, from first article inspection and production approval through to repair development, reverse engineering, in-service support and future maintenance programmes.

Yet behind every successful AI initiative sits something far more fundamental: trusted engineering data. For manufacturers producing safety-critical components, every engineering decision depends upon confidence that a part has been measured correctly, validated against specification and supported by complete traceability.

This approach aligns directly with AddQual’s expanding portfolio of qualification and inspection services, including FAIR and LAIR reporting, PPAP support, inspection planning, engineering investigations, re-engineering, turnkey plant support and increasingly sophisticated digital verification platforms. Ben Anderson, Managing Director of AddQual, said:

For Derby-based AddQual, this represents one of the most significant shifts taking place across aerospace manufacturing and maintenance. AddQual believes the industry’s next phase of digital transformation will be built around digital qualification, where metrology, inspection, verification and engineering

“Manufacturers already collect enormous quantities of inspection data. The real opportunity is transforming that information into engineering confidence. Qualification should accelerate decisions, support production and provide complete traceability throughout the life of a component.”

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That philosophy underpins AddQual’s continued development of MiDAS, its digital manufacturing intelligence platform, and AtlasQual, the company’s next-generation digital qualification environment. Together, the platforms are designed to create a connected digital thread that captures metrology data, inspection evidence, engineering knowledge and qualification records within a single managed environment. Instead of engineers navigating multiple systems and disconnected reports, qualification information becomes immediately accessible, searchable and reusable throughout manufacturing and MRO operations. As aircraft fleets continue to grow and maintenance activity expands worldwide, the ability to qualify repaired or newly manufactured components efficiently is becoming an increasingly valuable capability. Modern aerospace programmes generate millions of measurement points, inspection images, dimensional records and compliance documents. While collecting this information is essential, manufacturers are increasingly recognising that the greatest value comes from connecting it into an intelligent qualification workflow that supports engineering decisions in real time. This is particularly relevant as organisations embrace digital twins and data-driven manufacturing strategies. High-fidelity digital models are only as valuable as the engineering evidence that supports them. Accurate metrology, verified geometry and controlled inspection processes provide the trusted foundation upon which digital manufacturing is built. AddQual sees this as a natural evolution of quality engineering. Its roadmap extends beyond traditional inspection activities towards subscription-based digital qualification services through MiDAS, AtlasQual

and future intelligent platforms capable of supporting digital twins, managed qualification services, repair scheme development and fully integrated engineering programmes. Alongside software, AddQual continues to deliver practical engineering capability through tooling design, wire EDM, digital inspection visualisations, consultancy and turnkey qualification support, enabling customers to combine physical manufacturing expertise with digital engineering intelligence. Anderson added: “Digital transformation in aerospace begins with trusted engineering evidence. AI, digital twins and advanced analytics all depend upon reliable qualification data. By connecting metrology, inspection and verification into one digital ecosystem, manufacturers gain faster engineering decisions, stronger traceability and greater confidence throughout the product lifecycle.” As aerospace manufacturing enters its next phase of growth, qualification is evolving from a compliance activity into a strategic engineering capability. Organisations that can verify parts faster, capture engineering knowledge digitally and create trusted qualification records are placing themselves in a stronger position to accelerate new product introduction, streamline repair development and support increasingly connected manufacturing environments. For AddQual, the future lies beyond measuring components, rather creating the digital intelligence that allows every qualified part to become a trusted source of engineering knowledge.

Advanced Metrology Engineer Kasperska using automation in the inspection process

For more information, visit www.addqual.com

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FACTORS TO CONSIDER WHEN SELECTING A THERMOCOUPLE Thermocouples are widely used in temperature measurement across various industries, from manufacturing to research laboratories. However, with a myriad of options available, choosing the right thermocouple for your application can be daunting. To help you make an informed decision, here are seven factors to consider when selecting a thermocouple: 1. Temperature Range: The temperature range of your application is crucial in determining the type of thermocouple suitable for your needs. Thermocouples are classified into different types based on their temperature ranges, such as Type K (−200 to 1,350 °C), Type J (−210 to 1,200 °C), and Type T (−250 to 400 °C). Ensure the thermocouple you choose can withstand the temperatures present in your environment without compromising accuracy. 2. Accuracy Requirements: Consider the level of accuracy required for your temperature measurements. While most thermocouples offer sufficient accuracy for general applications, some high-precision environments may demand specialised thermocouples or additional calibration to meet accuracy standards. 3. Chemical Compatibility: Evaluate the compatibility of the thermocouple materials with the substances present in your application environment. Exposure to corrosive chemicals or gases can degrade the thermocouple, affecting its accuracy and lifespan. Choose materials resistant to corrosion and chemical reactions to ensure longevity and reliability.

mechanical impact, ensuring the thermocouple’s reliability and longevity. 6. Environmental Conditions: Take into account the environmental conditions in which the thermocouple will operate. Factors such as humidity, pressure, and atmospheric contaminants can influence the performance and lifespan of the thermocouple. Choose a thermocouple with suitable insulation and protective measures to withstand the specific environmental challenges of your application. 7. Cost and Long-Term Maintenance: Consider the initial cost and long-term maintenance requirements of the thermocouple. While budget constraints may influence your decision, prioritise quality and reliability to avoid frequent replacements or costly downtime due to equipment failure. Evaluate factors such as calibration frequency requirements, recalibration costs, and availability of spare parts to assess the overall cost of ownership. In conclusion, selecting the right thermocouple involves careful consideration of various factors, including temperature range, accuracy, chemical compatibility, response time, mechanical strength, environmental conditions, and cost. By prioritising these aspects and conducting thorough research, you can choose a thermocouple that meets your specific application requirements, ensuring accurate temperature measurement and reliable performance.

4. Response Time: The response time of a thermocouple refers to how quickly it can detect and accurately measure changes in temperature. Faster response times are essential for dynamic processes or applications where rapid temperature fluctuations occur. Consider the response time requirements of your application to select a thermocouple that can provide timely and precise measurements. 5. Mechanical Strength and Durability: Assess the mechanical strength and durability of the thermocouple, especially if it will be subjected to harsh operating conditions or physical stress. Choose a robust construction and protective sheathing to prevent damage from vibration, abrasion, or

Website:: www.labfacility.com | Email: sales@labfacility.com Tel: +44 (0) 1243 871280 | Tel:+44 (0) 1909 569446

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UK Manufacturer

INSTALLATION AND BUILDING AUTOMATION FROM ZAMEL UNIVERSAL MODULES FOR CONTROLLING LIGHTING, HVAC COMPONENTS, AND OTHERS. Automation has long ceased to be limited to industry – today it extends much further, reaching offices, apartment buildings, and single-family homes. Zamel modules make it possible to automate many installation elements at a relatively low cost: outdoor and indoor lighting, heating systems, and more. Below, we present an overview of the Zamel range in the field of installation automation. Most of the modules presented here are designed for DIN rail (TH35) mounting and can perform a variety of functions – although the offer also includes products intended for specific applications (e.g. lighting controllers). The presented solutions can be purchased directly from the TME catalog. This article covers the following topics: • Relays used for load control • Applications and capabilities of time relays • Electrical and environmental protection devices • Monitoring energy consumption and quality • Key building automation control elements • Sensors used in architectural automation Installation Automation First, it is worth focusing on universal components that can be used for a variety of purposes in diverse applications, both in homes and in industry. Relays and Contactors Zamel relays are available in bistable, impulse, monostable, and priority versions, meaning they can be controlled by pushbuttons, switches, pulses from monitoring devices, and other signals commonly used in electrical installations. They support maximum currents ranging from 5A to 100A. In most cases, the control voltage is 24V AC/DC or 230V AC, while the rated coil voltage ranges from 12V to 230V. Some models incorporate a relay state memory system, ensuring automatic restoration of the state prior to a power failure.

