Issuu

Engineering Process

Control &

MANUFACTURING

PECM

Global Success Through Innovation Issue 74 2025 £4.95 www.pecm.co.uk

ADAPTTECH - 58

EEMUA - 127

SEPURA - 106

Specialist guidance, training and events for industrial engineering

Introducing the SEP60 RAIL - specifically designed for use in the rail industry.

oil-water separator

Efficient & environmentally friendly automation with mk's NEW FULLY ELECTRIC pallet system

jasic.co.uk

Engineering Process

Sections

Control &

MANUFACTURING

Inside...

Inside Issue 74 FLEX

Editor’s Choice

Automotive Engineering

Machine learning’s role Murad Kurwa, VP of Advanced Engineering, Flex

Boilers &Maintenance

EK ROBOTICS

Control & Automation

Electrical & Electronics

Facilities Management

Gears, Drives & Motors

Health & Safety

Wiegand-Glas relies on AGVs from ek robotics

SICK

SICK’s End-of-Arm-Safeguard (EOAS) for Universal Robots excites distributors with possibilities for human-robot collaboration

SMART MANUFACTURING WEEK Unlock tomorrow’s manufacturing solutions and more at Smart Manufacturing Week 2025

SUBCON

The Manufacturing Solutions Show Preview

BECKHOFF

Why automation is key to the future of UK battery manufacturing

REGAL REXNORD

SWINDON SILICON

Machining & Machinery

Process Technologies

106

How custom ASICs enhance sensor performance in extreme environments

Pumps

112

POWER PROVE

Access complete powertrains for conveyors with Bauer Gear Motor

MASON UK LTD

How to rectify common testing pitfalls

The importance of quality engineering for effective pump isolation

CHEMUK

LANTEK

Storage, Handling & Distribution

118

Tools, Plant & Equipment

123

Training & Equipment

126

The UK expo for process engineers returns this May

Valves & Flow Control

128

Cover photo: Fanuc

Lungmetall transforms manufacturing processes with Lantek software

“The centre of excellence for strainer and ﬁltraaon technology”

www.bartonﬁrtop.co.uk Issue 74 PECM

Engineering Process

The leading source for innovators in Technology, Manufacturing and Maintenance within the Engineering & Processing industry worldwide. Published bimonthly, a subscription to PECM magazine is essential for Process Engineers, Chemical Engineers, Instrumentation Engineers, Mechanical Engineers, Plant Engineers, Precision Engineers, Environmental Engineers & General Engineers, Companies and Organizations in the Food, Dairy, Beverage, Brewing, Semiconductor, Pharmaceutical, Biotechnology, Chemical, Oil & Gas, as well as all UK's major manufacturing units. Every issue of the magazine contains the latest news, in-depth features, together with product innovations and case studies showing how process engineers are implementing new technologies to reduce costs and impact on the environment. With over 158,000 readers worldwide the publication is widely read, recognized, and well respected within the Process, Engineering & maintenance industries. A subscription to PECM magazine is the industry's 'must have' publication.

Hardcopy Edition SUBSCRIBE TO 6 BIMONTHLY ISSUES OF PECM FOR JUST £27 •

The magazine gets delivered directly to your door once every issue is published

•

The quality of the hard copy enhances the reading experience

MANUFACTURING

Control &

The Team EDITOR IN CHIEF Antony Holter editor@mhmagazine.co.uk

EDITOR Elizabeth Hutton elizabeth@pecm.co.uk

BUSINESS MANAGER Josh Holmes josh@mhmagazine.co.uk

STUDIO DESIGNER Richard Bland richard@mhmagazine.co.uk

SALES DIRECTOR Jake Page jake@pecm.co.uk Tel: 01227 937174

ACCOUNTS DEPT Alison Holmes accounts@pecm.co.uk Tel: 01227 936976

SALES MANAGER Martin Richardson martin@pecm.co.uk Tel: 01304 086039

PUBLISHING DIRECTOR Martin Holmes martin@mhmagazine.co.uk Tel: 01304 806039

DIGITAL MANAGER Jamie Bullock jamie@mhmagazine.co.uk Tel: 01227 936971

DIGITAL ASSISTANT Stacey Goodwood Tel: 01227 936971

To Subscribe please call 01304 806039

Digital Edition SUBSCRIBE TO OUR DIGITAL EDITION COMPLETELY FREE OF CHARGE Designed for the digital age, the magazine has been created for easy viewing on all electronic devices. All our issues stored in one place: get unlimited access to our previous and future issues.

To Subscribe please visit www.pecm.co.uk/subscribe

Please mention Process Engineering Control & Manufacturing when responding to items in this issue.

MH Media Global Ltd.

18/20 Newington Road, Ramsgate, Kent, CT12 6EE

Tel 01304 806039 l Fax: 08721 152240 l www.pecm.co.uk

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

Issue 74 PECM

EDITOR’S CHOICE

MANUFACTURING ADVANCEMENTS FLEX

Machine learning’s role Murad Kurwa, VP of Advanced Engineering, Flex AI and ML We have seen the rise of the fourth industrial revolution (Industry 4.0), which has not only introduced significant opportunities for manufacturers but also helped with optimising processes through automation and robotics, reduced costs and streamlined operations. However, it is vital that these advanced technologies are deployed where there is a strong use case and a clear benefit. AI is taking the world by storm, with almost every industry destined to be impacted in some way. Within manufacturing, AI is already being

PECM Issue 74

on the factory floor that could be improved.

Autonomous Robots and Human Collaboration

deployed for certain use cases and will continue to scale in 2025. As AI and machine learning (ML) technologies continue to evolve, it is crucial that organisations identify the right use cases for applying AI as a way to introduce greater efficiencies into existing processes, while also determining challenges

Advanced manufacturing technologies are quickly becoming essential tools for optimising the manufacturing process. An example of this is autonomous robots, which are used to improve the speed and efficiency of routine operations, particularly in warehousing and manufacturing spaces. They work side-by-side with humans for added efficiency and reduce the risk of employee injury in dangerous environments.

Combined with human-centric and data-driven decisionmaking, advanced manufacturing technologies can help improve productivity, eco-efficiency, agility, supply chain resilience and speed to market as well as customercentricity.

Predictive Maintenance and Quality Control Manufacturers can deploy AI and ML for predictive maintenance, which detects and alerts manufacturers to potential failures in their equipment. AI and ML algorithms also support quality control and can provide insights into process optimisation to make the manufacturing process more efficient. Products that require visual inspection are usually inspected by humans on the manufacturing line. Yet, as product demands and timeline speeds have increased, it becomes more difficult for the

avoiding problems later in the product testing phase.

Manufacturers can deploy AI and ML for predictive maintenance, which detects and alerts manufacturers to potential failures in their equipment. human eye to detect anomalies. In electronics manufacturing for example, printed circuit boards (PCBs) can be highly complex with hundreds, or even thousands of parts that are difficult for the eye to see. For greater accuracy at speed, AI is used to accurately validate components and their placement during high speed PCBA production, improving production quality and

Challenges and Future Success Organisations need to identify the right use cases for the business, find relevant data, process it, and then develop, fine-tune, and eventually deploy models. These steps all take time, but they are vital to reaping the greatest benefits. Of course, there are still challenges ahead, from data readiness - where the quality of an AI/ ML model is only as good as the training data - to quantifying the return on investment of AI/ML implementations. Manufacturers today are successfully using AI and ML in certain areas of their manufacturing processes, and while hurdles remain, advanced technologies are at the forefront of Industry 4.0 and have the power to transform production and operations on every level. Issue 74 PECM

EDITOR’S CHOICE

3.5 MILLION GLASS BOTTLES DAILY EK ROBOTICS

Wiegand-Glas relies on AGVs from ek robotics The Wiegand-Glas Group, a leading provider of glass and PET packaging solutions, has been relying on automated guided vehicles (AGVs) from ek robotics for over two decades to optimize its intralogistics processes. The third AGV system within the group has been in operation at the Schleusingen site in Thuringia since June 2020 – ensuring a smooth material flow in production.

Automated transport processes for maximum efficiency In Schleusingen, WiegandGlas produces up to 3.5 million glass containers a day on seven production lines. The finished products are palletized, shrinkwrapped and transported to heightadjustable transfer positions. From here, the driverless transport vehicles from ek robotics take over all transport tasks to the warehouse. “This automation solution significantly increases the efficiency of our site and secures our processes in the long term,” emphasizes Björn Bayer, Project Team Quality Assurance and Glass Control at Wiegand-Glas.

AGV solution specifically for the packaging industry Transport robots from the CUSTOM MOVE series from ek robotics are used, which have been specially designed for the requirements of the packaging and beverage industry. The robust vehicles impress with their high maneuverability and payloads of up to 3,000 kg. Equipped with two chain conveyors and holddown devices, they transport loads up to 2.8 m high and complete over 120 transport jobs per hour - even

The AGV system runs without additional personnel costs and fully meets our expectations. in the confined spaces of the 650 m long track.

personnel costs and fully meets our expectations,” summarizes Björn Bayer. “We see great potential for further automation projects.” With the successful implementation of the AGV solution, Wiegand-Glas is demonstrating how modern intralogistics increases efficiency and makes companies futureproof. ek robotics is once again demonstrating its expertise in the development of customized AGV solutions for industry.

Long-term success through automation After more than four years of operation at the Schleusingen site, Wiegand-Glas confirms the successful implementation of automation. Thanks to training at the ek Academy, employees are able to make adjustments to the system independently. “The AGV system runs without additional

For further information, please visit https://ek-robotics.com/en/about-us/news/

PECM Issue 74

EDITOR’S CHOICE

THE NEW GEMÜ

Pentagon delivers a full turnkey solution for plastic injection moulding from one site of UK Manufacture.

FROM

GEMÜ D40

DIAPHRAGM VALVE

GEMÜ 12A0

POSITION INDICATOR

DESIGN DEVELOPMENT

GEMÜ D41

DIAPHRAGM VALVE

MOULDING TOOLING BEYOND THE MOULD GEMÜ P40

TANK BOTTOM VALVE

www.pentagonplastics.co.uk websales@pentagonplastics.co.uk Tel: +44 (0) 1403 264 397 GEMÜ S40

MODULAR GLOBE VALVE

1533425274-Print Ad Designs- 148x105mm-A6-V1-CS.indd 1

14/02/2025 14:12

Scan to learn more:

Industrial Quality Interface & Protocol Converters

KDE485 C Programmable Converter An oven-ready solution for your new IoT, protocol conversion, data acquisition or telemetry project

◘ Free and license-free C development kit (STM Cube IDE) ◘ Ethernet TCP/IP with TLS HTTPS security & USB ◘ Four Serial Ports 232/4xx ◘ Analog I/O 16/22 bit & 4-20mA ◘ PT100/1k & TC input ◘ GPS-NTP Server ◘ Expandable I/O ◘ ARINC429 ◘ Remote fw updates

A new generation of valves, precisely tailored to your needs • Leaner and faster production using cleverly designed modules which are standardised across different product categories. • Modular and flexible design with a wide range of configuration options, optimising response time to your specialised requirements. • More agility, products can be ordered and manufactured faster than ever before with item prices and availability information easily accessible. • The platform product line enables faster conformity adjustments to ensure GEMÜ products are always optimised with the latest features.

KK Systems Ltd 01273 857185

kksystems.com/kde485

www.gemu.co.uk

Issue 74 PECM

EDITOR’S CHOICE

REAL-WORLD SOLUTIONS BYTESNAP DESIGN

Navigating the challenges of technological obsolescence in manufacturing Dunstan Power, ByteSnap Design

“We had a product we couldn’t produce anymore, but with just one meeting a week during development, ByteSnap have redesigned the device and successfully dealt with the technical issues. Very pleased – very little management from our side needed on this.”

The recent ublox withdrawal from cellular bombshell clearly illustrates how obsolescence poses a significant challenge for manufacturers. Some businesses reportedly face re-development costs of hundreds of thousands of pounds. A recent industry survey shows 90% of manufacturers face obsolescence issues at least once a year, with 28% experiencing these challenges more than once a quarter. This hampers product development, production efficiency and competitiveness, in a market where agility and innovation are key.

Overcoming Obsolescence Challenges Manufacturers facing complex design and obsolescence challenges need solutions that address immediate problems, and future-proof product designs and operations. UK-leading electronics engineering consultancy ByteSnap Design has been trusted by companies since 2008 to navigate such scenarios, by redesigning existing PCBs and replacing obsolete components. ByteSnap’s expertise in embedded systems development and product redesign are highly valued by clients. For example, global bearings manufacturers SKF benefitted from collaborating with ByteSnap on a rugged shaft alignment tools redevelopment project.

–Smart City Infrastructure Manufacturer

Future-Proofing Strategies

ByteSnap’s expertise in embedded systems development and product redesign are highly valued by clients. SKF were able to increase productivity and focus internal resources on major projects. Amongst other benefits: • The newly upgraded products have been SKF’s most successful devices ever with high perceived quality and very low warranty rates • ByteSnap’s strong technical ability, especially in legacy OS systems, ensured smooth project progression on time, within budget • Access to ByteSnap’s user interface framework, SnapUI, led to easier and quicker GUI development ByteSnap’s Redesign service is also a particularly effective match for addressing obsolescence challenges - avoiding costly upgrades or production halts:

Manufacturers should adopt best practice strategies to manage technological obsolescence, including: 1. Regular system audits: Conduct regular audits to identify potential obsolescence risks early. This allows for timely planning and mitigation. 2. Strategic partnerships: Collaborate with technology providers like ByteSnap to leverage their expertise in custom electronics design and IIoT solutions. Such partnerships can help manufacturers stay ahead of the competition by integrating the latest technologies seamlessly into their operations. 3. Check longevity plans: particularly on microcontrollers where the pain is not just in redesigning the PCB but could also be in many months of software porting to a new platform. By embracing these strategies, manufacturers can keep product development agile and responsive to technological advances, positioning themselves for long-term success in fast-moving markets.

For further information, please visit www.bytesnap.com

PECM Issue 74

DHS DOOR HANDLE SYSTEM: ENHANCE YOUR PRODUCTIVITY WITH VISIBLE MACHINE STATUS Schmersal’s innovative DHS door handle system combines the functions of a robust door handle with the signalling of machine status via illuminated handle or push-button. The door handle system is designed for use with the AZM40 solenoid interlock or with safety sensors from the RSS36 and RSS260 series or as a stand-alone solution. The illuminating handle signals various machine conditions over its area using seven different colours, enabling the user to control the colours individually to signal the machine status. In addition, a push button is available, which can be individually adapted to customer requirements using the coloured push button caps. The pushbutton can be used for tasks such as a reset function or a request to open the guard door.

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

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

EDITOR’S CHOICE

SENSOR INTELLIGENCE SICK

SICK’s End-of-Arm-Safeguard (EOAS) for Universal Robots excites distributors with possibilities for human-robot collaboration In collaboration with Universal Robots, SICK has developed their End-of-Arm-Safeguard (EOAS), which meets a growing need for closer human-robot collaboration. A collaboration between SICK Sensor Intelligence and Universal Robots has created the End-of-ArmSafeguard (EOAS), enabling more effective human-robot collaboration than ever before. A world-first, the patented technology ensures robots and humans can work in closer proximity with improved safety as the technology is mounted directly onto a robotic arm. Distributors of SICK and Universal Robots technology are excited by the prospect for safe, collision-free, reliable collaboration between humans and robots across a wide range of industrial settings. Bringing together SICK’s sensor expertise with the world’s largest cobot vendor for seamless teamwork, distributors predict it will generate new sales opportunities and applications. Gavin Ford, Sales Manager at Applied Automation UK, has been working as a Universal Robots distributor for more than five years. He immediately sees the benefits of the EOAS “from a technical aspect. From a price aspect. From an operator’s aspect”. Safer operation and peace of mind for operators With the EOAS, when the protective field is breached, a Safe Stop is triggered and the cobot immediately ceases movement, recommencing its task once it is restored. Lights on the EOAS indicate clearly when it has stopped and when it is moving,

PECM Issue 74

providing extra peace of mind for operators to work more closely and collaboratively with cobots. Timeof-flight technology provides a response time of ≤110 ms, speeding up productivity while maintaining safe operation. Mark Stephenson, Divisional Manager at WMH Robotics, notes: “The EOAS makes the operation

status of the cobot clear; it’s either red or green. It has been developed as a true partnership between SICK and Universal Robots, with all the benefits of both companies. We will see cobots working collaboratively as they were intended to; making people more confident about getting closer to the machine and being more interactive with it for safe productivity.”

Fewer stops, greater efficiency Creating a protective field around the robot tool at the end of the robot arm, the EOAS moves with the arm and operates in a much smaller, more defined area than previous products to protect a fixed hazard range of up to 400 mm. As factories become busier and more fluid, with greater use of AMRs, AGVs and mobile workstations, mounting the sensor directly onto the arm of the cobot means unnecessary stops are kept to a minimum. Mark Stephenson predicts, “The EOAS will result in a lower number of false triggers and false Safe Stops. It won’t stop until you are at the point where it is potentially hazardous.”

It’s great for small businesses as well as large corporates because it’s cost effective and easy to install.

Potentially reducing the need for additional safety measures According to distributors, one of the key benefits of the EOAS is the potential to remove additional safety measures for applications, such as physical guards. The EOAS provides a Safeguard Stop through an invisible, infrared, protective shell of 40 laser beams that covers the tool and workpiece to facilitate space-free operation. As industrial real estate costs climb, the most expensive thing in many factories is floor space. Allowing humans to work more closely and efficiently alongside cobots by protecting the end effector, potentially without the need for mechanical or light guards, significantly reduces the safe zone of the cobot and therefore the overall footprint, length and cost of projects. Ross Lacy, Sales Director at RARUK Automation, explains, “It’s much easier to put into small environments. In the UK you don’t exactly have much space at the end of the line, so anything that reduces the footprint and the size of the cell is a huge benefit.” Compatible with URCap software and easy to install The EOAS can be installed in just 15 minutes and the sensor is automatically recognised by Universal Robots technology. Configured using EOAS URCap software and provided with automatic updates, the EOAS makes

it easier for customers to protect end effectors and create safer, more collaborative human-robot applications. As Ross Lacy states, “There’s no additional software for the end user or the integrator as it can be programmed directly from the Universal Robots pendant. Anything that can make the risk assessment easier for the customer to carry out and to do their own internal CE marking is a huge bonus for us. It’s great for small businesses as well as large corporates because it’s cost effective and easy to install.” A wide range of scenarios anticipated for the EOAS Distributors see a wide range of potential markets and applications for the EOAS, in sectors ranging from pharmaceuticals and electronics, to food & beverage and automotive. Ideal for machine tending and pick and place applications such as presenting components to operators for assembly or where there’s multiple picks of parts, the EOAS can also be installed on a collaborative robot arm that is mounted on a mobile robot, reducing the number of false stops for the robotic arm and creating greater flexibility within

industrial settings. Gavin Ford predicts, “I think the EOAS will open up a lot of opportunities for us in applications such as machine tending and pick and place by making them more collaborative. It’s a good product and a good solution and I can’t wait to start looking at applications for it.” Combining Universal Robots and SICK Sensor Intelligence expertise and available now Matthew van den Braak, Product Manager – Robotic & Mobile Platforms at SICK UK, says: “The EOAS is making collaborative robots more effective and affordable for end users. With the EOAS, you can work really close to it and interact with it. It is completely new technology that has been developed in partnership and is fully compatible with Universal Robots products. “We are delighted with the buzz this brand-new patented technology has created among distributors. I look forward to seeing the wide range of different applications it is used for and the challenges it meets. The EOAS is available and in stock now, with a lead time of just three days.”

For further information, please visit www.sick.com Issue 74 PECM

EDITOR’S CHOICE

PERISTALTIC PUMP POWER NORTH RIDGE PUMPS

Heavy duty grout transfer pumps for power station A construction company contacted North Ridge Pumps recently regarding two grout transfer pumps to be used for a new power plant being built. Of course, you’ll probably know what grout is and what it’s used for. So why is industrial grout any different? Like domestic grout used in domestic DIY, industrial grout is a composite material usually made of sand, cement and water. It can also include amounts of epoxy resins or other materials to give it greater durability and chemical resistance.

Peristaltic pumps are the ideal choice Peristaltic pumps are well suited for a variety of construction applications which need abrasive grout to be transferred and injected. They’re particularly suitable for projects where the grout transfer pumps may be inoperative for long periods, or when downtime during batches would not be an option.

So why are peristaltic pumps good for transferring grout? It’s the simplicity of the peristaltic pump design that makes them ideal for working with abrasive industrial grout. The rough composition of grout and the mix of sand, cement and assorted solids are not a problem for these units. Indeed, they can easily handle a high solids content. What’s more, the lack of valves on suction and discharge means there’s much less chance of the grout transfer pump clogging resulting in costly downtime.

The pumps are easy to use with high suction lift, self-priming capability and very little shear when pumping. In addition, they are easy to maintain should it dry within the pump. The design is seal-less too and has only one wearing part, so leakage and excessive wear are kept to a minimum. All in all, the pump offers reduced downtime and much less need for regular maintenance.

Which type of peristaltic pump did we specify for this client? For this construction project requiring abrasive grout transfer up to 15 bar and 3 tonnes an hour, we supplied the client with two of our brand new RBT-40 pumps. These are shoe-type peristaltic pumps specifically designed to

handle high pressures with the hose bathed in lubricant.

Easy maintenance We designed these units to be simple to use and easy to maintain with very little training. In addition, if a hose rupture should take place, we incorporated a built-in leakage detector to stop the pump and prevent leakage. The two abrasive grout pumps were supplied with a spare set of hoses and sufficient lubricant to ensure that the client had enough spares for at two years of uninterrupted service. If you have an application which requires the transfer of viscous fluids or dense slurries containing solids, and aren’t sure which pump to specify, speak to North Ridge Pumps to see how we can assist you.

For further information, please visit www.northridgepumps.com/contact-us

PECM Issue 74

At North Ridge Pumps, we make dosing, metering and transferring as easy as...

DSM Control

AMP16 Control

In fact, we have a whole range of non-clog metering pumps which will give you incredibly precise measurement of gaseous, viscous and shear-sensitive fluids without any loss of flow. We’re North Ridge Pumps, the UK’s largest pump supplier with over 25 years’ experience. We’re expert at specifying exactly the right pump for every client – not just an off-the-shelf, one-size-fits-all solution.

FMP30 Control

That’s probably why we’ve completed over 2,000 successful projects for clients all around the world. You can read case studies at www.northridgepumps.com

Got an application and not sure which pump you need? Call +44 (0) 1773 302 660 or go to www.northridgepumps.com

+44 (0) 1773 302 660 | sales@northridgepumps.com | www.northridgepumps.com North Ridge House, 3 Chrysalis Way, Eastwood, Nottingham, NG16 3RY, United Kingdom

EDITOR’S CHOICE

A REVOLUTION IN RADIOMETRY BERTHOLD

Introducing the new Berthold LoopSeries LB 430 Expertly designed to provide reliable and precise measurements under any conditions, the LoopSeries LB 430 radiometric detector is the ideal solution for demanding applications. Engineered to meet the rigorous requirements of modern industrial environments, the LB 430 detector combines cutting-edge technology with Berthold’s renowned quality, setting new standards in radiation detection. No additional power wires necessary The innovative 2-wire design simplifies installation by eliminating the need for extra power cables, reducing both material and labour costs. With data transmission and power supply combined in a single pair of wires, connecting the LoopSeries LB 430 is both efficient and straightforward, minimising potential points of failure and setup time. Silicon photomultiplier technology (SiPM) The use of SiPM technology represents a groundbreaking advancement in photodetection, offering high measurement performance and exceptional reliability. The compact and energyefficient design results in a smaller installation and up to 99% reduction in energy requirements. The SiPM

The innovative 2-wire design simplifies installation by eliminating the need for extra power cables, reducing both material and labour costs. technology also provides enhanced mechanical and electromagnetic robustness, making it a resilient and durable solution for a wide range of applications.

access to measurement data even in challenging environments such as hard to reach locations or remote sites. Representing the future of radiation detection, the LoopSeries LB 430 combines state-of-the-art technology and Berthold’s superior quality, making it an ideal choice for modern measurement applications where ease of use and performance are paramount. Berthold Technologies – the experts in radiometry

Optional external display The LoopSeries LB 430 can be equipped with an optional external and removable display, positioned up to 20 meters away from the detector via cable. This added functionality and flexibility provides convenient and reliable info.uk@berthold.com | www.berthold.com

PECM Issue 74

MEASUREMENT SOLUTIONS FOR YOUR APPLICATION Optimize your production throughput with increased safety and reliability www.berthold.com

Come and see us on stand F54

Berthold Technologies (UK) Ltd. Unit 6, Allied Business Centre, Coldharbour Lane, Harpenden, AL5 4UT, United Kingdom Email: info.uk@Berthold.com Tel: +44 (0)1582761477

EDITOR’S CHOICE

PRECISION & EFFICIENCY VISION ENGINEERING

Vision Engineering introduces new ‘HALO’ 4K digital inspection microscope Vision Engineering, a UK based manufacturer of ergonomic microscopy and digital 3D visualisation technology unveils the EVO Cam HALO, a new 4K digital microscope that redefines the standard for clarity, precision and consistency in inspection and measurement tasks. Suitable for a wide range of inspection applications, EVO Cam HALO combines stunning 4K image quality with advanced, adaptive illumination, and new intelligent software, empowering users to capture the most challenging details with unparalleled accuracy. HALO’s key features include 4K resolution which reveals previously obscured details with remarkable clarity, ensuring nothing escapes the user’s view. A Super-Wide Dynamic Range ensures the user captures images with exceptional brightness and contrast, even in challenging lighting conditions. Additionally available with HALO comes a new enhanced Illumination package, including a quadrant light, panel light, and white/UV light, to optimise illumination for a variety of inspection needs. New Intelligent Hardware and Software automatically detects lenses and adjusts magnification settings, ensuring seamless workflow and accurate results. Real-time insights are available providing intuitive image capture, measurement, and analysis tools, enabling faster and more informed decision-making. Vision Engineering’s popular 360 Direct/ Oblique Viewer also works with

PECM Issue 74

HALO, enabling users to inspect details from different angles, revealing hidden features that would otherwise be inaccessible. HALO is suitable for a wide range of applications, including Medical Devices Manufacture and testing especially in the practices of inspecting translucent tubes, electro-polished devices, and other medical components with enhanced clarity and accuracy. It is also effective at capturing fine details on small, reflective metal parts for precise inspection and quality control – perfect for Micro Mechanics. In the laboratory HALO cam improve the examination of Petri dishes with translucent samples, enhancing contrast and

clarity for detailed analysis, and in Industrial Manufacturing, intricate assemblies, solder joints, and other components are inspected with much improved precision and efficiency.

Pricing and Availability: EVO Cam HALO is available for purchase from April 2025, with configurations starting at 6500GBP. Commenting on the launch, Paul Newbatt, Group Sales and Marketing Director at Vision Engineering says “We are delighted to bring EVO Cam HALO to market, confirming our reputation for innovation, whilst improving the inspection performance available within digital microscopy. 4K image quality plus fully controllable lighting and flexible software available in multiple configurations means that our customers in a wide range of sectors can easily choose the most accurate and consistent

HALO’s key features include 4K resolution which reveals previously obscured details with remarkable clarity, ensuring nothing escapes the user’s view. digital system for their inspection requirements.”