PBM-01 Installation Relays STM-25-40 Contactors SPM-05-11 Auxiliary Contacts The supplier’s contactors offer similar parameters. They support currents of 25…100A and are available in 2-, 3-, and 4-pole configurations (mostly NO contacts). Complementary products include auxiliary contacts – 24

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slim-profile modules that extend the functionality of Zamel contactors to additional circuits. Time Relays Zamel time relays are available in digital and analog versions. Digital models offer extensive functionality, with up to 25 independent operating modes (delays, hold functions, cyclic operation, or bistable counting ranges from 0.1s to 100h, and even up to 1 year). The modules feature a configuration interface (buttons and LCD display) located on the front panel, simplifying installation and adjustment. Alternatively, for example in the case of the ZCM-42 model, programming can be carried out remotely via WiFi. ZCM-11 Digital PCM-10 Analog A more economical alternative to digital models is analog time relays. These also offer multiple operating modes and support long timing periods (from 0.1s to 100 days). This product group also includes flushmounted versions, enabling functions such as timed lighting control (e.g. in corridors or stairwells) without requiring additional modules in the distribution board. Monitoring Relays Monitoring relays are devices used in automation and electrical installations for continuous monitoring of selected operating parameters. Their purpose is to detect abnormalities and trigger an appropriate response, such as activating an alarm, switching on equipment, or disconnecting the power supply. Zamel offers several types of such protection devices: PNM-31 Voltage Monitoring Relays PZM-10 Liquid Level Monitoring Relays PRM-10 Temperature Monitoring Relay RTM-02 Temperature Controllers The product range includes relays that monitor electrical network parameters (voltage), liquid levels in tanks (boilers, reservoirs), and temperature. It is also worth mentioning that for more advanced control applications related to thermal conditions, Zamel manufactures precise and multifunctional temperature controllers, where the device can be used

to control heaters, air conditioners, fans, and similar equipment by comparing the current measurement with a reference temperature or programmed thresholds. Such controllers are used to maintain specific room temperatures, water temperatures in tanks, or temperatures of various objects. They can operate fully automatically or in cooperation with other components or adjustment elements operated by third parties (e.g. residents/employees adjusting thermostat settings).

well as dimmers that allow the brightness of various

Meters, Protection Devices and Accessories

Another building-specific installation component

The Zamel range also includes modules that facilitate supervision of the entire installation. These include energy meters and voltage indicators, essential components in many systems, especially those based on renewable energy sources such as photovoltaic installations or wind turbines.

is the miniature shutter controller, which enables

Power limiters and protection modules are adjustable devices that perform a role similar to traditional fuses (i.e. circuit breakers), but with configurable parameters. Both the trip threshold and the automatic reset time can be adjusted. Such protective devices have numerous applications and help reduce installation downtime and maintenance time.

while being easy to install within existing wiring

LEM-02 Energy Meters LKM-01-30 Voltage Indicators PMM-02 Power Limiter BZM-03 Protection Module

The Zamel building automation range is

Other practical Zamel installation modules include useful solutions such as transformers (secondary voltage relative to mains voltage: 8V, 12V, or 14V), audible signaling devices (alarms with various functionalities), and DIN rail-mounted (TH35) switches that can be used, for example, to temporarily disconnect circuits without wearing out the contacts of a circuit breaker.

board.

light sources to be adjusted using wall-mounted switches. ASM-03 Stairwell Timer DIM-20 Dimmer SRP-01/M Shutter Controllers

local or remote operation of window shutters (e.g. security shutters). Other compact automation components designed specifically for buildings include flush-mounted relays – offering functionality and parameters similar to DIN rail-mounted versions, during modernization projects. PEP-01_024 Flush-Mounted Relays WZM-01_S1 Twilight Switches

complemented by twilight switches, typically used to control lighting based on ambient daylight intensity. However, the parameters of these switches also allow them to control other loads. Some models are mounted directly in sunlit locations, while others feature connections for externally installed probes, with the switch itself mounted inside the distribution

Sensors The aforementioned light probes are just some of the many sensors available in the Zamel portfolio. The manufacturer supplies products designed to work with the automation components described above, including flood, motion, and temperature

TRM-12 Transformers ED-1 Audible Signaling Devices PIM-03 Switch Module

sensors. These accessories are intended for use with the supplier’s modules, enabling both the expansion of existing installations and their maintenance and servicing. SZH-03 Flood Sensor

Building Automation Most of the products presented above can be used as components of building automation systems, although they have a much broader range of potential applications. Zamel also offers highly specialized modules, such as stairwell timers designed for energyefficient lighting control in corridors and staircases, as

MCR-01 Motion Sensor SOH-05 Light Probes STZ-02 Temperature Sensors

www.tme.eu

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“The centre of excellence for strainer and ﬁltraaon technology”

www.bartonﬁrtop.co.uk

Visit our website www.ﬁlterserve.com

Call Us 01922 668347

Email Us Filterservesales@power-utilies.com

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Partner with ﬁlterserve for ﬁltration solutions that deliver performance, reliability and peace of mind

NEW DC UPS WITH SUPERCAP BUFFERING FOR FAIL-SAFE 24V SYSTEMS EMERGENCY POWER SUPPLY NOW WITH USB-C AND MODBUS COMMUNICATION.

Bicker Elektronik GmbH, Donauwoerth/Germany, is expanding its portfolio of industrial UPS solutions with the intelligent DC UPS UPSI-2406R2DP2MB – designed and manufactured entirely in Germany. The 24V uninterruptible power supply with maintenancefree Supercaps (EDLC) is ideally suited for reliable bridging of short to medium backup times, protecting connected systems against power failures, voltage dips, and flicker. The compact DC UPS for DIN rail mounting combines a regulated 24VDC backup output voltage at 6A with a completely maintenancefree Supercap energy storage unit and front-panel communication interfaces (USB-C, RS485/Modbus, relay contact). Robust design for continuous industrial operation The UPSI-2406R2DP2MB is rated for an extended operating temperature range of −20°C to +65°C. A robust aluminium housing and high immunity to burst and surge events in accordance with 28

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EN 61000-4-4 and EN 61000-4-5 ensure reliable operation in electromagnetically demanding industrial environments. Comprehensive protection functions – including reverse-polarity, short-circuit, and overcurrent protection – contribute to high operational safety and a long service life. The PowerSharing function dynamically distributes available input power between the load supply and the Supercap charger, so that upstream AC/DC power supplies need not be oversized. Completely maintenance-free Supercap technology (EDLC) Instead of conventional batteries, the DC UPS UPSI2406R2DP2MB is equipped with high-performance electric double-layer capacitors (Supercaps/EDLC) offering an extremely high cycle durability of up to 500,000 charge and discharge cycles. Compared to other energy storage technologies, supercapacitors enable particularly short charge times and guarantee

completely maintenance-free operation throughout the entire service life. Furthermore, the capacitive, purely physical storage principle of Supercaps provides a maximum level of safety, as energy is stored without electrochemical reactions. Interfaces and system integration For integration into existing control and automation environments, the UPSI-2406R2DP2MB features frontpanel USB-C and RS485 Modbus interfaces as well as a configurable relay contact for power-fail signalling. The UPS can transmit system status information and enables seamless integration into higher-level monitoring and control systems.

Key product features at a glance •

DC UPS 24V / 6A (144W) “Made in Germany”

•

Maintenance-free Supercap technology (EDLC) with up to 500,000 cycles

•

Extended operating temperature range from −20°C to +65°C

•

USB-C and RS485 Modbus communication interfaces

•

Relay contact for power-fail signalling

•

Regulated output voltage in backup mode and intelligent power distribution

•

Plug & Play – automatic UPS recognition by the operating system

•

Shutdown & Reboot function, timer, and minimum-load detection

•

Includes intelligent management software “UPScom”

•

Safety approval to IEC/EN/UL 61010-1 / -2-201

UPS Management software “UPScom” For configuration, monitoring, and management, Bicker Elektronik provides the newly developed UPS management software ‘UPScom’ free of charge. The software is based on a WebAssembly architecture and is operated via a web-based user interface in the browser. It supports x86 and ARM-64 systems running Microsoft® Windows and various Linux distributions. In addition to real-time state-of-charge monitoring, parameters such as shutdown delays, maximum backup time, minimum load threshold, and e-mail notifications can be configured. Shutdown & Reboot function for IPC systems In the event of a power failure, the DC UPS signals the power-fail condition and can initiate a controlled shutdown of connected industrial PCs or embedded systems to prevent data loss. Optionally, applicationspecific scripts can be executed prior to shutdown in order to close processes in an orderly manner. Once the supply voltage is restored, the integrated reboot function automatically restarts the system – particularly beneficial for self-sufficient or remotely located installations. The software also supports event-based e-mail notifications, for example in the event of a mains failure, system shutdown, or communication errors. Versatile applications The UPSI-2406R2DP2MB is suited for uninterruptible operation of embedded IPCs, controllers, motor drives, sensors, and measurement, control, and safety equipment. Typical applications include control cabinet solutions, decentralised power supply concepts, and industrial systems where continuous power availability is essential. The DC UPS is approved to IEC/EN/UL 61010-1 and IEC/EN/UL 61010-2-201 and is available ex-stock.

www.bicker.de

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RETHINKING DEBURRING FOR MODERN MANUFACTURING For decades, deburring has been regarded as a necessary finishing operation, an essential but often overlooked step at the end of the manufacturing process. As manufacturing becomes increasingly automated and software-defined, manufacturers are beginning to question whether traditional deburring methods remain suitable for today’s production environments. Burrs may be small, but their impact is anything but. They can affect component assembly, compromise product performance, and introduce unnecessary variation into production. In sectors such as aerospace, automotive, and precision engineering, where quality and repeatability are paramount, deburring has become far more than a cosmetic process. Historically, manufacturers have relied on mechanical techniques such as grinding, brushing or abrasive blasting. While these methods remain effective for many applications, they often depend on dedicated tooling, manual intervention, or operator experience to achieve consistent results. As component designs become more intricate, and production shifts towards higher-mix, lower-volume manufacturing, these traditional approaches can struggle to provide the flexibility, repeatability, and scalability increasingly required by modern manufacturing

When integrated with collaborative robotics, softwarecontrolled deburring becomes even more adaptable. Manufacturers can adapt automated production cells to be reprogrammed and accommodate changing component designs without extensive retooling, helping manufacturers respond more efficiently to evolving production demands. As manufacturers continue to invest in smarter, more flexible, production systems, deburring is evolving from a standalone finishing operation into an intelligent, digitally controlled manufacturing process. It is becoming an intelligent, programmable manufacturing operation in its own right. The future of deburring will not be defined by increasingly complex tooling, but by software that enables manufacturers to specify, control, and optimise the desired outcome with confidence.

The broader shift towards software-defined manufacturing is beginning to reshape finishing processes too. Rather than relying solely on dedicated tooling, manufacturers can increasingly define the desired surface outcome digitally, adapting process parameters quickly for different components while maintaining consistency across production. At TextureJet, this philosophy underpins the development of software-controlled Electrochemical Jet Machining. By combining intelligent software with a non-contact electrochemical process, manufacturers can remove burrs with higher levels of precision while preserving the integrity of the surrounding material. Without mechanical contact, there is no tool wear, and because the process generates no thermal damage, it eliminates concerns associated with heat-affected zones on sensitive components.

www.texturejet.com

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GREATER FLEXIBILITY FOR YOUR INDUSTRIAL IT: HOW MODULAR IPCS OPEN UP NEW POSSIBILITIES The demands placed on industrial IT systems are constantly evolving. A diverse range of machinery, custom interfaces, and harsh operating conditions require solutions that offer more than just standard performance – they require adaptability. Where rigid, “one-size-fits-all” systems quickly reach their limits, modular concepts are stepping in to provide future-proof scalability. Industrial PCs (IPCs) serve as the vital link between process technology and IT. Box PCs, in particular, have long been favoured for their robustness and low-maintenance 24/7 operation. However, their greatest advantage today lies in modularity. Rather than being locked into pre-configured hardware, companies can now specify and expand their IPCs to meet exact application requirements and environmental challenges. The Box PC series from Shuttle is a prime example of this evolution. Engineered for resilience, these systems feature reinforced aluminium and steel chassis and a fanless design for maximum reliability. Beyond their physical durability, it is their modular DNA that sets them apart. Through a wide array of expansion

modules and accessories, each device can be tailored to the task at hand. For instance, dedicated daughterboards allow for the seamless integration of additional interfaces, including serial connections, enhanced networking options, or specialised industrial communication protocols. Options for RF modules or a wide DC voltage range of 9–36V provide further flexibility – a critical factor in complex production environments where power sources can vary. Furthermore, versatile mounting kits ensure that these systems can be integrated into any workspace, whether mounted horizontally, vertically, or via DIN-rail. Shuttle’s latest Box PC models push these boundaries even further. Powered by 12th-generation Intel Core processors, they combine high-performance computing with a flexible I/O architecture designed for diverse IoT scenarios. Whether the application involves Edge AI, real-time data analysis, or high-speed image processing, the systems scale to meet the demand. With an impressive operating temperature range of -20°C to +60°C, they are as dependable in the field as they are on the factory floor. The result is a future-proof, cost-effective solution that balances high performance with bespoke customisation – a decisive advantage in today’s dynamic industrial landscape.

Discover how Shuttle’s modular solutions can empower your infrastructure: https://go.shuttle.eu/rAsYf www.tbafirefly.com

BOX-PC BPCAL02/03

URES FLEXIBLE FEATS RT PO D AN

Fanless operation for silent and maintenance-free use Intel Core i7, i5 or i3 processor Supports up to 64 GB DDR5 RAM High-speed NVMe M.2 SSD Expandable with up to 4× LAN, 4× COM, 20× USB, DVI, VGA, DP, HDMI, LTE, Wi-Fi, DIO and more Industrial-grade aluminium chassis Extended temperature support from -20°C to +60°C (optional) Multiple mounting options including VESA, DIN rail and ear mounts

FROM £429*

Further information at WWW.SHUTTLE.EU

MODULAR INDUSTRIAL PCS WITH A ROBUST, FANLESS DESIGN Shuttle is offering it’s second gen of very robust industrial PCs with a compact design. The complete systems from the family of Box-PCs come packed in a multi-reinforced aluminium and steel chassis. Equipped with an Intel Core i7, i5 or i3 processor, they can handle any task. Their modular design means that the functional scope and ports can be customised individually to suit the customer’s wishes.

* Recommended RPP from official Shuttle distributors, plus VAT. Subject to errors and alterations.

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e PC ‒ as uniqu TIP: Your Box- Use our product ! ct as your proje ur and tailor yo configurator rfectly to your barebone pe . requirements /cEMWl go.shuttle.eu

As one of the world's leading companies in the field of electronic linear and angle encoders RSF Elektronik offers an extensive portfolio which includes almost all designs which are essential in the market. Due to the required positioning accuracy for the realisation of many modern products high precision measuring devices are an important basis. RSF Elektronik provides encoder systems for the electronic industry, for general automation as well as precision metrology.