About Vision Engineering Limited Vision Engineering Ltd is a global leading-edge designer and manufacturer of patented ergonomic stereo optical and digital instruments, used for inspection, manipulation, measurement, and

analysis of manufactured parts, by many of the world’s leading manufacturers and their extended supply chains. Vision Engineering’s contract manufacturing division offers comprehensive contract manufacturing, design, and commercialisation packages, giving customers access to the latest technology, as well as a team of experienced designers and engineers. Founded in 1958 and wholly Britishowned, Vision Engineering’s Global HQ, design, and manufacturing facilities are based in state-ofthe-art modern premises in Woking, Surrey, UK, with extensive manufacturing facilities in the UK and the US. Regional sales and tech support offices are located throughout North America, Europe, and Asia, supported by a fully trained network of distributors.

For more information, please visit https://www.visioneng.com/products/digital-microscopes/evo-cam-halo Issue 74 PECM

EDITOR’S CHOICE

PUMP SUCCESS STORY CASTLE PUMPS

A Pump That “Paste” The Sundried Tomato Test With a huge variety of products needing to be handled, when it comes to the manufacturing and process industries, no two pump requirements are the same. Getting the right pump, rather than just one that “does the job” is the key to saving yourself from excessive wear, unnecessary maintenance, product waste, process failures and energy costs. This case study is an example of the importance of just that.

thick and therefore a pump capable of handling the viscous nature at a reasonable flow rate without clogging was required. One of the services Castle Pumps offer when it comes to container emptying pumps, is pump testing, where they will trial the pump handling the fluid in question to confirm that it can move it as expected. Due to the viscous, dry and abrasive nature of the sundried tomato paste and its solid content, a sample keg was requested to be sent to the factory to perform the test with one of their Viscopower progressive cavity drum pump models. These models can handle high viscosity fluids up to 100,000cP and solids up to 8mm in diameter thanks to the flexibility in the stator.

A manufacturer and supplier of bulk food pastes and marinades to the catering industry contacted Castle Pumps with a container emptying pump enquiry to improve the productivity of their current manual process. They were looking to pump sundried tomato paste from their processing machine, where the sundried tomatoes get chopped into the blend, into 15kg buckets that are then supplied as the final product. The challenge of this particular food transfer pump requirement is the product itself that is being

handled. As well as being very viscous, it contains various degrees of solids including abrasive tomato seeds and stringy tomato skin, which for many pumps result in clogging or component wear. Constant unblocking of a pump and consequential maintenance is not something the client could accept due to the considerable impact on process productivity.

A Tried & Tested Clog-Free Solution The viscosity of the fluid being pumped is always an initial consideration for pump specification, which can sometimes be difficult when the customer doesn’t know exactly what viscosity it is. Castle Pumps knew however from looking at a picture of the fluid that it was

To meet its requirement as a food grade barrel pump, the FDA Viscopower is designed with minimal dead space, a closed mechanical seal and electropolished surfaces for hidden voids or inaccessible parts. It can also be disassembled in just 30 seconds for quick cleaning with minimum effort. After seeing how well the Viscopower high viscosity drum pump worked with the tomato paste, the customer was confident that the solution would handle the viscosity, seeds and skin without clogging, and placed the order for the pump complete with food grade PVC hose and hygienic Triclamp fittings. If you’re looking for the right pump to deliver your process or perhaps have a challenging fluid you need to transfer, contact the pump exerts at Castle Pumps.

For further information, please visit www.castlepumps.com

PECM Issue 74

Pumps To Drive Your Process Efficiency

Pump smarter, not harder. Use our 15 years’ experience to save excessive wear, process failures, product waste & operator time. ✓ Solid-laden, viscous fluids without clogging/wear ✓ Safe handling of chemicals, fuels & flammables

✓ Highly accurate dosing of chemicals & ingredients ✓ Difficult to pump or delicate, shear sensitive fluids ✓ 99.98% barrel emptying to prevent product waste

✓ FDA & 3A models for food and hygienic applications

Contact our technical sales engineers now!

A division of the CTS Group, Part of FlowMax Ltd

T. +44 (0)1773 533 283 | E. sales@castlepumps.com | W. castlepumps.com

EDITOR’S CHOICE

OVERCOMING THE EXTREME SWINDON SILICON

How custom ASICs enhance sensor performance in extreme environments Science fiction novelist, Arthur C. Clarke once said, “any sufficient advanced technology is indistinguishable from magic”. In industries like oil and gas, aerospace, and industrial automation, advanced sensor technology is making the impossible possible, enabling operations in environments once considered unreachable. Here Ross Turnbull, Director of Business Development and Product Engineering at ASIC design and supply specialist Swindon Silicon Systems, explains how Application Specific Integrated Circuits (ASICs) enhance sensor performance in extreme environments. From the depths of the ocean to the vacuum of space, modern industry relies on technology that can endure the harshest conditions on Earth and beyond. Sectors such as oil and gas, aerospace and industrial automation depend on sensor technology to maintain safety, precision, efficiency and performance in increasingly extreme environments.

Ensuring safety and precision In environments where failure could lead to catastrophic outcomes, sensors are essential. They deliver critical data for predictive maintenance, real-time decisionmaking and system optimisation. By monitoring factors such as temperature, pressure, strain and vibration, sensors help prevent system failures that could jeopardise safety, productivity and the wellbeing of both people and the environment. For instance, in the oil and gas industry, downhole sensors allow for real-time monitoring of temperature,

PECM Issue 74

pressure and fluid composition at depths where temperatures can exceed 200 degrees Celsius, and where pressures may surpass 20,000 pounds per square inch (psi). These sensors enable real-time data acquisition, helping engineers detect anomalies such as transient pressure spikes — early indicators of potential well blowouts. To function reliably, the associated signal processing electronics must endure high thermal stress, electrical noise and mechanical shock. In aerospace, flight sensors monitor altitude, velocity and structural integrity to reduce the risk of catastrophic failures during flight. These sensors must also endure intense vibrations, rapid accelerations and extreme temperature fluctuations. Similarly, in high-speed, highpressure manufacturing environments, sensors embedded in robotic systems regulate temperature, monitor mechanical

stress and maintain precise control. This monitoring helps reduce manufacturing defects and optimise production efficiency. Ensuring reliable sensor performance in these harsh environments requires robust integrated circuits (ICs) designed for precision signal acquisition, noise immunity and extended operational lifetimes. Application-Specific Integrated Circuits (ASICs) are increasingly critical in this domain, offering tailored solutions optimised for extreme thermal, mechanical and electromagnetic conditions. Unlike general-purpose ICs, ASICs provide custom-designed architectures that enhance sensor accuracy, minimise power consumption and integrate advanced fault-tolerance mechanisms.

Advancing sensor performance with custom ASICs ASICs are custom-designed chips tailored to meet the unique demands

of specific applications. Unlike standard ICs, which are designed for general-purpose use, they provide significant advantages when it comes to handling complex sensor data in extreme environments. In environments with high electromagnetic interference (EMI) or radio frequency interference (RFI), such as aerospace or oil and gas, ASICs employ advanced analogue-to-digital (ADC) and digitalto-analogue (DAC) converters, along with noise filtering techniques and active noise cancellation systems. These design features work together to reduce electrical noise, ensuring that the ASICs maintain high signal integrity and accurate sensor data, even in the presence of external interference. Temperature resilience is another critical factor. Silicon-on-Insulator (SOI) and Silicon Carbide (SiC) materials are commonly used in ASIC designs to enable them to withstand extreme thermal conditions. SOI technology enhances thermal stability, allowing ASICs to function reliably at temperatures up to 300 degrees Celsius, while SiCbased ASICs are capable of operating at even higher temperatures, up to 600 degrees Celsius. To further optimise performance in high-temperature environments, ASICs can incorporate thermal management solutions such as

From the depths of the ocean to the vacuum of space, modern industry relies on technology that can endure the harshest conditions on Earth and beyond. micro-channel cooling systems and heat sinks, which actively dissipate heat and prevent thermal damage. Furthermore, temperature compensation circuits can be integrated directly into the ASICs, adjusting sensor outputs to ensure accurate readings even in rapidly fluctuating or extreme thermal conditions. In environments where power is limited, ASICs can be designed for energy efficiency, helping to extend sensor lifespans. By incorporating low-power analogue and digital circuitry, ASICs reduce overall energy consumption. Additional features, such as sleep modes, dynamic power scaling and the ability to power down inactive components, further minimise power usage and enhance the operational lifespan of sensors. For particularly power-constrained

applications, energy-harvesting technologies, such as solar, thermoelectric or vibration-based generators, can be integrated into the ASIC, enabling sensors to operate autonomously for long periods without the need for frequent battery replacements. These technologies are especially valuable in applications like deepsea exploration, remote monitoring in space and other areas where traditional power sources are scarce or difficult to maintain Swindon offers a full turnkey solution that supports the design and optimisation of ASICs for extreme environments. This comprehensive approach, which spans from initial concept through to manufacturing and testing, ensures that each solution is tailored to meet the specific performance and reliability of demanding applications, allowing for seamless integration into industries with unique environmental challenges. Custom ASICs are turning what was once thought to be impossible into reality. As industries continue to push the boundaries of what’s possible in extreme environments, these advanced chips are advancing sensor performance. With the help of ASIC technology, industries can now operate in some of the harshest conditions on Earth and in space, turning complex challenges into opportunities for innovation.

For further information, please visit www.swindonsilicon.com Issue 74 PECM

EDITOR’S CHOICE

DURABLE LOCKER SOLUTIONS TEKNOMEK

Teknomek introduces new lockers for security-sensitive environments Hygienic furniture and equipment specialist Teknomek has introduced wire mesh lockers to its product range. The lockers provide a hygienic, safe and secure environment for the storage of personal belongings and workwear, whilst also providing clear visibility of what’s inside to mitigate security concerns. Teknomek has added two wire mesh lockers to its catalogue. The first is manufactured from rustresistant 304-grade stainless steel with a cleaned and pickled finish, making it ideal for environments where harsher cleaning protocols are required, and the second is made from mild steel with a bright zincplated (BZP) finish. The open mesh construction ensures that the contents of the locker can be seen: a vital consideration for environments where security is particularly important. The mesh structure also promotes ventilation, so that damp clothing can dry naturally and odours are reduced. The lockers have been designed to be highly durable and easy to use, with a single door, high-level hat or helmet shelf and a sturdy hook for coats or overalls. Each door has a lock with a hasp and staple mechanism, making it extremely secure. This mechanism can accommodate a variety of padlocks. The sloping top prevents users from leaving items on the top of the locker. This supports hygienic protocols whilst also helping to maintain a tidy changing room and supporting ventilation and visibility. With a 150mm raised base, there is plenty of space beneath the lockers

We know that these extremely durable lockers will be a game-changer for many customers. for easy cleaning access. The raised base also allows the lockers to be placed over heating pipes in drying rooms. The lockers are supplied fully welded and pre-assembled, so they are ready to be installed using the floor and fixing brackets supplied. Each locker is 305mm wide by 1900mm tall. They can be supplied as single, double or triple units. “Providing employees with secure storage for their belongings is a fundamental responsibility of any business,” says Michelle

Locke, product and marketing manager at Teknomek. “However, in environments which are securitysensitive, being able to quickly view what is in lockers is of significant benefit. “Our new lockers not only provide both customers and their staff with peace of mind from a visibility perspective, the wire mesh construction also supports ventilation and drying of clothing and workwear, reducing unpleasant changing room odours. With the option of 304-grade stainless steel, for environments where hygienic protocols involve the use of harsh chemicals, or mild steel with a BZP finish, we know that these extremely durable lockers will be a gamechanger for many customers.” For more information about any products in the Teknomek range, please call the customer services team on +(0)1603 788 833 or visit www.teknomek.co.uk.

For further information, please visit www.teknomek.co.uk.

PECM Issue 74

Leading the way in hygienic design Trusted by professionals worldwide, Teknomek provides hygienic furniture and equipment tailored to the highest industry standards. • High quality materials • Innovative designs • Bespoke and customised solutions Visit our website at teknomek.co.uk or call us on +44 (0)1603 249 663 today!

EDITOR’S CHOICE

SUPER FAST DELIVERY MENZEL

Six days instead of six months Motor customers in the UK are currently particularly pleased with the fast delivery capability of German manufacturer Menzel Elektromotoren. In early June, the family-run company received two orders for large machines within one week. Due to motor failures, the water supply to 30,000 households was threatened and production in a cement plant was halted. After delivery times of only six and ten days, respectively, both the pump and the cement mill could be restarted in the shortest imaginable time. Faced with unexpected downtime due to equipment failures, customers often cannot afford to wait for a motor manufactured from scratch – standard delivery times in higher output ranges start at six months. Menzel has proven itself to be a strong partner in an emergency, quickly configuring suitable motor systems for a wide range of highoutput applications from its large, diverse stock of motors, cooling units and ancillary equipment – such as the current two jobs for British customers.

Menzel’s large warehouse and modular design for motors and coolers allow fast delivery of tailored motor systems for industrial applications (here: 2000kW 11kV cement mill motor)

The squirrel cage pump motor has a nominal output of 1380 kW operating at 3300 V. The slip-ring motor for a cement mill delivers 2000 kW at 11 kV. Its special features are increased ingress protection rated IP55 and a closed cooling system with a top-mounted air-toair heat exchanger (cooling type IC 611), ideal for dusty environments and large temperature fluctuations. Large industrial motors from stock and quickly tailored to order:

The squirrel cage pump motor has a nominal output of 1380 kW operating at 3300 V

For further information, please visit https://www.menzel-motors.com/article/large-lv-mv-hv-motors/

PECM Issue 74

®®

UK's largest largest distributor distributor UK's

AUTHORISED HUCK TOOLING SALES, HIRE & REPAIR RIVETS,THREADED INSERTS INSERTS RIVETS,THREADED

MAGNA-LOK® BOBTAIL® BOBTAIL® PENTALOK PENTALOK MAGNA-LOK®

HUCKTAINER® C5OL® C5OL® MAGNA-GRIP® MAGNA-GRIP® BOM® BOM® HUCKTAINER®

·�· -·�·

TraditionallyInnovative Innovative Traditionally

starfasteners.co.uk

Telephone: +44 (0)1159 324 939

Email: sales@starfasteners.co.uk

EDITOR’S CHOICE

A TRUSTED SOLUTION STAR FASTENERS

The Most Asked Questions About Huck® Fasteners Huck® fasteners have long been a trusted solution in industries requiring high-strength, vibrationresistant fastening. These fasteners play a crucial role in ensuring structural integrity and safety in a wide range of applications and industries. Given their significance, many engineers and professionals frequently turn to search engines with technical queries about Huck® fasteners. In this article, we address some of the most commonly asked questions about these specialised fasteners. What are Huck® fasteners? Huck® fasteners are advanced fastening solutions designed to provide secure, high-strength joints that resist vibration and loosening over time. What are the different types of Huck® fasteners? Huck fasteners come in various types, each designed for specific applications. ®

HuckBolts®: also known as LockBolts® are a two-piece, highstrength fastening system consisting of a pin and a collar, designed for permanent, vibration-resistant joints. They are installed using a swaging process, which eliminates the need for re-tightening, making it ideal for structural, transportation, and heavy-duty applications requiring superior strength and longterm reliability. Huck® Blind Fasteners: are highstrength, one-sided (blind-side) fastening solutions used when access to the blindside of a joint is restricted. They provide vibration resistance, high shear strength, and consistent clamping force, making them ideal for aerospace,

PECM Issue 74

automotive, rail, and structural applications where reliability and quick installation are essential. Which industries use Huck® fasteners? Huck® fasteners are widely used across multiple industries, including: Automotive & Heavy-Duty Trucks: Common in truck chassis, suspensions, and trailers for secure, maintenance-free fastening. They can be used in anything, including defence vehicles and F1 racing cars! Railroad & Transportation: Applied in railcar construction and track infrastructure to withstand constant vibrations. Construction & Infrastructure: Utilised in bridges, portable buildings and large metal framed structures for strong, permanent joints. Solar Energy: Huck® fasteners are used in solar panel mounting systems to secure structures against wind loads and environmental stress. Wind Turbines: Huck® fasteners are used in tower assembly, nacelles, and rotor components for secure, vibration-resistant connections. Shipbuilding & Marine: Resistant to corrosion and extreme conditions, making them ideal for naval and commercial ships. Manufacturing & Industrial Equipment: Used in a multitude of production lines for durable and efficient fastening solutions. Aerospace: Used in aircraft assembly for their lightweight strength and vibration resistance. If there’s a fastening requirement, Huck® fasteners have a solution.

How do Huck® fasteners differ from traditional bolts? Huck® fasteners differ from conventional bolts in several ways: Vibration Resistance: Unlike bolts and nuts that can loosen over time due to vibrations, Huck® fasteners maintain their hold, making them ideal for high-vibration environments. Installation Speed: Huck® fasteners are installed using hydraulic, pneumatic and battery tools, making the process faster and more efficient than tightening a bolt and nut. Structural Integrity: The swaging process of Huck® fasteners creates a permanent joint, eliminating the need for re-torquing or maintenance. What installation tools are required to install Huck® fasteners? Installing Huck® fasteners requires specialised tools. These tools include: Pneumatic: Powered by compressed air, these tools are commonly used in high-volume assembly lines. Hydraulic: Used for heavy-duty applications, providing more force for larger fasteners. Battery-Powered: Offering mobility and flexibility for production and field applications. Are Huck® fasteners reusable? No, Huck® fasteners are designed to be permanent. Once installed, they cannot be removed without damaging the fastener. If disassembly is required, the fastener must be mechanically removed and replaced. Reusing nuts and bolts can also compromises structural integrity due to thread deformation, fatigue, and reduced clamping force.

Torque relaxation and material wear increase failure risks, especially in high-load or vibrationprone applications.

on selecting the right Huck® fasteners based on load requirements, material compatibility, and environmental conditions.

For safety and reliability, engineering best practices recommend new fasteners to maintain precise tension and prevent mechanical failure.

Product Range & Availability: We offer a wide selection of Huck fasteners, including LockBolts®, blind fasteners, and installation tools, ensuring you get the right solution for your needs.

How do Huck® fasteners compare to welding? Many industries choose Huck® fasteners over welding due to the following advantages: Speed of Installation: Huck® fasteners can be installed in seconds, whereas welding is time-consuming. Consistent Strength: Welds can be inconsistent due to material variations and operator skill, whereas Huck® fasteners provide uniform strength. Safety: Welding requires specialised training and safety precautions, whereas Huck® fasteners can be installed quickly with minimal training and risk. No Heat-Affected Zones: Welding can weaken surrounding materials, whereas Huck® fasteners maintain the integrity of the structure. How do you select the right Huck® fastener for your application? Choosing the right Huck® fastener depends on several factors: Load Requirements: Determine the strength needed for the application. Material Compatibility: Ensure the fastener material matches or is compatible with the materials being joined. Environmental Conditions: Consider factors like corrosion resistance, temperature, and exposure to chemicals. Accessibility: Choose between blind (one-piece) or LockBolts® (twopiece) fasteners based on assembly constraints.

What are the maintenance requirements for Huck® fasteners? Since Huck® fasteners create a permanent joint, they require little to no maintenance. Unlike traditional fasteners, which need periodic re-tightening, Huck® fasteners maintain their strength and integrity throughout their service life. However, regular inspections of the structure in which they are used are still recommended to ensure overall safety. Huck® fasteners have revolutionised fastening technology with their strength, durability, and vibrationresistant properties. As industries continue to seek reliable and maintenance-free fastening solutions, the demand for Huck® fasteners remains strong. Whether you’re an engineer, technician, or procurement specialist, understanding the fundamentals of Huck® fasteners can help you make informed decisions about their applications and benefits. How can Star Fasteners help with Huck® fasteners? Star Fasteners UK Ltd is a leading distributor and expert in Huck® fasteners, offering comprehensive support to help you make informed decisions about their applications, benefits, and installation. Here’s how we can assist: Expert Technical Advice: Our team provides specialist guidance

Installation Support: We supply pneumatic, hydraulic, and batterypowered installation tools and can provide training on proper usage for efficient and secure fastening. Cost & Performance Optimization: We can help to identify costeffective fastening solutions while ensuring long-term reliability in high-vibration and structural applications. After-Sales Service: We provide ongoing support, maintenance advice, and troubleshooting to ensure your fastening solutions perform optimally. Do Star Fasteners offer a tool repair and hire service? Tool Repair Service: We provide comprehensive maintenance and repair services for installation tools, ensuring your equipment remains in optimal condition. Tool Hire Service: Star Fasteners offers short- and long-term tool hire options, ideal for busy periods or specific projects requiring specialised equipment. We also provide service hire tools while your equipment is under repair in our workshop. By addressing these frequently asked questions, Star Fasteners hopes to provide valuable insights for those considering Huck® fasteners for their projects. Their superior performance and reliability make them a leading choice for industries where strength and durability are paramount.

For further information, contact Star Fasteners at +44 (0) 115 932 4939 or email sales@starfasteners.co.uk. Issue 74 PECM

EDITOR’S CHOICE

REDEFINING VALUE AXAIR FANS

Challenging the status quo to transform industry norms delays to immediate action, from silence to continuous support, from cold interactions to meaningful relationships all neatly packaged in a striking visual with the balls to back it up. Ultimately it boils down to what we do best; we engineer trust.

Andrew Jones, the Technical Director at Axair Fans talks about how Axair have dug deep and put the work in behind the scenes to challenge the status quo of the antiquated fan industry to better serve their customer base. I’ll be frank, our team have worked their backsides off to ensure we had the tangible evidence to back up what we’ve been saying for months and months. I’ll reiterate quickly for anyone who may have missed previous pieces I’ve shared here. Niche markets dominated by tradition and transactional relationships ruled by industry giants urgently needed for change. So, a year ago, Axair Fans launched our bold and disruptive “We’re Revolting” campaign, not just to capture attention but to champion a fundamental shift in the way industrial fan suppliers engage with their customers, or the other way around. This wasn’t a gimmick or a fleeting marketing stunt; it was, and remains, a declaration of our commitment to redefining what value should look like in this industry.

The Why: Breaking the Mould of an Antiquated Fan Industry The industrial fan sector has long been rooted in practices that prioritise products over people. At Axair, we’ve always placed an emphasis on people being our greatest assets, but we’ve encountered frustrations from customers who’ve had to navigate complicated processes, insufficient technical support, and a lack of meaningful customer service from other suppliers. The often chose

The How: Transparency and Accountability Andrew Jones

the big industry giants as they feared smaller companies believing they’re not as good, because let’s be honest no one ever got fired for hiring IBM as the saying goes. Yet evidence shows that for decades, the status quo has been characterised by minimal pre-sales engagement with companies showing a limited understanding of customer specific needs during the buying process, Post sales gaps shown through inadequate troubleshooting and follow up support, and a focus on the transaction rather than long term partnerships built on trust and customer centric solutions. We launched “We’re Revolting” to make a clear statement: we’re rejecting this outdated model. More than that, we’re proving that industrial fan supply can, and should, offer more.

The What: A Customer-Centric Revolution At the heart of Axair core values lies a series of actions that elevate customer experience and redefine supplier accountability. Here’s what we’re revolting against, and what we’re doing instead, from sales-first to solutions-first, from Learn more at www.axair-fans.co.uk

PECM Issue 74

Launching a campaign as audacious as “We’re Revolting” required more than words; it demanded actionable proof that challenging the status quo came with positive benefits for the customer. Transparency has been one our guiding values for years but recently we’ve made it clear to customers what they can expect from us around enhanced technical expertise, customer centric internal culture, and measurable outcomes that demonstrate the tangible impact of our approach to you the customer. Basically, we show our customers that they’re partnering with a team that cares about their success. While “We’re Revolting” is a bold statement about our mission, it’s also a call to action for the industry as a whole. Customers deserve more than products, they deserve a partner who understands their challenges and invests in their long-term success. This revolution is a leading movement that will live beyond you all seeing the visuals, it isn’t just about redefining who we are, it’s about reimagining the standards of the entire industrial fan industry. Because when customers trust their suppliers, innovation thrives, efficiency improves, and everyone wins.

Fabien Carbonell Pre-Saes Technical Support

Revolt. Reshape. Revolutionise. Don’t take our word for it, meet the experts who made it happen. We challenged an industry by revolting, and you listened. But that message, bold as it was, only scratched the surface. It’s easy to say you’re different. It’s harder to be different, every day, with every quote, call, and customer. That’s what our team does. So now, we’re passing the spotlight to them, the doers, the thinkers, the rebels, because they’re the reason this revolution is real. From first quote to final fan delivery, these are the faces turning revolt into results. Get in touch, and join the fan revolution. Axair. Revolutionary Fan Expertise.

www.axair-fans.co.uk

EDITOR’S CHOICE

REDEFINING PRECISION LINMOT

Gardena is moving into the future of water with LinMot GARDENA has always proven to be a particularly sustainable innovator. Thanks to a partner, the basic requirements for future-oriented and sustainable production have been met: With the latest linear rotary and linear technology from the drive specialist LinMot, GARDENA has succeeded in redefining the precision, speed and sustainability of its production systems.

extremely complex challenge with conventional servo solutions. The LinMot PR02 provides both the rotary and linear servo motion combined in one compact motor avoiding the need for more complex and heavy servo motors and guides.

The Micro-Drip System (MDS) is a resource-efficient irrigation solution that delivers water drop by drop to where plants need it: to the roots thus greatly reducing water consumption. The new generation of production should offer more process reliability, increased precision in force control and process parameters as well as sustainability and energy efficiency, which led GARDENA to choose LinMot.

precisely. Thanks to their flexibility, the LinMot motors adapt to all adjustments to the production machines at lightning speed and all changes can be made very quickly.

Precision with Feedback Force and Torque sensors are available as options for the LinMot PR02 which enable real-time monitoring and evaluation of process parameters with an accuracy of equal or better than 1% of the demanded value. Thanks to the precision of the LinMot PR02 motors, GARDENA have found their systems are 3 to 4 times faster than their older process.

PR02 – Linear /Rotary modules. Implementing industrial systems for precise and dynamic locking, screwing or assembly is an

Thanks to the precision of the LinMot PR02 motors, GARDENA have found their systems are 3 to 4 times faster than their older process.

DM01 / SM01 – Linear modules The modularity of the LinMot linear modules such as the DM01 and SM01 also impressed the GARDENA engineers. This provides a way for X and Y pick and place units to be quickly and easily assembled.

Total Flexibility

Sustainability or efficiency?

Parameters and contours can change fundamentally and quickly on both the product and the machine side, so that the reteaching of the individual positions must be done quickly, easily and

The question of having sustainability and efficiency working together has been well and truly answered as the collaboration between GARDENA and LinMot proves.

For further information, please visit www.quin.co.uk/linmot

PECM Issue 74

Linear motors for

Dynamics & Precision ..clean room & wash down applicaons

www.quin.co.uk/linmot -- Linmot distributor for the Ireland www.quin.co.uk/linmot Linmot distributor forUK the&UK & Ireland

EDITOR’S CHOICE

SMART MOVE BY HART HART DOORS

From Speedor Storm, the largest Speedor available, Hart Door Systems has now revealed Speedor Smart, the smallest Speedor available Doug Hart, Hart’s Chairman, says the development of Speedor Smart was very much driven by demand from global airports. “We have experience in delivering door solutions for very many international airports so we welcomed the opportunity to demonstrate our Speedor skills in the area of automated baggage handling. “This is a great achievement. We have been able to increase the range of solutions offered by the Speedor brand, in this case by delivering a secure, automatic, door to work repeatedly with conveyor belts, Speedor Smart. “Overall this strengthens our skills in an important area for airports be it baggage check in, conveyor separation or equipment automatic high speed access doors to the tarmac. There is increasing sophistication in the process at a time when airports are becoming busier. Being able to interface and automate, reliably over millions of operations is key.” Hart has a considerable range of assets for airports from a range of fire/security shutters capable of delivering protection from smoke and fire threats in a frequent operations environment to roller shutters for Storage/Access areas in airports to high-speed doors up to 6m wide x 8m high. This includes roller shutters tested to 5000 pascals pressure. Uppermost is the ability of Hart to deliver high quality solutions across a very

wide range of industries not just in the UK but abroad. Airport customers, for example, come to Hart for solutions and highquality ones at that which comply with UK, EU and US international standards confirming the endproduct achieves a standard which complies with the expectations of our customers and any applicable contractual and legislative requirements. Hart can be relied on to deliver the results and one that understands how airport projects are managed having a proven track record of British engineering and service excellence on nearly 40 international airports. These include Heathrow, where Hart installed forty eight check-in desks with a unique design, developed specifically for Heathrow in combination with an international

conveyor manufacturer, combining features from other Hart products namely fire, security and high speed, automatic, operation. Hart’s innovative products, problemsolving approach and practical experience help companies to maintain quality working conditions as well as containing noise, odour and environmental contaminants. This spirit of innovation is embedded in in the philosophy of continually evolving product range of Speedor high-speed doors, fire shutters, Terror Screen security rated shutters and specialist doors such as ATEX compliant high-speed doors and shutters. Hart’s products are manufactured to international standards such as the ISO9001:2015 Quality Assurance scheme and LPS 1056 and LPS 1271, Loss Prevention Council Standards for Fire and security doors third party tested to international standards.