INCREMENTAL EXPOSED LINEAR ENCODERS MS 14 | MS 15 Two versions. One commitment. n n n n

STABLE ACCURACY THROUGH ACTIVE ONLINE STABILIZATION RELIABLE OPTICAL LIMIT FUNCTION EASY REFERENCE MARK SELECTION PLUG & PLAY INTEGRATION BASED ON INDUSTRY STANDARDS

RSF Elektronik are distributed in the UK & Ireland by HEIDENHAIN GB Ltd. T: 01444 247711 | E: sales@heidenhain.co.uk

ON-SITE, ON-DEMAND: RETHINKING WATER DISINFECTION FOR THE CONNECTED PLANT Across both industrial and commercial estates, water treatment infrastructure is being asked to meet a widening set of demands: regulatory compliance, operational resilience, energy performance, and increasingly, integration with the control and monitoring systems that govern the rest of the built environment. These are the same priorities driving specification decisions everywhere else in the plant, yet water disinfection is one area where legacy practice often persists unchallenged, even as automation and IoT connectivity transform decision-making across every other system. That gap has consequences: for compliance, for plantroom design, and for the operational data that most engineers now expect as standard from every system on site. The limits of legacy dosing Bulk sodium hypochlorite dosing remains the default disinfection method across many commercial and public buildings, as it’s familiar and widely 34

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understood. Familiarity, however, is not the same as suitability. Stored hypochlorite is chemically unstable: it degrades progressively, accelerated by heat, light and prolonged storage, meaning the concentration held in a bulk tank is never fixed. Any system relying on stored solution for consistent disinfection is, by definition, dosing from a chemistry in continuous decline. Maintaining reliable residual levels demands ongoing manual adjustment, and the margin for error narrows as the solution ages, a poor fit for operations that increasingly expect predictable, auditable performance data from every system they run. On-site generation, engineered for integration Electrochlorination offers a different model. Sodium hypochlorite is generated on-site, on-demand, from salt, water and electricity via an electrolytic process. The underlying chemistry is established; what has changed is the sophistication of the systems delivering it. Current-generation platforms, including our

Hyprolyser® iSEC® range, are compact and modular, engineered to integrate directly into building management and control systems rather than sit apart from them. Patented vacuum blending technology maintains a precisely controlled rate of flow, producing consistent chlorine concentration without manual intervention. An IoT platform built into the system extends that control further: engineers can access full diagnostics and carry out remote maintenance, service partners can manage equipment and generate compliance reports, and operators can monitor disinfection performance and system status in real time, from any connected device. Because the solution is generated continuously and used almost immediately, there is no degradation. Dosing is repeatable, and performance is verifiable. Simplifying the plant footprint Removing bulk chemical storage from the plantroom has a direct, measurable effect on design. Storage footprint, secondary containment, ventilation requirements and delivery access all fall away. Pipework configurations simplify, and the number of potential failure and compliance points reduces accordingly, outcomes that matter to any engineer managing constrained plant space. In retrofit projects, where every square metre is contested, that reduction can be decisive. In new-build specification, designing electrochlorination in from the outset removes an infrastructure burden before it exists, rather than engineering around it later.

removes the associated transport emissions and the embedded carbon cost of manufacturing, packaging and distributing concentrated hypochlorite. Chemical waste from degraded or unused stored solution, a persistent issue with bulk dosing, is eliminated entirely. For projects targeting BREEAM, NABERS or net-zero operational benchmarks, these are quantifiable inputs that sit squarely within the scope of water management strategy. Specify early, benefit longer Electrochlorination systems are not difficult to retrofit, but the greatest returns come from decisions made at specification stage: plantroom layout, electrical supply and system integration all deliver better long-term outcomes when planned upfront rather than engineered in later. Modern systems are available off-the-shelf with short lead times and straightforward commissioning once on site, lowering the practical barriers considerably. Water disinfection infrastructure shapes a building’s performance in ways that rarely feature in early design and automation planning. As control systems, IoT platforms and remote monitoring become standard expectations across the built environment, on-site generation is no longer a niche alternative. It is a proven, connected technology that belongs in the specification conversation for any project built for long-term performance.

Reducing risk at source Minimising stored chemical volume in occupied buildings is a safety and liability question as much as an operational one. Concentrated hypochlorite requires careful handling, and the risks associated with storage failure, mishandling or accidental exposure are not trivial. On-site generation reduces the volume of hazardous material held at any given time, limits the number of personnel required to handle it, and removes dependency on external supply chains, chains that recent years have repeatedly shown are not immune to disruption. For engineering and facilities teams accountable for compliance signoff, that reduction in stored risk simplifies the case considerably. The sustainability calculation The environmental case is more measurable than it first appears. Eliminating regular chemical deliveries

For more information on Gaffey’s Hyprolyser® iSEC® electrochlorination systems, visit gaffeytechnology.com

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Plan your career development...

Mechanical Integrity Training • Satisfy industry requirements at each competency level – Awareness, Basic application, Practitioner, Leader. • Covering: * Legislative environment * Industry good practice * WSE * Equipment design * ALARP

* Asset condition * Test techniques * Operational considerations * Inspection roles, process & reports * User responsibilities & competencies * Feedback * Postponement * Responses to findings * Audit * Record keeping * Operating Limits * Decision Making * More. • Certificated up to 5 years – CPD / PDH approved. • Flexible delivery to suit Learners and companies – Blended, Live online, Classroom, E-learning. • Courses throughout each year available to all – free or discounted to EEMUA Members and Associates. EEMUA Hydrogen Damage Mechanisms Basics Mechanical Integrity Practitioner Certificate – blended, live online – for those with at least 1 year (MIPC®) – part-time, blended, live online learning of experience – flexible learning 4 hours per week – – on-site or on-call – 1:1s and Mentor Support – CPD 21 hours – next course starts 5 April 2027. workbook builds from day-1 for immediate on-site application of EEMUA 177, 231 and 232 guidance, EEMUA 231 Mechanical Integrity Basics and the PSSR ACOP – certificated for 5 years – blended, online learning – Basic application via exam and portfolio assessment – in-depth competency level – flexible 4 hours of learning per learning for 27 weeks, flexible 4 hours per week week for 3 weeks 12 hours of CPD – certificated – 110 hours of CPD. The MIPC course adapts to via exam – next course starts 28 September 2026. engineering needs of each Learner, company and EEMUA 231 Mechanical Integrity e-learning – site/s via a 2-hour induction (to fit work schedules) Awareness level – with 1 hour of CPD – On-demand. – next course starts 19 October 2026. Also... EEMUA and AMPP Benelux

Internal Corrosion and Cathodic Protection Seminar – Antwerp, BE – 22 October 2026 www.eemua.org training@eemua.org +44 (0)20 7488 0801

Improve performance with timely monitoring Promptly identify steam trap faults and steam system issues with our monitoring solutions. Quick deployment from a pilot to whole site installation, no invasive work (no shutdown requirement) and no integration with local networks or IT systems necessary. ⦿ Simple - Quick install on steam traps and equipment ⦿ Cost effective - High return on investment through loss reduction ⦿ Zero maintenance - Energy harvesting eliminates battery changes ⦿ Timely reporting - Regular performance reports and real-time data view ⦿ Flexible - Run standalone, or integrate with existing on-site systems ⦿ Wireless Technology - With support for world-wide LoRaWAN and BLE standards

t: +44 (1285) 359059 e: sales@dcosystems.co.uk w: www.dcosystems.co.uk 36

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FLEXIBLE SCREW CONVEYOR WITH TROUGH HOPPER

Quick-disconnect clamps near the drive point and a removable cleanout cap at the opposite end of the conveyor (shown) allow for easy removal and cleanout of the flexible screw during material changeovers. This Flexicon® flexible screw conveyor with trough hopper can receive material from multiple outlets of feeders, grinders, blenders, bulk bag dischargers, or any process equipment with a wide-style discharge.

sensors enable real-time monitoring of material levels within the hopper and transmit signals to address critical issues such as overflow or conveyor starvation, ensuring efficient and uninterrupted operation.

Measuring 108 in. (275 cm) in length, the hopper’s low (36 in/92cm) profile enables it to be positioned beneath the discharge point of most vessels. The hopper’s bottom features a U-shaped channel that exposes the flexible screw for the entire length of the vessel, allowing material entering the hopper at any point to charge the conveyor. The hopper is equipped with a stainless-steel grate for worker safety and to prevent oversized particles from entering the conveyor.