For further information, please visit www.hartdoors.com

PECM Issue 74

EDITOR’S CHOICE

Issue 74 PECM

EDITOR’S CHOICE

EFFICIENT HIGH SHEAR MIXING SILVERSON MACHINES

High Speed, High Shear Hygienic mixing equipment from Silverson Machines Silverson Machines has a vast product range, from Laboratory-scale mixers capable of mixing as little as 1ml, to large production-scale models, including hygienic and Ultra Hygienic mixing equipment specifically designed for Pharmaceutical applications. Scaling-up is a relatively simple process as all Silverson mixers are manufactured to the same precision engineered tolerances. This year, Silverson Machines will be showcasing some of their mixers at CHEMUK on Stand G54.

Laboratory Mixers The Silverson L5M-A model is now available with the body finished in white engineered polymer for increased durability and ease of maintenance. The updated radiused edges allow for easier cleaning. With its integral tachometer, ammeter and programmable timer, the L5M-A offers a level of instrumentation invaluable in applications where process validation and repeatability are required. These mixers are ideal for small batches from 1ml up to 12 litres, and can mix in-line with flow rates up to 20 litres/minute using an In-Line mixing assembly, further increasing versatility.

Small-Scale In-Line Mixers Part of the newly launched SmallScale In-Line mixer range, the 088/150 Small-Scale Multistage In-Line Mixer will be on the stand. The 088/150 UHS is the first small-scale Multistage InLine mixer from Silverson Machines. These mixers increase the number

This year, Silverson Machines will be showcasing some of their mixers at CHEMUK on Stand G54.

50 litres, depending on viscosity. Featuring the same pumping rotor design as the HV model, the FMX10 is able to process higher viscosity mixes, and the option of a high speed motor, capable of 9,000rpm, and Flameproof specification makes this model even more versatile.

Hygienic Bottom Entry Mixer of shearing actions per revolution of the rotor, resulting in substantially faster mixing times and increasing the number of products that can be processed in a single pass. The Multistage workhead also allows customers to configure the mixer to their individual requirements.

Powder/liquid Mixers

Silverson’s hygienic series of high shear Bottom Entry mixers are designed to fit into the bottom or side of a mixing vessel. These high shear mixers are typically used in conjunction with a slow speed anchor stirrer or scraper unit for high viscosity products. Visit Silverson Machines at Stand G64 at CHEMUK 2024.

The FMX10 and larger FMX25 powder/ liquid mixer will also be on the stand. The FMX10 was designed to bridge the gap between the laboratory scale FMX5 and the larger Flashmix product range. It provides a simple, effective and hygienic means of powder/liquid mixing on a small scale, with a batch size of up to

www.silverson.co.uk | sales@silverson.co.uk

PECM Issue 74

EDITOR’S CHOICE

LOAD BANK TESTING POWER PROVE

How to rectify common testing pitfalls Load bank testing is a vital process for ensuring the reliability of power systems, but even experienced teams can make errors that compromise results or lead to equipment downtime. From underestimating testing requirements to over relying on outdated testing equipment, Andrew Keith, division director of load bank manufacturer Power Prove, explores five of the most common pitfalls seen in load bank testing and provides actionable tips to avoid them. There are very few industries that don’t benefit from load bank testing to ensure they remain operational. Whether it’s preventing unplanned downtime in continuous processing or keeping vital infrastructure online when mains power fails, load bank testing is a non-negotiable requirement for any industry relying on electrical power. However, testing can be rendered ineffective if it’s carried out incorrectly. So, what are some of the main errors that maintenance teams should avoid? Skipping regular testing Since backup power supplies are largely used in the case of emergencies, it’s easy to neglect regular testing. However, this increases the risk of unexpected failures when generators are needed most. Routine load bank testing should be part of a comprehensive maintenance schedule to identify issues early, prevent costly repairs and ensure backup power sources are fully operational. Regularly scheduled testing also helps businesses remain compliant with industry standards, for example to ensure

that emergency lighting systems are functioning and able to safely guide building occupants outside. Low loading While regular testing is key, simply connecting power units to a load bank and running them at a low load can lead to serious issues in itself. When generators operate under loads rated at less than 40 per cent of their rated power for prolonged periods, carbon deposits can accumulate, leading to ‘wet stacking’ and reduced efficiency. This can also increase maintenance costs and reduce the lifespan of the generator. Regular load bank testing at the optimum load ensures that generators operate within optimal parameters, improving performance and reliability. Underestimating load testing requirements With low loading in mind, it’s important to properly assess the power requirements for testing. Selecting a load bank with insufficient capacity can lead to incomplete testing and an inaccurate assessment of backup power systems. On the other hand, significantly overestimating requirements can result in unnecessary costs. You should aim for a load bank setup with a slightly higher capacity than your current equipment requirements, allowing for effective testing and room for future growth. Relying on outdated load bank technology Ageing load bank technology is often less precise than more modern load banks, which can lead to inaccurate

test results. Additionally, older load banks often lack the automation required for modern power testing. Their manual systems require on-site adjustments, making it difficult to conduct thorough and frequent tests, particularly in remote or hazardous locations. Advancements in digital load bank control systems allow for real-time data collection, remote operation and predictive maintenance. Investing in modern load bank solutions ensures faster, more accurate testing and enhances overall power system reliability. Disregarding test data Load bank testing is only as valuable as the insights gained from it. Failing to record and analyse test results can render the process ineffective, as businesses miss out on key trends and early warning signs of potential failures. Traditional manual data collection methods can be time-consuming and prone to errors, making it difficult to track performance over time. Modern load bank systems, such as Power Prove’s DIGILOAD, automatically record and store test data in easily accessible formats that are downloadable onto a USB. This streamlined approach enables quick analysis and integration into predictive maintenance strategies, ultimately reducing downtime and improving overall system reliability. By avoiding these common pitfalls, organisations can enhance the effectiveness of their load bank testing and ensure their backup power systems are ready for any situation.

For further information, please visit www.powerprove.com

PECM Issue 74

Secure your FREE ticket at the ultimate dairy processing event Register today!

Informative seminars covering all sectors of the dairy industry.

Cutting edge dairy innovations and equipment presented by a diverse range of exhibitors.

Exhibitor & Sponsorship enquires please contact Samantha Bull sam@bellpublishing.com • Tel: +44 (0) 1474 558 970

dairyindustriesexpo.com #DairyIndustriesExpo

EDITOR’S CHOICE

JTS ‘THE PROCESS’ JTS

Engineered solutions, designed & built in Britain James Technical Services Limited are a well-established UK specialist manufacturer. Designing, building and servicing high performance environmental test chambers for a wide variety of industries. Test chambers are used throughout industry to ensure the excellence of a product before it hits the open market. Depending which industry you are in, aerospace, cosmetics, defence, pharmaceuticals, medical, technology, or automotive, you most likely use or order items that have gone through rigorous environmental test chamber testing. JTS has transitioned to an employeeowned company over the past 12 months and are looking forward to some exciting times ahead. This with new employees starting, roles changing the journey is in its infancy but the whole team are behind the solutions we provide JTS journey is not only with the employee ownership its also with its customers when they team up on the test chamber purchasing road

Your idea & Requirement Most products will require testing at some stage and here at JTS we will work with you to supply a test chamber that will cover all your testing needs.

assembly drawing will be issued for approval this will be agreed before we proceed to the manufacturing stage.

Build & test

to fit in with the environment its going to be used.

We will prepare a quote After the discussions and concept layouts have been agreed a quotation and chamber / room specification will be formally issued to the customer catching all the requirements and full details on the scope of supply that JTS offer for this project.

Design stage & approval Initial discussions This can be by telephone or email we will listen to your requirements and start to pull together ideas and layouts of chamber designs that will suit your needs. A site visit maybe worthwhile to look in detail at the product that requires testing and the facility layout to design the chamber

After order placement discussions will take place regards the detailed design and this will involve the sales and design teams from JTS ensuring a smooth hand over of all the technical information and a discussion with the team purchasing the equipment to ensure all aspects have been captured. A detailed general

All JTS test chambers are manufactured at the purposebuilt factory in mid Wales using local engineers and suppliers where we can. The chambers go through the various sections in the manufacturing area ranging from mechanical, electrical & refrigeration before going into the test department for final setup specification and performance checks.

Commission & Handover After completing its testing procedure and setup site commissioning maybe required which will include delivery of the chamber / room with the complete installation. The equipment will then go through site performance checks with a JTS service engineer showing all the chamber operating parameters and performance charts to the customer before final sign off and hand over of the fully installed equipment.

For further information, please visit www.jts-test-chambers.co.uk

PECM Issue 74

ENGINEERED SOLUTIONS | DESIGNED & BUILT IN BRITAIN

t.01874 711 209

www.jts-test-chambers.co.uk e. sales@jts-test-chambers.co.uk Unit 3 | Talgarth Business Park | Brecon | LD3 0PQ

JTS

JAMES TECHNICAL SERVICES LTD TEST CHAMBERS & TESTING EQUIPMENT

LOW TO

HIGH

TEMPERATURE CHAMBERS HUMIDITY CHAMBERS

EDITOR’S CHOICE

DUCATO GETS UPGRADE KLARIUS

Klarius strengthens parts support for the Fiat Ducato and more Klarius Products continues to support the aftermarket automotive sector with the introduction of 23 new emission control components for a selection of popular cars and vans. This release provides coverage for over 680,000 vehicles in the UK and over 2.9 million across Europe. Included in this release are new emissions control components for brands such as Chevrolet, Citroën, Fiat, Ford, Lexus, Mercedes, Mini, Peugeot, Renault and more. Any owners of a Fiat Ducato, one of Europe’s favourite vans, will be pleased to hear that two new exhaust components have been launched for the 2015 (onwards) models, covering over 408,000 across Europe. Ever since the first Fiat Ducato rolled off the assembly lines in 1981, the brand has been a popular choice for campervan conversions, as well as operators looking for lightweight commercial vehicles. 41 years, four generations and many facelifts later, you’re still just as likely to see a Ducato parked aside popular bike trails as you are to see it outside your local builders merchants. No matter what the Ducato is being used for, we know that their owners rely on them to get the job done. Which is why Klarius has launched exclusive aftermarket exhaust parts that match or exceed the original equipment standards.

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

Klarius releases new batch of emission control components to support the Fiat Ducato and more

MANUFACTURER OF HIGH QUALITY

ANTI VIBRATION PRODUCTS

Fast facts about the Fiat Ducato

New grow

• The Ducato’s name derives from the Ducat; a coin from the Middle Ages that was used throughout Europe • It has been voted “Best Motorhome Base Vehicle” sixteen years in a row (2009 – 2024) • It is the 10th most popular selling van of all time (over 3.5 million sold) The introduction of the latest emissions components to the Klarius product portfolio means that Ducato owners across the UK, and throughout Europe, can continue to enjoy the freedom of the road with total peace of mind. There are over 11,000 parts in the Klarius Products catalogue and next-day delivery on orders placed before 5:30pm, helping to keep UK drivers on the road.

sales@fibet.co.uk | www.fibet.co.uk

For further information, please visit www.klarius.eu/

Fibet Rubber Bonding (UK) Ltd Unit 9 Dale Mill, Hallam Road, Nelson, Lancashire, BB9 8AN

PECM Issue 74

WIDE RANGE OF STOCK AVAILABLE FOR NEXT DAY DELIVERY

01282 878200

INDUS E is proud of custo automa special After w and aut for seve leading has rece premise increasi of bespo control The new allow us wider ra

EDITOR’S CHOICE

Daimler Truck workshops pioneer new rating scheme to enhance commercial vehicle maintenance The new Maintenance Provision Rating Scheme (MPRS), launched at the Commercial Vehicle Show to provide a standardised, tiered rating system for HGV workshops across the UK, has completed an 18-month pilot that included using Daimler Truck workshops as a benchmark for its scoring criteria of competency levels and facilities. With an objective to raise industry standards for commercial vehicle maintenance, reduce MOT failures or prohibitions, and improve safety, reliability and compliance, the MPRS was jointly developed by Logistics UK, RHA, CPT, IRTE, SMMT, BVRLA, and NFDA, and is backed by the Office of the Traffic Commissioner, DVSA and DfT. Daimler Truck has been closely involved in the development of the MPRS and was proud to be a partner for the pilot. The tiered ratings of Entry, Bronze, Silver, Gold and Platinum help commercial vehicle operators make more informed decisions when deciding where to maintain their trucks. Workshops participating in the MPRS will be able to show their commitment to excellence

“We believe the MPRS will help raise the bar in aftersales and, in the longer term, we hope customers start asking workshops for their MPRS ratings and that dealers start promoting their own scores. Daimler Truck takes customer service and compliance very seriously and although we already assess the standards of our own dealer network regularly, the MPRS now provides a useful independent benchmark to prove that when a customer sends their fleet into our workshops, they’re being looked after by the highest standards,” continued Amy.

and boost their reputation to give them a competitive advantage. It will also encourage them to invest in training and improving their facilities to enhance their rating. Amy Carter, Head of Product, Daimler Truck UK, commented: “As an OEM, Daimler Truck UK has welcomed being involved in the development of the MPRS as we believe it is important for the commercial vehicle industry to be setting new standards. It has needed a consistent, nationwide rating scheme for a long time.”

www.daimlertruck.com/en

HMA 2A Up to 30:1 turndown

FDB

High efficiency

Choice of operating fuels

Customised design to suit each install

Ideal for variable plant conditions

Reduced NO₂/CO Emissions

Proven in a wide range of applications

Air replacement or “Make-Up”

Choice of burner heat inputs up to 1150 kW

Larger heat input available on request APL technology -modulating gas and air

Up to 205 kW per foot

FDGA APL technology - modulating gas and air Ideal for variable plant conditions Heat input range up to 1,550 kW Choice of operating fuels

BESPOKE DESIGN

Our gas burner systems offer users reliable, high efficiency, process heating solutions. From design, manufacturing and supply to installation, commissioning and ongoing support, we fulfill process liquid, oven and air heating needs for both new-build and conversion projects.

FULL RANGE OF INTERNATIONAL ACCREDITATIONS

FDC Heat input range up to 1,550 kW Choice of operating fuels Packaged burner design Up to 40:1 turndown

BURNERCARE SERVICE

Lanemark Combustion Engineering Limited Lanemark House, Whitacre Road, Nuneaton Warwickshire CV11 6BW United Kingdom

info@lanemark.com +44 (0) 24 7635 2000

Issue 74 PECM

EDITOR’S CHOICE

REDUCING CARBON FOOTPRINTS BABCOCK WANSON UK

Babcock Wanson UK expands environmental solutions with DCT regenerative oxidisers & solvent recovery systems Following the acquisition of Donau Carbon Technologies (DCT) by the Babcock Wanson Group in 2022, industrial process heating equipment and solutions specialist Babcock Wanson UK has expanded its range of regenerative oxidisers and is now able to offer complete solvent recovery systems to help reduce customers’ carbon foot print and meet increasingly stringent emission limits for solvents and volatile organic compounds (VOC). DCT solvent recovery systems feature activated carbon adsorption, using steam or inert gas for the regeneration. A distillation section (batch or multi-columns) allows for a very high level of purity – frequently exceeding international standards - for the recovered solvents to then be reused in production, making for a rapid return on investment. These solvent recovery systems are easy to use and, because they are modular, can be expanded and reconfigured to meet changing site requirements. With its compact size, plug and play design, plus easy maintenance, the latest solvent recovery system, the X-CSR, has been specifically designed for printers using smaller solvent quantities (as little as 300 tons/y), extending this valuable technology beyond the traditional, large print plants. Babcock Wanson UK has been providing oxidisers for many years but with the addition of DCT regenerative and recuperative oxidisers can now meet a wider range of industries and requirements than ever before.

DCT regenerative oxidiser capacities range from 3.000 to 300.000 Nm3/h. They boast low maintenance costs and consistency of performance across their life time. Additional DCT products supported by Babcock Wanson UK include VOC Concentrator Units for the purification of polluted air with low solvent concentration; Catalytic Oxidation to treat waste air or gases; and Scrubber and Filter Treatment Systems for inorganic polluted fumes. The DCT range has already proven extremely popular in the UK and Babcock Wanson is currently working on a number of high profile projects, including its largest ever oxidation project, with a building materials manufacturer.

The company aims to not only help optimise customer’s energy production but to also be the European leader in environmental solutions for industry. DCT regenerative oxidisers enable up to 99% VOC abatement by increasing the polluted air temperature to over 750-800°C with a high efficiency (up to 95%) heat recovery system based on the use of ceramic material; all whilst using minimal energy.

The DCT range of oxidisers and solvent recovery systems are one of the latest additions to Babcock Wanson’s comprehensive range of products and services for boiler houses and other process heating needs, including firetube boilers, coil type steam generators, thermal fluid heaters, hot water boilers, VOC and odour treatment by thermal oxidation, water treatment and process air heating solutions. The company aims to not only help optimise customer’s energy production but to also be the European leader in environmental solutions for industry. For more information, please contact Babcock Wanson on 020 8953 7111 or email info@babcock-wanson.com or go to www.babcock-wanson.com

For further information, please visit www.babcock-wanson.com

PECM Issue 74

EDITOR’S CHOICE

High performance stainless steel valves and pressure switches for tough environments Versatile Controls Ltd was established in October 1987 by the current owner Mr Jon Slim and the late Mr Edward Dowty. The Company started as a distributor for The Versa Products Inc of New Jersey to serve the Oil and Gas industry in The North Sea with high quality pneumatic and hydraulic control valves. During the following years, the company acquired other distribution rights with ITT Neodyn pressure switches, ITT Conoflow regulators, Ruelco switches and regulators and Deltrol flow control products. In recent years, the company has made progress in the manufacture of high quality mixing systems for The Pharmaceutical industry and was responsible for many of the systems required during the recent covid epidemic. AUTOMATION & CONTROL SYSTEMS INNSWORTH TECHNOLOGY PARK GLOUCSTER, GL3 1DL sales@versatilecontrols.co.uk 01452-731447

www.versatilecontrols.co.uk

“It is not the strongest of the species that survives, nor the most intelligent that survives. It is the one that is most adaptable to change.” Charles Darwin In our uncertain environment, energy adaptability is key. When it comes to process heating, Babcock Wanson offers more choice and flexibility to achieve your decarbonisation goals, reduce your fuel bill and allow for energy diversification.

Babcock Wanson UK Ltd. 7 Elstree Way, Borehamwood, Hertfordshire WD6 1SA, UK Tel: 020 8953 7111 | info@babcock-wanson.com

www.babcock-wanson.com

Issue 74 PECM

CHEMUK PREVIEW

ENGINEERING SPOTLIGHT CHEMUK

The UK expo for process engineers returns this May The Process & Chemical Engineering Show, running as part of the CHEMUK 2025 ‘Group of Events’, will return this 21st & 22nd May at the NEC in Birmingham, presenting hundreds of exhibitors and a full programme of expert speaker sessions over two packed days. The Process & Chemical Engineering Show will showcase the latest technology and specialist services to attending process, plant, and control engineering professionals across the chemical, food & beverage, pharma, oil & gas, water & waste, and energy sectors.

Records numbers of NEW exhibitors confirmed 2025 will welcome over 60 brand new exhibitors for visitors to meet with including: 6ix Process Design, Abacus Valves, ABLE Instruments & Controls, Addison, Ambic Equipment, Andritz, APIS MC, APMG Plastics, ARTECH ULTRASONIC SYSTEMS, AVA-Alms Valve Agency, AZO, Barriquand Heat Exchangers, Beckhoff Automation, Buckley Industrial, C&P Engineering, Chemviron Carbon, Co-ax Valves, Cognite AS, dataPARC, DESAL Supplies, DINNISSEN Process Technology, Elta Group, EPC Handelges, EUROTEC, Framatome, Friedheim International, G Bopp & Co, GMM Pfaudler, Hecht Technologies, HYDAC, Hydrodif Products, Innomotics, Intertec-HESS, J1 Technologies, John Mayes Engineers, Johnson Valves, Kecol Pumping Systems, Knitwire, KROHNE, Meller, Merinox, OLG, Portobello Engineering, PR Electronics, R&G Fluid Power, Sampling Systems, Sandfield Penstok Solutions, Sigma-HSE, Simmatic Automation, SM Gauge Company, Spiroflow, Step on Safety, Stepart Plastics, Sulzer Pumps Wastewater, Tantaline, Transworld Steel Enterprise,

UK Extrusion, Visilume, VOOVIO Technologies, W.E.C (Leeds), Watlow, Ytron-Quadro Limited, and Zwick.

IChemE and IMechE to headline engineering speaker programme The Process & Chemical Engineering Show speaker programme is an unmissable opportunity to hear from the heads of industry and academia as they discuss the challenges, opportunities, and innovation affecting the process engineering industries. The IChemE and IMechE will be presenting a series of expert panel discussions, keynotes, and technical clinics at the show. Their respective membership teams will also be exhibiting, ready to meet with current and potential members and companies to see how they can support their personal and business development. The full speaker programme will be released in March 2025. Please see the website for full details.

‘The Big Education Debate’ at CHEMUK This feature session, running on Thursday 22nd May, will invite senior panel leaders from across academia and industry to discuss the UK’s educational framework and commitment to supporting its science skills and science base requirements. This critical debate comes in response to the recent pressures facing higher education chemistry departments across the UK.

Innovation Ecosystem at CHEMUK 2025 CHEMUK 2025 will present several of the UK’s primary innovation support organisations, giving startups and spinouts the opportunity to receive the support they need to continue

their development journey towards full-scale commercialisation. Participating partners include the Henry Royce Institute, Innovate UK Business Connect, Aston University, RSC Changemakers, Materials Innovation Factory, and the Biorenewables Development Centre.

Waste2Race: The sewage-powered car on track to make history Visitors this year will be able to see the hydrogen-powered Le Mans Prototype class 3 car, fuelled by sewage in a project entitled Waste2Race. The engineering team behind the project from the University of Warwick will be at the show to meet with visitors and explain the technology creating green hydrogen from wastewater, powering the groundbreaking vehicle.

UK Government at CHEMUK Attendees will be invited to a full UK Government programme at CHEMUK. HSE and DEFRA will be providing industry briefings on Wednesday 21st May. The UK Export Academy team will be exhibiting at the show, ready to meet with visitors that are looking to develop international trade opportunities. The academy team will also be running a one-hour panel session on Thursday 22nd May, outlining the international trade landscape.

DATES FOR THE DIARY The Process & Chemical Engineering Show at CHEMUK 2025 takes place on Wed 21st & Thu 22nd May 2025 Venue: NEC - National Exhibition Centre, Birmingham, B40 1NT Opening Times: Day 1: 9.30am – 5.00pm Day 2: 9.30am – 4.00pm

PECM Issue 74

21st & 22nd May 2025 The NEC, Birmingham, UK

Running as part of the CHEMUK 2025 Group of Events

FREE ENTRY

WHEN ERED PRE-REGIST

2 Packed Days Hundreds of Exhibitors Panel Sessions Plant & Process Intensification Control & Instrumentation CHEMICAL 4.0 Automation / Digitisation Plant Management Flow & Thermal Solutions Thousands of Specialist Products... plus more!

Supporting Partner

PRE-REGISTER FOR FREE ENTRY! Supporting Partners include:

Issue 74 PECM 47 21st & 22nd May 2025 REGISTER FREE AT WWW.CHEMICALUKEXPO.COM

SMART MANUFACTURING SHOW PREVIEW

DISCOVER, DEVELOP, DISRUPT SMART MANUFACTURING WEEK

Unlock tomorrow’s manufacturing solutions and more at Smart Manufacturing Week 2025

Smart Manufacturing Week, the UK’s largest manufacturing and engineering exhibition, will take place at the NEC Birmingham on 4th–5th June 2025. The event returns bringing together a powerful lineup including Smart Factory Expo, Drives & Controls, Maintec, Design + Engineering Expo and the Air-Tech and Fluid Power and Systems zones. The event’s educational programme features seven Solutions Theatres, each dedicated to a critical aspect of modern manufacturing. These include Digital Transformation, Industrial Data & AI, IIoT &

PECM Issue 74

Connectivity, Design & Innovation, Automation & Robotics, Leadership & Strategy and Maintenance. Each of the sessions are designed to provide attendees with practical, actionable insights that can be directly applied to improve their operations. A session visitors should be sure not to miss will be delivered by the ‘Godfather of Industry 4.0’, Professor Henrik von Scheel. His talk, The Future of Manufacturing: Megatrends that Shape the Next Decade, will examine the forces that will dominate the manufacturing landscape in the years ahead,

including smart automation, AI integration and the evolving dynamics of the workforce. It’s an essential part of a visit for those looking to stay ahead in the fastevolving manufacturing landscape. Emphasising the ‘industry under one roof’ nature of the event is the presence of prominent exhibitors including Schneider Electric, FANUC UK, 3M, Epicor, Binder UK, Cembre, Charter Controls, Ericsson, IFS, Biffa, Hoffmann Group and ifm Electronic. Alongside other big names the exhibition floor will showcase the most influential players in industry.

Amongst these giant players are the startups and innovative small businesses set to revolutionise the sector. Part of Smart Factory Expo, ‘Innovation Alley’ will feature emerging manufacturing technologies from early-

stage businesses, providing an opportunity to source the transformative technologies that promise to shape manufacturing over the next decade. New for 2025 is ‘Smart Tank,’ where these entrepreneurs will pitch their

products and services to a panel of experts. In addition, Smart Manufacturing Week will continue its commitment to inspiring the next generation through its STEM Programme,

Issue 74 PECM

Manufacturers & Engineers of the Future, sponsored by FANUC. Now extended to include school year students, as well as those in further education, hundreds of students and apprentices will have the chance to interact directly with industry experts, offering a handson introduction to the exciting world of advanced manufacturing and engineering. As part of the programme, visitors can also witness the FANUC WorldSkills UK Industrial Robotics Competition qualifier. For some fun, the popular Guitar Legends competition returns, with a 3D-printed guitar for the winner, plus the house band The Shadow Monkeys will pop up all around the event and return with their signature high energy and crowd-pleasing hits to close out the first evening’s visitor party. Meanwhile, the Best of British

With so much to explore, Visitor Trails are the perfect way to navigate Smart Manufacturing Week with ease. Showcase celebrates the finest in UK manufacturing, spotlighting groundbreaking designs, pioneering methods, and export successes. With so much to explore, Visitor Trails are the perfect way to navigate Smart Manufacturing Week with ease. These curated pathways help attendees make the most of their time, guiding them to the most relevant exhibitors, mustsee presentations, and technologies based on their interests. Whether

you are seeking the latest innovation and smart technology advancements or looking for groundbreaking sustainability and circular economy solutions, or products and services designed specifically for SMEs, these tailored routes ensure you don’t miss anything. Smart Manufacturing Week takes place at the NEC Birmingham on the 4th-5th of June 2025. Other exhibitions taking place at the NEC at the same time include Automechanika run by Messe Frankfurt; Med-Tech Innovation Expo and TCT 3Sixty from Rapid News Group and Subcon from the Mark Allen Group. One visitor badge provides access to all events.