The rugged inner screw is the only moving part contacting material and is offered in numerous designs to handle both free- and non-free-flowing materials, including products that pack, cake, or smear, with no separation of blends. As it rotates, the flexible screw self-centers within the tube, providing ample clearance between the screw and tube wall to eliminate or minimize degradation. Material exits the conveyor below the drive point, precluding contact with bearings or seals. Quick-disconnect clamps near the drive point and a cleanout cap at the opposite end of the conveyor allow for easy removal and cleanout of the flexible screw during material changeovers.

The hopper walls are equipped with ports designed for the optional installation of level sensors. These

www.flexicon.com

MACHINERY, AUTOMATION, CONTROL & ENGINEERING

THE MISSING LINK IN MIXED POWERTRAIN MANUFACTURING CONTROLLING VARIABILITY FOR FLEXIBLE ICE-EV-HYBRID PRODUCTION. operators and tools adjusting to different parts, structures and electrical systems as each vehicle or component is built. This reflects a market still in transition, where manufacturers must support multiple powertrain types in parallel because demand has not settled around a single technology. As of May 2026, the “battery electric car market share had crept up by just half a percentage point to 23.1 per cent”, still below the 33 per cent share required under the ZEV mandate, underlining the gap between regulatory targets and current demand. This uncertainty extends beyond vehicle manufacturers. Tier suppliers must increasingly support multiple platforms, shorter programme cycles and changing specifications without compromising process control. Where variability becomes risk As automotive manufacturers respond to increasing volatility in demand, regulation and powertrain strategy, flexibility has moved from competitive advantage to operational requirement. Production systems are no longer being optimised solely for efficiency or volume stability, but for their ability to absorb uncertainty. Here, Josh Scanlon, Area Sales Manager at automotive assembly tools manufacturer Desoutter Tools, explains how connected fastening systems can help manufacturers maintain process control as production environments become increasingly complex. Automotive manufacturing is undergoing its most significant change since the introduction of the original assembly line, as predictable multi-year cycles give way to shorter timelines and greater variation. This is most visible in the rise of mixed-model manufacturing: where ICE, hybrid and electric vehicles are built on shared or rapidly reconfigurable assembly lines. A system of controlled variability On today’s assembly lines, the process is no longer identical from one vehicle to the next. ICE, hybrid and electric models pass down the same line, with 38

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Nowhere is this shift more pronounced than in fastening operations. Fastening sits at the intersection of structural integrity, electrical safety and production execution. Its importance is heightened in electric and hybrid platforms, where it governs battery enclosures, high-voltage systems and lightweight structures. In mixed-model environments, fastening complexity increases significantly, since different vehicle variants require different torque specifications, tightening sequences and joint strategies. Recent recalls have shown how even small deviations in fastening integrity can have significant consequences. In May 2026, Ford recalled almost 180,000 Ranger and Bronco vehicles after identifying that a front seat frame bolt could become loose or dislodged, reinforcing how critical accurate fastening and verification remain. Fastening has become a point of process control where manufacturing variability is either contained or allowed to spread through the rest of the production system. For UK manufacturers operating in high-value, lower-volume environments, maintaining fastening quality while increasing production flexibility is therefore becoming a defining operational challenge.

Connected fastening as a process control layer As production environments become more variable, fastening systems must do more than just deliver a specified torque. They must help ensure that the correct fastening process is applied to the correct vehicle, at the correct stage of assembly, every time. This requires connected fastening systems that integrate tooling, process control and production data within a closed-loop manufacturing architecture. Desoutter’s connected assembly ecosystem brings together intelligent tools, controllers and software platforms to support tightening execution, process control and production traceability within a single mixed-model manufacturing environment. Within this model, tightening parameters are defined at system level and assigned according to production inputs, including vehicle variant identification. Connected tools can automatically apply the correct fastening strategy for each application, enabling multiple vehicle configurations to be managed within the same production environment. This enables manufacturers to adapt to production variability while reducing reliance on manual process selection and ensuring the right settings and quality checks are applied.

Crucially, each fastening operation is validated at the point of execution through real-time feedback and process confirmation, ensuring deviations are identified immediately rather than retrospectively. This prevents non-conforming assemblies from progressing downstream and creates a traceable record of critical fastening operations. Tightening data can be captured and analysed to support process verification, traceability and continuous improvement across production runs. Within this framework, fastening becomes a connected process control function embedded within the wider manufacturing system. Flexibility has become a prerequisite as manufacturers continue to balance ICE, hybrid and electric vehicle production. The ability to control variability at the point of assembly will determine how effectively they can scale changing production strategies while maintaining quality. Fastening sits at the centre of this challenge. By connecting execution, verification and production data, manufacturers can turn a traditionally fixed assembly operation into an adaptable process control point, enabling greater flexibility without compromising consistency.

For a live demonstration of how Desoutter’s connected assembly ecosystem supports mixed-model automotive manufacturing, schedule a visit to the Innovation Centre in Congleton, Cheshire.

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10 THINGS TO CONSIDER WHEN SPECIFYING PNEUMATIC CYLINDERS FOR WASHDOWN AREAS CAMOZZI AUTOMATION UK HAS OUTLINED TEN KEY FACTORS ENGINEERS, OEMS AND DISTRIBUTORS SHOULD CONSIDER WHEN SPECIFYING PNEUMATIC CYLINDERS FOR WASHDOWN ENVIRONMENTS. Pneumatic cylinders used in washdown areas will be exposed to water, cleaning chemicals, detergents, temperature changes and high-pressure spray. These conditions can accelerate corrosion, damage seals and allow contamination to collect around the cylinder body, piston rod and mounting points.

2. Assess Direct Exposure

Selecting a cylinder based only on bore, stroke and mounting dimensions can therefore lead to premature failure, increased maintenance and unplanned downtime.

considered alongside the possibility of splash, vapour

Camozzi Automation UK recommends considering the following ten areas before selecting an ISO-profile pneumatic cylinder for a washdown application.

A standard aluminium-profile ISO cylinder may be

1. Understand the Washdown Process

resistant versions featuring stainless-steel piston rods,

Washdown conditions vary considerably. Some machinery may receive an occasional low-pressure rinse, while other equipment is cleaned daily using heated water, aggressive chemicals or highpressure jets. Engineers should establish the cleaning frequency, water pressure, temperature, spray direction, chemical concentration and expected contact time.

MACHINERY, AUTOMATION, CONTROL & ENGINEERING

A cylinder protected behind guarding may require a different specification from one positioned directly within the wash zone. The level and direction of exposure should be and cleaning-fluid run-off. 3. Select the Correct Cylinder Construction

suitable for light, occasional or indirect exposure. For more demanding environments, corrosiontreated fasteners, protective coatings or alternative scrapers may provide a better balance between durability and cost. Camozzi Series 63 ISO 15552 cylinders are available in configurations developed for demanding conditions, including corrosion-resistant, hydrolytic, food and beverage, dirty and dusty, and polyurethane-coated versions.

4. Consider Whether Stainless Steel Is Required For intensive washdown or highly corrosive environments, a stainless-steel cylinder may be more appropriate. Camozzi Series 90 cylinders comply with ISO 15552 and feature AISI 316 stainless-steel construction. They are designed for applications requiring high corrosion resistance, including food, marine and offshore environments. However, “stainless steel” should not be treated as a complete specification. The precise grade and

Open profile grooves, exposed threads, recessed fasteners and poorly positioned pneumatic ports may retain water or cleaning residues. Unused grooves should be covered where practical, while tubing and fittings should be positioned to support drainage and effective cleaning. 9. Protect Sensors and Pneumatic Connections Sensors, cables, connectors, tubing and fittings must withstand the same washdown conditions as the cylinder.

5. Review the Complete Assembly

The environmental and chemical resistance of magnetic sensors, cable glands, valve plugs, pushin fittings and pneumatic tubing should all be confirmed.