For more information and to register for free visit: https://www.smartmanufacturingweek.com/

PECM Issue 74

4-5 JUNE 2025 | NEC, Birmingham

The Festival of Advanced Manufacturing & Engineering AGENDA NOW LIVE!

Also gain access to events including

smartmanufacturingweek.com

Organised by

SUBCON PREVIEW

CUTTING-EDGE INNOVATION SUBCON

The Manufacturing Solutions Show Preview

Subcon 2025 is back at The NEC, Birmingham, from the 4- 5 of June, bringing together over 170 exhibitors and thousands of manufacturing professionals! This premier event is where manufacturers and buyers across aerospace, automotive, defence, medical, and more connect to redefine the supply chain with cutting-edge innovations.

workshop programme – key speakers from JLR, LEGO Group, Airbus Commercial Aircraft and more.

and meeting new contacts. Enjoy refreshing drinks and classic ‘pub’ games for a relaxed, fun atmosphere.

• Free networking drinks from 16:30 on Day 1!

• Access to co-located events running at the NEC on the same dates - Automechanika Birmingham, Med-Tech Innovation Expo, Smart Manufacturing Week, and TCT 3Sixty— all under one roof.

Expect UK and International solution providers, hands-on product demos, CPD-accredited workshops, and thought-provoking keynote presentations tackling the industry’s hottest trends.

• Pro motorsport simulators - go headto-head with a real racing superstar. We’ll be joined by Michael O’Brien, one of the most successful drivers in the modern history of McLaren motorsport. The winner of the fastest lap will receive a PalmerSport driving experience day.

Event Highlights • 170+ exhibitors – 10% bigger show floor compared to 2024. • New and improved forum and

PECM Issue 74

• The Manufacturing Solutions Show Awards on Day 2 – celebrate the best and brightest in the industry.

• PUB-CON – our vibrant new networking hub, perfect for reconnecting with old friends

• VIP buyers programme – open to senior manufacturers, offering exclusive networking opportunities.

Conference Programme From Human-Robot collaboration and sustainable practices to clean mobility and breaking silos, this programme tackles the hottest topics shaping the industry. Explore challenges like manufacturing security, IP management, and global

trading, plus game-changing insights on PLM, composites, and connecting the shop floor to the top floor. Here’s a sneak peek at what you can expect:

Presentations and Q&A discussion • Matthew Atkinson, Lead Research Engineer - Jaguar Land Rover ( 14:00 - 14:30 – 4th June) Composite Cross Car Beam: A Case Study in Sustainable Design - Exploring the common misconception that sustainability has to come at a cost, how changing perspectives can alter the definition of sustainability, and how this is critical to our future business. This presentation will outline the replacement of environmentally damaging magnesium with a right-materialright-place solution, the journey to get there, and where we need to go next. • Dr Benjamin Silverstone, Associate Professor, Head of Skills Policy and Strategy - WMG – University of Warwick (11:10 - 11:40 – 4th June) We Know What We Need, Now, How Do We Get It? - A lot of focus has been placed on understanding the needs of skills for the future and, in many ways, this will always be a challenge as things will always change. However, we are now in a much better position to more accurately predict capability shifts and plan to assess what industry will need to do. We now need to better understand how to ensure that the actual interventions needed are in place. From ensuring that we have a robust skills system to effectively linking employers, individuals and the educators together to deliver there needs to be a more joined up look at how we get what we need once we understand what it is that we want. Every stakeholder has a role to play in this. • Jesper Toubol, Vice President Operations - Moulding Production LEGO Group (10:25 - 11:00 – 5th June) Unlocking the Power of Data and Al for Smarter Manufacturing - Jesper will share his insights into how you can:

Expect UK and International solution providers, hands-on product demos, CPDaccredited workshops, and thought-provoking keynote presentations. - Leverage machine learning to enhance condition-based maintenance and reduce downtime. - Empower connected workers with accessible, real-time data through shop floor data democratization.

towards more strategic roles. It will also highlight existing skills gaps and obstacles to AI implementation, as well as provide strategies for developing a workforce prepared for the future. • Paul Moss, Director - Intergage

- Analyse and address process variances to drive operational excellence and sustainable improvements.

Workshops: • Dr Muddassir Ahmed, Founder & CEO - SCMDOJO (11:45 - 12:40 – 4th June) Supply Chain Talent Needs in the Age of AI - This presentation will address the changing requirements for talent in supply chain management due to increased digitalisation and AI integration. Digital skills are becoming essential for supply chain professionals. The presentation will explore how AI is transforming supply chains, necessitating a shift

(15:30 - 16:20 – 4th June) Discover the Power of Precision Marketing - Does your marketing sometimes feel like a cracked egg—spilling everywhere but never quite landing where it matters most? Perhaps you’re frustrated with lack of ROI, struggling with stagnant sales or lost in a sea of sameness. The truth is, you’re spreading yourself too thin and trying to implement short-term initiatives to a long-term business problem - stifled growth. In this workshop you’ll learn how to target the right clients with precision and purpose. This is the essence of Fried Egg Marketing®, a focused strategy designed to guide your ideal client through a personalised journey, Issue 74 PECM

from first contact to becoming a loyal, profitable, long-term customer. Forget the strategies that have had you scrambling for quick fixes. Implement a methodology that will help you build meaningful, long-term results for your business. • Speakers from I4Excellence Ltd. and Unipart Group (11:25 - 12:25 – 5th June) Foundations for Excellence - Many organisations are already on their journey to excellence – their best-practice has informed useful ‘models’, principles, methods and tools. The manufacturing sector has led much of this development, but a lot of misunderstanding remains in many organisations. All of these ‘Excellence’ approaches are widely applicable in any organisation and can deliver significant long-term benefits. The workshop will provide key insights on ‘Organisation Excellence’ and challenge attendees to identify the next steps toward becoming an excellent organisation.

PECM Issue 74

Panel Discussions: • Speakers from Rolls Royce SMR, NHS Supply Chain, University of Warwick, Hexagon Consultants Limited and Digital Catapult (12:45 - 13:30 – 4th June) Manufacturing Supply Chains Under Geopolitical Uncertainties - The global manufacturing landscape is undergoing a profound transformation, driven by geopolitical uncertainty, trade realignments, and shifting economic policies. In an

era marked by rising protectionism, supply chain disruptions, and heightened concerns over national security, businesses and policymakers must rethink traditional sourcing and production strategies. In this talk, we will explore how these geopolitical dynamics are reshaping supply chains for critical products, from semiconductors and pharmaceuticals to renewable energy technologies. By examining the risks and opportunities emerging from global trade

tensions, reshoring initiatives, and technological advancements, we will provide insights into how firms can build resilience and adaptability in an increasingly volatile world. This panel discussion will bring together industry leaders and academics to delve deeper into the practical implications of these geopolitical shifts. We will examine scenarios of recent supply chain disruptions, discuss the role of government interventions, and assess the impact of diversification, nearshoring and friendshoring strategies. With global supply chains at a crossroads, this discussion will offer a timely perspective on how manufacturers can navigate uncertainty while ensuring the security and sustainability of their supply networks. • Speakers from National Manufacturing Institute Scotland, IBM and The University of Sheffield Advanced Manufacturing Research Centre (11:45 - 12:30 – 4th June) Adopting Technology [in Manufacturing]. The Opportunities, What’s Holding it Back and How to Move Forward -

An opportunity to listen to a panel discussion around the adoption of technology in manufacturing. It will cover what opportunities technology can offer, what is holding manufacturers from adoption and how they can overcome hurdles to exploit the potential. The panel has eminent industry experts from the world of technology, innovation and manufacturing.

to manufacturing? This panel will seek to try and answer some of the outstanding questions and open a debate on how to progress this in the future.

• Speakers from Airbus Commercial Aircraft, Cranfield University, Fanuc UK and Automate UK

Exhibitors

( 14:15 - 15:00 – 5th June) Human Robot Collaboration in Manufacturing, the Future or Just Hype? - The use of human robot collaboration is often put forward as a key future enabler in manufacturing combining the skills and capabilities of both to provide optimal automation solutions. However, the reality is proving to be very different, lack of understanding, fear, mistrust and technical limitations among other barriers mean that very few truly collaborative systems exist in industry. Why is this and what should we be doing to unlock this potential, game changing approach

Make sure to check out the full conference agenda at https:// www.subconshow.co.uk/contentprogramme for more details on session times and speakers!

Over 170+ exhibitors will be attending the trade show. Innovations and solutions will be showcased ranging from CNC machining, metal fabrication, electronics and component parts. Other solutions on show include additive manufacturing and metrology solutions, frictionless bearings and cables and controls. Here are some of the key exhibitors you can expect to see:

Sponsors and Partner highlights: • Allstar– Allstar have been serving businesses large and small for over 40 years. They have the UK’s largest combined fuel and electric charging network, savings on diesel and our online platform will help reduce your costs and admin. Issue 74 PECM

• Smiths Metal Centres - Smiths Metal Centres is a world-class supplier of engineering material alloys & plastics into a broad range of industrial applications. We aim to offer all our customers, from the small machine shop to large multi-national corporation, a supply path that continuously provides the highest levels of service, quality and value. • EEPC India – EEPC India has been the Face of Indian Engineering exports over a span of 69 years when India grew from a meagre $10 million engineering export nation in 1955 to USD 109.32 Billion (Apr 2023- March 2024 ) and is regarded as the model EPC in India by the Union Ministry of Commerce and Industry. EEPC India is the premier trade and investment promotion organisation in India. It is sponsored by the Ministry of Commerce & Industry, Government of India and caters to the Indian engineering sector. It has many firsts to its credit. The First Indian EPC to have a website, to be ISO certified and to e-catalogue the product profiles. • Qimtek – We help manufacturing buyers to find quality UK-based subcontract suppliers that have immediate or long-term capacity. Upload your drawings on Drag, Drop, Source or send them to us by email, tell us your requirements and we will put you in contact with our manufacturing partners who will quote you directly.

• The MTA - The Manufacturing Technologies Association is the UK’s trade association for companies in the manufacturing technology sector. MTA members design, manufacture and supply the advanced machinery, equipment and intellectual property that enable the creation of the products we rely on from day to day and that drive our economy. • The BTMA - The BTMA is ‘THE’ Trade Association for high-quality UK based Manufacturing Companies, producing precision turned parts and machined components. Members of the BTMA are proactive companies who, collectively, have raised the profile of the UK subcontract industry. Membership of the association provides many benefits, including credibility by association, inclusive advertising and networking opportunities.

Networking Opportunities at the Exhibition: Take advantage of the opportunity to meet with exhibitors and explore the latest trends and innovations in manufacturing. Whether you’re seeking to make business connections, explore new technology, or simply discover what’s new in the market, the exhibition is the perfect place to make valuable connections.

Benefits of attending for manufacturing professionals 1. Access to Top Suppliers: With over 170 exhibitors, attendees can connect with leading subcontract and outsourced engineering services across various industries, ensuring they find reliable partners for their manufacturing needs. 2. Networking Opportunities: From networking drinks to our exclusive VIP lounge, the event provides ample opportunities to meet decision-makers, suppliers, and industry leaders, fostering potential collaborations and partnerships. 3. Practical Learning: Attendees can participate in CPD-accredited talks and workshops, keeping up to date with the latest trends and advancements in manufacturing. 4. Inspiration and Innovation: There are thousands of products to explore with live demos presentations. 5. Fresh Perspectives: Attendees can step outside of the office for fresh insights and solutions.

Stay Connected Follow us on LinkedIn (SUBCON) for updates, sneak peeks, and behindthe-scenes content leading up to the event. #SubconShow

For further information, please visit www.subconshow.co.uk

PECM Issue 74

DON'T MISS

THE UK’S B GGEST MANU ACTURING S PPLY CHA N SH W 170+

Expert-led

Live

Networking

Motorsport

suppliers

talks and workshops

product demos

The Manufacturing Solutions Show

VIP buyers

Chill and charge

Awards

programme

lounge

drinks

games zone

THE MANUFACTURING SOLUTIONS SHOW 4 - 5 JUNE 2025 • THE NEC, BIRMINGHAM

SOURCE

NETWORK

SUBCON

@Subconuk

WWW.SUBCONSHOW.CO.UK

LEARN

BENCHMARK

CONTROL & AUTOMATION

CONVEYOR TECHNOLOGY ADAPTTECH

Efficient & Environmentally Friendly Automation with mk’s NEW FULLY ELECTRIC Pallet System mk have been working intensively to further develop their conveyor technology offering with a range of innovative products and expansions. One of their latest developments, Versamove Electric, is focused on enhancing efficiency, versatility, and environmental sustainability. Versamove is a modular transfer system for transporting workpiece carriers that can be optimally tailored to the customer’s specific requirements. mk have now added an electric version to the Versamove Standard weight and size class, offering customers a much greener option.

be retrofitted into existing Versamove standard systems with ease.

Modular. Versamove’s modular design allows for quick and transparent scheduling and project planning. It has the flexibility to be expanded and is perfect for adapting to conditions on site. Compatible. While developing the system, mk ensured its compatibility with other systems currently available on the market, for example those from Bosch. As a result, thirdparty workpiece carriers can be used on the Versamove standard. It is therefore possible to extend existing systems effortlessly. Versatile. Versa stands for versatility. Versamove can be used in virtually all automation and material flow applications. Transfer lines are constructed from proven mk dual-line conveyors with timing belts, chains or accumulating roller chains, depending on your application. These are then combined

with basic modules such as lift-andtransfer conveyors, positioning units, stoppers and lifts to create a transfer system that is precisely tailored to the customer’s needs. mk’s Versamove, standard electric has a range of fully electric functional units. For efficient and environmentally friendly process automation, the lift-and-transfer conveyor HQZ, the lift-and-rotate unit HDE, the lift-and-locate unit PE, and the stopper SU/SD are now also available in fully electric variants. This completely eliminates the need for a compressed air supply and can

Versamove standard transports workpiece carriers from 240 x 240 to 400 x 400 mm, with custom dimensions or dimensions in 80 mm intervals possible. The system can move pallets weighing up to 40 kg. The special feature of this system is its affordable curve modules, which are equipped with a flat top chain or, for compact curves in tight spaces with a round belt. Other example Versamove accessories include the ZRF-P Timing Belt Conveyor, the SRF-P Accumulating Roller Conveyor, the FPF P 2045 Flat Top Chain Conveyor, as well as a workpiece carrier. As the sole distributor of mk products in the UK and Ireland, AdaptTech is the only place that this new product can be purchased. Visit their website now to find out more and to download a free brochure. Email info@adapt-tech.co.uk Call (01949) 823751

For further information, please visit www.adapt-tech.co.uk

PECM Issue 74

Compact pallet system for efficient automation

Now also ric t c e l e y l l u f

No compressed air required Pre-assembled cabling (Plug & Play) Quick commissioning High energy efficiency – more environmentally friendly No hidden cost drivers such as air leaks

www.adapt-tech.co.uk

CONTROL & AUTOMATION

CLOSING THE GIGAFACTORY GAP BECKHOFF

Why automation is key to the future of UK battery manufacturing According to a 2023 House of Commons Committee Report, the UK faces a “gigafactory gap,” and will need 100GWh of capacity by 2030 and 200GWh by 2040. While the focus of debate around gigafactories is often on high-level policy decisions, international investment and government funding, automation technologies are the unsung heroes of the gigafactory,

PECM Issue 74

argues Stephen Hayes, manager director at automation specialist Beckhoff UK.

in automation, like China and South Korea, dominate the battery manufacturing industry?

Recent commentary has drawn attention to the lack of gigafactories in the UK, but what is sometimes missing from the conversation is the role of automation in making the gigafactory possible. Is it a coincidence that countries leading

Automation and the gigafactory Battery manufacturing requires high precision, which is where automation excels. Consistency in electrode coatings, cell assembly, and electrolyte filling is vital to ensure battery performance and

safety. Automated systems minimise human error, maintaining stringent quality control standards. Battery cell production is a complex manufacturing process. It involves mixing and coating active materials, precision assembly of electrodes and separators into cells, electrolyte filling and cell sealing and formation cycling. The latter is a time-intensive process where cells are charged and discharged to stabilise chemistry. These steps demand tight process control, which is best achieved through automation, reducing contamination risks and improving throughput. PC-based control technology is key to precision manufacturing tasks described above. Beckhoff’s centralised control platform integrates various automation

to reduce the carbon footprint of production.

Battery manufacturing requires high precision, which is where automation excels. functions, enabling synchronised and efficient management of complex manufacturing tasks. This approach is particularly beneficial in battery cell production, where precision and speed are critical. Gigafactories aim to produce massive quantities of battery cells, often measured in gigawatthours (GWh) per year. Automation enables continuous, high-speed production lines. It also lowers labour costs and reduces waste through efficient resource use and advanced monitoring of production parameters. Automation also delivers benefits by improving worker safety. Certain processes involve hazardous materials or high-voltage systems, for example lithium handling or electrode coating. Replacing manual workers with machines ensures safe handling of dangerous materials, protecting workers from exposure. Automation is also increasingly in demand for its ability to facilitate flexibility and innovation. Automated systems can adapt to different battery chemistries (e.g., NMC, LFP, solid-state) with relative ease, supporting innovation through customisable production lines. Smart factories use sensors and IoT devices to monitor every stage of production, enabling predictive maintenance and real-time optimisation. There are also the environmental benefits to consider. As a general rule, automation improves resource efficiency by minimising waste and optimising material use. Automated gigafactories also integrate renewable energy systems and smart energy management

The automated road ahead Automation requires significant upfront costs in robotics, software, and training. Operators and maintenance workers need advanced skills to manage automated systems, highlighting the importance of workforce training. The Committee report was right to recommend investment in training and upskilling, as well as financial support. The Catapult Scheme could be key in helping UK manufacturing embrace automation. The scheme is a network of innovation centres designed to drive the development and commercialisation of new technologies. We recently showcased XPlanar, an intelligent transport system using magnetic levitation technology, at the National Manufacturing Institute in Scotland, a state-of-the-art facility that has received funding through the Catapult Scheme. Technologies like this will play a role in support the automation needs of UK gigafactories. These centres bridge the gap between academic research and industry, helping to turn ideas into products and services that contribute to economic growth. The programme is overseen by Innovate UK, the government’s innovation agency. The High-Value Manufacturing Catapult and the UK Battery Industrialisation Centre (UKBIC), part of the scheme, are particularly relevant to the UK’s efforts in developing gigafactories. Increasing battery manufacturing capacity to meet future demand and remain competitive in a global market will require a concerted effort from multiple stakeholders in the UK government and economy. If the goal is to be achieved, it will require increased automation in UK manufacturing. Wider adoption of automation technologies, while not automatically solving the gigafactory gap, can surely help steer us in the right direction.

For all the latest product news visit beckhoff.com/en-gb/ Issue 74 PECM

CONTROL & AUTOMATION

OPTIMISING PLANT EFFICIENCY ROTECH

Manufacturers of Shaft Encoders, Speed Relays and Vibration Sensors Simple installation and reliable performance

Founded in 1983, Rotech Systems has become a global leader in providing high-quality, reliable equipment for monitoring and measuring the speed, position, and direction of rotating shafts. Specializing in motion sensors and encoders, Rotech has built an unparalleled reputation for durability and performance, making it a trusted name in industries such as food processing, mining, steel, and power generation. Heavy-duty construction for harsh environments Rotech products are engineered to withstand even the harshest industrial conditions. Whether it’s a quarry, mine, or power plant, Rotech’s equipment is designed for longlasting, maintenance-free operation. Their products offer heavy-duty construction, ensuring reliability in environments prone to mechanical wear and tear. The sensors are quick and easy to install, making them a hassle-free solution for businesses looking to protect their machinery from potential damage.

Rotech products are engineered to withstand even the harshest industrial conditions. detection of problems like conveyor belt slip or mechanical failures. By triggering visual or audible alarms and even shutting down machinery when necessary, Rotech ensures that operators can take swift action to avoid costly damage. Wide range of applications

Preventing costly downtime and damage In industries where material handling is crucial, such as bulk processing, even a small disruption can lead to significant costs. A minor slowdown or stoppage of equipment like conveyors, crushers, or mixers can result in product spillage, mechanical failure, and costly downtime. In some cases, these disruptions may also contaminate products, leading to production losses or quality issues. Rotech’s motion sensors help prevent these issues by providing early

Rotech motion sensors are used across various industries, including food, textiles, glass, grain, power generation, and chemicals. In these settings, the equipment plays a vital role in protecting conveyors, elevators, screws, crushers, and mixers. The sensors continuously monitor the speed of the equipment, providing alerts when the speed drops by as little as 5%, a feature that can be adjusted between 5% and 90%. This level of sensitivity helps safeguard equipment and ensures smooth production operations.

Installation of Rotech systems is straightforward, requiring just a single hole to be drilled into the shaft or conveyor. This quick setup eliminates the need for complicated designs or adjustments, making it easy for businesses to standardize their equipment across various machines. With no target discs, sensor brackets, or guards to install, Rotech’s system simplifies the process and reduces maintenance time. Rotech systems are also known for their accuracy, with pulse rates ranging from 1 pulse per revolution to 1000 pulses per revolution. The units are digital pulse generators, ensuring precise monitoring even at low speeds (as slow as 0.03 RPM). A cost-effective solution While Rotech sensors are built to last, their cost-effectiveness makes them an attractive option for businesses. With competitive pricing and a focus on long-term reliability, Rotech delivers a solution that minimizes maintenance costs while maximizing uptime and operational efficiency. In conclusion, Rotech Systems offers reliable, durable, and cost-effective monitoring equipment that helps industries prevent downtime, reduce maintenance costs, and improve overall productivity. Their products ensure that critical machinery operates smoothly, even in the most challenging environments.

For further information, please visit www.rotechsystems.co.uk

PECM Issue 74

CONTROL & AUTOMATION

TIME TO AUTOMATE FANUC

Shifting the manufacturing narrative towards productivity By Oliver Selby, Head of Sales for FANUC UK and Chair of BARA (British Automation and Robotics Association) The latest IFR figures show just how far British manufacturing has to climb in terms of automation adoption. At 23rd in the global robot density league table, the UK has just 119 robots per 10,000 workers, against a global average of 162. The UK has also dropped out of the top 10 world manufacturing rankings, falling to 12th place. In Q4 2024, our productivity was estimated to be 0.8% lower compared with a year ago, and 19%

lower than the US. With a clear correlation between automation adoption and higher productivity rates, why aren’t more UK manufacturers investing in robots?

Where are the workers? One reason is a focus on job creation over productivity. A shift in government and media focus towards increasing productivity levels among manufacturing firms of all sizes – rather than job creation via investment in large corporations – would be more useful for boosting overall manufacturing output. Support for investment in automation projects would be a sure-fire way to do this.

Oliver Selby, Head of Sales for FANUC UK and Chair of BARA

Working culture has changed hugely over recent years and digitally native Gen Zs are looking for stimulating roles that offer career progression

PECM Issue 74

cost of ownership over initial purchase price gives a far truer representation of the real cost, and value, of an automation solution. This is reflected in Europe where companies expect payback in three to five years – and may account for their higher levels of both automation and productivity.

Leveraging automation expertise A final barrier is a perceived lack of automation expertise. Outdated perceptions of robots as complicated, difficult to programme and inflexible have prevented some manufacturers from taking the plunge. Yet today’s industrial and collaborative robots are user-friendly, easy to configure and simple to operate, with many plug-and-play options available.

Robots can carry out palletising tasks with ease and don’t get sick or tired. They can work 24/7 even in the dark, increasing output for manufacturing firms.

Exacerbating the labour crisis is the fact that young people are not currently entering the sector in sufficient numbers to replace workers leaving the industry.

value tasks – while a company employing robotics, automation, vision technology and AI will find it easier to attract new talent.

TCO over purchase price Another potential barrier is an unrealistic attitude towards payback. Prioritising total

Robot suppliers such as FANUC, as well as our system integrator partners, can help to further reduce the risk of investing in automation. Using our experience and expertise, we work with manufacturers across all sectors to understand the problems they need solving, ensuring they get the right solution, at the right price, at the first time of asking. The time for manufacturers to invest in automation is now. FANUC will be exhibiting at Smart Factory Expo 2025 in conjunction with a number of its system integrator partners on stand 5/F40, NEC Birmingham, 4-5 June 2025.

Attracting new talent Exacerbating the labour crisis is the fact that young people are not currently entering the sector in sufficient numbers to replace workers leaving the industry. Investing in automation to replace dull, dirty and dangerous roles means existing workers can be upskilled and redeployed to higher

Today’s industrial and collaborative robots are user-friendly, easy to configure and simple to operate, with many plug-and-play options now available.

For further information, please visit www.fanuc.eu/uk/en Issue 74 PECM

CONTROL & AUTOMATION

DRIVE SOLUTIONS EVOLVED REGAL REXNORD

Access complete powertrains for conveyors with Bauer Gear Motor For decades, drives from Bauer™ Gear Motor have set new durability and efficiency standards in the most demanding conveyor applications. Now, the company is bringing its expertise to the intralogistics and material handling sectors, providing seamless access to fully integrated conveyor powertrain solutions in conjunction with other leading brands of Regal Rexnord Powertrain Solutions. Developing superior conveyor motors As the backbone of processes in the intralogistics and material handling sectors, operators require highly reliable and efficient conveyors to secure throughput and profitability. Bauer Gear Motor specializes in providing a full suite of drives for various applications, including standardized units for general logistics applications, as well as its asepticcoated or stainless-steel HiflexDRIVE motors for use in hygienic environments in the food, beverage, and pharmaceutical industries. Application experience in mining, quarrying, water, and metals ensures that all Bauer motors are incredibly robust and offer a long service life. A range featuring high efficiency ratings and permanent magnet synchronous motor (PMSM) technology delivers market-leading efficiency across different modes of operation. Combined, these two factors ensure Bauer motors offer end users a lower total cost of ownership (TOC), protecting profitability. The product range is not static either. Bauer continuously develops new geared motor solutions to meet the needs of the market, reaching higher levels of durability and energy saving.

Building on its own expertise, the company also collaborates with other brands of Regal Rexnord Powertrain Solutions to provide conveyor operators with single source support for the complete driveline. A holistic approach to conveyor design As part of this service, customers can access motors, gearboxes, couplings, chains, monitoring solutions and more from one supplier. This allows a holistic approach to conveyor powertrain design with fully interoperable products, which serves to improve the efficiency and reliability of the entire system. A dedicated conveyor design team works with customers on a case-bycase basis, specifying an optimal combination of products to perfectly meet application goals. In addition to the benefits of a fully engineered system, single source support also eases procurement, reduces time to deployment, and simplifies maintenance. Instead of having to spend the time and expense of managing multiple vendors, teams can access products and expertise quickly from one knowledgeable expert. This means that operators can spend more effort on day-to-day operations. Adding Intelligence and ensuring compatibility To further improve uptime and productivity, Bauer customers can also access Regal Rexnord’s next generation Perceptiv™ condition monitoring and predictive maintenance solution. A unified platform combining hardware

and software, Perceptiv™ uses its broad sensing capabilities and inbuilt intelligence to provide accurate insights into equipment performance. This helps operators graduate from reactive maintenance to a proactive or predictive approach, enabling repairs to be conducted strategically to increase conveyor uptime. While providing access to end-toend solutions, Bauer facilitates a changeover to new powertrain systems with products that can be easily integrated with existing infrastructure. This includes compatibility with different electronics and controls, ensuring faster set up and minimal impact on overarching automation logic. Moreover, Bauer geared motors can be customized to fit with existing mechanical interfaces, while many models are designed to be interchangeable with previously installed equipment, fitting within the same footprint. Therefore, time-consuming and costly plant modifications can be avoided. Empowering operators of conveyors Conveyor efficiency and reliability are dependent on the perfect operation of multiple powertrain components. Via Bauer Gear Motor, customers can not only access world-class geared motors for almost any intralogistics and material handling application, but also a full powertrain system backed by the single source expertise and support of Regal Rexnord. This way, operators can capitalize on superior motor performance by combining it with a holistic, system-orientated solution that offers maximum uptime and value.

For further information, please visit www. RegalRexnord.com

PECM Issue 74

CONTROL & AUTOMATION

EA PLCC028-D8I4R4AR EA HMI043 & HMI070 Automated Water & Effluent Ltd

COMPACT PLC WITH SATELLITE DISPLAYS

We at Automated Water & Effluent believe that accurate measurement and precision control is the key to process control, water and effluent treatment.

• Core with color display • Incl. touch panel

That’s why everything in our equipment range for measuring pH, Redox, Conductivity, Dissolved Oxygen, Turbidity and Liquid Level are of the highest quality for precision measurement.

• 1,000 cd/m2 (typ.) • WIFI, LAN, RS-485 • 4 relays

We offer a wide range of products and services including:

• 8 inputs

• pH & Redox Controllers & Electrodes

• RS-232

• Conductivity Controllers & Probes

• 4-20 mA / 0-10 V

• Liquid Level Controllers & Electrodes • Open Chanel & Magnetic Flow Meters • Data Loggers • Dosing Pumps & Tanks • Custom Designed & Built Control Panels

PROGRAMMABLE LOGIC CONTROLLER (PLC)

• And much more. Contact us today to discuss your needs, or visit our website to view our product range!

+ ModBus HMI 2.8", 4.3", 7.0" Connect to any PLC

www.mmselectronics.co.uk

AWE House, Antom Court, Tollgate Industrial Estate, Stafford, ST16 3AF

awe-ltd.co.uk

01785 254 597 sales@awe-ltd.co.uk

ALC1101 Level Controller

LE24 Level Electrode

www.versatilecontrols.co.uk

Issue 74 PECM

ELECTRICAL & ELECTRONICS

ROBOTALIGN HARRIS TECHNOLOGY

Automated alignment system sets new standard for industrial motor Precision RobotAlign by Harris Technology ** is a state-of-the-art solution for electric industrial motor shaft alignment, engineered to deliver unparalleled precision and efficiency. Designed to automate the alignment process, RobotAlign eliminates the risk of manual error, allowing for highly accurate results with minimal human intervention. The system features intuitive fiber optic digital indicators, a user-friendly color touchscreen interface, and seamless Ethernet connectivity, enabling remote operation via mobile devices for added convenience. With capabilities for both horizontal and vertical alignments, RobotAlign adjusts in real time, calculates and eliminates static error movements to achieve total dynamically stable movements during the alignment process. The system also includes a *Soft Foot Correction Program*, ensuring optimal positioning and reducing alignment-related issues. In addition it offers a *Shaft to Housing * Vertical , Horizontal, Angular and Parallel alignment program. One of RobotAlign’s standout features is its optional unique horizontal automated positioning system in addition to its standard automated alignment program, which eliminates the need for manual distance input—streamlining the process and enabling rapid, precise total dynamically stable adjustments with a tolerance as accurate as 0.00005”. For industries where alignment accuracy is non-negotiable, RobotAlign offers a robust, dependable solution

that combines convenience with unmatched precision.

AI-ALIGN DEMONSTRATION MODEL $4995.00 normally sells $6495.00 Control And Computing Module Enclosed in a heavy Duty Industrial Carry Case Including 2 Fowler Sylvac Mark V digital indicators Accurate to .00005” , Digital Indicator Mounting Brackets, Fiber Optic

Communication Cables, Built in 5 G WiFi, Automated Jacking System input with Necessary Automated and manual Jacking Software Installed. Free Shipping anywhere in the USA. Made in the USA by Harris Technology LLC. Automated Jacking System Hardware Not Included. 2 Year Warranty “Aligning and Balancing Industry with Efficiency one Motor/ Blower/ Rotor at a time”

For further information, please visit www.robotalign.com

PECM Issue 74

ELECTRICAL & ELECTRONICS

VERSATILE & MULTI PURPOSE LABFACILITY

Hermetically Sealed Wire Thermocouple & RTD Sensors An IP67 wire sensor that is hermetically sealed for use in corrosive or wet environments. This versatile multi-purpose sensor has been specifically designed for use in and to protect against corrosion in harsh or wet environments. It has a quick response time and can be easily cleaned. The impermeable PFA insulated flexible wire thermocouple provides exceptional resistance to oils, fluids, gases, and chemicals and is electrically isolated. The tip contains the sensing connection, which is weld-sealed to give a continuous PFA coating along the entire length and provide an atmosphere that is airtight and moisture-proof. Available in IEC, ANSI and PRT calibrations, in 1,2 or 5m lengths, with bare tails or thermocouple plug termination. • Hermetically sealed airtight tip • Waterproof & suitable for insertion into liquids • Oil & Chemical resistant PFA insulation • For use in temperatures ranging from -75 to +260 Degree C • Electrically insulated tip tested to 1.0Kv as standard (can be tested at higher voltages) • Flexible 7/0.2mm stranded conductors (24AWG) • 1.5 x 2.3mm nominal wire diameter (thermocouple) • 2.6mm nominal wire diameter (RTD) • Available with standard tails

or mini thermocouple plug terminations Typical Applications • Pharmaceutical, Autoclaves and Sterilisation • Food & Catering • Environmental & Geothermal • Laboratory and Research & Development Company Profile For more than 50 years we’ve been leading the way in temperature measurement excellence. Here’s to the next 50... From small beginnings in 1971, Labfacility has grown and evolved into the UK’s leading ISO 9001-accredited manufacturer and supplier for the complete temperature chain. From Temperature Sensors, Thermocouple Connectors and Cabling to supporting instrumentation and components, we are the GO-TO people for temperature measurement products.

Ask the experts... Our sales team goes above and beyond to provide swift, expert technical advice and support for sensing and instrumentation as and when YOU need it – help is freely available. Our Sales Team has a mass of experience, plus they are approachable and reliable – just one of the reasons major PLCs and international industry leaders like working with us. Rest assured, you’re in safe hands and not just when it comes to support and advice... Email: sales@labfacility.com Tel: +44 (0) 1243 871280 Tel: +44 (0) 1909 569446

To sustain longevity, you have to evolve...

For further information, please visit www.labfacility.com

PECM Issue 74

TEMPERATURE & PROCESS TECHNOLOGY

HERMETICALLY SEALED WIRE SENSORS www.labfacility.com Cable / Wire Thermocouple Connectors Temperature Instrumentation Temperature Sensors Sensor Fittings

• Quality & Service Since 1971 • Hermetically sealed airtight tip • Suitable for insertion into liquids • Oil & Chemical resistant PFA insulation • Available with standard tails or mini

XE6350001

Hermetically Sealed Wire Thermocouple IEC with Bare Tails Type K

XE6359001

Hermetically Sealed Wire Thermocouple IEC with Mini Plug Type J

thermocouple plug terminations

• Available in IEC, ANSI & PRT versions This versatile multi-purpose sensor has been speciﬁcally designed for use in and to protect against corrosion in harsh or wet environments. It has a quick response time and can be easily cleaned.

XE6362001

XE6377001 Hermetically Sealed Wire Thermocouple IEC with Mini Plug Type T

Hermetically Sealed Wire Thermocouple ANSI with Bare Tails Type K

XE6381001 Hermetically Sealed Wire RTD Sensor with Bare Tails

IEC

XE6355001 Hermetically Sealed Wire Thermocouple IEC with Mini Plug Type K

ANSI

PRT

Rated ‘Excellent’ on Trustpilot

Explore Our Range

In Stock For Immediate Worldwide Dispatch

Labfacility Ltd Head Oﬃce & Accounts - Bognor Regis tel: +44 (0) 1243 871280 Labfacility Ltd Production & Stores - Sheﬃeld tel: +44 (0) 1909 569446

www.labfacility.com sales@labfacility.com

ELECTRICAL & ELECTRONICS

WHY CHOOSE UNIS GROUP? UNIS GROUP

Quality, continuity and sustainability When production processes come to a halt due to electronic failures, every minute counts. UNIS Group helps companies get back up and running quickly and reliably, without the need for immediate investment in new systems. With over 40 years of experience in industrial electronics, UNIS Group is the trusted partner for the repair, refurbishment, and support of electronic equipment across industries. We carry out over 70,000 repairs per year for clients worldwide. Whether it involves PLCs, HMIs, frequency inverters, or power supplies, our technicians possess indepth knowledge of a wide range of brands and systems. With more than 1,400 test setups, our extensive test centre allows us to perform realistic and reliable testing, ensuring high-quality repairs and minimal downtime. Customers choose UNIS Group for our unique combination of speed, quality, and sustainability. Thanks to our large stock of critical components, we are able to deliver repairs with an average turnaround of three to four weeks. In addition to being a cost-efficient alternative to replacement, repair is also a conscious, sustainable choice. By restoring existing equipment instead of discarding it, we help businesses significantly reduce their environmental footprint. With locations in Europe, South America, and Asia, we are locally available and globally active. Whether it’s about extending the lifespan of systems, preventing breakdowns, or safeguarding

Customers choose UNIS Group for our unique combination of speed, quality, and sustainability.

production continuity, we offer tailored solutions that keep industries moving. Want to learn more about our approach and how we keep your operations running? Visit www.unisgroup.co.uk or get in touch with us.

Contact UNIS Group: +44 1604 499 777 | uksales@unisgroup.com

PECM Issue 74

WHY REPAIR YOUR INDUSTRIAL ELECTRONICS AT

UNIS GROUP? 70,000+ REPAIRS ANNUALLY:

Trusted for our proven reliability, handling tens of thousands repairs every year.

QUALITY SINCE 1984: Decades of experience ensure in-depth knowledge and craftsmanship.

COMPREHENSIVE TEST CENTRE: Over 1,400 test rigs for thorough and reliable testing.

A ‘GREEN’ CHOICE: Reduce your carbon footprint by choosing to repair/refurbish.

FAST REPAIRS: WITHIN 3-4 WEEKS ON AVERAGE: Thanks to an extensive stock of components.

We can fully test your industrial electronics! UNIS Group specialises in the repair of end-of-life as well as used and new electronics. Skilled technicians repair at component level, supported by advanced measuring and testing equipment. Contact us for more information!

www.unisgroup.co.uk uksales@unisgroup.com +44 1604 499 777

Quality in repair

ELECTRICAL & ELECTRONICS

CUTTING EDGE AI IMDT

IMDT expands edge-AI offerings with new SOM and SBC powered by Renesas RZ/V2N processor IMDT, a global leader in vision and AI-powered solutions, proudly announces the launch of its latest System-on-Module (SOM) and Single-Board Computer (SBC) products: IMDT V2N SOM and IMDT V2N SBC. These platforms, built on the newly introduced Renesas RZ/V2N processor, offer a costeffective, energy-efficient solution for developers seeking to accelerate AI-driven vision applications at the edge. Following the successful release of the IMDT V2H-based solutions, the new V2N SOM and V2N SBC are designed to make AI-powered embedded systems more accessible to a broader range of applications, including robotics, smart cities, industrial automation, IoT, and smart retail.

said Avi Shimon, CEO of IMDT. “With the launch of our V2N-based SOM and SBC, we are reinforcing our role as a trusted provider of EdgeAI computing platforms, enabling developers to deploy AI applications faster and more efficiently.”

Compared to its counterpart, the IMDT Renesas V2N-based family of products features up to 15 TOPs (Sparse) AI performance and supports up to two 4-lane MIPI CSI-2 camera connections, making it an ideal choice for cost-sensitive edgeAI applications.

The IMDT V2N SOM provides a modular and flexible AI computing solution, featuring: • Renesas RZ/V2N processor with quad Arm Cortex-A55 (1.8GHz) CPU cores • Integrated AI accelerator (Renesas DRP-AI3) for vision-AI workloads • Compact form factor (58x36x6mm) • 2 x 4-lane MIPI CSI-2 camera connectivity • 4K encoder/decoder • Customizable memory (DDR, eMMC) • Customizable carrier board and the associated SW services

“As an official Renesas ecosystem partner, IMDT is committed to delivering scalable, production-ready AI hardware solutions that leverage the power of Renesas processors,”

The IMDT V2N SBC transforms the V2N SOM into a highly integrated, compact mini-computer, ideal for rapid AI application development. Key features include:

The Renesas RZ/V2N processor brings efficient AI capabilities, a quad-core Arm® Cortex®-A55 CPU, and an integrated AI accelerator, while focusing on optimized power consumption and affordability.

• Multi-Camera Solution by up to 2 x 4-lane MIPI CSI • Internal and external ISPs • Full connectivity options: M.2 NGFF Key-E for Wi-Fi/AI accelerators, M.2 NGFF Key-B for cellular modules • 2 x RJ-45 (Gigabit Ethernet) with optional PoE • Small Form Factor (125x80x20mm) • CAN-FD transceiver on board • 6-DOF IMU, 3-Axis Magnetometer for motion sensing • Comprehensive evaluation kit for quick prototyping The V2N product family and its evaluation kits are currently open for pre-order. By expanding its Renesas RZ/V series processor product line, IMDT continues to bridge the gap between cutting-edge AI technology and real-world embedded applications. The V2N-based SOM and SBC provide a cost-effective and flexible foundation for developers building vision-enabled AI solutions across multiple industries.

For more information, visit www.imd-tec.com/product-category/renesas

PECM Issue 74

ELECTRICAL & ELECTRONICS

Expert Technology & Component advice At Texim Europe we constantly invest in people, gather knowledge and expand our worldwide network, so we can select quality devices, modules and platforms that suit every application in the industry.

+44 (0)1522 789 555 www.texim-europe.com uk@texim-europe.com

The optoelectronics behind factory automation Factory automation is reshaping industries by enhancing precision, efficiency, and cost-effectiveness. Central to this transformation are photoelectric sensors—optical switches used for presence detection, fill-level measurement, and safety. These sensors use a light emitter and receiver to detect objects across various configurations: transmissive (longrange detection), retro-reflective (ideal for shiny surfaces), diffuse reflection (versatile for sizing), and measuring

light curtains (broad detection fields). Hamamatsu Photonics leads in sensor integration, offering high-performance photodiodes and near-infrared LEDs resistant to ambient interference. Their wide emitter and detector range supports tailored solutions for automated systems. As Industry 4.0 evolves, Hamamatsu’s innovations ensure reliability and precision in complex manufacturing environments. www.hamamatsu.com/jp/en.html

Issue 74 PECM

ELECTRICAL & ELECTRONICS

POWER SUPPLY PROCUREMENT IDEAL POWER

Why your sourcing strategy could be costing you time, money, and product reliability – and how to fix it. Sourcing power supplies shouldn’t slow down your product development. Yet for many electronics manufacturers, product managers, and design engineers, procurement becomes a constant obstacle. Chasing quotes, checking certifications, reviewing technical data sheets, and trying to find a reliable supplier often eats up valuable time and resources. More critically, it introduces unnecessary risk into your production process. Too many sourcing teams settle for a transactional approach. They focus on cost, availability, and speed — often at the expense of long-term reliability, compliance, and product performance. That’s where problems start. Without the right partner, procurement becomes fragmented and reactive, leading to supply chain delays, product quality issues, or even compliance failures.

You shouldn’t have to compromise At Ideal Power, we believe sourcing high-quality power supplies should be straightforward, efficient, and stress-free. Our goal is to simplify the process without sacrificing technical performance or commercial value. We do this by removing the common procurement pain points that slow you down and cost you more in the long run.

We don’t just sell power supplies — we manage the entire process for you. Our service starts by understanding your product, your technical requirements, and your commercial pressures. We then source the right solution from our extensive product range or develop a bespoke power

At Ideal Power, we believe sourcing high-quality power supplies should be straightforward, efficient, and stress-free. supply built around your exact needs. Whether you require AC/DC converters, DC/DC modules, or LED drivers, we’ll make sure you get the right product, first time.

Certified. Tested. Trusted. All products we supply are fully certified and tested to meet UKCA, CE, RoHS, REACH, TUV-GS and other international safety and efficiency standards. You won’t waste time checking paperwork, chasing certification, or worrying about compliance issues. We take responsibility for that and make sure your procurement team has full visibility at every stage. Every power supply we provide is approved to meet the latest industry standards. You can trust that your product will comply with the regulations required in your market — without last-minute surprises. Our commitment to compliance protects your reputation and keeps your production line moving.

Bespoke Solutions for Unique Designs Not every project can use an off-theshelf power supply. Some demand a different output voltage, a custom

footprint, or enhanced protection features. That’s why we offer bespoke product development — managed from initial specification through to global delivery. You get a solution built around your product, without the hassle of managing multiple suppliers.

Fewer Suppliers. Fewer Headaches. By working with us, you simplify your sourcing process. You won’t waste time juggling multiple contacts, chasing stock availability, or resolving technical queries. Our joined-up approach means fewer suppliers, streamlined communication, and far less wasted time for your procurement and technical teams. You’ll benefit from expert account management and proactive stock support. We don’t wait for problems to arise — we help you plan ahead, manage supply levels, and avoid the last-minute issues that derail production timelines.

Simplify. Protect. Deliver. Simplifying your sourcing strategy doesn’t just save time. It safeguards your product quality, protects your compliance, and helps you deliver better results for your customers. Stop letting procurement slow you down. Work with a sourcing partner who understands your technical and commercial pressures — and gives you complete control over your supply chain. To find out how Ideal Power can simplify your power supply procurement, contact us at salessupport@idealpower.co.uk or visit www.idealpower.co.uk

For further information, please visit www.idealpower.co.uk

PECM Issue 74

Reliable Power Supplies The Ideal choice for your electronics project Stay ahead with our expert knowledge and bespoke products tailored to your business needs. Benefit from our reliable worldwide distribution and convenient call-off service, ensuring you get the components you need, when you need them.

Visit our Website

309865 Find out more at www.idealpower.co.uk or call us on 01733 Issue 74 PECM 77

ELECTRICAL & ELECTRONICS

BLITZDUCTORCONNECT DEHN

Tool-Free Surge Protection The BLITZDUCTORconnect product range from DEHN represents a significant advancement in surge protection technology, offering unparalleled ease of installation, robust performance, and comprehensive safety features. Designed to meet the diverse needs of information technology systems, BLITZDUCTORconnect is the ideal solution for protecting measuring and control circuits, bus systems, and general IT interfaces. One of the standout features of BLITZDUCTORconnect is its push-in cable connection technology, which allows for tool-free installation. This

PECM Issue 74

The LifeCheck function provides a visual indication of whether the arrester is functional, while the optional remote signalling contact keeps users informed about the status of the arrester in real-time.

secR module locking mechanism ensures that individual modules remain securely in place, even in environments subject to vibrations. This feature not only prevents the arrester module from working loose, but also allows for safe and precise removal when necessary. Additionally, the signal disconnection and protection against polarity reversal can be easily achieved by turning the module 180° and plugging it back into the base part, facilitating straightforward maintenance.

Safety sits at the heart of BLITZDUCTORconnect. The

BLITZDUCTORconnect is built to withstand the rigors of demanding

innovative design not only saves time, but also ensures a secure and reliable connection. The compact 6mm width means that it occupies minimal space in the cabinet, making it an excellent choice for installations where space is at a premium.

Devices like the DEHNventil, DEHNguard, and DEHNrail ensure the protection of power systems and building infrastructure at the hands of potentially ruinous surge events, giving you peace of mind and potentially saving thousands on repair and recovery costs. In fact, DEHN can be credited for developing the first ever SPD all the way back in 1954!

applications. With a lightning current carrying capability of 1.5kA, and a nominal discharge current of 5kA per line, it provides optimal protection for systems against surges and lightning strikes. The robust design ensures high system availability and reliability, making it a trusted choice for safeguarding critical infrastructure. The product range is versatile, catering to various interface signals such as MODBUS RTU, PROFIBUSDP/FMS, RS 485, and xDSL, among others. Our online selection guide helps users quickly identify the right product for their specific application, ensuring that they always have the best protection solution at hand - you can find this on www.dehn-international.com/ dehnselect-it In conclusion, BLITZDUCTORconnect by DEHN is a cutting-edge surge protection solution that combines ease of use, safety, and robust performance. Its innovative features and versatile applications make it the right choice for protecting information technology systems, ensuring that they remain operational and secure in the face of electrical disturbances. With BLITZDUCTORconnect, users can have peace of mind knowing that their systems are protected by the best this industry has to offer.

BLITZDUCTORconnect is built to withstand the rigors of demanding applications. About Dehn Based in Leeds, DEHN UK has operated as a subsidiary of the German electrical engineering company DEHN for nearly three decades, adding to the organisations overall operational experience of over 115 years! A family-owned business with a comprehensive portfolio, DEHN is a market leader in the electrotechnical safety industry, offering a level of quality and innovation that simply can’t be found anywhere else. Few others can boast the vast library of surge protection, lightning protection, earthing and safety equipment that we offer, and DEHN UK is committed to creating a safer country for ourselves and our customers through the work we do. Take our revolutionary RedLine technology for instance, a product range that has fundamentally changed the world of surge protection, and has continued to do so since 1993.

DEHN UK is also an equally experienced provider of lightning protection & earthing solutions. Protecting your building against lightning can be very important depending on the type of building, and we’re here to make the process of insulating yourself against its harmful effects as simple and streamlined as possible. We pride ourselves on having an extremely knowledgeable technical team, ready to assist you with product support, direct training, and CPD – not just in lightning and surge protection, but with our entire product catalogue, as well as crucial topics relevant to the wider sector. The recent release of Edition 3 of the BS EN 62305 (protection against lightning) is a great example of how our technical expertise can benefit you, through helping you understand the important changes being made to how you must protect yourself. Our specialisations don’t stop there though. Whether you’re after the highest quality safety equipment on the market, or interested in software to handle your risk assessment and lightning protection planning needs, we have you covered. From hazard warning devices like our DEHNsense EFD, a portable device that alerts you to the presence of dangerous nearby electrical fields, to web-based software like DEHNrisk, taking the time and hassle out of your lightning risk assessments. At the end of the day, our mission is simple: ensuring your safety against surge and lightning events in the most effective manner possible. To learn more about how our robust electrotechnical solutions can benefit you, visit www.dehn.co.uk.

For further information, please visit www.dehn.co.uk Issue 74 PECM

ELECTRICAL & ELECTRONICS

30 YEARS OF INNOVATION LASER SOS

Expanding global reach with tailored laser solutions for diverse industries Today, after successfully operating for over 30 years, Laser S.O.S. Group’s core business sectors are in the support of a comprehensive range of solid-state lasers and IPL platforms used in various industrial applications such as drilling, cutting, welding, marking, diamond cutting, the manufacture of jewellery, medical and beauty application. These days, lasers have become as common as drills and lathes and their application has grown exponentially. LaserSOS has grown from an operation that supplies consumable items such as laser lamps, laser crystals, laser optics and mirrors, cooling systems and power supplies to an organisation that not only supplies but also produces and maintains complete laser delivery systems throughout the world. It continues to develop tailor made solutions for specialist application such as diamond cutting and marking. LaserSOS is an independent operation that through its success in the international laser market has been able to develop close and effective working relationships with a broad range of providers of technologies, products and services used by laser systems. These close relationships and the volume of business the company can place has helped obtain better and quicker levels of service and support for its clients worldwide. The breadth of stock held by the organisation is second to none and where competitors may

These days, lasers have become as common as drills and lathes and their application has grown exponentially.

and sales of a broad range of components and services plus its own in-house facilities. Frequently, a client will provide photos or samples of products it requires but will only have the laser system name and no part number. Finding solutions quickly can help facilitate business growth along with the maintenance of comprehensive stock levels.

offer a client a single laser lamp, LaserSOS can provide several types with a variety of technical and commercial options. On frequent occasion, speed of delivery can be the paramount consideration and LaserSOS has developed a knowledge and experience of the necessary logistics to deliver an item anywhere across the globe.

Today, the business is not simply a merchanting operation. Over time, it has created and enhanced its inhouse assembly and test facilities. Its current facilities located several miles outside of Cambridge offers a one stop shop providing components and technical services direct to all laser end-users.

LaserSOS provides its clients with extensive and in-depth technical understanding of key laser technologies, gained by the development of procurement

LaserSOS has active operations in the USA, Germany, Poland and India providing technical and commercial support across the globe.

For further information, please visit www.lasersos.com

PECM Issue 74

FACILITIES MANAGEMENT

DECARBONIZING HEAT DEMAND ENERGYNEST

ENERGYNEST signs commercial agreement with LEONHARD KURZ to decarbonize industrial manufacturing facility with its thermal storage ENERGYNEST, the global leader in thermal energy storage solutions, has signed a commercial agreement with LEONHARD KURZ, a worldleading family business in thinfilm technology, to implement an innovative power-to-heat system with thermal storage. This commercial sale of ENERGYNEST’s power-to-heat system will decarbonize over 70% of the heat demand at KURZ’s Sulzbach-Rosenberg facility, reducing natural gas consumption by more than 3.5GWh per year, and cutting more than 700 tons of CO2 emissions annually. Industrial manufacturing including chemicals companies like KURZ, and others in production of food and beverage, and paper and pulp, have heavy heat requirements and outputs. ENERGYNEST’s thermal storage enables these companies to optimize their energy costs while decarbonizing. This is achieved through drawing electricity from the grid or from on-site renewables, at times of abundance and low cost, creating heat on-demand and reducing reliance on higher carbon gas, producing a positive outcome for both the power and heat-intensive industry and the environment. ENERGYNEST CEO, Alex Robertson, said: “Electrification of industrial heat is essential for decarbonizing global manufacturing and supply chains. By partnering with LEONHARD KURZ, ENERGYNEST is showcasing a scalable and effective decarbonization strategy that can be replicated worldwide. This agreement proves that industrial

PECM Issue 74

energy transition is not simply a necessity. It’s happening now.” ENERGYNEST’s turnkey power-toheat solution, featuring a 3 MWe electrical heater and a 12 MWhth ThermalBattery™, will be integrated into KURZ’s existing thermal oil infrastructure, providing stable, on-demand heat while drastically reducing the facility’s reliance on natural gas.

First-of-its kind The landmark agreement is ENERGYNEST’s first power-toheat deal, and the first-of-itskind power-to-heat with thermal

storage. The deal demonstrates scalability of ENERGYNEST’s technology and shows that it can rapidly decarbonize large swathes of hard-to-abate industries. With LEONHARD KURZ’s global footprint, the success of this system demonstrates the crossborder potential for power-to-heat technology to decarbonize industrial sectors worldwide. Front footed companies with ambitious decarbonization targets are getting ahead of the curve using thermal storage – testing its applicability and the carbon and cost savings and flexibility it affords at their plants, well before mandatory net zero targets start to bite. As ENERGYNEST’s first commercial thermal storage deal in the German market, this milestone underpins the Company’s growth in the industrial manufacturing sector in Germany, following successful deals including with Yara, ENI, and Avery Dennison.

Blueprint for decarbonizing manufacturing sectors More than just a single initiative, this project is a blueprint for the future: setting a new industry standard by seamlessly integrating renewables and optimizing efficiency to phase out fossil fuels. It is a replicable model which can be applied to industrial manufacturing sectors, including food and beverage, paper and pulp, chemicals, steel, and cement, paving the way for industrial decarbonization in Germany and beyond. ENERGYNEST is in active conversation with many of the players in these energy-intensive manufacturing sectors, focused on customers with a strong commitment to decarbonizing operations, with stated net zero ambitions and a belief in and commitment to the energy transition.

dependence on fossil fuels while maintaining operational efficiency.