The service life of a pneumatic cylinder can be limited

10. Consider Maintenance and Failure Analysis

the materials used for the piston rod, fasteners and mountings should also be confirmed.

by its least resistant component. The cylinder body, piston rod, fasteners, brackets, sensors, fittings, tubing and accessories should therefore be assessed as one complete assembly. A stainless-steel cylinder fitted with standard platedsteel mounting hardware may still leave vulnerable points within the installation.

The cylinder should be positioned so that it can be inspected, cleaned and replaced without unnecessary disruption. Where repeated failures occur, the underlying cause should be investigated rather than simply replacing the cylinder. Misalignment, side loading, unsuitable seals, poor air quality or chemical incompatibility may be contributing to the problem.

6. Check Piston Rod Protection ISO Compliance Is Only Part of the Specification The piston rod is one of the most exposed and operationally important parts of a cylinder. Corrosion, scratching or contamination can damage the rod seal and allow contaminants to enter the actuator. Rod material, surface finish, direct spray exposure, scraper type and the risk of impact should all be considered. Protective bellows or scraper seals will provide additional protection in some environments. 7. Confirm Seal and Chemical Compatibility A seal material that performs effectively with water may not tolerate alkaline cleaners, acids, disinfectants or elevated wash temperatures. Chemical type, concentration, contact duration, operating temperature and cleaning frequency should be provided to the cylinder supplier so that the correct sealing arrangement can be selected. 8. Avoid Water and Contamination Traps Cylinder orientation and installation design can influence how effectively water drains away.

ISO compliance confirms dimensional compatibility, but it does not guarantee identical materials, sealing systems or environmental performance. Specifying a reliable cylinder for a washdown area requires engineers to consider the complete operating environment, including construction materials, chemicals, seals, accessories, drainage and maintenance access. Camozzi Automation UK supports pneumatic component distributors, OEM engineers and plant automation teams with ISO-profile cylinders, stainless-steel cylinders, mounting accessories, sensors, fittings and air-preparation equipment. To discuss a washdown application or request technical support with pneumatic cylinder selection, contact Camozzi Automation UK.

www.camozzi.co.uk/news/how-to-specify-iso-profile-cylinders-for-washdown

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HOW AI IS BECOMING EMBEDDED IN ROBOTICS ENGINEERING BY CALUM MACDOUGALL, SENIOR MECHANICAL DESIGN ENGINEER, DEXORY Warehouse robotics adoption is accelerating. The 2026 Intralogistics Robotics Survey, covering organisations across manufacturing, transport and warehousing, wholesale and retail, found that 52% of organisations are using one or more types of robot. The commercial market is growing alongside adoption. The global warehouse robotics market was valued at $14.7 billion in 2024 and is projected to reach $117 billion by 2034. For robotics engineering teams, this growth creates a practical challenge: shortening product development cycles without compromising performance or reliability. This is where AI comes in. Much of the discussion around AI and robotics has understandably focused on intelligence within the robot itself. But there is another change happening behind the scenes. AI is beginning to influence the engineering processes used to design, simulate and test physical products. 42

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At Dexory, we are testing what this looks like in practice. Building on our existing use of SimScale’s AInative cloud simulation platform, we have deployed its Engineering AI technology to explore how AI agents can automate parts of our simulation workflows and accelerate engineering analysis. Moving from manual simulation to agentic workflows Simulation is fundamental to mechanical engineering because it allows us to understand how a component or assembly is likely to behave under load before committing to physical prototypes or production. But simulation carries its own overhead: defining the load cases and boundary conditions, configuring and meshing each analysis, running it, and interpreting the results - then repeating the cycle as the design evolves. At Dexory, we are using Engineering AI to help reduce the time engineers spend investigating structural component failures through FEA, and by enabling more simulation iterations during critical design phases. The programme is also intended to automate parameter sweeps, effectively testing multiple combinations of design variables and generating

comparative results without an engineer having to configure every simulation individually. SimScale’s platform also automates simulation reporting, making it easier to analyse, compare and share results across the engineering team. The important distinction is that this does not remove engineering judgement from the process. Engineers still need to understand the problem, define appropriate constraints and determine whether the results make physical sense. The opportunity is to reduce the repetitive work around that process so engineers can spend more time interpreting results and making design decisions. Turning previous engineering work into reusable knowledge There is another opportunity that is potentially just as important: engineering memory.

AI still has a blank-sheet-of-paper problem The bigger question, however, is not simply what AI can automate. AI currently has what I think of as a “blank sheet of paper problem” in engineering. We know the technology can automate certain tasks, but engineering organisations are still working out where it creates the greatest practical value. This distinction matters. The objective should not be to insert AI into every engineering workflow simply because the technology is available. We need to understand which activities benefit from automation, where human engineering judgement remains essential, and where AI can genuinely improve the speed or quality of engineering decisions. That is one reason our work with SimScale’s

Engineering teams accumulate knowledge continuously. A simulation from an earlier project may contain an approach or insight that could help solve a problem months or years later. The challenge is making that knowledge easy to find and reuse. As part of this programme, the agents will capture simulation knowledge from previous projects to create a searchable engineering memory. The aim is to help engineers reuse proven approaches and preserve expertise as the business grows.

Engineering AI is not focused solely on productivity. We also want to learn where AI agents deliver the greatest value for our engineering organisation and establish best practices that can guide future adoption. The engineer’s role will evolve AI’s impact on engineering may therefore be less about replacing individual engineering tasks and more about changing how engineers interact with the design and validation process.

This could change the value of simulation data. Rather than each project existing largely as a record of a particular engineering problem, previous work can become a body of knowledge that engineers can draw on when tackling new ones.

If agents can configure and execute more routine simulation work, engineers can potentially explore more design options and focus more of their attention on interpreting what those simulations tell them. This makes engineering expertise more important, not less. Faster analysis is only useful if someone understands the physics behind the result, recognises when something looks wrong and knows which question to ask next. We are still early in understanding exactly how that relationship will develop. That is precisely why engineering teams need to start learning now. For us, deploying Engineering AI agents is not simply about solving today’s engineering challenges faster. It is an opportunity to understand how AI could reshape engineering over the coming years and, importantly, where it can genuinely make engineers better at what they do.

www.dexory.com

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VISION ENGINEERING LAUNCHES PICOZOOM, A NEW AUTOFOCUS DIGITAL INSPECTION MICROSCOPE FOR GLOBAL QUALITY CONTROL New benchtop system combines motorised autofocus, focus stacking, and built-in measurement and reporting to help electronics, medical device and precision manufacturing teams inspect faster and document results more consistently.

One-click autofocus and a motorised 0.7× to 4.5×

Vision Engineering, a UK-based designer and manufacturer of magnification and inspection systems, today announced the global launch of PicoZoom, a new autofocus digital inspection microscope built for electronics, component amotorised zoom, one-click autofocus, focus stacking, and built-in measurement and reporting tools in a single workflow, helping inspection and quality teams achieve clearer images, faster set-up and more consistent, documented results.

keep results consistent between operators and shifts.

Manufacturers are under growing pressure to meet tighter quality control requirements and to document inspection results more thoroughly, without slowing down production. PicoZoom has been developed to meet that need, sitting between low-cost USB microscopes and higher-end digital inspection platforms and giving manufacturing and quality control teams access to autofocus imaging, measurement and reporting within one accessible system.

at different focal planes into one sharp composite,

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optical zoom (18.9× to 121.8× system magnification) allow operators to move between parts, surfaces and magnification levels without changing lenses or manually refocusing, reducing set-up time and helping

Quadrant-controlled LED lighting gives operators directional control over illumination and automatic exposure, making edges, marks and surface detail easier to see on reflective or low-contrast parts. On parts with depth, such as solder joints, stepped surfaces and threaded components, a single image often only shows one area in sharp focus. PicoZoom’s focus stacking function combines images captured extending depth of field across the part without manual refocusing. Built-in dimensioning and annotation tools, together with custom report output, let operators capture on-screen measurements and images and compile them into formatted reports without leaving the system, supporting quality control documentation and traceability.