The landmark agreement is ENERGYNEST’s first power-to-heat deal, and the first-of-its-kind powerto-heat with thermal storage.

Through demonstrating the practicality of power-to-heat systems, ENERGYNEST and LEONHARD KURZ are paving the way for widespread adoption of industrial electrification in key manufacturing sectors worldwide, with a scalable, repeatable model for decarbonizing industrial heat.

Powering the energy transition Power-to-heat technology converts renewable electricity such as solar, wind or off-peak grid power into high temperature heat. When paired with advanced thermal storage, it provides a reliable, flexible, and carbon-free energy source for industrial processes, helping customers to reduce

With the global push to reach net zero emissions, the plastics, film, and packaging industries, which provide a variety of essential products used in our daily lives, are facing increasing pressure to decarbonize. ENERGYNEST’s modules represent an innovative, cost efficient, reliable and flexible green solution, efficiently and sustainably decarbonizing energyintensive processes which require process heat or steam from 120°C up to and beyond 300°C, with the ThermalBattery™ capable of operating up to 390 °C. The modules are manufactured by the Company’s partners offsite and delivered to customers for easy assembly onsite – all cutting costs and increasing value. The agreement with LEONHARD KURZ represents ENERGYNEST’s strategy in action: providing a flexible, scalable power-toheat solution which delivers efficiency and reliability, enabling the Company to progress its decarbonization journey and move towards carbon neutrality. Harnessing electrification with grid connection and renewable energy, ENERGYNEST’s high temperature thermal energy storage system will play a critical role in advancing the green transition, enabling companies to improve efficiencies and to substantially reduce their carbon footprint. ENERGYNEST’s solution is driving the transition to net zero, today, while enabling these essential industries to future-proof their operations.

For further information, please visit www.energy-nest.com Issue 74 PECM

FACILITIES MANAGEMENT

PORTABLE, PRACTICAL, POWERFUL CPA GROUP

Why portable cooling is the smarter choice As summer temperatures rise, and energy costs remain a concern, keeping indoor conditions comfortable and productive is increasingly difficult. In large or open industrial spaces, fixed air conditioning can be expensive, disruptive, and often ineffective. Portable evaporative cooling offers a practical, flexible alternative without the complexity of permanent systems. At CPA Engineered Solutions, we specialise in engineered solutions built around real-world challenges. Our range of Enerbreeze portable evaporative coolers are designed for businesses seeking energyefficient, adaptable, and immediate relief from heat without the capital outlay of traditional systems.

no downtime, and no specialist contractors required.

Unlike fixed HVAC systems, portable evaporative cooling is designed to adapt. Even in ventilated industrial and commercial environments, heat can build unevenly across the space, creating hot zones that shift with process or layout. While fixed systems are effective at delivering targeted cooling, portable units offer the benefit of being repositioned to provide spot cooling and respond to changing conditions, providing extra flexibility where it’s needed. Enerbreeze works by drawing warm air through water-saturated pads reducing air temperature through a simple, natural process. It’s a convenient, easy to use solution for managing heat in dynamic or hard to cool spaces. Units are fully self-contained, fill the tank, plug into a standard socket, and switch on. There is no complex installation,

Available from UK stock for fast delivery, Enerbreeze is supported with genuine replacement parts, to support ongoing maintenance and maximise product lifespan. It’s a hassle-free solution with service and support built in. Heat stress can reduce concentration, slow operations, and create health risks. Creating a comfortable indoor climate is essential to productivity and employee retention, especially in manufacturing or warehousing environments where physical work is involved. Portable evaporative cooling is a flexible solution to manage heat across a wide range of environments. While common in industrial settings, its ease of positioning makes it equally

sales@cpa-group.com | Enerbreeze.com

PECM Issue 74

effective in warehouses, mezzanines, workshops and temporary structures where fixed cooling may not be practical. Enerbreeze is designed to perform wherever localised cooling is needed, making it a valuable option for businesses seeking fast, effective temperature control without the complexity of permanent systems. Whether used on its own or as part of a broader approach to cooling, Enerbreeze delivers comfort and flexibility where it’s needed most, helping facilities stay productive and comfortable, even as summer temperatures rise. To find out more about Enerbreeze, or to speak to one of our experts about the right cooling solution for your space, please get in touch. Enerbreeze is a product of CPA Engineered Solutions, part of the CPA Group

HEALTH & SAFETY

Swiss precision, global dedication forteq UK located in Huddersfield produce high volume injection moulded plastic components. They are a well-established supplier into the Automotive and Industrial product sectors. Plastic gear applications is a focus area for forteq Group, they have world class development facilities in Switzerland that support the manufacturing plants globally. Technical expertise and knowhow allow forteq to develop and produce very precise gears of all types using engineering and advanced polymers.

PENICO ROTARY GRINDING TABLE

Converts surface grinders to rotary work

For further details contact Penico Guages Limited info@penico.com 01274 511044 www.penico.com

PECM Issue 74

At forteq UK, applications such as door latch plastic gears and worm mechanisms, gears for valve actuators, power steering worm-wheels, over-moulded gear shafts with magnet for wiper motors are some automotive components produced. forteq are also specialists at plastics used in Industrial applications such as gas and water meter components, valve mechanisms and internal functional components, including 2K moulding. forteq UK have capacity for new projects, please get in touch with Steve Roberts on 01484 483516 – or email steve.roberts@forteq-group.com to discuss upcoming projects.

GEARS, DRIVES & MOTORS

• Machine Guarding design, fabrication & installation • Safety Related Control System design, build & installation • PUWER & CE/UKCA Consultancy • Light Curtain Testing • EN60204 - 1 Testing

T 08450 750008 | E info@safetysys.co.uk www.safetysys.co.uk Issue 74 PECM

HEALTH & SAFETY

Nuclear Scien

MSc - 1 year full t MSc - 2 or 3 year PG Diploma • PG Short Courses fo

Designed to create a gene and scientists with the sk and safe future for nuclea Key features: Demand-driven •

Course delivered by: The University of Birmingham • University of C The University of Manchester • The University

Improving food safety and hygiene with projected signs The never-fade, never-wear alternative to traditional signs Our LED projected safety signs are harder to ignore, longer lasting & more cost-effective than painted & printed signage. No contamination Consistent and never-fade Adaptable and versatile Reduce sign blindness Completely customisable

Find out more or book a site visit at projectedimage.com 88

PECM Issue 74

Nuclear and Technology nce and Science Technology

MSc - 1 year full time time MSc MSc --12year time or 3full year part time Diploma • PG Certificate partPG time MSc - 2 or 3 year part time Short Courses for CPD

Certificate PG Diploma • PG Certificate Designed to create a generation of nuclear engineers and scientists with the skills to secure a sustainable or CPD Short Courses for CPD and safe future for nuclear energy.

to create a generation of erationDesigned of nuclear engineers nuclear engineers and Key features: Demand-driven •scientists Breadth of learning • Delivered by experts • Flexibility • Short-course format kills to secure a sustainable with the skills to secure a ar energy. sustainable and safe future for Course delivered by: The University of Birmingham • University of Central Lancashire • The University of Leeds • The University of Liverpool The University of Manchester • The University of Sheffield • The Nuclear Department of the Defence Academy

nuclear energy.

For more information: email: info.ntec@manchester.ac.uk or visit www.ntec.ac.uk

Breadth of learning • Delivered by experts • Flexibility • Short-course format

Key features:

Central Lancashire • The University of Leeds • The University of Liverpool y of Sheffield • The Nuclear Department of the Defence Academy

For more information: info.ntec@manchester.ac.uk • email: Demand-driven or visit www.ntec.ac.uk

• Breadth of learning • Delivered by experts • Flexibility • Short-course format

Choose from a selection of 19 courses units delivered by the Consortium members For more information: visit www.ntec.ac.uk

email: info.ntec@manchester.ac.uk tel: +44 161 529 4799

HEALTH & SAFETY

ROBUST MECHANICAL SOLUTIONS SENTRIC SAFETY GROUP

Key industry trends and the enduring role of mechanical safety Industry Outlook

As industries evolve with developments in automation, digital transformation, and sustainability, it is essential to recognise that core mechanical safety systems remain fundamental. Regardless of how sophisticated technology can and will become, robust mechanical solutions are vital to ensure ultimate worker safety and operational security.

Adapting to Industry Trends Industrial operations continue to transform, but the importance of implementing and maintaining reliable mechanical safety measures cannot be overlooked. Key trends we are seeing shape the industry include:

effective regardless of technological advancements.

Industry 4.0

Sustainability and Compliance

The rise of Industry 4.0 has established intelligent systems and real-time monitoring into industrial environments – and this is fantastic for the future of industry. However, while digital innovations enhance operational efficiency, they must be supported by fundamental mechanical safeguards to ensure fail-safe protection of the people involved. For example, a data centre, which is an enabler of industry 4.0, requires UPS (uninterruptible power supply) to provide continuous power to critical equipment, ensuring minimal downtime and protecting sensitive data from loss during power interruptions. The UPS needs to be secured with reliable trapped key interlocks to ensure the safety of those who need access to maintain it. Safety therefore cannot rely exclusively on digital systems alone – mechanical trapped key interlocks and other physical safety measures provide a critical and essential layer of security that remains

As regulatory bodies advocate for more sustainable industrial practices, safety solutions must align with both environmental and workplace safety standards. Durable, longlasting mechanical systems play a crucial role in reducing workplace incidents, minimising downtime, and ensuring compliance with global safety regulations. These foundational solutions contribute to safer and more sustainable industrial operations in the long run.

Automation and Human-Machine Interaction With the increasing presence of automation in high-risk environments, ensuring robust safety measures at the foundation of operations is more important than ever before. Properly implemented mechanical safety solutions prevent unauthorised access to dangerous areas and help mitigate the risks associated with the maintenance of automated machinery.

According to Deloitte’s 2025 Manufacturing Industry Outlook, manufacturers are prioritising highROI use cases such as customer service and product innovation while leveraging AI for efficiency and cost savings. Investments in data lifecycle management are also a growing focus as companies work to overcome challenges related to data quality and accessibility. However, despite the shift towards digital transformation, maintaining core safety infrastructure remains imperative to ensure operational resilience and the protection of personnel.

The Role of Castell in Industrial Safety For over 100 years, Castell Safety International Ltd, part of the Sentric Safety Group, has provided reliable and high-quality safety solutions across industries in harsh and safety-critical environments. As industries continue to embrace new technologies, Castell remains committed to delivering safety solutions that integrate seamlessly with evolving industrial needs. A longstanding dedication to excellence also means that businesses who partner with Castell can operate with confidence, knowing that foundational safety systems are in place and can be effectively maintained.

For further information, please visit www.sentricsafetygroup.com

PECM Issue 74

TOGETHER FOR A SAFER TOMORROW The Sentric Safety Group unites the world’s leading safety brands to create the long-term protection of people, productivity, and business reputation

Learn about our safety solutions in the energy and industry sectors on our website

www.sentricsafetygroup.com

HEALTH & SAFETY

FUTUREPROOF SOLUTIONS LS WASTEWATER & PROCESS CONSULTING

Your Trusted Partners in Environmental and Process Consultancy LS Wastewater & Process Consulting Limited offers bespoke consultancy services for Water Process management and monitoring, with a long-term focus on energy and environmental conservation. Together with its sister company, Leachate Solutions: an industryleader in closed landfill engineering and bespoke leachate treatment plants, our consultancy brings over 35 years industrial experience, and an extensive network of engineering professionals working across the water and process industries. LS Wastewater & Process Consulting Limited has considerable expertise in the following four overarching areas: Using a consultancy service can bring a multitude of benefits such as pinpointing blockages and optimising process plant efficiency, streamlining process performance without rising costs and methodical action points to upgrade structural processes.

• Leachate Monitoring and Treatment: Customised solutions focused on compliant and sustainable discharge and monitoring protocols • Robust Maintenance & Management Plans: Expert-led closed landfill and leachate management systems. • Tailored solutions: Meticulous site assessments and surveys are carried out prior to any advice or recommendations being discussed or offered • Adherence to environmental regulations: All advise is in alignment with current Environmental Agency, or HSE regulations so removing any ambiguity, and avoiding unnecessary issues with stakeholders or regulators. LS Wastewater & Process Consulting offer informed, expert-led

solutions for water and wastewater management across the entire process industry, agriculture, farming and closed landfill applications. Using LS Water and Process Consulting, ensures you have all the tools and expertise at your disposal, enabling you to optimise and monitor your business development, while at the same time ensuring you remain compliant with current regulations

With all UK companies now looking for sustainable best practices, and a route to Net Zero, LS Wastewater & Process Consulting Limited and its sister company, Leachate Solutions pride themselves on providing innovative, futureproofed solutions for the water and process industries, as demonstrated by Leachate Solutions reaching the finals of the Lancashire Business Environment Awards 2023. To enquire further about our comprehensive consultancy practice, and find out more about the services we offer, see the website and details below:

Tel: Mobile 07764449299 | Email: info@lswpconsulting.com | www.lswastewater.com

PECM Issue 74

Pioneering Consultancy for Landfill and Environmental Management. Your trusted partners in Environmental Consultancy We’re more than just consultants: we’re your partners in achieving your organisation’s goals. Our commitment is to provide bespoke solutions for every project, regardless of size. Our team brings over three decades of engineering expertise to the table, delivering long term solutions with a focus on cost efficiency, energy conservation and sustainability. CONTACT US

07764449299 info@lswpconsulting.com

Closed Landfill Expertise Management Monitoring Treatment Tailored Solutions Regulatory Alignment Water & Wastewater Management Monitoring & Control Cost Control Quality Monitoring Rainwater Cost Reduction Process Performance & Management Monitoring & Control Productivitv Enhancements Systematic Analysis Cost Effective Solutions

MACHINING & MACHINERY

SPECIALISTS IN TOOLS & GAUGES WISEMAN THREADING TOOLS LTD

WISEMAN THREADING TOOLS LTD Specialists in Tools & Gauges for Screw Threads We have been supplying threading tools and gauges since 1987. Together with supplying plain plug and ring gauges this is all that we do, we therefore consider ourselves to be specialists in this field. We supply worldwide. We hold extensive ready stocks that include all of the standard stuff that others offer, but also includes taps, dies, die nuts, die head chasers, thread rolls and gauging for threads not normally available 'off the shelf '. Our real time stocks can be checked and purchased online at www. threadtools.com Just enter the thread details into the search box on the home page. You will be directed to the item, if stocked, or to our specials, (custom manufacture), sales team. who will quote to supply at competitive rates, in good time. As an account holder you can also order online from our listed in stock items, at your normal terms. We realise that you need the right item at the right price and quality, and in a reasonable time frame. We are geared to provide that. We can ship stocked items same day. Our experienced sales staff can assist and advise you on any technical issues. We welcome enquiries from resellers and can offer terms to suit.

WISEMAN THREADING TOOLS LTD 11 Padgets Lane, South Moons Moat, Redditch B98 0RA UK +44(0)1527 520 580 sales@threadtools.com www.threadtools.com

For further information, please visit www.threadtools.com

58 94 86

66 PECM Issue 74 67

Threading Tool Specialists

HSS DIES & DIE NUTS Large shelf stocks for all Standard and many Special Threads. Check our stocks online.

THREAD CUTTING AND ROLLING HEADS and parts and repair service

THREAD ROLLS FOR ALCO & FETTE HEADS. READY STOCKS CUSTOM MANUFACTURURE

HSS TAPS Huge Stocks for all Standard threads CUSTOM MADE taps our SPECIALITY! We stock taps for many non standard (SPECIAL) threads All types; Spiral flute and point, Fluteless, Left Hand, etc, etc.

Wiseman Threading Tools Ltd 11 Padgets Lane, South Moons Moat. Redditch B98 0RA Worcs UK +44(0)1527 520 580 sales@threadtools.com www.threadtools.com

THREAD GAUGES all types. Large stocks for standard and SPECIAL threads. Any non stocked can be quoted for custom manufacture.

CHASERS FOR COVENTRY & LANDIS TYPE DIE HEADS Ready stocks for most size heads most standard and some special threads Geometry available for most materials. Custom manufacture our speciality!

MEASUREMENT & MONITORING

RELIABLE MEASUREMENT VEGA

VEGA joins All-Energy Exhibition & Conference 2025 • Compressor and liquefaction systems • Pipelines and injection wells for long-term storage By delivering reliable data in these complex applications, VEGA helps operators maximise process safety, ensure system availability, and stay compliant with strict environmental regulations.

We’re excited to announce that VEGA will be making its debut exhibiting at All-Energy for the very first time, joining the UK’s leading renewables and low-carbon energy exhibition at SEC Glasgow on 14-15 May 2025. At Stand P61, we’ll be showcasing how our level and pressure measurement technology is supporting the energy sector’s transition toward cleaner, safer, and more efficient solutions. Our products are designed for the most demanding renewable energy applications, including:

• Biomass: Whether using radiometric measurement for difficult biomass fuels or radar and pressure sensors for bulk solid handling, VEGA ensures reliable operation under changing media, build-up, and temperature conditions.

• Energy from Waste (EfW) EfW plants operate under tough conditions, where reliability and performance are critical. VEGAPULS 6X radar sensors deliver accurate level measurement in fuel bunkers, combustion chambers, and ash silos, even in high dust, heat, and vapour conditions. VEGA solutions also help EfW plants significantly reduce wash water usage in bottom ash quenching systems, thanks to precise level control. One UK site reduced its water use by over 15 million litres per year using VEGAPULS radar—a major cost and environmental win.

• Hydrogen: From cryogenic storage and electrolysis to high-pressure pipelines, VEGA enables safe and efficient operation with reliable radar, guided wave radar, and pressure sensors. Our differential pressure transmitters are also ideal for

hydrogen applications such as electrolyser cell monitoring and coolant circuits, where robust, accurate, and compact measurement is essential. Whether aggressive media, an oxygen/hydrogen overlay, or low dielectric constants are involved: the entire range of hydrogen applications is covered by VEGA’s trusted solutions in level and pressure measurement.

• Carbon Capture and Storage (CCS): Carbon capture processes present a wide range of challenges—from extremely high pressures and corrosive media to foam, build-up, and temperature fluctuations. VEGA’s robust level radar and pressure instruments ensure accurate, continuous measurement in all key CCS stages, including: • Absorber and stripper columns • Intermediate CO2 tanks

For wood chip bunkers, the VEGAPULS 6X radar sensor delivers highly accurate level measurement, even in the presence of dust, irregular surface profiles, and challenging filling dynamics.

• Biogas: From fermenters and digesters to gas storage and flare stacks, VEGA instruments provide continuous, stable level and pressure measurement in biogas systems. Our sensors are designed for aggressive gases, foaming media, and challenging conditions— ensuring safe, efficient biogas production.

Join Us at All-Energy 2025 We’ll be at Stand P61 from 14–15 May—stop by to speak to our team, explore our latest innovations, and discover how VEGA can support your renewable energy project with world-class level and pressure measurement technology.

For further information, please visit www.vega,com

PECM Issue 74

Light molecules, challenging measurements? We have the solutions!

Whether for mobility, energy, chemicals or steel, Hydrogen is part of the future! To get there we need capacity, infrastructure and, of course, the right measurement technologies. Our level and pressure instrumentation will ensure your hydrogen processes and measurements are safe, efficient and simple. Everything is possible. With VEGA.

vega.com

Ernst Ernst Industrieanlagen Industrieanlagen GmbH GmbH

Specialized in high quality used machines of the brands:

Company Company Profile Profile Your investment Your investment deserves the best deserves the best result result advantages of of advantages buying used buying used machines instead ofof machines instead newnew ones are: ones are: Low Low purchasing costs purchasing costs Avoiding depreciation lossloss Avoiding depreciation ShortShort timetime of availability of availability Lower insurance costs Lower insurance costs Environmental awareness Environmental awareness

Ernst Industrieanlagen GmbH is an international trading company for high-quality used machinery, in thetrading Waldrich Siegen Ernst Industrieanlagen GmbH specialising is an international company forand Waldrich Coburg Thespecialising company in was 1987 and by Mr high-quality used brands. machinery, thefounded Waldrich in Siegen and has been The continuously developed with Elmar ErnstCoburg Waldrich brands. company was foundedtogether in 1987 by MrMrs Susanne Ernst since 1988. continuously As a former sales engineer Waldrich and has been developed togetherat with Mrs Elmar Ernst Susanne As years a former sales engineer Waldrich for Siegen andErnst due since to his1988. many of experience as aatspecialist Siegen and to Mr his Ernst manyhas years of experience as a specialist for machines anddue tools, a great deal of specialist knowledge, machines and tools, Mrand Ernst hasbest a great deal of in specialist knowledge, absolute competence the contacts this sector. Satisfied absolute competence and the best contacts Satisfied customers all over the world have been usinginusthis for sector. 38 years now. We customers all over been using us for SIEGEN/WALDRICH 38 years now. We to the dealworld onlyhave with WALDRICH have decided

to deal only with WALDRICH SIEGEN/WALDRICH have decided COBURG machines, as these brands are characterised by a high COBURG machines, as these brands are characterised by a high

degree of reliability, precision and efficiency. Thanks to their degree of reliability, precision and efficiency. Thanks to their

hydrostatic guide system, Waldrich machines are characterised by an hydrostatic guide system, Waldrich machines are characterised by an

almost unlimited service life and freedom from wear, as well as almost unlimited service life and freedom from wear, as well as

maximum performance and quality for efficient use over many maximum performance and quality for efficient use over many

decades. In the event of expected expansions and replacement decades. In the event of expected expansions and replacement

purchases, we recommend that you purchase a high-quality used purchases, we recommend that you purchase a high-quality used

machine from Ernst Industrieanlagen GmbH instead of a new machine from Ernst Industrieanlagen GmbH instead of a new

machine. allour ourmachines machines without CNC control machine.As Asaarule, rule,we we dismantle dismantle all without CNC control

and are older olderthan than1212years. years. This must andwithout withoutelectrics electrics ifif they they are This must be be replaced and aa new newCNC CNCcontrol control system before replacedwith with new new electrics electrics and system before

reassembly. in organising organisingthe theretrofit retrofit and name reassembly.We Wesupport support you you in and cancan name companies out this this retrofit retrofitprofessionally. professionally. After companiesthat that can can carry carry out After thethe retrofit, an almost almostnew newmachine machine value at an retrofit,our ourmachines machines achieve achieve an value at an extremelyfavourable favourable price, price, less of of a comparable extremely less than than15% 15%ofofthe theprice price a comparable new machine. new machine.

Contact Contact Tel.: +49 +49 (0) (0) 2245/915 Tel.: 2245/91575 7565 65 CEO Elmar Ernst

CEO Elmar Ernst

E-Mail: maschinen@web.de

E-Mail: maschinen@web.de www.ernstmachines.com

www.ernstmachines.com @ernstmachines

@ernstmachines

High quality machines for sale

CNC LATHE WALDRICH SIEGEN DH 1600/40 X 12000-1, SER.NO. 13.152 HYDROSTATIC GUIDEWAYS IN Z AND X AXIS IN AN EXCELLENT MECHANICAL CONDITION

L4 axis CNC Plano Miller WALDRICH COBURG type 17 – 10 FP 75 kW 275 CNC/3 P

CNC Plano Miller WALDRICH SIEGEN Type V/H – FR – 58 kW 275/160/250 x 400 (2)

Roll Grinder WALDRICH SIEGEN Type: WS II a 100/25 x 5000 CONTACT US FOR MORE INFORMATION: E-MAIL: MASCHINEN@WEB.DE TEL.: +49 (0) 2245/915 75 65 WEBSITE: WWW.ERNSTMACHINES.COM

��

Tel: 0191 410 5886 Web: www.rondean.co.uk Email: info@rondean.co.uk

Units 11 & 13 First Avenue, Drum Industrial Estate, Birtley, Co Durham DH2 1AG

C LOSI NG DOWN-ALL STOC K O PEN TO O FFERS ! A�er 40 years supplyin� �uality used ENGINEERING, SHEET METAL FABRICATION & WOODWORKING machinery, Ron is re�rin� therefore the business is closin� and all stock is to be cleared. As well as machines already prepared for sale we also have a number of part ex / clearance / and machines in need of refurbishment too, not to men�on vast amounts of toolin� s�ll bein� sorted.

XYZ CNC/Manual turret mill Colchester Mastiff 1400 80” gap bed lathe

AVM CNC Centre lathe

Harrison M250 Centre lathe

USED MACHINERY—TOOLING—WORKSHOP EQUIPMENT

Morticers

Wood & Metal Saws

Wood Lathes

Hand Presses

Saw Benches / Panel Saws

Corner Notchers

Planing / Thicknessing Machines Spindle Moulders Cross Cut Saws

Sheet Metal Bending Rolls

Treadle Guillotines

Hand Operated Folders

C O N TA C T U S N O W ! 0191 410 5886 We b : w w w. r o n d e a n . c o . u k E m a i l : i n f o @ r o n d e a n . c o . u k

Tel: 0191 410 5886 Web: www.rondean.co.uk Email: info@rondean.co.uk

Units 11 & 13 First Avenue, Drum Industrial Estate, Birtley, Co Durham DH2 1AG

C LOSI NG DOWN-ALL STOC K O PEN TO O FFERS !

Harrison M500 80” gap bed lathe

Boxford Centre Lathe

Jones & Shipman Tool & Cutter Ginder

Drills

Clarkson Tool & Cutter Ginder

End Mill Grinder

M A C H I N E S R E A D Y F O R D E S PAT C H

XYZ Manual Turret Mill

Tool Room Bandsaws

Pedestal Grinders

E N G I N E E R I N G — FA B R I C AT I O N — W O O D W O R K I N G

Chain & Chisel Morticer

Bar Presses

Sanding Machines

Saw Benches

Extractors

D E L I V E R Y T O S U I T YO U R N E E D S

Button Punch & Flanger

Lockformer

Swager

Conduit Bender

Sanding / Bowl Turning

AC/DC Welder

C O N TA C T U S N O W ! 0191 410 5886 We b : w w w. r o n d e a n . c o . u k E m a i l : i n f o @ r o n d e a n . c o . u k

MACHINING & MACHINERY

ABOUT US UK Manufacturer & Supplier of Lifting & Rigging Equipment.

INCLUDING HAKUFLUID -

Wire Rope Slings Round Slings Flat Slings Chain Slings Lifting Accessories Galv, Black & PVC Coated Wire Rope Fibre Rope Safety Bonds

– OIL-FREE COOLING LUBRICANTS

Precision Performance: Delivers consistent performance & cleanliness in machining with a safer, eco-friendly EHS profile. #AdvancedMetalworking info.uk@kluthe.com +44 (0) 330 175 9970

01777 948089

www.ropeandrigging.co.uks

VEHICLE LIFTS

BRAKE TESTING

DIAGNOSTIC EQUIPMENT

HARMONY IN CHEMISTRY

VEHICLE PITS

WHEEL SERVICING

WORKSHOP FIT-OUT

INSPECTION & SERVICE

www.kluthe.com

ONLINE TRAINING

Totalkare’s ergonomic positioners are single or double column devices that enable the lifting and rotation of a product during welding and assembly operations. With overall capacity from 2,000 - 90,000kg to suit, they are both compact and flexible.

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

102

PECM Issue 74

MACHINING & MACHINERY

The driving force in power transmission Cross+Morse is a Birmingham based manufacturer of Mechanical Power Transmission products and solutions with over 100 years of history, right in the centre of the engineering hub in the West Midlands region in the United Kingdom. We operate in a 5000m2 fully integrated factory with a dedicated and loyal staff who have amassed a depth of technical expertise and engineering experience over our many years of continued service. Cross & Morse are Mechanical Power Transmission solution specialists and at this present time we have £1.5m worth of finished stock on our shelves such as Roller Chain and Sprockets in both stainless and carbon steel, Gears, Racks, Couplings, Torque Limiters, Sprag Clutches, Timing & V belt Pulleys, timing & V Belts, Inverted Tooth Chain, Silent Chain, Sealmaster Bearings, McGill Cam followers, Shaft Clamping Elements, Freewheel & Overload Clutches. We value innovation highly at Cross+Morse, which is why we constantly invest in new machinery and technology as well as training programmes and apprenticeships to maintain the highest standards of quality

and service we are well known for. With our in-house team of application and design engineers at your disposal Cross+Morse are able to provide bespoke technical solutions to your power transmission problems in the most costeffective way. Have a specialised or ambitious requirement? Send us your drawings and application details and we will do our utmost to find the best solution possible, we welcome a challenge! We have been providing solutions for the food and drink, oil & gas, agricultural, pharmaceutical, quarrying, energy and environmental industries, bottling and packaging plants and many more for over 100 years. Our customers come from the widest range of industries and include original equipment manufacturers for packaging, conveying systems and material handling applications. We also export our quality products all over the world, through our network of long standing distributors or directly to the manufacturers and end users of mechanical power transmissions on every continent. At Cross+Morse we consider customer

support along with in-house design and manufacture an essential element in our service to industry, please browse our website for details and more information on our manufacturing capabilities as well as our stringent quality control. We are certified to ISO 9001:2015 and have been for over 25 years. Call or email us now to solve your mechanical power transmission problems.

www.crossmorse.com | +44 (0) 121 360 0155 | sales@crossmorse.com

Cross+Morse Power Transmission Manufacturing Specialists

Since 1984

◊ Manufacturing up to 1450mm diameter ◊ Turning - CNC lathes, Vertical Machining Centres ◊ Gear Cutting - Hobbing, Shaping, Gears, Sprockets & Pulleys ◊ Bevel Gears, Helical, External & Internal cut Gears ◊ Rack Shaping, Broaching, Keywaying ◊ Bore Honing ◊ Induction Hardening ◊ Drilling & Tapping ◊ Marking ◊ Blacking ◊ Vertical Boring, Centreless & Rotary Grinding ◊ Toothed Timing Belts stocked and cut to size ◊ Roller Chain in carbon steel, stainless steel - in stock - free cutting ◊ CAD - CAM Design & Development ◊ Large stocks of all products: sprockets, gears, pulleys toothed & V belt ◊ Shaft Clamping Elements ◊ Torque Limiters ◊ Overload Clutches ◊ ISO 9001 : 2015

Yes we can make it.

Cross + Morse. Shady Lane, Great Barr. Birmingham. B44 9EU sales@crossmorse.com Tel: +44 (0)121 360 0155 www.CrossMorse.com Issue 74 PECM

103

MACHINING & MACHINERY

New premises supports continued growth of control panel manufacture INDUS Engineering Services is proud to offer a wide range of custom control panels, automation systems and special purpose machinery. After working on major control and automation projects for several of the south’s leading brands, the company has recently acquired a new premises with the aim of increasing production capacity of bespoke and sub-contract, control panel manufacture. The new premises will also allow us to support the wider range of engineering

activities carried out by the company, such as the design, manufacture, and testing of special purpose machinery. Also, to further our goals to reduce our carbon foot print we will be installing a high efficiency solar PV array in the coming months. For more information on the services that are available please do not hesitate to contact and we will be happy to discuss your project needs and requirements. www.indusengineering.co.uk

HAKUFLUID – OIL-FREE COOLING LUBRICANTS

Precision Performance: Delivers consistent performance & cleanliness in machining with a safer, eco-friendly EHS profile. #AdvancedMetalworking info.uk@kluthe.com +44 (0) 330 175 9970 HARMONY IN CHEMISTRY

BRUNEL INDUSTRIAL ENGRAVING

Precision. Innovation. Engraving Excellence. - Electrical & Warning Labels - Control Panels - ID & Serial Plates - Valve & Tag Labels

Scan the QR code to view online 104 PECM Issue 74 1 PECM Issue 40

E: info@brunelengraving.co.uk W: www.brunelindustrialengraving.co.uk T: 01275 871720

www.kluthe.com

Linear Motion Specialists Authorised NSK & Nippon Bearing Distributor

RM Fowler Ltd •

High precision linear guides and ball screws

•

NH series available with high temperature design

• • • • • •

NSK K1 lubricating units to extend maintenance intervals RA roller guides for high load, rigidity and precision

PU/PE Miniature series with high corrosion resistance Precision cross roller non-recirculating slide ways Slide bush, Topball, Stroke bush and Ball splines Precision curved cross roller Gonio Ways

01565 651 051 sales@rmfowler.co.uk

www.rmfowler.co.uk

MACHINING & MACHINERY / PROCESS TECHNOLOGIES

Introducing our brand new product - SEP60 RAIL, specifically designed for use in the rail industry. Based on our industry leading SEP60 product, the new unit has been re-engineered to meet the demands, specification and safety requirements of the rail industry. It still contains our unique SILEXA™ filtration medium made from recycled glass bottles - but now its just a bit tougher.

www.sep60-rail.com environmental solutions for condensate filtration

t: +44 (0)1543 379212 e: sales@sepura-technologies.com

Looking for better edge breaking results? TextureJet has just completed an extensive

The electrolyte is delivered via a nozzle to the component. An electrical charge is passed between them, causing a controlled amount of material to be removed from the component surface.

research project into the repeatability of edge break treatments on nickel superalloy using its technology. TextureJet’s Stat® technology was already

The removed material is dissolved in the electrolyte, washed away, filtered, and the electrolyte is recycled through the process.

proven to achieve higher quality edge finishing in a 2024 White Paper. This result was achieved through increased repeatability and precision compared to the current methods utilised in edge finishing of aerospace components.

The new research shows that compared to manual brush deburring, TextureJet achieves four times more precision and, compared to automated brush deburring, it achieves nearly two times more precision. For precision component manufacturers this means better control for the edge profile created, which will improve the quality of the products processed and deliver cost savings by eliminating scrappage. What is Electrochemical Jet Machining technology? Electrochemical Jet Machining (ECJM) is a precise adaptation of more traditional Electrochemical Machining which can be used on any conductive material.

www.texturejet.com

106

PECM Issue 74

Key Benefits of Electrochemical Jet Machining · High Precision without Masking Ability to machine complex shapes with high precision without the need for masking, saving time, cost and waste. · Suitable for Hard to Machine Materials Suitability for hard-to-machine materials regardless of their hardness or toughness. · High Quality Finish Excellent surface finish with no microcracks, deformation or residual stress.

PROCESS TECHNOLOGIES

Monometer Foundry Furnaces: A Guide to Rotary, Crucible, Tilting, and Reverberatory Furnaces Metals

Monometer foundry furnaces are essential in the metal casting industry, providing hightemperature environments for melting metals and alloys. Different types of furnaces cater to specific needs, efficiency levels, and materials. This article explores four primary types: rotary, crucible, tilting, and reverberatory furnaces, highlighting their features, advantages, and applications.

metal is placed in a crucible inside a heating • Applications: unit, making them suitable for small batches - Used for casting large components like and specific metals. engine blocks, car parts, and industrial items • Key Features: - Fueled by electricity, gas, or oil 4. Reverberatory Furnaces - Available in various sizes Reverberatory furnaces have an elongated - Made from ceramic or refractory materials rectangular hearth and reflect heat from the • Advantages: roof onto the metal, enabling bulk melting. - Precise temperature control for high-quality • Key Features: casting heating unit. This method is effective for small the way -they absorb for heatlarge-scale from the furnace Designed melting and holding batches or specific metal types. is directed onto the metal via - Versatile for different metals, including roof. The- heat Uses natural gas, oil, or electric reflected heat from the roof, allowing for largerods for quantitiesheating to be melted simultaneously. They Keyprecious Features: ones S- Can be fueled electricity, gas, or oil. are designed with a large vertical loading door Lower initialbyinvestment • Advantages: S Available in various sizes for small or large on the end of the furnace and a large hearth to • Applications: - Ideal for large aluminium chunks operations. deposit the metal tomelting be melted Used inmade die-casting foundries and specialized S- Typically from ceramic or refractory and copper with oxy-fuel burners Key Features: materials that withstand high temperatures. metal applications - Scalable for different production needs

Monometer Foundry Furnaces: A Guide to Rotary, Crucible, Tilting, and Reverberatory Furnaces Monometer foundry furnaces play a crucial

role inFurnaces the metal casting industry, providing 1. Rotary

the high-temperature environments necessary

for melting various metals and alloys. Rotary furnaces feature a rotating chamber Different types of furnaces are designed to thatcater enables continuous and uniform heating. to specific needs, efficiency, and types The of rotation promotes efficient mixing materials processed. In this article, weand will explore the four primary types of Monometer faster melting. foundry furnaces: rotary, crucible, tilting, and • Keyreverberatory Features: furnaces, detailing their features, advantages, and applications. - Continuous operation for higher productivity - Handles up to 70 tonnes of iron 1. Rotary Furnaces - Suitable for ferrous non-ferrous metals Rotary furnaces are and designed with a rotating chamber that allows for continuous and • Advantages: uniform heating of materials. The rotation - High thermal efficiency and automated facilitates mixing of the charge, promoting efficient and faster melting than stationary operation hearth furnaces. - Reduced labor costs - Ideal processing scrap metal Keyfor Features: S Continuous operation, which enhances • Applications: productivity. - Commonly used in metal recycling and alloy S Ability to handle large volumes of metal up production to 70 tonnes iron

S Suitable for both ferrous and non-ferrous metals.

2. Crucible Furnacesalloys. S and producing Crucible furnaces use a simple design where 2. Crucible Furnaces

Crucible furnaces utilise a simple design where a crucible containing the metal is placed in a

S Designed for bulk melting and holding applications. 3. Tilting Furnaces • Applications: S Uses either natural gas or oil or electric rods The tilting feature on Monometer furnaces is 3. Tilting Furnaces - Common in aluminium alloy production and for heating. designed to pour molten metal easily. Tilting Tilting allowallowing controlled pouring ofS Excellent large-scale for meltingfoundries large chunks of can be to furnaces various angles, for precise aluminium, Can be used with copper control during thereducing pouring process which molten metal, spillage and waste. melting with oxy-fuel burners minimises spillage and waste.

• Key Features:

Conclusion

- Tilting design for improved pouring control Each type of Monometer foundry furnace Key Features: Each Monometer furnace typeoffers offers S- Enhanced capability due to their distinct advantages and applications crucial to Availablepouring in electric, gas, or oil-powered unique advantages for metalworking and tilting design. various metalworking and casting processes. versionsin electric or gas or oil powered S Available Understanding capabilities best uses improves casting.the Selecting theand right furnace for rotary, crucible, tilting, and reverberatory - versions. Suitable for ferrous and non-ferrous efficiency, productivity, and quality in foundry furnaces can help foundries and manufacturers S Suitable for both ferrous and non-ferrous materials operations. Investing in suitable technology choose the right equipment to meet their materials. Advantages: production goals and enhance their efficiency. S• Frequently used in foundries for casting helps businesses enhance output and maintain By investing in the appropriate furnace components, suchefficiency as engine blocks, - larger Enhances safety and highbusinesses standards inimprove metal casting. technology, can their car components , manholes, and industrial - parts. Can melt large metal quantities in one cycle output and high-qualityplease standards in Formaintain more information contact their metal casting operations. - Quick crucible changes for different metals Christopher Hall c.hall@monometer.com 4. Reverberatory Furnaces T +44 (0)1702 472201 Reverberatory furnaces are characterised by www.monometer.com www.monometer.co.uk their elongated rectangular shaped hearth and

FURNACES AND FOUNDRY EQUIPMENT SINCE 1913 At Monometer Holdings Limited we specialise in furnace specification and manufacture utilising latest metal melting and recovery, with capacity from 200kgs up to 55 tonnes. Our professional consultation services are tailored to meet your unique needs, covering everything from furnace design and spare parts specification to equipment installations and servicing.

You can find all products and services online: www.monometer.co.uk 12

Company sponsors this issue of Best Practice – see them on page 3

For more information call +44 (0) 1702 472201 or email c.hall@monometer.com

Issue 74 PECM

107

FACILITIES MANAGEMENT

POWERING NET-ZERO GAINS EMR

How EMR is driving carbon savings in UK manufacturing The manufacturing industry will play a critical role in the UK’s journey to net-zero, but knowing how to focus efforts to make the greatest impact is a real challenge for manufacturers. EMR, a global leader in sustainable materials, has been helping UK manufacturers to decarbonise, reduce waste and improve resource security for decades. Through traditional recycling solutions, opportunities to reuse and repurpose materials, as well as take-back schemes and lifecycle analysis, EMR is on hand to transform production models for good. By supplying high-quality recycled metals and plastics, EMR reduces the demand for virgin raw materials, which are far more carbon-intensive to produce. It’s a simple switch with a powerful impact. For industries looking to cut emissions without compromising on quality or performance, EMR’s processed materials provide a reliable, resilient alternative. Whether it’s reclaiming steel from vehicles or salvaging aluminium from deconstructed buildings, EMR ensures that valuable resources are not lost to landfill but returned to productive use. The company’s ongoing investment in advanced sorting and processing technologies is also raising the bar for the performance and usage opportunities of these recycled materials. By improving the purity and consistency, EMR makes it easier for manufacturers to integrate recycled content into more of their production lines without compromising on quality.

EMR, a global leader in sustainable materials, has been helping UK manufacturers to decarbonise, reduce waste and improve resource security for decades. More than just a service provider, EMR can be your partner in transformation, helping manufacturers reduce waste and reimagine their entire production models to use compliance and CSR

as a competitive advantage. It’s a shift that aligns perfectly with both government policy and consumer expectations for more circular, responsible products. What truly sets EMR apart, though, is its values. Integrity, innovation, and care - for people, the planet, and the communities it serves - are at the heart of everything it does. These principles drive a culture of transparency, continuous improvement, and collaboration. They’re also why manufacturers trust EMR as a long-term ally in the fight against climate change. In short, EMR isn’t just here to help the manufacturing sector reduce emissions; it’s here to advise and reshape the future of industry.

For further information, please visit www.emrgroup.com

108

PECM Issue 74

EMR, PARTNERING FOR A SUSTAINABLE, CIRCULAR FUTURE IN MANUFACTURING

With over 60 facilities across the UK, we guarantee a consistent supply of low-carbon materials and provide efficient, local disposal solutions for the materials you no longer need.

WHAT WE

OFFER

EXPERT GUIDANCE ON DESIGNING FOR RECYCLABILITY SUSTAINABLE CONSULTANCY TAILORED TO YOUR NEEDS RELIABLE SUPPLY OF LOW-CARBON MATERIALS

By recycling, reusing, and repurposing materials, we’re working to build a future where nothing needs to be extracted from the earth—creating a truly circular supply chain. TOGETHER WE

REMAKE TOMORROW

FOR MORE INFORMATION Wayne.Hill@emrgroup.com +447423436501

emrgroup.com Issue 74 PECM

109

PROCESS TECHNOLOGIES

THE FASTEST WAY TO EFFICIENCY DMN WESTINGHOUSE

The DMN-WESTINGHOUSE PTD plug diverter valve What if speed isn’t just an advantage but the new standard in servicing? Every second counts – and downtime counts tenfold. As an established supplier of rotary and diverter valves for a large range of dry bulk solids processing industries, DMN-WESTINGHOUSE is committed to providing futureproof value. This is why we launched the improved PTD plug diverter valve.

The PTD plug diverter valve at a glance The PTD is designed to route powders and pellets in pneumatic conveying systems with minimum degradation. This diverter valve minimises service time, ensuring more uptime and lower costs. This isn’t just servicing – this is efficiency. Every single time. • Aluminium housing & end covers, dual-pipe plug • Stainless steel product contact surfaces • No outside moving parts, no atmospheric leakage • Suitable for systems with positive pressures 3–6 barg, pressure shock resistant up to 10 barg* • Static belly seals with solenoid valve & inductive position sensors; optional: terminal box • Inflatable belly seals with electropneumatic control system (inc. solenoids, terminal box, inductive position sensors) • Standard version suitable for product temperatures -25–80°C (ambient temperatures -10–40°C); versions for higher temperatures available

• Easy, two-sided access – service from the most convenient side • Adhesive-free belly seals

The PTD is designed to route powders and pellets in pneumatic conveying systems with minimum degradation. • Versions with electrical drive and/ or wear-resistant pipes available • EC 1935/2004 compliant; ATEX 2014/34/EU certification available *Size 200 excluded The PTD plug diverter valve is suitable for a range of dry bulk solids processing industries: Aquaculture • Animal feed • (EV) Batteries • Biomass • (Petro) Chemicals • Cosmetics • Dairy • Food • Infant formula • Minerals • Paint • Pet food • Pharmaceuticals • Plastics • Recycling • Rubber

Benefits of the PTD plug diverter valve These features help your operators work smoother and faster, leading to minimal downtime:

• Quick-connection position sensors • Easy-release actuator linkage • Reinforced jacking points • Minimal service required Your benefits? The PTD sets a new standard in servicing efficiency, ensuring more uptime and reduced costs.

Conclusion The PTD plug diverter valve exemplifies DMN-WESTINGHOUSE’s commitment to providing dry bulk processing industries with futureproof value. It slashes servicing time and offers unparallelled ease of use. The PTD provides the fastest way to efficiency.

About DMN-WESTINGHOUSE DMN-WESTINGHOUSE is an established leader in high-end rotary valves and diverter valves, supplying innovative, future-proof solutions trusted by industries worldwide. With our experts and global network of sales offices and distributors, we help customers meet the highest standards of safety, hygiene, reliability, and efficiency in their production processes.

For further information, please visit www.dmnwestinghouse.com

110

PECM Issue 74

THE FASTEST WAY TO EFFICIENCY THE IMPROVED PTD PLUG DIVERTER VALVE 8-10x faster seal replacement Spend less time servicing to boost your production hours Plug position indicator on both sides Service from your preferred side Learn more at dmnwestinghouse.com

R&D trials commissioned by DMN-WESTINGHOUSE, 2024/2025.

PUMPS

VIBRATION ISOLATION MASON UK LTD

The importance of quality engineering for effective pump isolation Low-price acoustic products may have their appeal. However, if they are not correctly engineered, the consequences of failure could be devastating. In hazardous industries where safety is of the utmost importance, getting the vibration isolation right from the outset is paramount. Here Steve Hart, director at industrial vibration control specialist Mason UK, discusses the key considerations for effective pump isolation. The pumps market is expected to grow from 61.32 billion USD in 2024 to 79.01 billion USD by 2029, growing at a compound annual growth rate (CAGR) of 5.2 per cent. Pumps are used in water supply processes to move fluids throughout the pipe runs within a building, or series of buildings. The impeller within the pump creates regular pulses that can be transmitted through the water

column within the pipework. The frequency of the pulses is determined by the pump speed and the design of the mechanism. These pulsations can sometimes coincide with the natural frequency of sections of pipework. Should this occur, it causes the pipework at that location to resonate and introduces noise and vibration into the building structure which in turn can cause disturbances throughout the building. In high precision Blue Chip companies for instance, these disturbances can affect production output by increasing failure rates in the production of expensive microchips. If pumps aren’t isolated properly, resonances in the pipework can also lead to the fatigue of joints within pipe runs, increasing the risk of failure and the release of fluids into the building environment. If a serious leak occurs, it’s possible that the whole plant room may

need to shut down, leading to costly maintenance works or major safety concerns. From damage to equipment to severe injury — the repercussions could be huge. To ensure that vibration caused by pumping applications is unable to pass into the main building structure, the disturbing forces should be isolated at source using suitable vibration control products. At Mason UK we’re often called upon to provide retrofit support for vibration isolation projects that have gone wrong. But how do you ensure the vibration isolation is right in critical pump applications the first-time round?

Don’t compromise on quality The key to effectively isolating pump equipment is to isolate the vibration producing equipment at source from the main building structure. This would normally involve a combination of inertia bases, flexible pipe connectors and acoustic hangers. The first step involves isolating the pump from the building structure. The usual procedure for reducing structure borne noise and vibration levels is for the pump to be installed on concrete inertia bases mounted on high deflection spring mounts. The inertia base provides an air gap between the equipment and the structure, and the springs are normally selected to provide at least 95 per cent isolation efficiency from the main disturbing frequency of the pump. The second step is to provide flexible pipe connectors or expansion joints at the inlet and outlet joints of the pumps. The main misconception is that these connectors accommodate

112

PECM Issue 74

differential movement and misalignments between pumps and the adjacent pipe work. While this is true to some extent, the main benefit of flexible pipe connectors is to interrupt the vibration pulses within the fluid created by the pump. When the pulses hit the arched construction of the connector, the regular frequency of these pulses is changed into random patterns. With random frequencies passing through the fluid, there is no opportunity for coinciding resonances between fluid and pipework. For piping systems, we recommend opting for flexible pipe connectors and acoustic hangers. To suspend the piping, you will need to use durable hangers. The selection of which will depend on load, frequency and other system specifications. Some applications require the flexible pipe connectors to be

We cannot stress enough the importance of getting vibration isolation right the first time around. able to accept hot water, steam or chemicals passing through them at high pressure and elevated temperatures. Cheaper variations of flexible pipe connectors are generally moulded using EPDM with nylon reinforcement, and can become brittle if heated water passes through, leading to premature failure. In contrast, Mason Industries’ flexible pipe connectors offer superb durability and can be tailored to suit each project. The Mason Safeflex range offers unparalleled protection against

failure. Every connector is pressure tested in the factory to 150 per cent of rated pressure prior to release. The special design features include a uniquely robust flange design with Kevlar reinforcement, which has fantastic heat resistance, wrapped around a solid steel ring preventing pull out failures. Pump isolation often requires an engineered solution. We cannot stress enough the importance of getting vibration isolation right the first time around. The first step to effective pump isolation is partnering with experienced acoustic engineers. These industry specialists will be able to specify quality vibration isolation products that can be tailored to your project and will last the test of time. Are you looking for vibration isolation support for your pump application? Get in contact with Mason UK today to discuss your project’s requirements.

For further information, please visit www.mason-uk.co.uk Issue 74 PECM

113

PUMPS

Bespoke Engineered Pump Packages YOU DEFINE. WE DESIGN. At Cat Pumps we can provide engineered pump packages that are bespoke to customer requirements. We have over 50 years’ experience of providing Cat Pumps pump packages to a variety of industries and can provide skid systems with the following options: Electric Motors There are number of options available. Drive Systems Our pumps can be connected to a motor in a variety of ways. Base or Frame Configuration We can mount the pump package simply on a base plate or on a frame designed specifically to meet your installation needs and space envelope. Motor Controls To control the pump package, we can supply DOL or VSD controls configured to meet your exacting requirements. Pump Package Accessories To compliment the Cat Pumps pump package, we can supply a multitude of pump accessories.

Global lubricants manufacturer chooses new Borger pump A new jet-mixing pump system has significantly reduced capital, installation, maintenance and energy costs at Moove, the leading global lubricants manufacturer and distributor, in the UK. For a closed-top 50m3 tank used in the manufacturing process of quality lubricating, engine, hydraulic and gear oils, Moove wanted to trial a set-up that would not only be better economically, but also provide more redundancy.

Borger also provided the system as a skidmounted unit, working closely with Moove to supply a customised control panel with a specially written program. “The fact that Borger were able to deliver a complete, all-in-one package was a real bonus,” continued Ian. ‘So simple to look after’ “With a 9kW motor (compared to 12kW for the

paddle mixers), we are automatically saving on energy, but one of the other main benefits is that the Borger equipment is so simple to look after. There’s easy access to the pump-head, and no special tools required. Retrofit to an existing tank is also very straightforward. “We’re very pleased with solutions provided by Borger that allowed us to achieve the goals of our project.”

Ian Lowe, Moove’s Manufacturing General Manager, explained; “A motor failure on a blender could mean as much as four days impact on production, so it was important for us to take the opportunity to prove a different technology.”

‘A better option’ He added: “The performance of our existing paddle mixers has been good, but Borger were recommended as a company that would work with us to provide a better option; one that could be easily replicated.” The team at Moove drew up a logic for Borger to examine, outlining their objectives, which ultimately resulted in a pump (plus two nozzles), for a 3-bar application with a flowrate of up to 60m3/hr. To meet the space requirement at the Gravesend site in Kent,

Borger UK | 01902 798 977 | www.boerger.com | uk@boerger.com

114

PECM Issue 74

EXCELLENCE – MADE TO LAST

FLOW OPTIMIZATION SECOND TO NONE

THE NEW BLUELINE NOVA ROTARY LOBE PUMP The BLUEline Nova sets new standards in pump technology. With or completely without casing protection – the BLUEline Nova achieves unrivaled volumetric efficiencies. Made for one another – the newly developed DIUS rotors in combination with the flow-optimized pump chamber ensure perfectly smooth running at pressures of up to 12 bar.

BLUEline

NOVA www.newblueline.com

Börger UK Limited | +44 1902 798977 | uk@boerger.com | www.boerger.com

PUMPS

PUMPS FOR A GREENER WORLD BORGER

Pumps perfected for first-of-a-kind plant to have the power to be its best Pumps for circulating clean engine oil; a reasonably ordinary application? But then there’s nothing ordinary whatsoever about Arjun Infrastructures’ remarkable power plant in London, which generates 17MW of renewable energy from food waste and can also utilise fats, oils and greases (FOG). ”This is a first-of-a-kind plant”, said Phil Jones, Director at 2OC, who developed the plant and now manage it on behalf of Arjun. He added: “Joining up assets that haven’t previously been linked together before has presented many engineering challenges”. Originally specified by Jacobs Engineering, the two 90kW lubrication pumps for the Combined Heat and intelligent Power (CHiP) plant had to be installed by main contractor J. Murphy and Sons in a very tight space, presenting the first in a series of obstacles to be overcome.

protection was required too. All a bit tricky, but often the case when there’s not much space available.“

David Brown, from the pump manufacturer Börger explained: “At first we thought that this was going to be a relatively uncomplicated job, but then the small footprint was just one of many hurdles to negotiate – not to mention the fact that the pumps had to go below ground, beneath the plant’s engine”.

Producing enough energy for approximately 40,000 homes, Arjun’s power station presents no shortage of high temperatures for its assets to cope with. This includes the Börger pumps, which had special cooling radiators for the gearboxes and motors installed.

He added: “We designed a special base frame so that the very robust EL1550 Classic pumps could be mounted vertically into the small footprint (just 3m by 4m) – and then for easy servicing, lifted out and put on their side. Over-pressure

So far so good, but with the Börger pumps and the rather demanding need to make all of the new power plant’s equipment work together efficiently and economically, came a demanding, non-extendable deadline.

116

PECM Issue 74

“We were fully aware of this from day one”, continued 2OC’s Phil Jones, “but I can’t deny that the pressure was well and truly on. We had to meet the deadline for all-important government ROCs (Renewables Obligation Certificates) that support largescale renewable electricity projects in the UK. To get the plant off on the right operational and financial footing, we had to make things happen to hit that deadline. We could not take our time”. The construction contractors’ engineers were initially concerned about the noise and vibration of the two Börger pumps. As everyone in the supply chain knows, this can

be a delicate balance when both parties believe they are right! “The pumps were performing fine, but we were a little anxious at first”, added Phil Jones. “Failure wasn’t an option”.