PicoZoom connects via HDMI, USB 3.0 and LAN. It uses a 2 MP CMOS sensor delivering 1080p resolution at 60 fps, and occupies a compact benchtop footprint of 320 x 308.6mm. “Manufacturers today face increasing pressure not only to carry out inspections consistently, but also to demonstrate and document the results,” said Sam Crossley, Managing Director of Vision Engineering. “PicoZoom combines imaging, illumination and reporting in a single, easy-to-use system that can be deployed quickly and adopted with minimal training. By making documented, repeatable inspection more accessible, it enables a wider range of manufacturers to benefit from capabilities that have traditionally

required a significantly greater investment. PicoZoom is a natural extension of our digital inspection portfolio and reflects our commitment to helping customers improve quality, traceability and efficiency.” Typical applications for PicoZoom include PCB and solder joint inspection, medical device inspection, incoming goods inspection and defect analysis, alongside broader use in component inspection and quality control across aerospace, motorsport, welding, automotive, research and education environments. PicoZoom is available now through Vision Engineering’s global network of branches and authorised distributors, with a UK list price starting at £3,250.

Full technical specifications and further information are available at www.visioneng.com

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Unlock efficiency with control panels tailored to your needs At INDUS Engineering Services, we specialise in bespoke control panels designed for reliability, performance and ease of use. From manufacturing and automation to FMCG, our systems are engineered to streamline operations and optimise performance.

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MANUFACTURERS FACE AUTOMATION DIVIDE AS FUTURE-FIT BUSINESSES ACCELERATE INVESTMENT.

Banelec’s recent aerospace fan casing lift £500k order

The manufacturers that embrace integrated automation over the next five years are set to pull decisively ahead of competitors still relying on disconnected production systems, according to new global research highlighting one of the biggest shifts in industrial manufacturing for decades.

Rather than viewing automation as a series of individual projects designed to improve a single production line, more manufacturers are looking at how electrical controls, machinery, robotics, energy systems and production data can work together as part of a wider operating environment.

PwC’s Global Industrial Manufacturing Sector Outlook 2026 predicts that the proportion of manufacturers with highly automated core processes will more than double by 2030, rising from 18% today to 50%. Among the industry’s most advanced businesses, automation levels are expected to reach 65%, creating an increasingly significant competitive advantage through higher productivity, greater agility and faster decisionmaking.

Dean Banner, Managing Director of Banelec, believes the conversation around automation has fundamentally changed.

For Black Country based electrical control systems manufacturer and automation integrator Banelec, the findings reflect a trend that has been steadily gathering pace across UK manufacturing. 48

MACHINERY, AUTOMATION, CONTROL & ENGINEERING

“Five or ten years ago, many automation projects focused on replacing a manual process or making one machine work more efficiently,” he said. “Today our customers are looking at their entire operation. They want production equipment, electrical controls, robotics, energy systems and factory data to communicate with one another so the whole business becomes more responsive.” That shift places greater emphasis on the engineering infrastructure underneath digital manufacturing. A

modern automated production environment may bring together PLC and HMI systems, SCADA, variable speed drives, robotics, safety systems and industrial networks, with the control architecture providing the link between individual pieces of equipment. It is an area in which Banelec works across the full project lifecycle, from control-system design and panel manufacture through to programming, integration, installation and commissioning. Its engineers work with a range of PLC, HMI and SCADA platforms, including Siemens, Allen-Bradley, Mitsubishi and Schneider, allowing systems to be integrated around the requirements of individual production environments rather than forcing manufacturers into a single technology stack. The PwC research, based on interviews with 443 senior manufacturing executives across 24 territories, concludes that future performance will depend less on simply acquiring new technologies and more on integrating them effectively. Production and operations are expected to become the largest users of advanced technologies by 2030, while the research also identifies a widening gap between future-fit manufacturers and their peers. That distinction is particularly relevant as factories become more interconnected. Adding a robot, upgrading a PLC or introducing a monitoring system can deliver a local improvement, but the wider gains come when those technologies can exchange information and contribute to a coherent production strategy. According to Dean Banner, this systems-level thinking is where many manufacturers now gain their competitive advantage. “The real value isn’t simply adding more automation. It’s making every part of the factory work together. If machines operate in isolation, you only improve individual processes. When electrical control systems integrate production equipment, energy management, quality monitoring and operational data, manufacturers gain visibility they simply didn’t have Dean Banner MD discusses automation trend

before. That allows faster decisions, better productivity and much greater resilience.” The same principle is increasingly being applied to maintenance. Industry 4.0 technologies can allow manufacturers to move from reactive “fail and fix” maintenance towards more predictive approaches, using equipment data to identify potential problems before they result in unplanned downtime. Banelec’s Industry 4.0 work includes remote monitoring, live data streaming and predictive maintenance applications, reflecting the broader move towards using production data not simply to observe what has happened, but to inform what should happen next. PwC also expects manufacturers to generate an increasing proportion of revenue from activities beyond traditional product manufacturing. Its research projects that 44% of total revenue could come from outside the manufacturing of industrial and consumer products by 2030, as businesses expand into connected solutions, services and intelligent technologies. For engineering companies, that evolution is creating demand for automation infrastructure capable of supporting more flexible production, digital manufacturing, predictive maintenance and remote monitoring. It also means that integration needs to be considered from the outset. Retrofitting new technologies into an existing production environment can involve legacy equipment, different control platforms, safety requirements and the practical constraints of keeping a working factory operational. Banelec’s integration engineers work on both new systems and existing production equipment, including projects involving PLCs, robotics and HMI systems. The company also provides relocation and integration services where existing equipment needs to be incorporated into a new or modified production environment. Dean Banner believes this represents a natural progression for manufacturers investing for long-term growth. “Automation cannot purely be viewed as a capital investment to reduce labour. It’s becoming part of wider business strategy. “Customers want systems that can adapt as production changes, accommodate new equipment, provide better operational information and support future expansion without rebuilding everything from scratch.” That requirement for scalability is particularly important as manufacturers invest in technologies that may need to remain operational for many years. The electrical control system is often the point at which MACHINERY, AUTOMATION, CONTROL & ENGINEERING

different technologies ultimately meet, making its design and integration an important consideration in determining how easily a factory can adapt.

Dean Banner believes that principle mirrors the

Banelec’s approach is consequently not limited to standalone control panels or individual automation components. The company provides bespoke electrical control systems alongside automation, robotics, PLC and HMI programming, conveyor controls and Industry 4.0 applications, with engineering support extending from initial design through installation and commissioning.

“The businesses moving fastest aren’t necessarily

As manufacturers continue investing in digital transformation, Banelec expects electrical control engineering to become an increasingly strategic discipline rather than simply a supporting function.

As UK industry continues its drive towards smarter

The PwC report reaches a similar conclusion from a broader industry perspective: the manufacturers best placed to benefit from the next wave of technology adoption will not necessarily be those buying the greatest number of new tools, but those capable of combining technology, data and interoperable systems effectively.

direction already being taken by many of Britain’s most successful manufacturers.

buying the most technology, because they’re investing in engineering that allows everything to work together. That’s where automation delivers its biggest return, the control system becomes the foundation that connects people, processes and technology into one efficient manufacturing operation.”

factories, the distinction between automation leaders and laggards is likely to become increasingly defined not by the number of machines they own, but by how intelligently those machines are connected. For manufacturers considering that transition, the challenge is therefore becoming less about automating one more process and more about creating the control, data and integration infrastructure that allows the entire operation to evolve.