Börger were totally professional – taking our concerns very seriously to get to the bottom of this mystery. “For us”, continued David Brown from Börger, “we believed it was simply down to natural pulsation, but as well going to site, we also brought over our top engineers from Germany. It didn’t help us or 2OC that due to the space limitations, the pipework for one pump was straight, whilst the other one was more complex, so had to cope with some pressure loss. Ultimately, we ran a test in Germany with 2OC in attendance to show that the pumps were performing fine. As it turned out, the vibration was down to nothing more than extra torque being required. Later, after another 500 hours running time, an inspection confirmed that there were no issues. It has been a bit of journey, but we always knew there was a reason, a solution. 2OC’s Phil Jones added: “Börger were totally professional – taking our concerns very seriously to get to the bottom of this mystery. Through the very positive dialogue between the two companies, it was also decided to change the pump’s removable rotor tips from rubber to a fully stainless-steel solid rotor design because of the high temperatures. Together with the stainless-steel pump-head, it now means that there is almost zero maintenance required”. Built by J. Murphy and Sons, Arjun’s power plant sees 75GWh of the

electricity sold to Thames Water for its Beckton sewerage processing plant (home to 64 Börger pumps), whilst the remaining 55GWh is purchased by Centrica. Heat from the engine is supplied to the adjacent gas pressure reduction station owned by the Cadent (with whom Börger also has pumps in a very important application), largely replacing old gas boilers that used to pre-heat the gas – whilst heat recovery

cycles of the CHiP technology increase the thermal efficiency of the Arjun plant. Phil Jones from 2OC concluded: “Our pursuit of getting this unique power station where it needs to be has not been easy, but very much in line with what government is promoting, we now have a very neat and efficient plant. This includes the Börger pumps, which are proving very efficient, reliable and easy to maintain thus far”.

For further information, please visit www.boerger.com/en/ or call 01902 798977 Issue 74 PECM

117

STORAGE, HANDLING & DISTRIBUTION

SPACE THAT ADAPTS COPRI SYSTEMS

Short-term warehousing solutions with long-term flexibility The warehousing and distribution industry is facing a duality of excess space available and a severe lack of it. Businesses are wary about how much space they are willing to commit to, no doubt influenced by the significant fluctuations and disruption experienced by supply chains in recent years. However, if the warehouse buildings intended for manufacturing, processing, optimum storage, efficient goods handling, careful loading and unloading etc are not fit for purpose then the whole operation is likely to be at risk. Wasted space will waste money but a lack of space could reveal weaknesses in warehouse operations during intense periods. Efficiency is paramount and scalability is critical. For over 35 years, we have been designing industrial warehouse buildings that are flexible enough to evolve with a business and adaptable enough to respond to changing market dynamics. They are built to last but, in this climate of caution, more and more clients are looking for temporary solutions. Businesses that are unable to look too far ahead, are adopting shorter-term strategies with the anticipation of having to adapt quickly. Temporary warehousing can remove the long-term commitment of adding more bricks and mortar or entering into a fixed rental agreement on a site. Innovation is key and obviously, there has been a lot of progress made in automation and robotics, artificial intelligence, cloud-based management and advanced data

Businesses that are unable to look too far ahead, are adopting shorter-term strategies with the anticipation of having to adapt quickly. analytics but innovation doesn’t just apply to technology. Rethinking how best to optimise the space you’ve already got and the space you need, can also help to innovate your operations so they can cope effectively in a fluctuating, rapidly evolving industry. With a traditional build, the space is rigid and doesn’t offer the elasticity that businesses need to thrive. Our buildings are fully bespoke and designed to your specifications, no matter how awkward the shape, height, size or orientation. They are quick to deploy and can be easily modified to provide the muchneeded flexibility required.

Strategically located warehouses can further enhance the agility of a business and our buildings help to address this issue as they can be easily removed, relocated and repurposed. Their versatility also makes them suitable for collaborative, shared warehousing, which can help increase efficiency by pooling resources and sharing expenses. If one company decides to move on and go solo, the structure can be easily modified to suit new tenants or work even harder for the remaining business. If warehouse buildings are going to remain relevant, they need to evolve with the industry they serve.

For further information, please visit www.coprisystems.com

118

PECM Issue 74

GET MORE

SPACE

FAST

Our warehouse and logistics structures are individually designed to meet the needs of your organisation. All our installations meet building standards, require no additional, or minimal groundworks in many cases, and are quickly deployable. We oﬀer a full turnkey service covering every aspect, including ﬁnance options.

For a site visit or quick quote: call us on 01380 830 697 email sales@coprisystems.com visit www.coprisystems.com

FACILITIES MANAGEMENT

WEG UNVEILS W51XDB MOTOR WEG

Motor combines compact size and high efficiency WEG, a global leader in electrical equipment design and manufacturing, has introduced its new high-efficiency, high-voltage (HV) flameproof motor, the W51Xdb. Tailored for industries in explosive environments, such as petrochemical, oil and gas and energy transition sectors, the W51Xdb motor represents a significant leap in power density, efficiency and sustainability. Its flameproof design enhances safety and performance in hazardous areas, setting a new standard for reliability in critical applications. Building on the renowned W22Xdb series, the W51Xdb retains its predecessor’s flexibility while delivering several crucial innovations. At its core, the W51Xdb offers the highest power density in its class, making it possible to generate more power in a smaller, lighter machine. This advancement helps address the growing need for compact, spaceefficient equipment in industries where space is a premium. “We designed the W51Xdb to meet both the current and future needs of our customers,” said João Cardante, sales and marketing director at WEG Portugal. “With its high density and energy efficiency, the motor is tailored to support global energy transition goals by offering a product that is ready today but designed for tomorrow.”

Key features of the W51Xdb motor Offering the highest power density on the market, the W51Xdb features a compact design that delivers up to 800 kilowatts (kW) in a frame smaller than the market standard, allowing for more efficient use of space in applications such as

reduction goals faster. Because the motor is built for explosive atmospheres and compatible with environments such as Zone 1 and Zone 2, this makes the unit ideal for petrochemical, chemical, oil and gas and hydrogen applications.

pumps, compressors and fans. It is also up to 20 per cent lighter than previous models, providing additional flexibility for installations. Offered as standard with IE4 — the highest efficiency level defined by IEC/EN 60034-30-3, the first global standard for classifying the energy efficiency of high-voltage induction motors — the W51Xdb exceeds current regulatory requirements and is future-ready for upcoming legislation. While this standard does not mandate customers to specify motors with a particular efficiency level, as this is governed by regional regulations, it is anticipated that the EU will soon introduce minimum efficiency requirements for HV motors. “At WEG, we are deeply committed to helping customers maximise energy efficiency in their motors,” said Cardante. “Although flameproof motors are currently excluded from this new standard, the W51Xdb line has been engineered to meet or exceed the highest efficiency levels outlined within it.” The W51Xdb supports the industry’s drive towards a net-zero future by reducing energy consumption and helping companies meet their carbon

In addition, the W51Xdb series is designed with manufacturing efficiency in mind, reducing lead times by up to four weeks compared to previous models.

Designed for high-performance industrial use The motor is currently available in frame sizes of 355 and 400, with a maximum output of 800 kW. WEG plans to gradually expand the range of frame sizes available, further enhancing the motor’s versatility and applications. With over 90 units in high-voltage format already sold, even before its official release, the W51Xdb has been eagerly adopted by key industries, particularly in the Middle East. The initial applications focus on highdemand projects involving pumps, compressors and other high-power machinery. The official global launch will take place at ADIPEC 2024 in Abu Dhabi, one of the world’s largest and most influential energy exhibitions, and also at SPS, a leading international event for industrial automation held in Nuremberg, Germany. “The W51Xdb is a testament to WEG’s commitment to continuous improvement and innovation in motor technology,” added Cardante. “Its launch is expected to set a new industry benchmark for efficiency, sustainability and performance.”

For further information, please visit www.weg.net

120

PECM Issue 74

Doors Ready for Action

British design and manufacture, wide range of models covering high security, large doors with high wind resistance (3,000 to 5,000 pascals), fire and high speed automation with systems’ interface. Hart protects people, products and premises through leading brands.

Globally recognised Hart’s high speed doors and shutters deliver options and solutions for industry wherever you are.

Take control of your business environment. Call 0191 214 0404 info@hartdoors.com www.hartdoors.com

SOFTWARE & SYSTEMS

MULTI-SOFTWARE SOLUTION LANTEK

Lungmetall transforms manufacturing processes with Lantek software Lantek has implemented a multisoftware solution to streamline manufacturing and operational process for Lungmetall OHG, a German manufacturer specialising in sheet metal and machining technology. With a history spanning over 100 years, Lungmetall started life forging tools for the natural stone sector, but now works with clients across many diverse sectors including beverage and food, pharmaceuticals, medical technology, aerospace, tool and mold making, motorsports and vehicle manufacturing. Since joining the family business in 1997, Managing Director, Marcus Lung, has been instrumental in modernising operations. By incorporating advanced manufacturing techniques such as water jet and laser cutting, Lungmetall diversified its offerings and successfully entered new markets, including aerospace, pharmaceuticals, food and beverage and motorsports.

held by individual employees rather than stored in a centralised system. If a key team member was absent, production slowed as others struggled to access vital information.

The solution Recognising the need for a more efficient and data-driven approach, Lungmetall partnered with Lantek to integrate a suite of software solutions.

However, during this period of growth, Marcus Lung recognised the pressing need for a robust ERP system and identified that Lantek provided a solution tailored to its evolving business needs.

Lantek proposed the implementation of its Lantek Expert for 2D-CAD/CAM programming and Lantek Flex 3D for 3D cutting processes, expanding Lungmetall’s operational capabilities.

The challenge Lungmetall’s expansion highlighted inefficiencies in its production planning and data management processes. Pricing inconsistencies arose due to reliance on multiple Excel spreadsheets for quoting. Procurement was also based on estimations rather than real data, often leading to incorrect material orders and unnecessary costs.

122

PECM Issue 74

On the production floor, outdated manual processes created additional challenges. Each morning, large volumes of printed work orders were distributed to employees, making it difficult to track real-time progress. Another challenge arose due to the lack of technology as critical operational knowledge was often

The company later introduced its Lantek Integra software for enterprise management and Lantek MES for production control and warehouse management, creating a seamless production process. These solutions provided a fully integrated and efficient system that allowed for real-time tracking of production, more accurate pricing and better resource allocation.

Results The implementation of Lantek’s software enabled the automation of pricing calculations, eliminating inconsistencies and ensuring accurate quotations. With automated nesting for laser cutting, Lantek significantly increased sales leads and profitability for Lungmetall. Lantek helped Lungmetall transition to digital workflows which enabled better access for work orders and all employees, resulting in a smoother and more organised work flow. By centralising all operational knowledge with Lantek’s system, Lungmetall eliminated its dependence on individual employees for critical information, providing reliability. Procurement also became more precise, moving away from estimations to a system based on real-time data and nesting requirements. Lantek’s software also helped Lungmetall focus on the circular economy and adapt to more sustainability practices as it tracked every material waste to prioritise its use before cutting new sheets.

Lantek wasn’t just another software provider; the company offered a complete solution, unlike competitors offering isolated solutions. The improved accuracy and efficiency of Lungmetall’s processes not only transformed its manufacturing operations but strengthened its customer relationships and increased overall business profitability.

What’s next for Lungmetall? Lungmetall is now preparing to implement Lantek Analytics, a cloud-based tool designed to further enhance process optimisation and customer relationship management. By leveraging advanced data analytics, the company aims to refine its decision-making processes and strengthen its competitive edge in the market.

Marcus Lung explains: “We had no time to define processes during our growth and we lacked proper production planning because our ERP system couldn’t handle laser processing or assembly of components. The Lantek system stood out as it provided everything we needed.” He adds: “Lantek wasn’t just another software provider; the company offered a complete solution, unlike competitors offering isolated solutions. With Lantek, we can map almost all our processes and we knew that by mapping these processes in Lantek, we could continue to grow.” Christoph Lenhard, Commercial Director of Lantek Germany, shares: “Lantek’s strength lies in its adaptability and independence from specific machine manufacturers. This suits Lungmetall perfectly, as the company values the ability to choose their machinery freely. For Lungmetall, partnering with Lantek wasn’t just about getting software— it was about having the freedom to break away from industry limitations.”

For further information, please visit For more information visit www.lantek.com Issue 74 PECM

123

TOOLS, PLANT & EQUIPMENT

FULLY CERTIFIED MENZEL

TÜV certification for Ex p motors Menzel Elektromotoren has been certified for the production of large squirrel-cage motors in ignition protection type Ex p pressurization for operation in zone 1 hazardous areas where an explosive gas/air mixture is likely to occur in normal operation. The test specimen, a compressor motor for the petroleum industry, underwent a gas displacement test (test of the air purge system), leak test and pressure test. The German technical inspection service TÜV Nord comprehensively tested and certified the construction method. To win the approval, the manufacturer had to prove its ability to control the purging air flow for all its relevant motor series in such a way that no gas pockets remain inside the motor casing. Menzel can apply this manufacturing procedure to stock motors in a wide output range and is thus able to flexibly and quickly provide competitively priced Ex p motors featuring the product categories 2G and 3G. Pressurized motor construction is typically suitable for squirrel-cage motors from 400 mm shaft height. It is available for all voltage ranges and with air-to-air or air-to-water heat exchangers (cooling types IC 611, IC 616 or IC 81W). An air-purge system allows potentially flammable gases to be removed from the motor frame before the motor is started and to maintain a constant positive pressure during operation to prevent the ingress of explosive gases. The terminal boxes feature the ignition protection type Ex eb increased safety.

Menzel can quickly configure squirrel-cage motors in ignition protection type Ex p pressurization, product categories 2G and 3G and in a wide output range from stock (pictured: Ex p compressor motor for an oil refinery)

Plant operators often face the challenge that they cannot find suitable replacements for obsolete motors. The choice of explosionproof drive systems in particular is limited. Up until now, the only alternative was to buy a standard motor with the required explosionprotection rating and adapt the installation site and/or driven machine, sometimes at considerable time and expense. Menzel’s certification for the construction and manufacture of protected motors now gives customers more freedom of choice and flexibility. The German manufacturer specializing in large electric motors always configures motors for the individual application and installation conditions. Likewise, the air purge system for pressurized

motors is individually calculated and implemented, ensuring that the finished systems meet the highest safety standards. For a petrochemical company, Menzel has recently manufactured an Ex p compressor motor based on its MEBKSL series, which matches the original motor in all mechanical and electrical interfaces. The compressor motor for an oil refinery is labeled II 3G Ex pzc ec ic IIC T3 Gc for zone 2. It has a rated voltage of 6000 V and a rated output of 1635 kW. Before shipping, the motor was rigorously tested in the company’s inhouse test facility, including load and type testing. Menzel’s Ex p motors were named the Product of the Year in the 2023 AEMT Awards.

For further information, please visit www.menzel-motors.com/pressurized-exp-motors-zone1-operation/

124

PECM Issue 74

emco.co.uk sales@emco.co.uk 02392 637100

[ Designed for your profit ]

Two tool turrets for double punching power HYPERTURN 45 CNC TURNING CENTRE

RRP £209,895

SPECIAL OFFER £169,900

Up to 35% more autonomy

The HYPERTURN 45 is multitalented: With two tool turrets for a total of 24 tools, it increases your productivity by up to 50%. In combination with the highly dynamic motor spindle, the hybrid machine bed, and a Y-axis, you can rise to any production challenge. Flex your muscles – with precision components, a wide range of parts, and faster delivery times. And all of this on a smaller footprint, enabling you to reduce your investment volume while boosting your competitive ability.

PUNCH PERFECT HYPERTURN 45CNC Power features TWO TOOL TURRETS • Shorter changeover time • Less part set-up time • Up to 50% higher productivity BEST IN CLASS Y-AXIS DESIGN • Maximum stability • Less tool wear • Fewer employees tied to the machine

SINUMERIK ONE:

Supreme efficiency round after round The HYPERTURN 45 relies on the latest control technology from Siemens. The flexible SINUMERIK ONE CNC system features extremely powerful processors, producing a shorter feeding time and smooth simulations. As such, you can enjoy faster programming and more convenient operation. The result is a high level of efficiency.

Up to 39% lower TCO

HIGHLY DYNAMIC MAIN AND COUNTERSPINDLE • Shorter cycle times • Wider range of parts • Improved competitive ability UNIQUE HYBRID MACHINE BED • Maximum thermostability • Greater process reliability • Longer autonomy

Upgrades for even greater precision and reach. The HYPERTURN 45 relies on the latest control technology from Siemens. The flexible SINUMERIK ONE CNC system features extremely powerful processors, producing a shorter feeding time and smooth simulations. As such, you can enjoy faster programming and more convenient operation. The result is a high level of efficiency. Technology package:

£6,300

Production package:

£15,400

EMCO bar loader package:

£20,300

Universal bar loader package:

£9,500

Universal robot package:

£10,400

High recision package:

£14,800

Tool measurement package:

£3,900

TRAINING & RECRUITMENT

LR LAUNCHES NAVAL PATH LLOYD’S REGISTER

First engineering apprenticeship scheme launched to strengthen naval expertise LR aims to develop engineers for the global naval industry to survey vessels throughout the full life of design, build, in service and disposal. Lloyd’s Register (LR) has launched its first Engineering Apprenticeship Programme, set to begin this September at its Naval Centre of Expertise in Barrow-in-Furness. The programme will equip apprentices with the skills, knowledge and hands-on experience to qualify as a Junior Surveyor for LR’s submarine division, and provide a stepping stone to developing a career further within LR or the naval sector. Over the course of three and a half years, apprentices will be fully engaged in the real-world challenges of naval surveying. By combining practical experience with academic study at Furness College, the programme equips participants with the competencies required in a highly specialised and rewarding industry. From inspecting vessels during construction and maintenance phases to delivering high-quality engineering reports, apprentices will play an important role in helping clients meet rigorous technical and regulatory standards. In doing so, they will also support the operational readiness and environmental compliance of naval vessels and assets. The training is based on real industry demands, with modules

Over the course of three and a half years, apprentices will be fully engaged in the realworld challenges of naval surveying. covering everything from Computer Aided Design (CAD) and root cause analysis to Six Sigma and lean manufacturing principles. This broad curriculum ensures that apprentices not only become

proficient engineers, but also problem-solvers ready to meet the evolving needs of the maritime sector. Jane Green, LR’s Global Talent Acquisition and DEI Director, said: “Our apprenticeship scheme is more than a training programme, it’s a pipeline for future leaders in naval engineering. It is designed to provide comprehensive training in industry, allowing the successful candidate to develop practical skills and knowledge under the guidance of experienced professionals. “By investing in new talent today, we are safeguarding the technical standards and safety of tomorrow’s fleet.”

For further information, please contact kimberley.johnson@furness.ac.uk

126

PECM Issue 74

Specialist guidance, training and events for industrial engineering A selection of how to guidance for the tank storage sector from EEMUA

More for Engineering from EEMUA... People in engineering work to make businesses and everyone’s future prosperous and safe.

• EEMUA’s guidance publications for industry’

Alarm systems

Recommendations for refrigerated liquefied gas storage tanks

Publication 159

Publication 191

Publication 1 4 7

Edition 6

Edition 4

Edition 3

ew n N itio Ed

• Developed ‘by industry,

a guide to design, management and procurement

a guide to inspection, maintenance and repair

ew n N itio Ed

and other resources help people in engineering to get their work done, using proven and practical how to guidance.

Above ground flat bottomed storage tanks

incorporating the collective experience of EEMUA’s Members and other stakeholders with reference to appropriate national and international standards, e.g. ISO and API.

• Practical resources used by engineers in their work

Emission reduction

wherever they are, whatever time they have.

• Available to all in industry

all publications and many other resources are ready for immediate download from EEMUA, where you can also register to take part in EEMUA events and training.

A Practitioner's Handbook for potentially explosive atmospheres

Above ground plastic tanks

Publication 186

Publication 225

a guide to their specification, installation, commissioning, inspection, maintenance, repair and disposal

Edition 7

Edition 1

from oil storage tanks and loading operations

Publication 213 Edition 1

Engineering Equipment and Materials Users Association

www.eemua.org

Supporting

• All resources free or discounted for Members and Associates. New corporate Members are always welcome to share EEMUA resources and influence.

Upcoming Events... EEMUA Functional Safety Seminar 22 May 2025 – Manchester, UK

EEMUA 159 TankInspector course 8-10 September 2025 – live online CST time zone to suit Houston / Edmonton

Control Rooms

A guide to their specification, design, commissioning and operation

A guide to civil, structural and building asset management in process, industrial and production environments

Publication 201

Publication 238

Edition 3

Edition 1

EEMUA Inspection Seminar

Publication 244

Edition 1

a guide to periodic examination and testing

EEMUA Storage Tanks Seminar

EEMUA Publication 231

27 November 2025 Ridderkerk, NL.

Scan for the full list of publications

a guide to their specification, installation, commissioning, inspection, maintenance, repair and disposal

The mechanical integrity of plant containing hazardous substances

25 September 2025 – London, UK

ask@eemua.org +44 (0)20 7488 0801 www.eemua.org

Above ground horizontal rectangular metallic storage tanks

Edition 1

SAFed Publication IMG 1

Statistical analysis of in-service tank floor inspections

Management of ageing electrical assets

Publication 247

Publication 227

Edition 1

Scan for the full list of training courses

Edition 1

Scan for the full list of events

VALVES & FLOW CONTROL

MICRONICS UX5000 ATEX USM ABLE

Safe & accurate flow monitoring without compromise Introducing the Micronics UX5000 Clamp-on Flow Meter for use in Hazardous Environments. A high performance ATEX USM, made in the UK with a remarkably low price point.

ABLE, as Micronics’ exclusive UK representatives for the Model UX5000, are delighted to announce the arrival of a truly technically elite and commercially advantageous clamp-on ultrasonic flow meter. The UX5000 flow meter uses a cross-correlation transit time algorithm to achieve precise flow measurements. It generates an ultrasonic beam at a specific frequency, transmitting it between transducer crystals in two directions: first from the downstream transducer to the upstream, then reversing from upstream to downstream. As the liquid moves through the pipe, it slightly increases the speed of the ultrasound transmission. This time difference, calculated as T1−T2, is

directly proportional to the liquid’s flow velocity, providing an accurate measurement of flow rate. Applications for the UX5000 are many-fold. The UX5000 is ideal for harsh, heavy duty industrial measurement of liquid flow in

pipes. Being non-invasive and easy to install, it is particularly well suited to the chemical, water and oil industries. Key Features: • Non-invasive, efficient, and easy installation, no process downtime • Cutting edge technology at its most affordable • Certified for use in hazardous areas (ATEX) • Reliable measurement accuracy – up to 0.5% with process calibration • Separate Display (DCSIU) and Remote Measurement • Unit (RMU) allows flexibility in installation • Cost effective metering for harsh, heavy-duty applications • Single and Dual Channel Options • Remote System Setup and Monitoring Have a live application? Contact our flow specialists to book a demonstration.

Call us now on +44 (0) 1189 169 420, or email us now at info@247able.com

128

PECM Issue 74

Introducing the Micronics UX5000 Clamp-on Flow Meter for use in Hazardous Environments A high performance USM with a remarkably low price point ABLE, as Micronics’ exclusive UK representatives for the Model UX5000, are delighted to announce the arrival of a truly technically elite and commercially advantageous clamp-on ultrasonic flow meter. Applications for the UX5000 are many-fold - non-invasively. The UX5000 is ideal for harsh, heavy duty industrial measurement of liquid flow in pipes. Being non-invasive and easy to install, it is particularly well suited to the chemical, water and oil industries The UX5000 uses a cross correlation transit time algorithm to provide accurate flow measurements. An ultrasonic beam of a given frequency is generated and applied to the transducer crystals. This transmission goes first from the downstream transducer to the upstream transducer as shown in the upper half of Figure 1. The transmission is then made in the reverse direction, being sent from the upstream transducer to the downstream transducer as shown in the lower half of Figure 1. The speed at which the ultrasound is transmitted through the T1 - T2 + K*dt = flow velocity, liquid is increased slightly by the velocity of the liquid through the pipe. The subsequent time difference T1-T2 is directly proportional to the liquid flow velocity.

FEATURES: • Non-invasive, efficient, and easy installation, no process downtime • Certified for use in hazardous areas (ATEX) • Reliable measurement accuracy • Separate Display (DCSIU) and Remote Measurement • Unit (RMU) allows flexibility in installation • Cost effective metering for harsh, heavy-duty applications • Single and Dual Channel Options • Remote System Setup and Monitoring

If you would like more information or have an application to discuss, please email us at info@able.co.uk

www.247able.com

VALVES & FLOW CONTROL

EFFICIENT WATER SOLUTIONS GEMU

GEMÜ valves and solutions for water treatment

S TA N D E 2 0 A necessity for life, water provides individuals, communities and businesses with essential sustenance. An average person in the UK uses 146 litres at home per day and before it reaches their taps the water undergoes a complex purification process to ensure it’s safe for use and drinking. This intricate journey relies on a network of high-quality valves and equipment. GEMÜ offers expert solutions for water and wastewater treatment applications, all with efficiency, sustainability and digitalization in mind. Sustainable Water Management The growing global population, changing lifestyles and climate change are leading to an increase demand for water, the treatment of municipal and industrial wastewater

for reuse is essential for achieving sustainable water management. Membrane filtration processes play a key role in optimising water reuse. From plastic diaphragm valves for chlorination to intelligent electrical positioners for flow control, and butterfly valves with WRAS approved materials, GEMÜ can provide efficient solutions even for the most complex applications. Innovation and Technology Digitalization enhances water treatment plants by continuously monitoring the condition of infrastructure and efficiently collecting data to predict maintenance needs, preventing disruptions and costly downtimes. The GEMÜ App and CONEXO asset

management software can help to improve existing technology. The GEMÜ App manages datasheets, providing instant access to maintenance procedures and certification. Using Bluetooth, it can also operate GEMÜ valves when paired with an electrical positioner and process controller. GEMÜ CONEXO uses RFID chips on valve components for on-site data access with the CONEXO pen, supporting maintenance work and electronic recording. This is particularly beneficial for skid builders, OEMs, and complex maintenance tasks, improving data handling and the reduction of paperwork that supports quality and change control processes. Explore GEMÜ valves & solutions on STAND E20 at CHEMUK 2025 Expo.

For further information, please visit www.gemu.co.uk | Tel: 01925 824044

130

PECM Issue 74

THE FACTORY AUTOMATION COMPANY

Powering Smart Manufacturing Through Partnership No one shapes the future alone. Through strategic partnerships, FANUC is driving real change where it matters most!

Proud to partner with over 50 industry leaders to deliver the best automation solutions to our customers.

VISIT US & OUR PARTNERS @ STAND 5/F40!

MORE THAN

20.000 MOTORS

AVAILABLE FROM STOCK!

SUPPLIER OF LARGE MOTORS FOR ALL DRIVEN EQUIPMENT APPLICATIONS SQUIRREL CAGE MOTORS | SLIP RING MOTORS | DC MOTORS Motors up to 25 MW and 13.8 kV • Low voltage slip-ring and squirrel cage motors up to 3,000 kW • Medium voltage slip-ring and squirrel cage motors up to 15,000 kW • Direct current motors up to 2,000 kW • Frequency converter-proof drives • In-house load test facility up to 13.800 V, 2.300 kVA, 120 Hz

24/7 EMERGENCY SERVICE CUSTOM SOLUTIONS FOR ELECTRIC MOTORS

Customized special designs • Custom designs for special applications and operating conditions • Optimized motor design for higher efficiency • Mechanically and electrically interchangeable motors • Commissioning worldwide MENZEL Great Britain Ltd. | UK Branch Office Martin Rooney | Tel.: +44 1664 500 844 martin.rooney@menzelgb.co.uk

menzel-motors.com

AROUND THE CLOCK, AGAINST THE CLOCK!