Jennie Banner, Operations Director overseeing customer journey at Banelec

For more information visit: www.banelec.com

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CHOOSING THE PROPER FLEXIBLE SERVO COUPLING FOR HIGHTORQUE APPLICATIONS Disc, bellows and slit couplings from Ruland have high torque for use in precision systems: Bellows couplings provide best size-forsize torque capabilities with limited misalignment capabilities. Disc couplings have higher misalignment than bellows couplings with slightly reduced torque capabilities. Slit couplings have better misalignment and can fit in more confined spaces than a disc or bellows coupling.

capabilities at the expense of torque and stiffness. They are available in single and double disc styles. The single disc style is comprised of two aluminium hubs mated to stainless steel disc springs. It is a compact design with equivalent torque and higher stiffness than double disc styles. Designers must be careful when using a single disc coupling, as they have no accommodation for parallel misalignment. Since the torque values are the same, the primary benefit of using a single disc coupling is for space efficiency. Double disc styles feature two aluminium hubs, a center spacer, and two sets of disc springs. This design allows the double disc coupling to function like a double cardan u-joint, with each hub operating independently. Additional disc springs reduce stiffness while maintaining consistent torque compared to the single-disc style. Double disc couplings can accommodate all forms of misalignment, making them the preferred disc

Matching high-torque applications with the ideal servo coupling demands careful consideration of several factors, including torque and misalignment capabilities, speed requirements, and spatial constraints. Ruland offers a range of high-torque servo couplings – bellows, disc, and slit – each designed to address these factors in unique ways. Bellows couplings have the highest torque and torsional stiffness capabilities in the Ruland flexible coupling offering at the expense of misalignment. They are comprised of two aluminium hubs, and a flexible center element called a bellows. The thin walls of the stainless-steel bellows flex while remaining rigid under torsional loads, giving bellows couplings high rigidity to transmit position accurately in the most demanding applications. Bellows couplings are designed for applications requiring precise rotation and dynamic motion, making them an ideal choice for the most demanding servo-driven applications.

coupling choice for designers. Slit couplings are ideally suited for applications that require precise positioning and demand a balance of torque, stiffness, misalignment, and high-speed capabilities. This combination of performance characteristics makes them a suitable interchange for couplings such as single disc, which has misalignment and speed limitations. Slit couplings come in long and short styles. Short styles have higher stiffness, while long ones have increased misalignment capabilities. Speed is a primary differentiator with slit couplings compared to the other high-torque couplings. Bellows and disc couplings max at 10,000 rpm. Slit couplings, in comparable bore sizes, have speed capabilities up to 30,000 rpm. When selecting a high-torque coupling, it is critical to understand all factors to make the right choice. Each coupling style brings its own set of strengths and weaknesses, tailored to meet specific high-torque challenges. Choosing the proper coupling allows the

Functionally, disc couplings are close to bellows couplings but have slightly more misalignment

system to maximize its performance.

www.ruland.com

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•• Jaw, style available. available. Jaw,bellows, bellows, and disc style •• Torque Torque up up to to 300 Nm. Flexibility to to use the right coupling •• Flexibility couplingfor forthe the application with with three styles application styles offered. offered. Boresizes sizes up up to 45mm. •• Bore

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Increased Misalignment Bellows Couplings Increased Misalignment Bellows Couplings • More convolutions allow for increased misalignment. • More convolutions allow for increased misalignment. • Torque equivalent to similarly sized high-stiffness • Torque equivalent to similarly sized high-stiffness bellows couplings. bellows couplings. • Misalignment up to double the high-stiffness type. • Misalignment up to double the high-stiffness type. • Bore sizes from 4mm to 20mm. • Bore sizes from 4mm to 20mm.

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CEO Doug Allen celebrates landmark rapid tooling delivery

BRIGHAM PRESSINGS DELIVERS RAPID TOOLING SOLUTION FOR HIGH-VOLUME AEROSPACE AND AUTOMOTIVE APPLICATOR A six-week tooling programme for a global dispensing systems manufacturer has demonstrated how Brigham Pressings is combining design-formanufacture expertise, toolmaking and high-volume presswork to help customers improve products destined for demanding assembly environments. Brigham Pressings has completed a fast-track tooling and manufacturing project for a global supplier of hand-held chemical dispensing systems used across automotive and aerospace assembly lines. The Birmingham-based precision metal pressings specialist was approached to support the redesign of a chemical-compound applicator, with the customer seeking a lighter and more ergonomic assembly capable of improving change-over performance for operators. With an annual production requirement of 900,000 units, the programme called for a solution designed from the outset around repeatable, high-volume manufacture. 54

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For Brigham Pressings CEO Doug Allen, the project highlights the value manufacturers can unlock by involving an experienced presswork partner during the product development process. “The greatest value we can often bring to a customer starts well before the first component comes off the press,” said Allen. “By combining design-formanufacture thinking with our knowledge of tooling, materials and high-volume presswork, we can help shape a component around both its end use and the way it will ultimately be manufactured.” Working collaboratively with the customer, Brigham Pressings held a series of design-for-manufacture (DFM) workshops to translate the original CAD concept into two production-ready pressed components. Manufactured from DC04 mild steel in 2.3mm and 1.6mm thicknesses, the components were developed using 3D modelling to refine the finger contours and improve operator ergonomics while retaining the existing mounting envelope.

That compatibility meant the redesigned assembly could integrate directly into the customer’s existing production environment while delivering the required improvements in handling and servicing.

— helping optimise material choice, component geometry, tooling strategy, production efficiency and scalability.

The programme also placed tooling at the centre of the manufacturing strategy. New wear-resistant dies were developed with maintenance and long-term production requirements incorporated into their design.

Brigham Pressings combines precision metal pressings and stampings, presswork, tooling, design-formanufacture support and project management within a manufacturing operation equipped to support both technically demanding projects and high-volume production.

Brigham Pressings Managing Director Allan Murray said the project reflects the company’s ability to bring together engineering knowledge and practical manufacturing experience.

Its quality and environmental management systems are supported by ISO 9001 and ISO 14001 certification, alongside the company’s wider experience serving demanding engineering sectors.

“This was a great example of collaborative engineering translating directly into a production solution,” said Murray. “We were working towards very clear objectives around ergonomics, change-over performance, production volume and delivery, so every element of the tooling and presswork strategy was developed with those outcomes in mind.”

Allen believes that combination of engineering input and manufacturing capability is becoming increasingly valuable as customers look to move new products efficiently from concept into serial production.

Speed was another defining feature of the programme. Brigham Pressings completed the tool build within six weeks, followed by a further week of on-site commissioning to bring both dies up to full production speed. The resulting tooling was qualified to support production volumes of 900,000 units per year, with manufacture allocated across Brigham Pressings press capability, including Chin Fong, Bruderer and S&B equipment. On-site trials also validated the ergonomic improvements. Operators confirmed that the redesigned assembly achieved the required hand-force parameters and target change-over time, supporting smoother component changes within high-speed automotive and aerospace production environments.

“Customers want manufacturing partners who understand the complete journey,” he said. “Our role is to use our experience in pressings, tooling and production engineering to make that journey as efficient as possible. This project is a strong example: a redesigned product, new tooling delivered in six weeks and a manufacturing solution capable of supporting 900,000 units every year.” The outcome was equally clear from the customer’s perspective. “The new tooling went in flawlessly and delivery performance has been excellent.” For Brigham Pressings, the project provides another example of how early engineering collaboration, responsive toolmaking and established high-volume presswork capability can turn a product improvement brief into a production-ready manufacturing solution.

“A six-week tool build requires close coordination between engineering, tooling, production and the customer,” added Murray. “That joined-up approach is one of Brigham’s strengths. We can take a project from the initial engineering discussion through tool development, trials and commissioning and then into repeat production.” The programme illustrates a broader evolution in the role of specialist presswork manufacturers within modern supply chains. For customers developing components for automotive, aerospace and other advanced manufacturing applications, the manufacturing partner can increasingly contribute during product development

Managing Director Allan Murrary driving forward Brigham Pressing’s operational strength

www.brighampressings.com

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